Mitsubishi PUHY-P200YREM-A, PUHY-P250YREM-A Service Manual

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Page 1

Service Handbook

2004

AIR CONDITIONERS CITY MULTI

HEAD OFFICE: MITSUBISHI DENKI BLDG., 2-2-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

Issued in Mar. 2004 MEE03K220 Printed in Japan

New publication, effective Mar. 2004

Specifications subject to change without notice

Service Handbook Replace Multi PUHY-P200·250YREM-A

Page 2

Caution to REPLACE MULTI Installation Work

Flow of installation work in the field Items to be observed

•Please note that our Corporation is not liable to the reliability of existing piping, wiring and power system for reuse (in relation with the gas leak of piping, partially defective/disconnection of wiring, deteriorated insulation, characteristic faults due to worn out system).

•For limitation on the refrigerant piping and applicable piping diameter, check the existing piping for reuse in accordance with the specified check sheet by referring products catalogs and manuals for judgement to reuse.

•If vapor condensation was found in the past, check the thermal insulation.

•For a portion suffered by condensation dripping, check the deterioration of the insulation, and repair the insulation materials if required.

•When the copper piping is seriously deteriorated, do not use parts with verdigris or black spots.

•For reusing the existing control wiring between the outdoor unit, and remote controller, check the wire type , siz e or the lik e based on the chec k sheet to judge the possibility.

•Even when the above does not meet the item on the check sheet, existing wiring may be reused depending on the number of connecting indoor units and piping length. Ask us for detail.

•For the power source system, employ the voltage and number of phase meeting the outdoor unit, indoor unit and heat storage unit, and adopt the breaker capacity and wiring size based on the power source wiring connection diagram.

•When the existing power source system (including the power source wiring) is used, check the system for deterioration and damages.

•Check the refrigerating machine oil used in the existing system. (As is found at the oil inspection, if the refrigerating machine oil used in the existing system is mineral oil, use the ester oil sampling kit for inspection.

•When the length of piping for reuse is unknown, additional refrigerant charge is to be calculated based on the quantity of recovered refrigerant. For this reason, you are kindly requested to recover all refrigerant inside the existing outdoor/ indoor units and extended piping to check and record the quantity. (The standard of additional refrigerant is (Quantity of R22 recovered - Charged quantity of existing outdoor unit + 3kg). Adjust the refrigerant quantity after mineral oil recovery operation.)

■ Outdoor unit

•Confirm the space around the outdoor unit. (Verifying the installation space of the oil trap kit)

■ Turn the power source on, and confirm the normality of the system

•Check the remote controller or outdoor unit for error display.

•Run the indoor unit for fan operation after turning the remote controller on, and check the air feeding and direction.

Do not run the compressor until finishing the mineral oil recovery operation.

■Mount the valve to the field piping (extended piping). (The ball valve is being attached to the outdoor unit.)

■Execute an airtight test to check the existing piping for deterioration or leaking.

■Calculate the quantity required by the extended piping, and charge the addi-

tional refrigerant. Make sure to enter the value in the additional refrigerant charge column on the label of combined outdoor unit being pasted on the outdoor unit.

Without applying any operation, keep the ball v alves of the outdoor unit c losed

before mineral oil recovery operation.

It is necessary to charge refrigerant in a rated quantity and adjust the quantity. Be sure to execute when the piping length is unknown. For detail, consult the agent of your dealer.

Enter required items in the request form of REPLACE MULTI mineral oil recovery work.

During local installation work

Before local installation work

Confirming the possibility of existing refrigerant piping for reuse

Confirming the possibility of existing control wiring for reuse

Confirming the possibility of existing power source system for reuse

Confirming the objective range for replacing

Recovering the refrigerant of old system

Removing the outdoor/indoor units, remote controllers, etc.

Installing the outdoor/indoor units, remote controllers, etc., and executing electrical work

Setting the address, checking the system

Executing the piping work (mounting of ball valve). Air tightening and evacuating the existing piping and charging refrigerant

Operating mineral oil recovery

Executing test run and adjustment (for final verification of operation).

Page 3

Safety Precautions

• Before installing the unit, make sure you read all the “Safety precautions”.

• The “Saf ety precautions” provide very important points regarding safety. Make sure you f ollo w them.

Symbols used in the text

Warning:

Describes precautions that should be observed to prevent danger of injury or death to the user.

Caution:

Describes precautions that should be observed to prevent damage to the unit.

Symbols used in the illustrations

: Indicates an action that must be avoided. : Indicates that important instructions must be followed. : Indicates a part which must be grounded. : Beware of electric shock (This symbol is displayed on the

main unit label.) <Color: Yellow>

Warning:

Carefully read the labels affixed to the main unit.

Warning

Ask your dealer or specialized contractor for installation.

•If your own installation work is improper, fire, electric shock or water leakage may result.

Connect wiring using the specified cable and fasten it securely to prevent the external force of the cable from being transferred to the terminal connecting sections.

• Improper connection or fastening may cause heat

generation or fire.

Conduct specified installation work durable against strong winds around buildings.

•Improper installation work can cause trouble i.e. the unit toppling over.

Never attempt to repair the unit. For repair, ask your dealer.

•Improper repair may result in water leakage, electric shock or fire.

Do not touch the heat exchanger fins.

•Improper handling may cause cuts.

When refrigerant gas is leaked during work, conduct ventilation.

•If refrigerant gas comes into contact with fire, it may cause the generation of poisonous gases.

Please conduct correct installation work by observing this Installation Manual.

•Improper installation work may result in water leakage, electric shock or fire.

Conduct all electrical work by a licensed engineer according to “Technical Standard relating to Electrical Facility,” “Wiring Regulation of Power Company,” and instructions in this Manual, and always use an exclusive circuit.

•Insufficient power source capacity or improper installation may cause electric shock or fire.

When installing or moving the unit, do not charge other than the specified refrigerant (R407C) into the refrigeration cycle.

•Air if mixed generates abnormally high pressure inside the refrigeration cycle which may damage the unit.

Do not reconstruct or reset the protection devices.

•If the protection devices like the pressure switch or thermal switch is forcibly operated by short circuiting, or parts other than that specified by Mitsubishi Electric are used, fire or explosion may be caused.

Page 4

Precautions for Devices that Use R407C Refrigerant

Caution

Use refrigerant piping made of phosphorus deoxidized copper and copper alloy seamless pipes and tubes. In addition, be sure that the inner and outer surfaces of the pipes are clean and free of hazardous sulphur, oxides, dust/dirt, shaving particles, moisture, or any other contaminant.

•Contaminants on the inside of the refrigerant piping may cause the refrigerating machine oil to deteriorate.

Store the piping to be used during installation indoors and keep both ends of the piping sealed until just before brazing. (Store elbows and other joints in a plastic bag.)

•If dust, dirt, or water enters the refrigerant cycle, deterioration of the oil and compressor trouble may result.

Use ester oil, ether oil or alkylbenzene (small amount) as the refrigerating machine oil to coat flares and flange connections.

•The refrigerating machine oil will degrade if it is mixed with a large amount of mineral oil.

Use liquid refrigerant to seal the system.

•If gas refrigerant is used to seal the system, the composition of the refrigerant in the cylinder will change and performance may drop.

Do not use other refrigerant other than

R407C.

•Use of other refrigerants (R22 for example) may deteriorate refrigerating machine oil due to chlorine generation.

Use a vacuum pump with reverse flow protection.

•Otherwise the vacuum pump oil will reversely flow into the refrigerant circuit causing the possible deterioration of the refrigerating machine.

Do not use the following tools used for conventional refrigerant. (Gauge manifold, Charging hose, Gas leak detector, Reverse flow protector, Cap for refrigerant charge, Refrigerant recovery device)

•Mixing of conventional refrigerant /refrigerating machine oil may cause to deteriorate the refrigerating machine oil.

•Mixing with water may cause deterioration of the refrigerating machine oil.

•As this refrigerant does not contain chloride, the gas leak detector for conventional refrigerant gas can not be used.

Do not use a charging cylinder.

•Use of a charging cylinder changes the composition of refrigerant resulting in possible performance deterioration.

More careful management is required for the tools than that for the conventional.

•Dust, trash or water content if mixed into the refrigerant circuit may cause to deteriorate the refrigerating machine oil.

Caution to Equipment Used for Replacing

Caution

Do not operate any valves before conducting mineral oil recovery operation.

Operating valves before conducting mineral oil recovery operation may cause a deterioration in the performance of mineral oil recovery.

For mineral oil recovery operation, the system controller and MA remote controller may be required to be remove sometimes.

• Improper handling can lead to an inability to perform oil recovery operation.

• For removal, follow the instruction displayed on the PC for mineral oil recovery.

• Mount the controllers again after finishing the oil recovery operation.

Observe a safe distance from the indoor unit fan which runs during the mineral oil recovery operation.

Working in the surrounding of the indoor unit fan can cause personal injury.

Record the quantity of refrigerant replenished. (Enter into the column for replenished refrigerant quantity on the label of the indoor unit.)

• Missing the description may deteriorate the performance of mineral oil recovery.

• Malfunction or poor cooling/heating may also be caused.

During the mineral oil recovery operation, an error display may be shown on the remote controller or system controller.

• When an error display was shown during mineral oil recovery operation, reset the error display after finishing the operation.

To conduct the refrigerant recovery/evacuation of the inside of exiting piping, choose tools only used with R407C e.g. charging hose.

• Using a charging hose for R407C causes it to mix the conventional refrigerating machine oil leading to the deterioration of refrigerating machine oil.

Page 5

Before Conducting Installation Work/Electrical Work

Caution

Do not install the unit at a place where combustible gas can possibly be generated.

•Leaked combustible gas if stagnated around the unit may cause explosion.

Do not use the unit in a special atmosphere.

•Use in an atmosphere containing high levels of oil, steam or sulfide gas may seriously degrades the performance or damage parts.

Do not install the unit on a material which is not designed to be wet.

•If liquid drips from the oil trap kit, apply centralised drainage work to the oil trap kit.

Apply grounding work securely.

• Do not connect the grounding line to gas pipe, city

water pipe, lightning rod or telephone grounding line. Improper grounding may cause electric shock.

For the power source wiring, refrain from giving tensile force to the wiring.

• Disconnection, heat generation or fire may be

caused.

Make sure to mount a leak breaker to the power source.

• Otherwise electric shock may be caused.

Be sufficiently careful in transporting products.

•Do not transport a product with a weight exceeding 20kg by a single person.

•Some products are packed with PP band. Do not use it as a means of transporting.

•During transport cuts may be caused by the fin surface of the heat exchanger , please refrain from touching it without gloves.

Do not use the same switch or the like for plural outdoor units.

Otherwise, malfunction, heat generation or fire may be caused.

When installing the unit in hospitals or communication equipment plants, prepare measures to prevent noise generation beforehand.

•The noise may cause the erroneous operation or failure and may giv e negative effect to medial equipment or communication equipment to disturb medical treatment on human bodies or hinders image broadcasting or generates noise.

Check possibility for the reuse of existing refrigerant piping by observing this manual.

• The conventional refrigerating machine oil is con-

tained inside existing piping and some residual oil deteriorates oil recovery performance which may lead to the deterioration of refrigerating machine oil.

• The piping specification (diameter, length , height

difference) out of the use specified range may hinder the mineral oil recovery performance, possibly leading to deterioration of refrigerating machine oil.

Do not use breakers or fuses other than that with correct capacities.

•Use of a fuse with excessively large capacity or wire/ copper wire may cause troubles or fire.

For the power source wiring, use wire with rated current capacity.

• Otherwise an electric leak, heat generation or fire

may be caused.

When using existing wiring (for power source or transmission) or switches, check them for disconnection and deterioration beforehand.

• Otherwise an electric leak, heat generation or fire

may be caused.

Dispose the packing materials properly.

• As the packing materials are using metal products

or wooden pieces such as nails, nail wounds may be caused if it is improperly treated. Please observe caution to avoid this from occuring.

•Dispose the polyethylene bag for packing only after tearing. Otherwise a suffocation accident may be caused by children play with the disposed bag.

Be sure to mount the valve to the field piping (extended piping).

After mineral oil recovery, the oil trap kit can not be removed disabling air conditioning operation.

Provide thermal insulation to the valve on the field piping (extended piping) properly.

• Insufficient thermal insulation generates condensation that may cause to deteriorate the performance.

• Provide thermal insulation (including lagging) after recovering mineral oil.

Page 6

Before Conducting Mineral Oil Recovery Operation

Caution

Turn the power source on 12 hours or more before starting operation.

• Otherwise trouble may be caused. Do not turn the power off during the operating season.

Do not operate the unit without the panels or guard.

• Touching the rotating parts, high temperature parts or high voltage may cause personal injury such as burns or electric shock.

Do not operate switches with wet fingers.

• Electric shock may be caused.

Do not turn off the power source immediately after stopping.

• Be sure to wait for 5 minutes or more. Otherwise water leakage or troubles may be caused.

Do not touch the refrigerant piping during operation or immediately after stopping with bare hands.

• The refrigerant piping or the refrigerant circuit parts of the compressor during operation or immediately after stopping may have low or high temperature. Touching with bare hands may cause a burn or frostbite.

Do not run the outdoor unit during a test run until finishing the mineral oil recovery operation.

• The indoor unit fan will run.

Caution to Mineral Oil Recovery Operation

Warning

Caution

Be sufficiently careful to avoid the oil trap kit, falling or toppling over.

• If this happens the oil trap kit may be damaged and refrigerant piping may malfunction.

• Falling down during flushing operation causes the leak of refrigerant from the joint which is dangerous if contacts it human body.

After flushing operation, check the residual pressure inside the oil trap kit with a pressure gauge. If the residual pressure is exceeding 0.294MPa, recover refrigerant inside the oil trap kit to reduce the pressure to within 0.2 ~ 0.294MPa.

• Under high inner pressure, pressure rises during storing, inducing a dangerous situation.

• Under low inner pressure, water content or foreign matter enters during storing, causing corrosion to the oil trap kit which may cause troubles.

Be careful not to expose the oil trap kit unit (especially electrical parts) to rain water.

• The electrical parts if wet with rain water may cause machine trouble.

• The electrical parts if wet with rain water may cause electrical shock.

Conduct oil recovery from the oil recovery service valve outdoor or at a place with good ventilation. Use leather gloves when opening the oil recovery service valve and open it slowly.

• If done in a closed space, suffocation can be caused.

• Opening the oil recovery service valve fully and

quickly allows oil to splash, which is dangerous.

• As the oil recovered is of low temperature, frostbite may be caused if it touches skin.

When the oil trap kit is transported while lying sideways, do not place any thing on the sheet metal of the kit.

• Otherwise, the sheet metal or inner piping may be deformed leading to breakage.

Before removing the oil trap kit after flushing operation, make sure to discharge and process the oil recovered from the oil recovery service valve.

• If it is not discharged, the oil accumulated inside will flow out during flushing operation hindering proper recovery of mineral oil thus leading to machine trouble.

For inspection, use the ester oil sampling kit when the refrigerating machine oil used in the existing unit is mineral oil.

(

Confirm the type of refrigerating machine oil used in the

existing unit by reading the name plate or the like.

)

• Proper checking can not be executed if not using the kit meeting the refrigerating machine oil used by the existing unit. This possibly causes machine trouble.

Page 7

Contents

¡ PRECAUTIONS FOR DEVICES THAT USE R407C REFRIGERANT ... 2

[1] Storage of Piping Material................................................................. 2

[2] Piping Machining............................................................................... 3

[3] Necessary Apparatus and Materials and Notes on Their Handling .. 4

[4] Brazing.............................................................................................. 5

[5] Airtightness Test ................................................................................ 6

[6] Vacuuming ........................................................................................ 6

[7] Charging of Refrigerant..................................................................... 7

[8] Dryer ................................................................................................. 7

™ COMPONENT OF EQUIPMENT .............................................................

[1] Appearance of Components ............................................................. 8

[2] Refrigerant Circuit Diagram and Thermal Sensor........................... 14

[3] Electrical Wiring Diagram................................................................ 15

[4] Standard Operation Data ................................................................ 16

[5] Function of Dip SW and Rotary SW................................................ 18

£ TEST RUN .............................................................................................21

[1] Before Test Run ..............................................................................21

[2] Test Run Method ............................................................................. 25

¢ GROUPING REGISTRATION OF INDOOR UNITS WITH REMOTE

CONTROLLER.......................................................................................

∞ CONTROL.............................................................................................. 32

[1] Control of Outdoor Unit ................................................................... 32

[2] Operation Flow Chart...................................................................... 37

[3] List of Major Component Functions ................................................ 42

[4] Resistance of Temperature Sensor................................................. 44

§ REFRIGERANT AMOUNT ADJUSTMENT ............................................

[1] Refrigerant Amount and Operating Characteristics ........................ 45

[3] Refrigerant Volume Adjustment Mode Operation ........................... 48

¶ TROUBLESHOOTING ...........................................................................

[1] Principal Parts................................................................................. 50

[2] Trouble and Remedy of Remote Controller.....................................

[4] Self-diagnosis and Countermeasures Depending on the Check

Code Displayed...............................................................................

[3] Investigation of Transmission Wave Shape/noise ..........................

[5] LED Monitor Display ....................................................................... 95

• PREPARATION, REPAIRS AND REFRIGERANT REFILLING WHEN

REPAIRING LEAKS .............................................................................

113

[3]

Location of leaks: Extension piping or indoor units (when cooling)113

[4] Location of leaks: Outdoor unit (when heating) ............................ 115

114

ª CHECK THE COMPOSITION OF THE REFRIGERANT

........................

116

0 CAUTIONS WHEN REPLACING THE OUTDOOR UNIT MAIN

BOARD

...................................................................................................

118

[1]

[2] Location of leaks: Outdoor unit (Cooling mode)............................ 113

Location of leaks: Extension piping or indoor units

(Heating mode)

[2] Adjustment and Judgement of Refrigerant Amount ........................ 45

- 1 -

Page 8

[1] Storage of Piping Material

(1) Storage location

Store the pipes to be used indoors. (Warehouse at site or owner’s warehouse) Storing them outdoors may cause dirt, waste, or water to infiltrate.

(2) Pipe sealing before storage

Both ends of the pipes should be sealed until immediately before brazing. Wrap elbows and T’s in plastic bags for storage.

❇

The new refrigerator oil is 10 times more hygroscopic than the conventional refrigerator oil (such as Suniso). Water infiltration in the refrigerant circuit may deteriorate the oil or cause a compressor failure. Piping materials must be stored with more care than with the conventional refrigerant pipes.

¡ PRECAUTIONS FOR DEVICES THAT USE R407C REFRIGERANT

- 2 -

Page 9

[2] Piping Machining

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

Use only the necessary minimum quantity of oil.

Reason :

1. The refrigerator oil used for the equipment is highly hygroscopic and may introduce water inside.

Notes :

• Introducing a great quantity of mineral oil into the refrigerant circuit may also cause a compressor failure.

• Do not use oils other than ester oil, ether oil or alkylbenzene.

- 3 -

Page 10

[3] Necessary Apparatus and Materials and Notes on Their Handling

The following tools should be marked as dedicated tools for R407C.

<<Comparison of apparatus and materials used for R407C and for R22>>

Apparatus Used Use R22 R407C

Gauge manifold Evacuating, refrigerant filling Current product Charging hose Operation check Current product Charging cylinder Refrigerant charging Current product Do not use. Gas leakage detector Gas leakage check Current product Shared with R134a Refrigerant collector Refrigerant collection R22 For R407C use only Refrigerant cylinder Refrigerant filling R22

Vacuum pump Vacuum drying Current product

Vacuum pump with a check valve Current product Flare tool Flaring of pipes Current product Bender Bending of pipes Current product Application oil Applied to flared parts Current product

Torque wrench Tightening of flare nuts Current product Pipe cutter Cutting of pipes Current product Welder and nitrogen cylinder Welding of pipes Current product Refrigerant charging meter Refrigerant charging Current product Vacuum gauge Checking the vacuum degree Current product

Symbols :

To be used for R407C only. Can also be used for conventional refrigerants.

Tools for R407C must be handled with more care than those for conventional refrigerants. They must not come into contact with any water or dirt.

Identification of dedicated use for R407C :Record refrigerant

name and put brown belt on upper part of cylinder.

Can be used by attaching an adapter with a check valve.

Ester oil or Ether oil or Alkybenzene (Small amount)

- 4 -

Page 11

[4] Brazing

No changes from the conventional method, but special care is required so that foreign matter (i.e. oxide scale, water, dirt, etc.) does not enter the refrigerant circuit.

Example : Inner state of brazed section

When non-oxide brazing was not used When non-oxide brazing was used

Items to be strictly observed :

1. Do not conduct refrigerant piping work outdoors on a rainy day.

2. Apply non-oxide brazing.

3. Use a brazing material (BCuP-3) which requires no flux when brazing between copper pipes or between a copper pipe and copper coupling.

4. If installed refrigerant pipes are not immediately connected to the equipment, then braze and seal both ends of them.

Reasons :

1. The new refrigerant oil is 10 times more hyg roscopic than the conventional oil. The probability of a machine failure if water infiltrates is higher than with conventional refrigerant oil.

2. A flux generally contains chlorine. A residual flux in the refrigerant circuit may generate sludge.

Note :

• Commercially available antioxidants may have adverse effects on the equipment due to its residue, etc. When applying non-oxide brazing, use nitrogen.

- 5 -

Page 12

[5] Airtightness Test

No changes from the conventional method. Note that a refrigerant leakage detector for R22 cannot detect R407C leakage.

Halide torch R22 leakage detector

Items to be strictly observed :

1. Pressurize the equipment with nitrogen up to the design pressure and then judge the equipment’s airtightness, taking temperature variations into account.

2. When investigating leakage locations using a refrigerant, be sure to use R407C.

3. Ensure that R407C is in a liquid state when charging.

Reasons :

1. Use of oxygen as the pressurized gas may cause an explosion.

2. Charging with R407C gas will lead the composition of the remaining refr igerant in the cylinder to change and this refrigerant can then not be used.

Note :

• A leakage detector for R407C is sold commercially and it should be purchased.

[6] Vacuuming

1. Vacuum pump with check valve A vacuum pump with a check v alve is required to prevent the vacuum pump oil from flowing back into the refrigerant circuit when the vacuum pump power is turned off (power failure). It is also possible to attach a check valve to the actual vacuum pump afterwards.

2. Standard degree of vacuum for the vacuum pump Use a pump which reaches 65Pa or below after 5 minutes of operation. In addition, be sure to use a vacuum pump that has been properly maintained and oiled using the specified oil. If the vacuum pump is not properly maintained, the degree of vacuum may be too low.

3. Required accuracy of the vacuum gauge Use a vacuum gauge that can measure up to 650Pa. Do not use a general gauge manifold since it cannot measure a vacuum of 650Pa.

4. Evacuating time

• Evacuate the equipment for 1 hour after 650Pa has been reached.

• After envacuating, leave the equipment for 1 hour and make sure the that vacuum is not lost.

5. Operating procedure when the vacuum pump is stopped In order to prevent a backflow of the vacuum pump oil, open the relief valve on the vacuum pump side or loosen the charge hose to drawn in air before stopping operation. The same operating procedure should be used when using a vacuum pump with a check valve.

- 6 -

Page 13

[7] Charging of Refrigerant

R407C must be in a liquid state when charging, because it is a non-azeotropic refrigerant.

For a cylinder with a syphon attached For a cylinder without a syphon attached

Cylinder color identification R407C-Gray Charged with liquid refrigerant

R410A-Pink

Reasons :

1. R407C is a mixture of 3 refrigerants, each with a different evaporation temperature. Therefore, if the equipment is charged with R407C gas, then the refrigerant whose ev apor ation temperature is closest to the outside temper ature is charged first while the rest of refrigerants remain in the cylinder.

Note :

• In the case of a cylinder with a syphon, liquid R407C is charged without turning the cylinder up side down. Check the type of cylinder before charging.

[8] Dryer

1. Replace the dryer when the refrigerant circuit is opened (Ex. Change the compressor, full gas leakage). Be sure to replace the dryer with a CITY MULTI (For use with R407C).

If any other product is used, the unit will be damaged.

2. Opening the refrigerant circuit after changing to a new dryer is less than 1 hour. The replacement of the dryer should be the last operation performed.

Cylin-

der

Cylin-

der

Valve Valve

Liquid

- 7 -

Page 14

™ COMPONENT OF EQUIPMENT

[1] Appearance of Components

Outdoor unit

• PUHY-P200, 250YREM-A

Propeller fan

Accumlator

CSC

SCC

4way valve

Dryer

Compressor

Fan motor

Heat exchanger

Control box

- 8 -

Page 15

Controller Box

FANCON board

ACCT

INV board

MAIN board

Noise filter

Choke coil (L2)

Terminal block TB1A Power Source

Terminal block TB7 Transmission (Centralized control)

Terminal block TB3 Transmission

Inteligent Power Module (IPM)

G/A board

DCCT

Diode stack (DS)

Magnetic contactor (52C)

Capacitor (C2, C3) (Smoothing capacitor)

- 9 -

Page 16

MAIN board

CN51 Indication distance 3-4 Compressor ON/OFF 3-5 T roub le

CNRS3 Serial transmission to INV board

CN3D

SW1

CNTR CNFC1

CNVCC4 Power source for control(5V)

CN20 Power supply

3 L1 1 N

SW3

SW4

SW2 SWU2

SWU1

CNS1 CNS2 CN40 CN41 CNVCC3

Power Source for control

1-2 30V 1-3 30V 4-6 12V 5-6 5V

CN3S

CN3N

LD1 Service LED

SWU3

CNTYP1

- 10 -

Page 17

INV board

CNDR2 Out put to G/A board

CNTH

CNCT DCCT

CN15V2 Power supply

CNFG Frame grounding

for IPM control

CNCT2 ACCT

CNAC2 I Power source 1 L2 3 N 5 G

CN52AC Control for 52C

CNRS2CN FAN

Control for MF1

Serial transmission to MAIN board

SW1

CNVDC 1-4 DC-560V

CNVCC4 Power supply (5V)

CNL2 Choke coil

CNVCC2 Power supply

1-2 30V, 1-3 30V 4-6 12V, 5-6 5V

- 11 -

Page 18

FANCON board

CNFAN

CNPOW

CNFC2

CN15V1

CNDR1

CNIPM1

G/A board

Terminal for signal grounding

CNDC1 CNDC2

- 12 -

Page 19

- 13 -

RELAY 10 board

RELAY 4 board

Page 20

SLEV

ST2

TH5

SCC

TH8

ST7

ST4

LEV1

TH7

TH1

TH6

21S4

ST1

CJ1

O/S

63HS

Com

CJ2

CV1

ST3

SV1

CP1

ST5

63LS

63H

TH2

Dryer

CP2

ST10

SV4

ST9

HEX 1

ST11

HEX 2

SV2

ST6

BV3

CP3

SV3

ST8

BV1

BV2

[2] Refrigerant Circuit Diagram and Thermal Sensor

1PUHY-P200/250YREM-A

- 14 -

Page 21

[3]

1 PUHY-P200·250YREM-A

Electrical Wiring Diagram

Symbol

DCL

ACCT-U,W

52C

ZNR4 Varistor

DC reactor (Power factor improvement)

Current Sensor

Magnetic contactor (Inverter main circuit)

N a m e

Fan motor (Radiator panel)MF1

Solenoid valve (Discharge--suction bypass)SV1, SV2

4--way valve

21S4

✻1

Symbol

SLEV

SV3

Solenoid valve (Heat exchanger capacity control)

SV4

Solenoid valve (Heat exchanger capacity control)

LEV1

Electric expansion valve (Sub-cool coil bypass)

N a m e

Choke coil (Transmission)L2

IPM Intelligent power module

TH5

TH2

TH1

N a m eSymbol

OA temp. detect

Pipe temp. detect

TH6

Saturation evapo. temp. detect

Discharge pipe temp. detect

Thermistor

bypass outlet temp. detect at Sub--cool coil

TH8

Symbol N a m e

THHS Radiator panel temp. detect

Aux. relayX1~10 Earth terminal

DCCT

Current Sensor

Electric expansion valve (Sub-cool coil bypass)

63HS High pressure sensor 63LS Low pressure sensor

liquid outlet temp. detect at Sub--cool coil

TH7

R20

CNTYP1

(2P)

BOX BODY

F01 250VAC 6.3AF

F03 250VAC 6.3AF F02 250VAC 6.3AF

52C

ACCT

-U

BOX BODY

CNPOW

(5P)

SV3

SV4

circuit

detection

TB1B

BOX BODY

X10

21S4

63H

X06

CN36 (6P)

CNFC1

(6P)

CNFC2

(6P)

CNFAN

(5P)

Control circuit board

(MAIN board)

Blue

Red

White

Black

Brown

Red

BOX BODY

Power circuit board (INV board)

MF1

THHS

CNVCC3

(6P)

CNVCC4

(2P)

X10

X01

X02

Black

Red

White

CNTR1

DCL

52C

ZNR4

TB7

TB3

Blue

Black

Red

White

TB1A

CH1

SV1

12V

CN51

(5P)

2 4

Yellow

Orange

Purple

Black

White

Gray

1 2 3 4

V W

51234

L1 L2 L3

IPM

Orange

Brown

CN04

MC1

DCCT

DC-DC Converter

CN3S

(3P)

CN3N

(3P)

SNOW

OFF

1-2

CN3N

OFF

1-3 ON

OFF

Mode

Auto

changeover

Normal

HEAT COOL

✻

SV2

CN02

(8P)

321

TH6

63LS63HS

Red

White

Black

TH2

TH1

TH7TH5

LEV1

TH8

SLEV

no fuse breaker

Inverter Controller Box

PUHY-P200YREM-A PUHY-P250YREM-A

30A 30A

3216548721321321321543215421

CN03

(3P)

CN01

(2P)

CNH (3P)

CNL (3P)

CNLV1

(5P)

CNSLV

(5P)

Refer to the service handbook about the switch operations.

Crank case heater (Compressor)

High pressure switch

1 2 3

CN38

(3P)

6 5 4 3 2 1

X03

X04 X05

X01

X02

CN32 (3P)

CN33 (3P)

CN34 (6P)

Connect to Indoor and remote controller

Green/ Yellow

Blue

Black

Red

White

Blue

Black

Red

White

Power source 3N~ 380/400/415V 50/60Hz

Terminal Block

Noise Filer

Terminal Block

L1 L2 L3 N

Diode stack

R1 R5

3214

3 2

321476589

CNS2

(3P)

CNS1

(2P)

CN20

(3P)

32121

321321

CNTR

(3P)

F1 250VAC 2A T

F3 250VAC 1A F

T01

CNDC2

(4P)

UVW

Gate amp board (G/A board)

ACCT

-W

Motor (Compressor)

321654879 321654879

10 1211 13 14

3214321432 145

123123

Red

White

Black

Fan motor (Heat exchanger)

Fan control board (Fancon board)

CN3D

(3P)

Compressor

ON/OFF

NIGHT MODE

ORDEMEND

5: Trouble

4: Compressor ON/OFF

F02 700VDC 2A T

F01 250VAC 2A T

CNDR2

(9P)

CNVDC

(4P)

CNCT

(4P)

CNAC2I

(5P)

CNRS2

(7P)

CNVCC2

(6P)

CN15V2

(14P)

CNCT2

(4P)

1 2 3

5 6

2 4

5 6

2 4

1 2 3

1 2

5 6 7

2 4

5 6 7

2 4

CNRS3

(7P)

CNVCC4

(2P)

CNX10

(3P)

CN15V1

(14P)

CNDR1

(9P)

CNDC1

(4P)

321476589

121110 13 14

3 2 1

CN52CAC

(3P)

CNFAN

(3P)

CNTH

(2P)

CNL2

(2P)

2121

CNFG

(2P)

- 15 -

Page 22

• Cooling Outdoor unit

Items

PUHY-P200YREM-A

PUHY-P250YREM-A

Indoor Outdoor Quantity Quantity in operation Model Main pipe Branch pipe Total piping length

27.0/19.0 27.0/19.0

35.0/24.0 35.0/24.0 4 4

4 4

71 63 50 20 100 71 63 20

10 10 10 10 10 10 10 10

45 45

Hi Hi Hi Hi Hi Hi Hi Hi

11.7 11.7

270 420 360 250 360 270 420 250

122 200

1 272

2.00/0.55 2.08/0.54

81 80 42 44 16 16 17 17 20 20

55 44 44 20 22 13 13 20 20 14 14

0.23 0.23

10.6 9.7 14.4 13.2 380 415 380 415

Indoor unit fan notch Refrigerant volume Total current Volts Indoor unit SC (LEV1) Oil back (SLEV)

High pressure/Low pressure (after O/S) (before Accumulator)

Pressure

DB/WB

Set

–

A V

Pulse

MPa

˚C

Condition

Sectional temperature

Outdoor unit

LEV opening

Inlet Outlet

Outdoor unit

Indoor unit

Ambient temp.

Indoor unit

Piping

Discharge (TH1) Heat exchanger outlet (TH5)

Accumulator

Suction (Comp) CS circuit (TH2) Shell bottom (Comp) SCC outlet (TH7) Bypass outlet (TH8) LEV inlet Heat exchanger outlet

[4] Standard Operating Data

1 PUHY-P200·250YREM-A

- 16 -

Page 23

Outdoor unit

Items

PUHY-P200YREM-A PUHY-P250YREM-A

Indoor Outdoor Quantity Quantity in operation Model Main pipe Branch pipe Total piping length

20.0/– 20.0/–

7.0/6.0 7.0/6.0 44 44

71 63 50 20 100 71 63 20

10 10 10 10 10 10 10 10

45 45

Hi Hi Hi Hi Hi Hi Hi Hi

11.7 11.7

290 470 410 250 330 290 470 250

123

200

2.10/0.43 2.10/0.38

73 80

0 –2 20 20

42 –4 –6 33 33

34 34

60 60

0.28 0.28

11.4 10.5 15.1 13.8 380 415 380 415

Indoor unit fan notch Refrigerant volume Total current V

olts Indoor unit SC (LEV1) Oil back (SLEV)

High pressure/Low pressure (after O/S) (before Accumulator)

Pressure

DB/WB

Set

–

A V

Pulse

MPa

˚C

Condition

Sectional temperature

Outdoor unit

LEV opening

Discharge (TH1) Heat exchanger inlet (TH5)

Accumulator

Suction (Comp) CS circuit (TH2) Shell bottom (Comp)

Heat exchanger outlet

Heat exchanger inlet

Inlet Outlet

Outdoor unit

Indoor unit

Ambient temp.

Indoor unit

Piping

• Heating

- 17 -

Page 24

1 PUHY-P200·250YREM-A

Switch Function

Function according to switch operation Switch set timing

When off When on When off When on

SWU

SW1

SW2

SW3

SW4

1~2

1~8

9~10

4 5

5 6

8 9

Unit address setting Refrigerant model

For self diagnosis/ operation monitoring

–

Centralized control switch

Deletion of connection information.

Deletion of error history.

Refrigerant amount adjustments

– Disregard ambient air sensor errors, liquid overflow errors. Forced defrosting

Defrost prohibited timer

–

– SW3-2 Function valid/ invalid Indoor unit test operation

Defrosting start temperature of TH Defrosting end temperature of TH5. Opening angle of IC except when heater thermostat is ON during defrosting.

– Pump down

Target Tc (High pressure) in Heating

–

Models

Models SW4-2 Function valid/

invalid Configuration compensation value

–

Set on 51~100 with the dial switch.

LED Monitering Displa

See Note2.

R407C R22

– Centralized control not connected. Storing of refrigeration system connection information.

–

Ordinary control

– Errors valid.

Ordinary control

39 min.

–

– SW3-2 Function invalid

Stop all indoor units.

(no operation)

–

Ordinary control

49˚C

–

Invalid

–

– Centralized control connected. Deletion of refrigeration system connection information. Deletion

Adjustment operation

– Disregard errors.

Start forced defrosting.

90 min.

–

– SW3-2 Function valid

All indoor units test operation ON.

–7˚C

For 2 minutes.For 2 minutes.

2000

–

Pump down

53˚C

–

Valid

–

Before power is turned on.

During normal operation when power is on. Should be set on OFF. Before power is turned on.

Before power is turned on.

During normal operation when power is on.

During normal operation when power is on (only when switching from OFF/ON)

– During normal operation when power is on.

During normal operation when power is on. (Except during defrosting)

–

– During normal operation when power is on. When SW3-1 is ON after power is turned on. During normal operation when power is on. During normal operation when power is on. (Except during defrosting)

– During normal operation (only when switching from OFF/ON) During normal operation when power is on.

–

– Before power is turned on. During normal operation when power is on. When SW4-1 is ON.

–

––– – ––– – ––

– –

––

Night mode/Step demand

SWU3

R407C

Exist

R407C

Different unit model error

(7130)

Not exist

Different unit model error

(7130)

R22

TH2

Night mode

Step demand

During normal operation when power is on.

– –

–– –

–

– –

During normal operation when power is on.

10 minutes or more after compressor starts.

Note 1

Note 2

• SWU1~2=00 when shipped from the factory. Other factory settings are indicated by shaded portions.

• If the address is set from 01 to 50, it automatically becomes 100.

•

The refrigerant model is recognized with SW3 and TH2.

Changes as shown below by on off change 0% 3%

6% 9% 12% –6% –3% 0%

4 5 6 7 8 9

[5] Function of Dip SW and Rotary SW

(1) Outdoor unit

Before power is turned on.

SW3-9

OFF

P200YREM-A–P250YREM-A

–

SW3-10

10˚C 15˚C

– 10˚C

- 18 -

Page 25

(2) Indoor unit

DIP SW1, 3

Model P71 P80 P100 P125 P140 P200 P250 Capacity (model name) code

14 16 20 25 28 40 50

SW2 setting

Model P20 P25 P32 P40 P50 P63 Capacity (model name) code

45 681013

SW2 setting

OFF

Note 1: The shaded part indicates the setting at factory shipment. (For the SW not being shaded, refer to the

2: When both SW1-7 and SW1-8 are being set to ON, the fan stops at the heating thermostat of OFF.

table belo

Note 3: The DipSW setting is only effective during unit stopping (remote controller OFF) for SW1,2,3 and 4 commonly

and the power source is not required reset.

w.)

Setting of DIP SW2

Indoor unit inlet

None

100h

Ineffective Fan output display At stationary heating

Very low speed

SW1-7 setting

Ineffective

Heat pump

None

None None

1st setting

Down blow B, C

Effective

–

Effective

– –

Built in remote controller

Provided

2500h

Effective

Thermo. ON signal display

Always at heat.

Low speed

Set airflow

Effective

Cool.only

Provided

Provided Provided

2nd setting

Horizontal

–

Ineffective

– –

Room temp. sensor position Clogged filter detect. Filter duration OA intake Remote display select. Humidifier control Heating thermo. OFF airflow Heating thermo. OFF airflow Power failure automatic

return Power source start/stop Model selection

Louver

Vane Vane swing function Vane horizontal angle V Vane first angle

ane angle set for cooling

–

Heating 4deg up

– –

Alw

PLFY-VLMD-B only

ays ineffective for PKFY-P.VAM

Not provided for PKFY-P.VAM Provided for PLFY-P.VGM (ON) setting

Always down blow B,C for PKFY-P.VAM Horizontal (ON) setting for PLFY-P. VLMD-A

Ineffective (ON) setting for floor standing

SW1

SW3

1 2 3 4 5 6 7 8

3 4 5

7 8 9

Switch SW name

Operation by SW

Switch set timing

OFF ON OFF ON

Remarks

At unit stopping

(at remote

controller OFF)

Cooling capacity saving for PKFY-P. VAM, effective/ineffective

Model

Switch

SW1

SW3

3 6 7 3 4 6 8

PLFY-P

VAM-A(2)

OFF OFF

VLMD-B

VKM-A

OFF

OFFONON

PEFY-P

VML-A VMH-A

20~80VMM-A

100~140VMM-A

OFF

OFF ON

OFF OFF

OFF

ON OFF

ON OFF ON

OFF

PDFY-P PFFY-P PCFY-P PKFY-P

VM-A

VLRM-A, VLEM-A

OFF

VGM-A

PMFY-P

VBM-A

V AM-A VGM-A

OFF OFF

OFF

- 19 -

OFF

Page 26

Ceiling height 3 3.5 m 2 2.8 m 1 2.3 m

Switch Function Operation by switch Switch set timing

SWA

SWB

SWC

Ceiling height setting

External static pressure setting

For options

Setting of air outlet opening

Airflow control

(PLFY-P-VKM-A) (PCFY-P-VGM-A)

(PLFY-P125VLMD-B)

(PLFY-P-VKM-A)

(PLFY-P-VKM-A, PCFY-P-VGM-A, PKFY-P-VGM-A, PDFY-P-VM-A)

❇

The ceiling height is changed by SWB setting.

❇

As this switch is used by interlocking with SWC, refer to the item of SWC for detail.

SWA

SWB

123

2-way 3.5 m 3.8 m 3.8 m 3-way 3.0 m 3.3 m 3.5 m 4-way 2.7 m 3.0 m 3.5 m

❇

Set to the option to install the high efficiency filter

Always after powering

2-way

4-way

3-way

Option

Standard

(PDFY-P20 ~ 80VM-A, PEFY-P20 ~ 80VMM-A)

100Pa

50Pa 30Pa

❇

For other models, change the setting of static pressure by replacing the connector.

Setting of DIP SW4 Setting of DIP SW5

12345

ON OFF ON OFF

OFF

OFF OFF ON

ON OFF OFF

OFF

OFF ON OFF ON OFF

OFF

OFF ON ON

–

– –

–

––

–

–––

– – – –

– –

ON ON

OFF OFF

OFF

OFF OFF OFF

–

ON ON ON

–

OFF OFF OFF

–

ON OFF OFF

–

OFF OFF ON

–

ON ON ON OFF

PMFY-P-VBM-A PLFY-P125VLMD-B PDFY-P20 ~ 80VM-A PLFY-P40 ~ 63VKM-A PLFY-P80 ~ 125VAM-A(2) PCFY-P-VGM-A PKFY-P-VGM-A PKFY-P-VAM-A PEFY PLFY-P20~100VLMD-B

-P20 ~ 80VMM-A

PFFY-P-VLEM-A, P-VLRM-A PEFY-P20 ~ 32VML-A PEFY-P40 ~ 140VMH-A PEHY-P200·250VMH-A

PDFY-P100·125VM-A PEFY-P100 ~ 140VMM-A

Model Circuit board used

SW4

Phase control

Relay selection

220V 240V

- 20 -

Page 27

£ TEST RUN

[1] Before Test Run

(1) Check points before test run

1 Neither refrigerant leak nor loose power source/ transmission lines should be found.

2 Confirm that the resistance between the power source terminal block and the ground exceeds 2MΩ by measur-

ing it with a DC500V megger. Do not run if it is lower than 2MΩ. Note) Never apply the megger to the MAIN board. If applied, the MAIN board will be broken.

3 Confirm that the Ball valve at both gas and liquid sides is being fully opened.

Note) Certainly close the cap.

45Be sure that the cr

Prior to Ver.E

The number of indoor units and the total number of remote controllers id displayed within the parenthesis ( ).

16 (32) 16 (32)

200 or lower

200 or higher

After Ver.F

20 (40) 16 (32)

(

❇

1) Capability of the connected indoor units

Number of connected indoor units that

can be connected without a RP.

Remote controller type

Remote controller PAR-F25MA

ankcase heater has been powered by turning the main power source on at least 12 hours

before starting the test run. The shorter powering time causes compressor trouble.

(2) Caution at inverter check

Because the inverter power portion in outdoor unit electrical part box have a lot of high voltage portion, be sure to follow the instructions shown below.

During energizing power source, never touch inverter power portion because high voltage (approx. 580V) is applied to inverter power portion.

When checking,

Shut off main power source, and check it with tester, etc.

Allow 10 minutes after shutting off main power source.

Open the MAIN board mounting panel, and check whether voltage of both ends of electrolytic capacitor is 20V or less.

If any of the power supply wires (L1, L2, L3, N, ) are mistakenly connected, it is possible to damage the unit. Please exercise caution.

A transmission booster (RP) is required when the number of connected indoor unit models in a cooling system exceeds the number of models specified in the chart below. Note: The maximum number of units that can be controlled is determined by the indoor unit model, the type of

remote controller and their capabilities.

(

❇

1) If even one unit that is higher than 200 exists in the cooling system, the maximum capacity will be “200 or higher”.

❇

Please refer to the installation manual for more details.

❇

Before turning power on to the outdoor unit, first turn on the transmission booster. (If the outdoor unit are mistakenly

turned on first, turn on the transmission booster and then reset the outdoor unit power.)

- 21 -

Page 28

(3) Check points for test run when mounting options

(4) Attention for mounting drain water lifting-up mechanism

Check point

Local remote controller displays code No. “2503”, and the mechanism stops.

No overflow from drain pan. Drain water comes out by operations of

drain pump. Sound of pump operations is heard, and

drain water comes out. No water leakage from connecting

portions of water piping. Water is supplied to water supply tank,

and float switch is operating.

Built-in optional parts Mounting of drain

water removing mechanism

Mounting of permeable film humidifier

Content of test run

Release connector of pump circuit, check error detection by pouring water into drain pan water inlet.

After that, connect connector of circuit.

Check pump operations and drainage status in cooling (test run) mode.

Check humidifier operations and water supply status in heating (test run) mode.

Result

Work

Disassembling and assembling of drain water removing mechanism

Mounting of float switch

Electric wiring

Float switch moves smoothly. Float switch is mounted on

mounting board straigh and

without deformation.

Float switch has no contact with

copper pipe. Wiring procedure is exactly followed. Connector portion is tightly hooked.

Content of test run

Lead wire from the control box is not damaged.

Rubber cap is properly inserted into drain water outlet of the drain pan?

Insulation of gas and liquid pipe is dealt with as shown in the right figure?

Drain pan and piping cover are mounted without gap?

Drain pan hooked on cut projection of the mechanism?

Float switch is installed without contacting the drain pan?

No mistakes in wiring? Connectors connected securely and

tightly? No tension on lead wire when sliding

on control box?

1 2

Check point Result

Insulation pipe

No gap

- 22 -

Page 29

- 23 -

(5) Check points for system structure

ex. PUHY-P200YREM-A

Check points from installation work to test run.

Trouble

Not operate.

Not cool (at cooling). Not heat (at heating).

Not cool, not heat, error stop. Condensation drip in piping. Not cool, not heat, error stop.

Water leak, condensation drip in drain piping.

Error stop, not operate.

Electric shock. Error stop, not operate. Some electric parts should be damaged.

Classification

Installation and piping

Power source wiring

Portion

Check item

Instruction for selecting combination of outdoor unit, and indoor unit followed? (Maximum number of indoor units which can be connected, connecting model name, and total capacity.)

Follow limitation of refrigerant piping length? For example, 80m or less (total length : 240m) at the farthest.

Connecting piping size of branch piping correct? Refrigerant piping diameter correct? Refrigerant leak generated at connection? Insulation work for piping properly done? Specified amount of refrigerant replenished?

Pitch and insulation work for drain piping properly done? Specified switch capacity and wiring diameter of main

power source used?

Proper grounding work done on outdoor unit? The phases of the L line (L1, L2, L3) correct? L line and N line connected correct?

Page 30

Classification Transmission

line

Portion Check item

Limitation of transmission line length followed? For example, 200m or less (total length : 500m) at the farthest.

™ 1.25mm2 or more transmission line used?

(Remote controller 10m or less 0.75mm

)

£ 2-core cable used for transmission line?

Transmission line apar t from power source line by 5cm or more?

∞ One refrigerant system per transmission line?

The short circuit connector is changed form CN41 to CN40 on the MAIN board when the system is centralized control? (Just one outdoor unit. Not all outdoor units.)

¶ • No connection trouble in transmission line?

• Connection of wrong remote controller line terminals?

• MA Remote controller : TB15

• M-NET Remote controller : TB5

Trouble

Erroneous operation, error stop.

Error stop in case multiple-core cable is used.

Erroneous operation, error stop. Not operate. Not operate.

Error stop or not operate. Never finish the initial mode.

System set

Before starting

Error stop or not operate.

Can not be properly set with power source turned on.

Not operate. Set temperature not obtained at

heating operations (Thermostat stop is difficult)

Error stop.

Error stop, compressor trouble.

2 3

Address setting properly done? (M-NET Remote controller, indoor unit and outdoor unit.)

Setting of address No. done when shutting off power source?

Address numbers not duplicated? Turned on SW3-8 on indoor unit circuit board when

mounting room thermistor sensor?

Refrigerant piping ball valve (Liquid pressure pipe, gas pressure pipe) opened?

Turn on power source 12 hours before starting operations?

STAND BY DEFROST

ERROR CODE

D A I L Y

AUTO OFF

CENTRALLY CONTROLLED

CLOCK

REMAINDER

ON OFF

˚C

1Hr.

NOT AVAILABLE

˚C

CHECK MODE

FILTER

CHECK

TEST RUN

LIMIT TEMP.

ON/OFF

TEMP

FILTER

CHECK TEST

ON OFF

CLOCK

PAR-F27MEA

TIMER SET

2 31

Breakers

for Current

Leakage

Switch

- 24 -

1Hr.

˚C

ON OFF

CLOCK

REMAINDER

ERROR CODE

˚C

ON OFF

CLOCK

NOT AVAILABLE

CHECK MODE

LIMIT TEMP.

ON/OFF

FILTER

TEST RUN

FILTER

CHECK TEST

PAR-F27MEA

STAND BY DEFROST

CENTRALLY CONTROLLED

D A I L Y

AUTO OFF

CHECK

TEMP

TIMER SET

Page 31

[2] Test Run Method

Operation procedure

Turn on universal power supply at least 12 hours before getting started Displaying “HO” on display panel for about two minutes.

2 Press

TEST RUN

button twice Displaying “TEST RUN’’ on display panel.

3 Press

selection button Make sure that air is blowing out.

Press

select button to change from cooling to heating operation, and vice versa Make sure that

warm or cold air is blowing out.

5 Press

adjust button Make sure that air blow is changed.

6 Press

or button to change wind Make sure that horizontal or downward blow is adjustable.

7 Make sure that indoor unit fans operate normally. 8 Make sure that interlocking devices such as ventilator operate normally if any.

9 Press

ON/OFF

button to cancel test run Stop operation.

Note 1: If check code is displayed on remote controller or remote controller does not operate normally.

2: Test run automatically stops operating after two hours by activation of timer set to two hours. 3: During test run, test run remaining time is displayed on time display section. 4: During test run, temperature of liquid pipe in indoor unit is displayed on remote controller room temperature

display section.

5: When pressing

adjust button, depending on the model, “NOT AVAILABLE” may be displayed on remote

controller. However, it is not a malfunction.

6: When pressing

or button, depending on the model, “NOT AVAILABLE” may be displayed on

remote controller. However, it is not a malfunction.

- 25 -

Page 32

GROUPING REGISTRATION OF INDOOR UNITS WITH M-NET REMOTE CONTROLLER

(1) Switch function

• The switch operation to register with the remote controller is shown below:

Registration/ ordinary mode selector switch

Registration/ordinar mode selection switch

Switch to assign indoor unit address

Registration switch

Confirmation switch

Delete switch

Registered mode selector switch

Switch to assign interlocked unit address

A + B

This switch selects the ordinary mode or registered mode (ordinary mode represents that to operate indoor units).

❇

To select the registered mode, press the

FILTER

switch continuously for over 2 seconds under stopping state. [Note] The registered mode can not be obtained for a while after powering. Pressing the

FILTER

switch displays “CENTRALLY

CONTROLLED”. This switch assigns the unit address for “INDOOR UNIT ADDRESS

NO.”

This switch is used for group/interlocked registration.

This switch is used to retrieve/identify the content of g roup and

interkloced (connection information) registered.

This switch is used to retrieve/identify the content of group and interlocked (connection information) registered.

This switch selects the case to register indoor units as group (group setting mode) or that as interlocked (interlocked setting mode).

❇

The unit address is shown at one spot for the group setting mode while at two spots for the interlocked setting mode.

This switch assigns the unit address of “OA UNIT ADDRESS NO.”

Symbol

of switch

G Registered mode

selector switch

E Confirmation switch

C Switch to assign

indoor unit address

H Switch to assign inter-

locked unit address

D Registration switch

FILTER

TEST RUN

Name Name of actual switch Description

of TEMP

of TIMER SET

CLOCK ON OFF

Registration/ ordinary mode selector switch

STAND BY DEFROST

ERROR CODE

D A I L Y

AUTO OFF

CENTRALLY CONTROLLED

CLOCK

REMAINDER

ON OFF

˚C

1Hr

NOT AVAILABLE

˚C

CHECK MODE

FILTER

CHECK

TEST RUN

LIMIT TEMP.

ON/OFF

TEMP

FILTER

CHECK TEST

ON OFF

CLOCK

PAR-F27MEA

TIMER SET

F Delete switch

- 26 -

Page 33

(2) Attribute display of unit

• At the group registration and the confirmation/deletion of registration/connection information, the type (attribute) of the unit is displayed with two English characters.

Display Type (Attribute) of unit/controller

Indoor unit connectable to remote controller Outdoor unit

Local remote controller System controller (MJ)

[Description of registration/deletion/retrieval]

• The items of operation to be performed by the remote controller are given below. Please see the relating paragraph for detail.

¡ Group registration of indoor unit

• The group of the indoor units and operating remote controller is registered.

• It is usually used for the group operation of indoor units with different refrigerant system.

™ Retrieval/identification of group registration information of indoor units

• The address of the registered indoor units in group is retrieved (identified).

£ Retrieval/identification of registration information

• The connection information of any unit (indoor/outdoor units, remote controller or the like) is retrieved (identified).

¢ Deletion of group registration information of indoor units

• The registration of the indoor units under group registration is released (deleted).

∞ Deletion of the address not existing

• This operation is to be conducted when “6607” error (No ACK error) is displayed on the remote controller caused by the miss setting at test run, or due to the old memory remained at the alteration/modification of the group composition.

Caution:

When MELANS (MJ-103MTRA for example) is being connected, do not conduct the group/pair registration using the remote controller. The group/pair registration should be conducted by MELANS. (For detail, refer to the instruc-. tion exclusively prepared for MELANS.)

OA Processing Lossnay

- 27 -

Page 34

(3) Group registration of indoor unit

1) Registration method

• Group registration of indoor unit ........................................................................ ¡

The indoor unit to be controlled by a remote controller is registered on the remote controller.

[Registration procedure]

1 With the remote controller under stopping or at the display of “HO”, continuously press the + switch

FILTER

( A + B ) at the same time for 2 seconds to change to the registration mode. (See the figure below.)

2 Assign the indoor unit address to “INDOOR UNIT ADDRESS NO.” by operating the (Room temperature

adjustment) (C). Then press the switch (D) to register. In the figure below, the “INDOOR UNIT ADDRESS NO.” is being set

TEST RUN

to 001.

3 After completing the registration, press the + switch (A +B) at the same time for 2 seconds to

FILTER

change to the original ordinary mode (with the remote controller under stopping).

• Remote controller under stopping • “HO” under displaying

Ordinary mode

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

ERROR CODE OA UNIT ADDRESS NO

˚C

Group setting mode

• Confirm the indoor unit address No.

• Confirm the connection of the transmission line.

ERROR CODE OA UNIT ADDRESS NO

˚C

ERROR CODE OA UNIT ADDRESS NO

˚C

• Registration complete

• Registration error

Indicates the type of unit (Indoor unit in this case)

“88” flickers indicating registration error. (when the indoor unit. registered is not existing)

2 Assign the

address (C)

1 Change to the

registration mode (A + B)

3 Press the

registration switch (D)

Remote controller

Indoor units

Group

2 + 3

ON/OFF

TEMP

FILTER

CHECK TEST

ON OFF

CLOCK

PAR-F27MEA

TIMER SET

System example

- 28 -

Page 35

2) Method of retrieval/confirmation

• Retrieval/confirmation of group registration information on indoor unit ............... ™

The address of the indoor unit being registered on the remote controller is displayed.

[Operation procedure]

1 With the remote controller under stopping or at the display of “HO”, continuously press the

FILTER

+ switch (A

+ B) at the same time for 2 seconds to change to the registration mode.

2 In order to confirm the indoor unit address already registered, press

switch (E). (See figure below.) When the group

of plural sets is registered, the addresses will be displayed in order at each pressing of

switch (E).

3 After completing the registration, continuously press the

FILTER

+ switch (A + B) at the same time for 2

seconds to change to the original ordinary mode (with the remote controller under stopping).

• Retrieval/confirmation of registration information ................................................ £

The registered information on a certain unit (indoor unit, outdoor unit, remote controller or the like) is displayed.

[Operation procedure]

1 With the remote controller under stopping or at the display of “HO”, continuously press the

FILTER

+ switch (A

+ B) at the same time for 2 seconds to change to the registration mode.

2 Operate

switch (G) for the interlocked setting mode. (See figure below.)

3 Assign the unit address of which registration information is desired to confirm with the

(TIMER SET) switch (H). Then press the switch (E) to display it on the remote controller. (See figure below.) Each pressing of

switch (E) changes the display of registered content. (See figure below.)

4 After completing the retrieval/confirmation, continuously press the

FILTER

+ switch (A + B) at the same time

for 2 seconds to change to the original ordinary mode (with the remote controller under stopping).

• Registered

• No registration.

ERROR CODE OA UNIT ADDRESS NO

˚C

ERROR CODE OA UNIT ADDRESS NO

˚C

1 Press the switch for confirmation (E)

Note: Only one address will be displayed

when the registration is one even the switch is how often pressed.

Indicates the type of unit (Indoor unit in this case)

ON/OFF

TEMP

FILTER

CHECK TEST

ON OFF

CLOCK

PAR-F27MEA

TIMER SET

- 29 -

Page 36

3) Method of deletion

• Deletion of group registration information of indoor unit ...................................... ¢

[Operation procedure]

1 With the remote controller under stopping or at the display of “HO”, continuously press the

FILTER

switch (A + B) at the same time for 2 seconds to change to the registration mode..

2 Press the

switch (E) to display the indoor unit address registered. (As same as ™)

3 In order to delete the registered indoor unit being displayed on the remote controller, press the

CLOCK ON OFF

(F) switch

two times continuously. At completion of the deletion, the attribute display section will be shown as “– – ”.

(See figure below.) Note: Completing the deletion of all indoor units registered on the remote controller returns to “HO” display.

4 After completing the registration, continuously press the

FILTER

+ switch (A + B) at the same time for 2

seconds to change to the original ordinary mode (with the remote controller under stopping).

ERROR CODE OA UNIT ADDRESS NO

˚C

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

1 Set the address

2 Press the switch for

confirmation (E)

• Registered

• No registration

❇

Same display will appear when the unit of “007” is not existing.

1 Press the switch for confirmation ( F)

twice continuously.

• Deletion completed

In case group registration with other indoor unit is existing

In case no group registration with other indoor unit is existing

1 + 2

“– –” indicates the deletion completed.

˚C

(Alternative

display)

˚C

(Alternative

display)

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

ON/OFF

TEMP

FILTER

CHECK TEST

ON OFF

CLOCK

PAR-F27MEA

TIMER SET

ON/OFF

TEMP

FILTER

CHECK TEST

ON OFF

CLOCK

PAR-F27MEA

TIMER SET

- 30 -

Page 37

4) Deletion of information on address not existing

• Deletion of information on address not existing ................................................... ∞

This operation is to be conducted when “6607” error (No ACK error) is displayed on the remote controller caused by the miss setting at test run, or due to the old memory remained at the alteration/modification of group composition, and the address not existing will be deleted. Note: The connection information (connection between indoor unit and outdoor unit) on the refrigerant system can

not be deleted. An example to delete the system controller of “250” from the indoor unit of “007” is shown below.

[Operation procedure]

1 With the remote controller under stopping or at the display of “HO”, continuously press the

FILTER

+ switch (A

+ B) at the same time for 2 seconds to change to the registration mode.

2 Oper

ate

switch (G) for the interlocked setting mode ( ii ). (See the figure below.)

3 Assign the unit address existing to “OA UNIT ADDRESS No.” with the

(TIMER SET) switch (H), and press switch (E) to call the address to be deleted. (See the figure below.) As the error display on the remote controller is usually transmitted from the indoor unit, “OA UNIT ADDRESS No.” is used as the address of the indoor unit.

4 Press the

CLOCK ON OFF

switch (F) twice. (See the figure below.)

5 After completing the deletion, continuously press the

FILTER

+ switch (A + B) at the same time for 2 seconds

to return to the original ordinary mode (with the remote controller under stopping).

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

(Alternative

display)

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

(Alternative

display)

❇

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

INDOOR UNIT ADDRESS NO

ERROR CODE OA UNIT ADDRESS NO

˚C

(Alternative

display)

❇

When both indoor unit and interlocked unit addresses are existing

Deletion of address not existing

1 Set the address (H)

3 Press the deletion switch (F) twice

• Deletion completed

1 + 2

2 Press the switch for

confirmation (E)

ON/OFF

TEMP

FILTER

CHECK TEST

ON OFF

CLOCK

PAR-F27MEA

TIMER SET

- 31 -

Page 38

∞ CONTROL

[1] Control of Outdoor Unit

(1) Initial processing

• When turning on power source, initial processing of microcomputer is given top priority.

• During initial processing, control processing corresponding to operation signal is suspended. The control processing is resumed after initial processing is completed. (Initial processing : Data processing in microcomputer and initial setting of each LEV opening, requiring approx. 2 minutes at the maximum.)

(2) Control at staring

• For 3 minutes after starting, 60Hz is the upper frequency limit.

(3) Bypass, capacity control

• Solenoid valve consists of bypass solenoid valve (SV1, SV2) bypassing between high pressure side and low pressure sider. The following operation will be provided.

1) Bypass solenoid valves SV1 and SV2 (both “open” when turned on)

Item

When starting compressor After thermost “ON is returned

and after 3 minutes restart When compressor stops in

cooling or heating mode After operation stops

During defrosting operations During oil recovery opera-

tions During 20Hz operations, at

fall in low pressure or low pressure saturation temperature. (3 minutes or more after starting)

When high pressure rises (Pd)

When high pressure rises (Pd) during 20Hz operations (3 minutes after starting)

When discharge temperature rises (3 minutes after starting)

SV1

ON (Open) OFF (Close)

–

When Pd reaches

2.70MPa or more

When Pd is 2.35MPa or less 30 seconds

SV2

ON (Open) OFF (Close)

–

Turned on when high pressure (Pd) exceeds pressure limit

When discharge temp. is 100°C or less

Compressor

Bypass solenoid valve (SV1)

(4-minute)

(2-minute) (8-minute) (3-minute)

Start

Thermo. OFF

Thermo. ON

Defrosting time

(

❇

Stop

Turned on for 2 minutes Turned on for 2 minutes

Turned on for 4 minutes

Always turned on or until HPS and LPS is within 0.2MPa.

Turned on for 3 minutes or until HPS and LPS is within 0.2 MPa

Always turned on

Cooling operation normally OFF and heating operation normally ON when performing oil recovery after continuous operation at low frequency.

Turned on for 4 minutes

Always turned on

When Ps is 0.15MPa or less

When Ps is 0.25MPa or more

When Pd reaches

2.50MPa or more

When Pd is 2.25MPa or less after 30 seconds

When high pressure (Pd) is 1.96MPa or less

When temp. exceeds 115°C and Pb reaches

1.47MPa or more

- 32 -

Page 39

(4) Frequency control

• Depending on capacity required, capacity control change and frequency change are performed to keep constant evaporation temperature in cooling operations, and high pressure saturation temperature in heating operation.

• Frequency change is performed at the rate of 3Hz/second as follows.

1) Frequency control starting

• 60Hz is the upper limit for 3 minutes after starting.

2) Pressure control

3) Discharge temperature control Discharge temperature (Td) of compressor is detected during operation. If the upper limit is exceeded, the frequency is reduced. (Change rate : 5Hz of the present value)

• 30 seconds after starting compressor, control is performed every minute.

• Operation temperature is 110˚C : Td.

4) Periodical frequency control Frequency controll is periodically performed except for the frequency controls at operation start, status change, and protection.

1 Cycle of periodical frequency control

Periodical frequency control is performed every minute after the time specified below has passed.

• 60 sec after star

• 30 sec after frequency control by discharge temperature or pressure limit

2 Amount of frequency change

The amount of frequency change is controlled corresponding to evaporation temperature and high pressure saturation temperature.

3-1 Back up of frequency control by bypass valve

During low frequency operation, frequency is backed up by turning on (opening) bypass valve (SV1).

• Cooling 3 minutes after starting compressor, bypass valve is turned on when Discharge Pressure(Pd) is higher than

2.5 MPa, and turned off when Pd is less than 2.25MPa.

• Heating During low frequency operation,3 minutes after starting compressor, SV1 turned on when high pressure (Pd) exceeds pressure limit of 2.5MPa and turned off when Pd falls to 2.25MPa

or less .

ON OFF

2.25MPa 2.5MPa

The upper limit value for the high pressure (Pd) has been set for each frequency, when this value is exceeded, the frequency is reduced every 30 seconds.

ting compressor or 30 seconds after finishing defrostoing operations

Cooling Heating

Unit Minimum

❇

20Hz

...

TH6

20°C or TdSH

10deg.

❇

28Hz

...

TH6

20°C and TdSH

10deg.

Maximum

Unit Minimum Maximum

P200YREM-A 20Hz (28Hz) P200YREM-A 20Hz

61Hz

74Hz

66Hz

P250YREM-A 20Hz (28Hz) 79Hz

P250YREM-A 20Hz

100Hz

86Hz

3°C5°C

Pressure limit

Compressor Frequency (Hz)

2.65MPa

2.45MPa

Max

- 33 -

Page 40

(6) Subcool coil control (electronic expansion valve <LEV1>)

• The amount of super heat detected from the bypass outlet temperature of subcool coil (TH8) is controlled to be within a certain range for each 30 seconds.

• The opening angle is corrected and controlled depending on the outlet/inlet temperature of subcool coil (TH5, TH7) and the discharge temperature.

• However, the valve will be closed (0) at heating and compressor stopping.

• It will fully open during defrosting.

(7) Defrost operation control

1) Starting of defrost operations

•

After integrated 39 minutes : The compressor operations, defrosting operations start when – 10˚C(R407C),

– 6˚C (R22) piping temperature (TH5) is detected for 3 consecutive minutes.

• Forcible defrosting operations start by turning on forcible defrost switch (SW2-7) if 10 minutes have already elapsed after compressor star

• Defrost prohibit timer

Defrost will last a maximum of 15 minutes. Then next defrost time will be 39 minutes.

Minimum consecutive running minutes to defrost can be increaced from 39 minutes to 90 minutes by setting SW2-8 “ON”.

t or completion of defrosting operations and will last for 10 minutes.

2) Completion of defrosting operations Defrosting operations stop when 10 minutes : It has passed since start of defrosting operation, or piping temperature (TH5) reaches 10˚C or more. (Defrosting operations do not stop for 2 minutes after starting, except when piping temperature exceeds 25˚C.)

3) Defrosting prohibition Defrosting operations do not start during oil recovery, and for 10 minutes after starting compressor.

4) Trouble during defrosting operations When trouble is detected during defrosting operations, the defrosting operations stop, and defrosting prohibition time decided by integrated operation time of compressor is set to be 20 minutes.

5) Change in number of operating indoor units during defrosting operations

• In case number of operating indoor units changes during defrosting operations, the defrosting operations continue,

and control of unit number change is performed after the defrosting operations are finished.

• Even in case all indoor units stop or thermostat is turned off during defrosting operations, the defrosting operations

do not stop until expected defrosting activities are completed.

(5) Oil return control (Electronic expansion valve <SLEV>)

• Oil return LEV (SLEV) opening is dependent on compressor frequency and ambient temperature.

• SLEV is closed (0) when compressor stops, and SLEV is set (64) for 10 minutes after starting compressor.

Note 12TH5 - Y-Series

TdSH=Discharge Super Heat.

TdSH 40<TdSH 35<TdSH<40 20<TdSH<35 10<TdSH<20 TdSH<10

15°C<TH5/TH7

AL=0 AL=0 AL=0 AL=1 AL=2

20~45Hz

AL=0 AL=1 AL=1 AL=1 AL=2

Compressor

Frequency

46~70Hz

AL=0 AL=0 AL=1 AL=1 AL=2

71Hz~Fmax

AL=0 AL=0 AL=0 AL=1 AL=2

TdSH 80<TdSH 60<TdSH<80 40<TdSH<60 10<TdSH<40 TdSH<10

TH5/TH7 5°C

AL=0 AL=1 AL=1 AL=1 AL=2

TH5/TH7

5°C<TH5/TH7

15°C

AL=0 AL=0 AL=1 AL=1 AL=2

(8) Judgment of Refrigerant amount Accumulator design

Cooling

Heating

=Td-Tsg ( low pressure saturation temperature)

- 34 -

Page 41

(9) Refrigerant Recovery Control

1) Start of Refrigerant recover in Heating Start of Refrigerant recover is Cooling

2) Refrigerant recovery operation in heating

3) Refrigerant recovery operating in cooling

• Refrigerant is recovered by opening LEV of the objective indoor units (indoor units under stop. fan, and cooling

Refrigerant is recovered by the opening of the indoor LEV further than the operation position for 30 seconds. Refrigerant Recovery Control

modes, and that with heating thermostat being turned off) for 15 seconds.

• The regular capacity control of the outdoor unit and the regular LEV control of the indoor unit are not applied

during refrigerant recovery operation, but are fixed with the value before the recovery operation. These controls will be conducted one minute after finishing the recovery operation.

• Defrosting operation is prohibited during the recovery operation, and it will be conducted after finishing the recov-

ery operation.

Starts

LEV opening before change

LEV opening at refrigerant recovery (Indoor unit LEV opening 500 pulse)

Finish

15 seconds

Refrigerant recovery is performed to prevent refrigerant from accumulating in the stopping unit, the unit under cooling mode and that with heating thermostat being turned off.

Refrigerant recovery is started when all of the items below are satisfied.

• 30 minutes has passed after finishing previous

refrigerant recovery and compressor frequency is greater then 60Hz or Td less than 105°C or 15 minutes has passed since previous recovery was performed and frequency is less than 60Hz and Td is greater than 105°C.

• 15 minutes has passed from starting the

compressor.

• A1 = 0 for 3 minutes.

Refrigerant recovery is started when all of the items below are satisfied.

• 30 minutes has passed after finishing previous refrigerant recovery.

• Al = 0 for 3 minutes.

• Td is greater than 105°C or Pd is greater than 2.45

HPa and SCO is greater than 10°C.

(10) Control of outdoor unit fan and outdoor unit heat exchanger capacity control

1) Control system Depending on capacity required, control outdoor fan flow rate with phase control, for maintaining evaporation temperature (0˚C) in cooling operations, and high pressure saturated temperature (49˚C) in heating operations.

2) Control

• Outdoor unit fan stops when compressor stops.

• Fan is in full operation for 5 seconds after starting.

• Outdoor unit f

• Lower the fan strength upper limit to approximately 50% when performing night mode settings.

an stops during defrosting operations.

- 35 -

Page 42

Four-way valve

Compressor

Accumulator

CS circuit

TH2

LPS

Heat e

(HPS)

xchanger

Outdoor heat exchanger

Indoor heat

exchanger

Flow control

valve

(11) Circulating composition sensor (CS circuit)

•

• The condensing temperature (Tc) and the evaporating temperature (Te) are calculated from OC, high

pressure (HPS), and low pressure (LPS).

• The compressor frequency , the outdoor fan, and others are controlled according to the codensing temperature (Tc) and the evaporating temperature (Te).

• CS circuit configuration (Outline drawing)

As shown in the drawing below; the CS circuit has the structure to bypass part of the gas discharged from the compressor through the capillary tube to the suction side of the compressor, exchange heat before and after the capillary tube,and produce two phase (gaseous and liquid) refrigerant at the capillary tube outlet. The dryness fraction of refrigerant at the capillary tube outlet is estimated from the temperature of low pressure two phase (gaseous and liquid) refrigerant at the capillary outlet (TH2) and the pressure (LPS) to calculate the composition of refrigerant circulating the refrigeration cycle (

OC). In this series the high-pressure liquid refrigerant temperature is calculated based on the high pressure and ambient air temperature values. It is found by utilizing the characteristic that the temperature of two phase (gaseous and liquid) R407C under a specified pressure changes according to the composition and dryness fraction (gas-liquid ratio in weight).

(12) Control at initial starting

• The following initial start mode will be performed when the unit is started for the first time after the power has been turned on.

Start of initial operation mode

Initial operation mode is finished.

Step 1

••The compressor operated at F≤38Hz.

–

Finished operating time reaches 5 minutes.

Step 2

••The compressor is operated at less than or equal

to F

60 Hz.

Operates continuously for 20 minutes and finishes.

- 36 -

Page 43

[2] Operation Flow Chart

(1) Outdoor unit

Note: 1 For about 2 minutes after turning on power source, address and group information of outdoor unit, indoor unit, and remote

controller are retrieved by remote controller, during which “HO” blinks on and off on remote controller. In case indoor unit is not grouped to remote controller, “HO” display on remote controller continues blinking even after 2 minutes after turning on power source.

Note: 2 Two trouble modes included indoor unit side trouble, and outdoor unit side trouble. In the case of indoor unit side trouble,

error stop is observed in outdoor unit only when all the indoor units are in trouble. However, if one or more indoor units are operating normally, outdoor unit shows only LED display without undergoing stop.

Note : 3 Operation mode conforms to mode command by indoor unit. However, when outdoor unit is in cooling operation, the

operation of indoor unit will be prohibited even by setting a part of indoor units under operation, or indoor unit under stopping or fan mode to heating mode. Reversely when outdoor unit in heating operation, the same condition will be commenced.

YES

Normal operations Trouble observed Stop

“HO” blinks on the remote controller

Oil return LEV, SC coil LEV fully closed

Variable capacity unit

1. 52C OFF

2. Inverter output 0 Hz

3. Outdoor fan Stop

4. All solenoid valve OFF

5. LEV1, SLEV full closed.

Breaker

turned on

Error code blinks on the outdoor controller board

Start

Set indoor

address No. to

remote controller

Operation command

Operation

mode

Error mode

52C ON

Operation

mode

Heating opera-

tions

Cooling opera-

tions

Operation mode command to indoor unit controller

Error stop

Error command to indoor unit

Note: 1

Note: 2

Cooling, Heating

Fan

Note: 3

Error code blinks on the remote controller

- 37 -

Page 44

(2) Indoor unit

Note: 1 At indoor unit LEV full closed, the opening angle indicates 41. Note: 2 The error code includes that of indoor unit and that of outdoor unit. In the former case, the indoor unit in question only

stops in error mode, while in the later case, all indoor units connected to the outdoor unit stop in error mode.

Note: 3 The operation mode follows the mode command from the indoor unit. However, when the outdoor unit in cooling operation,

the operation of the indoor unit will be prohibited even a part of indoor units or indoor unit under stopping or fan mode is put into heating mode. Reversily, when the outdoor unit is under heating operation, the same condition will be

commenced.

YES

Normal operations Trouble observed Stop

Start

Breaker

turned on

Operation SW

turned on

1. Protection function self-holding cancelled.

2. Indoor unit LEV full closed.

Remove controller display extinguished

3-minute drain

pupm ON

FAN stop

Drain pump

Error mode

Error stop

Error code blinks on the remote controller

Indoor unit LEV full closed

Error code blinks on the outdoor controller board

Operation mode

Heating

mode

Cooling

display

Cooling mode

Dry mode

Heating

display

Fan mode

Fan display

Dry display

Prohibition Prohibition

Heating operations

Cooling operations

Prohibition

Dry operation

Fan operations

Prohibition “Remote controller blinking”

Note: 3 Note: 3

Note: 1

Note: 2

Note: 1

Error command

to outdoor unit

- 38 -

Page 45

(3) Cooling operation

YES

1.Inverter output 0Hz

2.Indoor unit LEV, Subcool coil bypass LEV fully closed

3.Solenoid valve OFF

4.Outdoor unit fan stop

1.Inverter frequency control

2.Indoor unit LEV, control

3.Solenoid valve control

4.Outdoor unit fan control

Cooling operation

4-way valve OFF

Indoor unit fan

operations

Test run start

Thermostat ON

Normal operations Test run Stop

3-minute

restart

prevention

- 39 -

Page 46

YES

(4) Heating operation

Normal operations Defrosting operations Stop Test run

1.Indoor unit fan very low speed operations

2.Inverter output 0Hz

3.Indoor unit LEV

4.Solenoid valve OFF

5.Outdoor unit fan stop

52C off

1.Indoor and outdoor unit fan control

2.Inverter frequency control

3.Indoor unit LEV

4.Solenoid valve control

52C control

1.Indoor unit fan stop

2.Inverter defrost frequency control

3.Indoor unit LEV fully opened

4.Solenoid valve control

5.Outdoor unit fan stop

6.52C control

Heating operation

4-way valve ON

Defrosting

operation

Test run start

4-way valve OFF

Thermostat ON

3-minute

restart

prevention

Note : 1 When outdoor unit starts defrosting, it transmits defrost operations command to indoor unit, and the indoor unit starts

defrosting operations. Similarly when defrosting operation stops, indoor unit returns to heating operation after receiving defrost end command of outdoor unit.

Note : 1

- 40 -

Page 47

YES

(5) Dry operation

Normal operations Thermostat ON Stop

1.Indoor unit fan stop

2.Inverter output 0Hz

3.Indoor unit LEV

4.Solenoid valve OFF

5.Outdoor unit fan stop

6.52C off

1.Outdoor unit (Compressor) intermittent operations

2.Indoor unit fan intermittent operations (Synchronized with compressor : low speed, OFF operations)

Dry operations

4-way valve OFF

Inlet temp. 18˚C

Note : 2

Thermostat ON

Test run start

Note : 1

Note : 1 When indoor unit inlet temperature exceeds 18˚C, outdoor unit (compressor) and indoor unit fan start intermittent operations

synchronously. Operations of outdoor unit, indoor unit LEV and solenoid valve accompanying compressor are the same as those in cooling operations.

Note : 2 Thermostat is always kept on in test run, and indoor and outdoor unit intermittent operation (ON) time is a little longer than

normal operations.

- 41 -

Page 48

Low pressure shell scroll type with capacity control mechanism Winding resistance: Each phase 0.583Ω (20˚C)

Setting

2.94MPa OFF R120=7.465kΩ

B25/120=4057 Rt =

7.465exp{4057

( - )}

0=33kΩ

0/100=3965

Rt = 33exp{3965( - )}

-20˚C : 92kΩ

-10˚C : 55kΩ 0˚C : 33kΩ 10˚C : 20kΩ 20˚C : 13kΩ 30˚C : 8.2kΩ

R0=15kΩ B0/100=3460 Rt = 15exp{3460( - )}

0˚C : 15kΩ 10˚C : 9.7kΩ 20˚C : 6.4kΩ 25˚C : 5.3kΩ 30˚C : 4.3kΩ 40˚C : 3.1kΩ

[3] List of Major Component Functions

63HS

63LS

63H

TH1 (discharge)

TH2 (low pressure saturation temperature)

TH5 (piping temperature)

TH6 (outdoor air temperature)

TH7

TH8 (subcool coil bypass outlet temperature)

Compressor

High pressure sensor

Low pressure sensor

Pressure switch

Thermistor

Adjust refrigerant circulation by controlling operating frequency and capacity control valve with operating pressure.

1) High press. detection.

2) Frequency control and high pressure protection

1) Detects low pressure

2) Calculates the refrigerant circulation configuration.

3) Protects the low pressure

1) High pressure detection

2) High pressure protection

1) Discharge temperature detection

2) High pressure protection

20˚C : 250kΩ 70˚C : 34kΩ 30˚C : 160kΩ 80˚C : 24kΩ 40˚C : 104kΩ 90˚C : 17.5kΩ 50˚C: 70kΩ 100˚C : 13.0kΩ 60˚C: 48kΩ 110˚C : 9.8kΩ

1) Detects the saturated vapor temperature.

2) Calculates the refrigerant circulation configuration.

3) Controls the compressor frequency.

4) Controls the outdoor unit’s fan air volume.

1) Frequency control

2) Defrost control and liquid level detection at heating

1) Outdoor air temperature detection

2) Fan control, liquid level heater, and opening setting for oil return

Subcool coil bypass LEV (LEV1)

Heat exchenger inlet pipe temperature

control (subcool coil outlet temperature)

Subcool coil bypass LEV (LEV1) control

Name Application Specification Check method

Pressure 0~0.98MP

0.3V/0.098MPa

Vout 0.5~3.5 V

Gnd (black) Vout (white) Vcc (DC5V) (red)

Pressure 0~2.94MP

0.1V/0.098MPa

Vout 0.5~3.5 V

Gnd (black) Vout (white) Vcc (DC5V) (red)

Connector

273+t

Continuity check

Resistance value

check

Resistance value

check

Outdoor unit

Symbol

(function)

63HS

63LS

273+120

273+0

- 42 -

Page 49

Name Application Specification Check method

Outdoor unit

Symbol

(function)

Thermistor

Solenoid valve

Linear expansion valve

Thermistor

THHS

SV1

SV2 (discharge suction bypass)

(discharge suction bypass)

SV3 ~ 4

SLEV

LEV1 (SC coil)

LEV

TH21 (inlet air temperature)

TH22 (piping temperature)

TH23 (gas side piping temperature)

1) Detects the inverter cooling fin temperature.

2) Provides inverter overheating protection.

3) Controls the control box cooling fan.

1) High/low press. bypass at starting/ stopping and capacity control at low load

Capacity control and high press. rise suppression (backup for frequency control)

Discharge press. rise suppression

Adjustment of liquid refrigerant (oil) return foam accumulator

Adjustment bypass flow rate from outdoor unit liquid line at cooling.

1) Adjust superheat of outdoor unit heat exchanger outlet at cooling.

2) Adjust subcool of indoor unit heat exchanger at heating.

Indoor unit control (thermostat)

21S4a 4-way valve Changes for cooling and heating

CH1 Crank case

heater

Heating of compressor refrigerant

1) Indoor unit control (freeze prevention, hot adjust, etc.)

2) LEV control in heating operation (Subcool detection)

LEV control in cooling operation (Superheat detector)

50=17kΩ

B25/50=4170 Rt = 17exp{4170( - )}

-20˚C : 605.0kΩ50˚C : 17.0k

Ω

-10˚C : 323.3kΩ60˚C : 11.5k

Ω

0˚C : 180.9kΩ70˚C : 8.0k

Ω

10˚C : 105.4kΩ80˚C : 5.7k

Ω

20˚C : 63.8kΩ90˚C : 4.1k

Ω

30˚C : 39.9kΩ100˚C : 3.0k

Ω

40˚C : 25.7k

Ω

AC 220~240V Open at energizing and close at deenergizing

DC12V stepping motor drive Valve opening 0~480 pulse

DC12V

Cord heater AC 220~240V

MC......1280Ω

.......45W

Opening of stepping motor driving valve 0~2,000 pulses

AC220~240V on cooling off heating

0 = 15kΩ

B0/100 = 3460

Rt = 15exp {3460 ( - )}

0°C :15kΩ 10°C : 9.7kΩ 20°C : 6.4kΩ 25°C : 5.3kΩ 30°C : 4.3kΩ 40°C : 3.1kΩ

• Continuity check by tester

• Temperature of inlet and outlet

Continuity check with tester for white-red-orange yellow-brown-

blue

Resistance value check

Continuity check with tester

Indoor unit

273+50

273+t

273+0

Control of heat exchanger capacity.

- 43 -

Page 50

- 44 -

Page 51

§ REFRIGERANT AMOUNT ADJUSTMENT

Clarify relationship between the refrigerant amount and operating characteristics of CITY MULTI, and perform service activities such as decision and adjustment of refrigerant amount on the market.

[1] Refrigerant Amount and Operating Characteristics

The followings are refrigerant amount and operating characteristics which draw special attention.

During cooling operations, required refrigerant amount tends to increase (refrigerant in accumulator decreases) in proportion to increase in the number of operating indoor units. However, the change of increase rate is small.

During heating operations, liquid level of accumulator is the highest when all the indoor units are operating.

Discharge temperature hardly changes when increasing or decreasing refrigerant amount with accumulator filled with refrigerant.

Judged as over replenishment when temperature difference from low pressure saturation temperature (Te)

is 5 K or less.

[2] Adjustment and Judgement of Refrigerant Amount

(1) Symptom

The symptoms shown in the table below are the signs of excess or lack of refrigerant amount. Be sure to adjust refrigerant amount in refrigerant amount adjustment mode, by checking operation status, judging refrigerant amount, and performing selfdiagnosis with LED, for overall judgement of excess or lack of refrigerant amount.

Tendency of discharge temperature

During cooling operation at high ambient temperature the discharge temperature may rise.

During heating operation at low ambient the discharge temperature may rise.

The lower operating frequency is, the higher discharge temperature tends to become of deteriorated compressor efficiency.

Comparison including control system

Emergency stop at 1500 remote controller display (excessive refrigerant replenishment)

Operating frequency does not fully increase, thus resulting in insufficient capacity

Emergency stop at 1102 remote controller display (discharge temperature trouble)

Excessive refrigerant replenishment

Insufficient refrigerant replenishment

Compressor shell temperature is 10~60 K higher than low pressure saturation temperature (Te) when refrigerant amount is appropriate.

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Page 52

(2)

1) Operate all the indoor units on cooling or on heating, checking the discharge temperature, sub-cooling, low pres-

sure saturation temperature, inlet temperature, shell bottom temperature, liquid level, liquid step, etc. and rendering an overall judgment.

Judgement

Refrigerant volume tends toward insufficient.

Rifrigerant volume tends toward overcharge.

Condition 1 Outlet temperature is high. (100°C or higher) 2 Low pressure saturation temperature is extremely low. 3 Inlet superheating is high (if normal, SH = 20 K or lower). 4 Shell bottom temperature is high (the difference with the low pressure saturation

temperature is 60 K or greater)

5 Shell temperature is low (the difference with the low pressure saturation tem-

per

Liquid level AL=2 (Determined based on the extent of overheating of discharged refrigerant)

Refrigerant Volume

Checking the Operating Condition

ature is 5 K or lower).

2) Check the refrigerant volume by self-diagnosis using the LED. Set the self-diagnosis switch (SW1) as shown below and check the past information (history) concerning the refrigerant volume.

Set SW1 as shown in he figure at right.

If LD1 lights up, it indicates the refrigerant charge abnormal delay state just before emergency stop due to refrigerant overcharge (1500).

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Page 53

(3) Additional Refrigerant Charge Volume

At the time of shipping from the factory, the outdoor unit is charged with the amount of coolant shown in the following table, but since no extension piping is included, please carry out additional charging on-site.

Outdoor Unit Model Name Refrigerant Charge Volume 13.0kg 13.0kg

Calculation Formula Calculate the additional refrigerant volume by calculating the size of the extension liquid piping and its length (units: m).

Additional Refrigerant Volume

2: Length of ø12.7 liquid pipe (m)

3: Length of ø9.52 liquid pipe (m)

1: Length of ø19.05 liquid pipe (m)

Length of ø6.35 liquid pipe (m)

efer to the calculation table.

In the calculation results, round up fractions smaller than 0.01 kg. (Example: 18.54 kg 18.6 kg)

( Calculation Table)

Total Capacity of

Connected Indoor Units

~160 1.5 kg

161~330 2.0

331~480 2.5

Caution : (R407C unit)

When charging with refrigerant, be sure to charge from the liquid side. If charging from the gas side, it will cause the refrigerant composition to change inside the unit and the composition of the refrigerant remaining in the canister will also change.

(kg) = (0.16 ✕ L1) + (0.12 ✕ L2) + (0.06 ✕ L3) + (0.024 ✕ L4) +

PUHY-P200

PUHY-P250

- 47 -

Page 54

–77–

[3]

(1)

Refrigerant Volume Adjustment Mode Operation

Procedure

Operation

Measure

The outdoor unit LEV1 diverges more than usual during cooling operation.

Depending on the operating conditions, it may be necessary either to charge with supplementary refrigerant, or to

drain out some, but if such a case arises, please follow the procedure given below flow chart.

TH1 TH5

TH7

Using these, judge TH1, Tc - TH5 and Tc - TH7.

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Switching the function select switch (SW2-4), located on the outdoor unit's control board, ON starts refrigerant volume adjustment mode operation and the following operation occurs. (Refrigerant recovery mode and oil recovery mode will be invalid.)

Additionary, if the LED monitor display switch (SW1) on the outdoor unit's control board is set to the composition of refrigerant circulating in the refrigeration cycle ( OC).

Note 1: Even if the refrigerant volume has reached a suitable level shortly after starting refrigerant volume

adjustment mode, if left for a sufficient length of time (once the refrigeration system has stabilized), there are times when this level may become unsuitable.

1) The refrigerant volume is suitable. When the refrigerant volume for TH5-TH7 is more than 5K at the outdoor unit, and 6 to 13K for SH at the indoor unit.

2) The current volume is suitable, however, may become unsuitable after a certain length of time. When the refrigerant volume for TH5-TH7 is less than 5K at the outdoor unit, or less than 6K for SH at the indoor unit.

Note 2: There are times when it becomes difficult to determine the volume when performing refrigerant

adjustments if the high pressure exceeds 1.37MPa.

Note 3: Based on the following flowchart, use TH1, TH5, TH7 and Tc to adjust the refrigerant volume. Use the

self-diagnosis switch (SW1) on the outdoor unit main PCB to display TH1, TH5, TH7 and Tc.

When running refrigerant volume adjustment mode in the cooling operation, if note 2 above applies, determine the suitable refrigerant volume after waiting until outdoor units TH 5-7 reach more than 5K, and the indoor unit SH is in the range of 6 to 9K.

Turn on the outdoor unit self-diagnosis switch and then monitor the LED for the indoor unit SH.

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Page 55

Refrigerant adjustment method PUHY-P200·250

Note 2 , Ensure that no refrigerant is released into the atmosphere

Note 1, Operated using outdoor unit DIP SW3-1 and 3-2.

Note 3 , Always charge the system with liquid refrigerant, if the system is charged with gas the composition will change and capacity will be reduced

Wait for 30 minutes of

Note 1

compressor operation

= Yes = No

Note 4 , K = Degrees Kelvin

273K = 0°C

Wait 5 minutes before making next judgment.

Wait 5 minutes before making next judgment

Start

All indoor units are run in test cooling mode

Minimum of 30minutes continuous operation

TH1 equal or less than 100°C

Add a small amount of refrigerant to the low pressure service port.

Power supply to outdoor unit has been on for 8 hours

or 30minutes of compressor running

and a stable compressor frequency.

Tc-TH5 is less than or equal to 10K and greater than or equal to 3K

TH1 less than or equal to 95°C

Tc-TH7 is greater than or equal to 20K

Tc-TH5 is less than 3K

Add asmall amount of refrigerant at the low pressure service port.

Add a small amount of refrigerant at low pressure service port.

Remove a small amount of refrigerant at lowpressure service port.

System has the correct amount of refrigerant

FINISH

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Page 56

¶ TROUBLESHOOTING

[1] Principal Parts

Pressure Sensor

(1)

1) Check for failure by comparing the sensing pressure according to the high pressure/low pressure pressure sensor and the pressure gauge pressure. Set SW1 as shown below to display the high and low pressure sensor data displayed digitally by the light emitting

diode LD1.

High Pressure

(Units are kg/cm

Low Pressure

1 In the stopped condition, compare the pressure readings from the gauge and from the LD1 display.

(a) If the gauge pressure is 0~1 kg/cm

G (0.0098MPa), the internal pressure is dropping due to gas leakage.

(b) If the pressure according to the LD1 display is 0~1 kg/cm

G (0.0098MPa), there is a faulty contact at the connec-

tor, or it is disconnected. Proceed to 4.

G (3.14MPa) for high pressure or higher, proceed to 3.

(d) If other than (a), (b) or (c), compare the pressure readings during operation. Proceed to 2.

2 Compare the pressure readings from the gauge and from the LD1 display while in the running condition.

(a) If the difference between the two pressures is within 1 kg/cm

G (0.098MPa), for high pressure and 0.03MPa

for low pressure both the affected pressure sensor and the main MAIN board are normal.

(b) If the difference between the two pressures exceeds 1 kg/cm

G (0.098MPa), for high pressure and 0.03MPa

for low pressure the affected pressure sensor is faulty (deteriorating performance).

3 Disconnect the pressure sensor from the MAIN board and check the pressure according to the LD1 display.

(a) If the pressure is 0~1 kg/cm

G (0.098MP for low pressurea) y, the affected pressure sensor is faulty.

(b) If the pressure is 32 kg/cm

G (3.14MPa) for high pressure or higher, the MAIN board is faulty.

If ambient temperature is below 30°C, main board is faulty. If ambient temperature is above 30°C, proceed to 5.

4 Disconnect the pressure sensor from the MAIN board and shor

Disconnect the 63HS connector from the main board and replace it with the 63LS connector and check the LD1 display.

t out the No. 2 and No. 3 pins of the connector (63HS, 63LS), then check the pressure by the LD1 display. (a) If the pressure according to the LD1 displa

(a) If data is 1.37MPa or above then main board is faulty.

y is 32 kg/cm

G (3.14MPa) for high pressure and 1.37MPa for low

pressure , the affected pressure sensor is faulty.

(b) If other than (a), the MAIN board is f

(b) If (a) is not the problem then the 63LS sensor is faulty.

aulty.

2) Pressure sensor configuration. The pressure sensors are configured in the circuit shown in the figure at right. If DC 5 V is applied between the red and black wires, a voltage corresponding to the voltage between the white and black wires is output and this voltage is picked up by the microcomputer. Output voltages are as shown below.

Output power voltage high pressure 0.1 V per (0.098MPa) Output power voltage low pressure 0.3 V per (0.098MPa)

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Connector

Pressure 0-2.94MPa

out 0.5~3.5 V

GND (Black) Vout (White) Vcc (DC5V) (Red)

63HS/

63LS

on the LD1 displa

- 50 -

Page 57

- 51 -

❇

Connector connection specifications on the pressure sensor body side

The connector’s pin numbers on the pressure sensor body side differ from the pin numbers on the main circuit board side.

Sensor Body Side MAIN Board Side

Vcc Pin 1 Pin 3

Vout Pin 2 Pin 2

GND Pin 3 Pin 1

Check if the control board’s output signals and the operation of the solenoid valves match. Setting the self-diagnosis switch (SW1) as shown in the figure below causes the ON signal of each relay to be output to the LED’s. Each LED shows whether the relays for the following parts are ON or OFF. When a LED lights up, it indicates that the relay is ON.

1) In the case of SV1 (Bypass

2) In the case of SV2 (Bypass)

Valve)

(a) When the compressor starts, SV1 is ON for 4 minutes, check operation by whether the solenoid valve is emitting

an operating noise.

(b) Changes in the oper

by LED display and the operating noise emitted by the solenoid valve.

ating condition by solenoid valve operation can be confirmed by the temperature of the

bypass circuit and the sound of the refrigerant.

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3) SV3, 4 (Control of heat exchanger capacity)

4) In the case of 21S4 (Multi-directional valve)

(a) Operations can be confirmed by LED display and operating sound of solenoid valve, because one or more of

SV3, 4 are turned on depending on conditions during cooling-only operations.

(2)

Outdoor unit fan

LED Display

Fan

Stop Full speed

0 100

(3)

Multi-directional valve features When power is OFF: Used as a conductor for the cooling circuit between the oil separator outlet and heat

exchanger, and the gas-ball valve (BV1) and accumulator.

When power is ON : Used as a conductor for the heating circuit between the oil separator and gas-ball valve, and

the heat exchanger and accumulator. It is possible to determine whether the unit is functioning properly by checking from which point to which point the current is flowing by monitoring the LED display, or by checking the temperature at the time at both the inlet and outlet of the multi-directional valve. Do not to check the temperature of the oil separator by direct contact due to the high temperature of the piping.

❇

Do not apply excessive external impact, as the valve will not function properly if the outer wall is deformed.

• The outdoor unit fan is phase control and controls the number of fan rotations. Confirm the number of rotations while monitoring the output status of the phase control output at the LED. The fan rotates at approximately 600rpm at full speed.

• Refer to the outdoor unit control section for details on fan control.

The fan operates at 100% for 5 seconds and then alternates between high and low pressure control. Turn the self-diagnosis switch ON to , the phase

control output status at the LED display.

❇

There are times when the AK does not go as high as 100 when in night mode etc.

12345678

SW1

LED

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Comp operation

SV1 SV2 SV3 SV4

52C1

Lights for normal operation

(a)

SV2 goes ON in accordance with the rise in the high pressure in the cooling mode and heating mode, so check its operation by the LED display and the operating noise emitted by the solenoid valve. (Conditions during operation: See Control of Outdoor Unit.)

(b)

Changes in the operating condition by solenoid valve operation can be confirmed by the temperature of the bypass circuit and the sound of the refrigerant.

Solenoid Valve (SV1, 2, 3, 4)

Page 58

- 52 -

Outdoor LEV

The valve opening angle changes in proportion to the number of pulses. (Connections between the outdoor unit’s MAIN board and LEV1 (PUHY-P200·250))

Pulse Signal Output and Valve Operation

1234567 8

ø1 ON OFF OFF OFF OFF OFF ON ON ø2 ON ON ON OFF OFF OFF OFF OFF ø3 OFF OFF ON ON ON OFF OFF OFF ø4 OFF OFF OFF OFF ON ON ON OFF

LEV Valve Closing and Valve Opening Operations

Output (phase)

Output states

Output pulses change in the following orders when the

Valve is Closed 1 23456781 Valve is Open 8 7 6 5 4 3 2 1 8

❇

1. When the LEV opening angle does not change, all the output phases are off.

2. When the output is out of phase or remains ON continuously, the motor cannot run smoothly, but move jerkily and vibrates.

❇

When the power is switched ON, a 520 pulse valve opening signal is output to make sure the valve’s position, so that it is definitely at point A . Pulse signal is output for approximatly 17 seconds.

❇

When the valve operates smoothly, there is no sound from the LEV and no vibration occurs, but when the valve is locked, it emits a noise.

❇

Whether a sound is being emitted or not can be determined by holding a screwdriver, etc. against it, then placing your ear against the handle.

❇

If there is liquid refrigerant inside the LEV, the sound may become lower.

Valve Opening Angle (Flow Rate)

Pulse Count

Valve Opening

Fully Open 480 pulses

Valve Closing

Brown Blue Orange Yellow

White

(4)

Page 59

- 53 -

Indoor LEV Pulse Signal and Valve Operation Output Phase Output State

12 3 4 1 ON OFF OFF ON 2 ON ON OFF OFF 3 OFF ON ON OFF 4 OFF OFF ON ON

Valve opening

2000 Pulses

LEV Pulses

80-100 Pulses

Indoor Control Board

DC12V

LEV

Wire joining connector

Brown

5 Red

15 41

Blue

Orange

Yellow

White

Indoor Unit Connector CN60

Indoor LEV, BC LEV1 and 2

The valve opening angle changes in proportion to the number of pulses. (Connections between the indoor unit’s MAIN board and indoor LEV)

Pulse Signal Output and Valve Operation

LEV Valve Closing and Valve Opening Operations

Output pulses change in the following orders when the

Valve is Closed 1 2341 Valve is Open 4 3 2 1 4

❇

1. When the LEV opening angle does not change, all the output phases are off.

2. When the output is out of phase or remains ON continuously, the motor cannot run smoothly, but move jerkily and vibrates.

❇

When the power is switched ON, a 2200 pulse valve opening signal is output to make sure the valve’s

signal is output for approximatly 17 seconds.)

❇

When the valve operates smoothly, there is no sound from the LEV and no vibration occurs, but when the valve is lock .

❇

Whether a sound is being emitted or not can be determined by holding a screwdriver, etc. against it, then placing your ear against the handle.

❇

If there is liquid refrigerant inside the LEV, the sound may become lower.

(5)

position, so that it is definitely at point A . (Pulse

ed or

E A , it emits a noise

Page 60

- 54 -

1 Disconnect the control board connector and connect

the check LED as shown in the figure below.

When the base power supply is turned on, the indoor LEV outputs pulse signals for 10 seconds, the outdoor LEV outputs pulse signals for 17 seconds, and BC controller outputs pulse signals for 10-20 seconds. If the LED does not light up, or lights up and remains on, the driver circuit is abnormal.

1 If the LEV is locked up, the drive motor turns with no

load and a small clicking sound is generated. Generation of this sound when the LEV is fully closed or fully open is abnormal.

Measure the resistance between the coils (red - white, red

- orange, brown - yellow, brown - blue) using a tester. They are normal if the resistance is within 150Ω ± 10%.

Measure the resistance between the coils (gray - orange, gray - red, gray - yellow, gray - black) using a tester. They are normal if the resistance is within 46Ω ± 10%.

1 If you are checking the indoor unit’s LEV, operate the

indoor unit’s blower and the other indoor units in the cooling mode, then check the piping temperatures (liquid pipe temperatures) of the indoor units by the operation monitor through the heat source unit’s control board. When the fan is running, the linear expansion valve is fully closed, so if there is leakage,

the temperature sensed by the thermistor (liquid pipe temperature sensor) will become low. If the temperature is considerably low compared to the remote control’s intake temperature display, it can be judged that there is not a fully

closed failure. In the case of minimal leakage, it is not necessary to replace the LEV if there are no other effects.

1 Check for pins not fully inserted on the connector and

check the colors of the lead wires visually.

2 Disconnect the control board’s connector and conduct

a continuity check using a tester.

Judgment methods and likely failure mode

Caution:

The specifications of the outdoor unit (outdoor LEV) and indoor unit (indoor LEV) differ. For this reason, there are cases where the treatment contents differ, so follow the treatment specified for the appropriate LEV as indicated in the right column.

Microcomputer driver circuit failure

LEV mechanism is locked.

The LEV motor coils have a disconnected wire or is shorted.

Fully closed failure (valve leaks)

Faulty wire connections in the connector or faulty contact.

Failure Mode Judgment Method Treatment Affected LEV

Thermistor liquid pipe (temperature sensor)

Linear Expansion Valve

In the case of driver circuit failure, replace the control board.

Replace the LEV.

Replace the LEV coils.

If there is a large amount of leakage, replace the LEV.

Check the continuity at the places where trouble is found.

Indoor

Outdoor

Indoor

Outdoor

Indoor

Outdoor

Indoor

Outdoor

Indoor, BC controller

Outdoor

Page 61

- 55 -

Outdoor LEV Coil Removal Procedure (configuration) As shown in the figure, the outdoor LEV is made in such a way that the coils and the body can be separated.

<Removing the Coils> Fasten the body tightly at the bottom (Part A in the figure) so that the body will not move, then pull out the coils toward the top. If they catch on the stopper and are difficult to take out, turn the coils left and right until the stoppers are free from the stopper indentations, then pull the coils out. If you take out the coils without gripping the body, undue force may be applied to the piping and the pipe may be bent,

be sure to fasten the body in such a way that it will not

move.

<Installing the Coils> Fasten the body tightly at the bottom (Part A in the figure) so that the body will not move, then insert the coils from the top, inserting the coils’ stopper securely in one of the indentations on the body. (There are four indentations for the stopper on the body around its circumference, and it doesn’t matter which indentation is used. However, be careful not to apply undue force to the lead wires or twist them around inside the body.) If the coils are inserted without gripping the body, it may exert undue force on the piping, causing it to become bent, so be sure to hold the body firmly so that it won’t move when installing the coils.

Coils

Stopper

Lead Wires

Body

Indentation for Stopper (12 places around the circumference)

Part A

Page 62

- 56 -

Inverter

(6)

a. Replace only the compressor if only the compressor is found to be defective.

(Overcurrent will flow through the inverter if the compressor is damaged, however, the power supply is automati-

cally cut when overcurrent is detected, protecting the inverter from damage.) b. Replace the defective components if the inverter is found to be defective. c. If both the compressor and the inverter are found to be defective, replace the defective components of both devi-

ces.

1) Inverter related defect identification and countermeasures

Error display/failure condition Measure/inspection item

[1]

Inverter related errors (0403, 4220, 4230, 4240, 4250, 4260, 5110, 5301)

[2]

Main power breaker trip

[3]

Main power earth leakage breaker trip

[4]

Only the Compressor does not operate.

[6]

Noise has penetrated the peripheral device.

[7]

Sudden malfunction (as a result of external noise.)

[5]

The compressor always vibrates strongly or emits an abnormal noise.

¶ [7] Check the details of the inverter error in the error log at the outdoor PCB LED monitor display. ¶ [6] Perform the measures corresponding to the error code and error details determined using the remote control error display self diagnosis and countermeasures.

a. Check the breaker capacity. b. Electrical system short circuit or grounding other than the

inverter

c. Refer to 3)-[1] if not a, or b.

a. Check to ensure that power supply wiring, etc. of the

peripheral device is not in close contact with the power supply wiring of outdoor unit.

b. Check to ensure that the inverter output wiring is not in

close contact with the power supply wiring and transmission lines.

c. Check to ensure that the transmission line shield wiring is

being used properly in the necessary environment, and that the shield wire ground is appropriate.

b. Check to ensure that the transmission line shield wiring is

being used properly in the necessary environment, and that the shield wire ground is appropriate.

1. Due to a large capacity electrolytic capacitor used in the inverter, voltage still flows through even after cutting the main power, creating the possibility of electric shock. As a result, wait for a sufficient length of time (5-10 min) after cutting the main power and check the voltage at both terminals of the electrolytic capacitor to performing any checks on the inverter.

2. Damage will result to the components of IPM, etc. if the inverter wiring is not properly secured with screws, or if the connector has not been properly inserted. It is likely that any errors occurring after replacing components are the result of wiring mistakes. Ensure that the wiring, screws, connectors and Faston, etc. are properly inserted.

3. Do not remove or insert inverter connectors with the main power supply on, as this will result in damage to the PCB.

4. The current sensor will be damaged if current flows without connecting to the PCB. Always insert connectors into the corresponding PCB when running the inverter.

c. Check to ensure that the neither the transmission line or

external connection wiring run close to another power supply system or run through the same conduct pipe.

e. Attach a ferrite core to the inverter output wiring. (Please

contact the factory for details of the service part settings)

g. If this problem occurs suddenly, there is a possibility that

the inverter output is ground ed. Proceed to 2)-[3].

f. Change the power to another system.

❇

Contact the factory for cases other than those listed above.

❇

Contact the factory for cases other than those listed above.

d. Meg defect for electrical system other than the inverter

a. Check to ensure that the unit is grounded.

· Check the inverter frequency at the LED monitor and proceed to 2)-[3] if the status is operational.

a. Earth leakage breaker capacity/sensitivity current check b. Meg defect for electrical system other than the inverter c. Refer to 3)-[1] if not a, or b.

Go to 2)-[3].

Page 63

- 57 -

Treatment of Inverter Output Related Troubles

Check item Phenomena Treatment

[1] Check the INV board error detection circuit.

Perform the following: 1Disconnect INV board

CNDR2. After removing, turn on the outdoor unit and check the error status. (The compressor does not operate because CNDR2, which carries the IPM drive signal, has been disconnected.)

1 IPM/overcurrent error.

(4250 detailed No. 101, 102, 103, 104, 105, 106, 107)

• Replace INV board.

[2] Check for compressor ground fault or coil error.

Disconnect the compressor wiring, and check the compressor Meg, and coil resistance.

1Compressor Meg failure

Error if less than 1MΩ.

❇

When no refrigerant is

accumulated in the compressor.

2Compressor coil resistance failure

Coil resistance value of 0.58Ω (20°C)

• Replace compressor

[3] Check to see if the inverter is damaged.

❇

Perform this

check if an error occurs immediately before or after turning on the compressor.

Perform the following: 1Reconnect the connector re-

moved at item [1].

2Disconnect the compressor

wiring.

3Turn on SW1-1 on the INV

board. Operate the outdoor unit after above steps. Check the inverter output voltage.

❇

It is recommend to use the tes-

ter used to determine the ¶ [1] (6) 5) IPM troubleshooting when checking the inverter output voltage.

❇

Measure when the inverter

output frequency is stable.

1 IPM/overcurrent error.

(4250 detailed No. 101, 102, 103, 104, 105, 106, 107)

2There is a high possibility of an

inverter circuit error if the voltage unbalance across all wiring is greater than 5% or 5V.

3No voltage unbalance across all

wiring

2No voltage unbalance across all

wiring

• Refer to item [5] for inverter circuit trouble.

[4] Check to see if the inverter is damaged.

❇

Perform this

check if an error occurs during steady operation.

Turn on the outdoor unit. Check the inverter output voltage.

❇

It is recommend to use the tes-

ter used to determine the ¶ [1] (6) 5) IPM troubleshooting when checking the inverter output voltage.

❇

Measure when the inverter

output frequency is stable.

1There is a high possibility of an

inverter circuit error if the voltage unbalance across all wiring is greater than 5% or 5V.

• Refer to item [5] for inverter circuit trouble.

See item [2]. Proceed to item [5] however if there is no problem at [2]. Replace the compressor if there is no problem at [5].

2 ACCT sensor circuit error.

(5301 detailed No. 117)

See to ¶ [1] (6) 4) "Current Sensor ACCT" Check the resistance and replace if erroneous. Replace the INV board if the ACCT status is normal.

3 DCCT sensor circuit error.

(5301 detailed No. 118)

• Replace DCCT Turn on the outdoor unit again after replacing the DCCT. If an error occurs:

• Replace the INV PCB (The DCCT condition can be regarded as normal.)

4 ACCT sensor circuit error.

(5301 detailed No. 115)

• INV board error detection circuit is normal. Because IPM can not drive, if the CNDR2 is disconnected.

Check whether the refrigerant is accumulating in the compressor again.

Page 64

- 58 -

Trouble Measures when Main Power Breaker Tripped

Check item Phenomena Treatment

[5] Check the inverter circuit trouble.

1Check to see if the IPM screw

terminal is loose.

3Check the resistances be-

tween each terminal of IPM. Refer to ¶ [1] (6) 5) for details on IPM troubleshooting.

2Check the exterior of the IPM.

1Screw terminal is loose. • Check all IPM screw terminals and

tighten.

2IPM is cracked due to swelling.

3Resistance error between each

terminal of IPM.

4All normal for items 1-3 above

• IPM replacement Check the operation in [3] or [4] after replacing the IPM. In the case of an output voltage unbalance or error recurrence: Replace the G/A board

In the case of an output voltage unbalance or error recurrence after replacement:

Replace the INV board

• IPM replacement Check the operation in [3] or [4] after replacing the IPM. In the case of an output voltage unbalance or error recurrence: Replace the G/A board

In the case of an output voltage unbalance or error recurrence after replacement:

Replace the INV board

• IPM replacement In the case of an output voltage unbalance or error recurrence after replacement: Replace the G/A board

In the case of an output voltage unbalance or error recurrence after replacement:

Replace the INV board

Check item

[1]

[2]

[3]

Phenomena Treatment

Perform Meg check between the terminals in the power terminal block Tba.

Turn on the power again and check once more.

Turn on the outdoor unit and check that it operates normally.

1Zero to several ohm, or Meg

failure.

1Operates normally without tripping

the main breaker.

2Main power breaker trip

1Main power breaker trip 2No remote control display

Check each part in the main inverter circuit.

❇

Refer to "Simple checking Procedure for

individual components of main inverter

circuit". a. Diode Stack b. IPM c. Rush current protection resistor d. Electromagnetic relay e. DC reactor f. Noise filter

a. There is a possibility that the wiring shorted

momentarily. Trace the short and repair.

b. If a. above is not the case, there is a

possibility that there was a compressor failure.

• A compressor ground fault can be considered.

Go to 2)-[2].

Page 65

- 59 -

Simple Checking Procedure for Individual Components of Main Inverter Circuit

Part name Judgement method

Diode Stack

Refer to "Determining Diode Stack Troubleshooting"

IPM (Intelligent Power Module)

Rush current protection resistor R1, R5

Electromagnetic contactor (52C)

DC reactor DCL

Cooling fan (MF1)

Current sensor ACCT

Refer to "Determining IPM interference"

Measure the resistance between terminals: 47Ω±10%

Measure the resistance between terminals: 1Ω or lower (almost 0Ω) Measure the resistance between terminals and the chassis:

Measure the resistance between terminals : 0.1k~1.5kΩ

Measure the resistance value at each terminal.

Disconnect the CNCT2 target connector and check the resistance between terminals: 280Ω±30Ω 1-2PIN (U-phase) 3-4PIN (W-phase)

❇ Check the ACCT connecting phase and direction.

Check Location

A1-A2

1/L1-2/T1 3/L2-4/T2 5/L3-6/T3

Judgement value

0.1k~1.3kΩ

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

W ACCT-WACCT-U

IPM

Transformar (To1)

Measure the resistance between terminals on the primary side (CNTR1) : 1.0k~2.5kΩ Measure the resistance between terminals on the secondary side (CNTR) : 20~60Ω

Page 66

- 60 -

5) Intelligent Power Module (IPM)

The measured v

Measure resistances between each terminal of IPM with tester, and use the results for troubleshooting.

alues for troubleshooting are shown in the table below.

6) Diode stack

(Restrictions to applicable tester are the same as those of IPM)

erform continuity check with tester. Judged as normal if the following characteristics are observed.

123

1 2 3

–

• External view • Internal circuit diagram

• Judged value

∞ ∞ ∞

Tester

Black

5~ 200

Ω

5~ 200

Ω

5~ 200

Ω

5~ 200

Ω

5~ 200

Ω

5~ 200

Ω

U V

NUV W

∞

∞∞∞

∞ ∞

Tester

Black

–

1 2 3

–

123

1 6

4 9

Pre-Driver

Over heating

Temperature sensor

protection circuit

16 10 7 4 1

1 Focus on whether there is a complete open (∞Ω) state or short-circuit (~0Ω).

The measured resistance value is a guideline and may deviate slightly. Measure between several similar measurement points. If the value does not differ by more than double or half from the other points, then judge the state as OK.

2 Restrictions to applicable tester

Use a tester with an internal power of 1.5V or more.

❇

Battery type tester

A card tester with button battery has a low applied voltage, so the resistance value of the diode characteristics cannot be measured correctly. Use a measurement range that measures the low resistance when possible. An accurate measurement with less fluctuation will be possible.

5~ 200

Ω

5~ 200

Ω

5~ 200

Ω

5~ 200

Ω

5~ 200

Ω

5~ 200

Ω

Tester

Red

∞∞∞

Tester

Red

Page 67

- 61 -

7) Caution at replacement of inverter parts

1 Fully check wiring for incorrect and loose connection.

The incorrect or loose connection of the power circuit part wiring like IPM and diode module causes to damage the IPM. Therefore, check the wiring fully. As the insufficient tightening of screws is difficult to find, tighten them together additionally after finishing other works. For the wiring of the base for IPM, observe the wiring diagram below carefully as it has many terminals.

2 Coat the grease for radiation provided uniformly onto the radiation surface of IPM /diode modules.

Coat the grease for radiation on the full surface in a thin layer, and fix the module securely with the screw for fastening. As the radiation grease attached on the wiring terminal causes poor contact, wipe it off if attached.

Motor

(Compressor)

G/A board

Red

UVW

White Black

Black

Capacitor

(C2,C3)

Red

IPM

CNDC2

Page 68

- 62 -

[2] Trouble and remedy of remote controller

(In the case of MA remote controller)

Phenomena Factors Check method and handling

If pushing the remote control operation SW does not make a sound such as feep with the crystal display lamp out, and no operate is possible.

(An appropriate display on the remote control is not on.)

When turning on the remote control operation SW, a temporary operation display is indicated, and the display lights out immediately, the unit stops.

1) Power supply from transformers is not turned on in Indoor Unit. 1 The original power supply of Indoor Unit is not

turned on.

2 The connector (CND. CNT, CN3T) on the

controller board in the room has come off.

Fuse on the control board in Indoor Unit has melting down. Transformer defects or damage to unit.

2) MA remote controller has been wired incorrectly. 1 Break of the MA remote controller line and the

connection to the terminals has come off.

2 Short circuit of the MA remote control wiring 3 Reversed connections of the wiring on remote

controller.

4 Incorrect connection of the MA remote control wiring

to the transmission line terminal block (TB 5).

5 Reversed connections between the MA remote

control wiring in the indoor unit and AC 200V power supply wiring.

6 Reversed connection between the MA remote

control wiring in the indoor unit and M-NET transmission wiring.

3) The maximum number of MA remote controllers connected to one is unit exceeded (two units).

4) The wiring length of the MA remote line and the used electric wire diameter is out of specifications.

5) The wiring of the remote display output to the outdoor unit is short circuited, or the relay is connected with reversed polarity.

6) Defective of the controller board in the room

7) Defects of MA remote control

1) M-NET transmission power supply from the outdoor unit is not supplied.

1 The original power supply of the outdoor unit is not turned on. 2 Disconnection of connectors on the board of the outdoor unit.

Main board --- CNS1, CNVCC3 INV board --- CNAC2, CNVCC1, CNL2 3 Power supply circuit defects of the outdoor unit. (For detail, refer to Pages 127)

•

INV board defects

•

Blown fuse (F1 on INV Board)

•

Diode stack destruction

•

Prevention resistance of rush current (R1) damage

2) Transmission line short

3) Wiring mistakes of the M-NET transmission line on the side of the outdoor unit

1 Break of transmission line, and removal of terminal block 2 The room transmission line is wired to the transmission line

terminal block (TB7) for the central control by mistakes.

4) M-NET transmission line break on the side of the room unit

Disconnection off wiring between the M-NET transmission terminal block (TB 5) and the room controller board CN2M and pulls off of connectors

a) Check the MA remote control terminal

voltage (between A and B). i) In the case of voltage DC8.5- 12V,

the remote controller is defective.

ii) In the case of voltage not available:

•

Check the left described 1) and 3), after checking , if these are factors, then modifications should be performed.

•

If there are no factors of the left described 1) and 3), move to b).

b) Remove the remote control wiring from

the terminal block TB13 for the MA remote control in the indoor unit, and check voltage between A and B. i) In the case of voltage DC9-12V

Check the left described 2) and 4), if these are factors, then modifications should be performed.

ii) In the case of voltage not available:

•

Recheck the left described 1) once again, if this is a factor, them modifications should be performed.

•

If there are no factors in the left described 1), check the wiring for the remote display (the relay polarity, etc.)

•

If there are no factors, replace the controller board in the indoor unit.

In the case of item 1), the LED 1 on the controller board in the unit is off.

In the case of factors 2) and

3) Indicated by 7102 error code on the self-diagnosis LED of the outdoor unit.

Page 69

- 63 -

Phenomena Factors

3 When the remote

control SW is turned on, the indication goes off after approximately 20- 30 seconds, and indoor unit stops.

1) Power supply from the transformer is not available to the control board of BC controller.

1 The original power supply of the BC controller is not turned on. 2 Removal of connectors (CN12, CN38, CNTR) on the control board of the BC controller. 3 Fuse on the control board of the BC controller is blown. 4 Transformer defects of the BC controller and a malfunction. 5 Defects on the control board of the BC controller

Check method and handling

YES

❇

Check the BC controller power terminal block voltage

220 ~ 240V?

Fuse blown off

Removed?

Within spec.?

Fuse check on the board

Connector removal checks (CN03, CN12, CNTR)

Connector connection defects

Modify the defective places

Check for factors of transformer cut Earth route on the board Earth route of sensor and LEV

Check for resistance value of transformer

BC controller Defects for the control board

Verify the power supply wiring original power supply.

Power supply reapplying

220 ~ 240V circuit short and ground checks

❇

1 As for transformer checks, It is subject to the failure judgment method of main parts in 4.5.

Page 70

- 64 -

4 “HO” indication on

the remote controller is not lit, and the ON/OFF switch does not work.

1) The M-NET transmission power supply form the outdoor unit is not supplied. 1 The original power supply of Indoor Unit is not

turned on.

2 The connector on the controller board in Indoor

Unit is removed. Main board ----CNS1, CNVCC3 INV board----CNAC2, CNVCC1, CNL2

Power supply circuit defects of the outdoor unit. (For detail, refer to Pages 127)

•

INV board defects

•

Diode stack defects

•

Prevention resistance of rush current (R1)

damage.

2) Short circuit of the M-NET transmission line

3) Error wiring of the M-NET transmission line on the side of the outdoor unit 1 A break of the transmission line or terminal block

removal

2 Indoor Unit transmission line is wired to the

transmission line terminal block (TB7) for the central control by mistake.

4) M-NET transmission line break on the side of Indoor Unit (Short/ Open)

Loose or disconnection of wiring between the M-NET transmission terminal block (TB 5) of Indoor Unit and Indoor Unit controller board CN2M and disconnection of connectors

6) Error wiring of the MA remote control

1 Short circuit of the MA remote wiring 2 A break of the MA remote control line (No.2) and

disconnection

of the terminal block connection

Reversed wiring, cross-over in the group control

4 Wire by mistakes the MA remote control to the

terminal block (TB5) for the transmission line

Connect by mistakes the M-NET transmission line to the MA remote control terminal block (TB13)

7) The unit address is not “00” as it should be with automatic address setting.

8) The address of

Indoor Unit

becomes 51 or more.

9) The master and slave setting of the MA remote control becomes the slave setting.

10)Use the M-NET remote control in spite of the automatic address.

11)Defects for the room controller board (MA remote communication circuits)

12)Defects for the remote controller

Check method and handling

Phenomena Factors

In the case of 2), 3) and 7) factors, indicate 7102 errors by the self-diagnosis LED of the outdoor unit.

YES

Check for 2) and 3) of factors

Modify the defective places

7120 error display?

Check for 11) item

Check for 4) item

19 ~ 12V?

Check the items of

5), 6), 8), 9), and 10)

Defects of the indoor unit controller board or MA remote control

Factors available?

Modify the defective places

Check for the terminal block (TB15) voltage for the transmission line of the indoor unit

The same

phenomena in all unit of the same

refrigerant system happen?

Self-diagnosis LED checks

YES

Factors

available?

Check for 1) item

Change the M-NET remote control to the MA remote control.

Page 71

- 65 -

(In the case of M-NET remote controller)

Symptom Cause Checking method & countermeasure

Despite pressing of remote controller ON/OFF switch, operation does not start and there is no electronic sound.

(No powering signal

appears.)

At about 10 seconds after turning remote controller operation switch ON, the display distinguishes and the operation stops.

1) M-NET transmission power source is not supplied from outdoor unit. 1 Main power source of outdoor unit is not

connected.

2 Disconnection of connector on outdoor unit circuit

board. Main board : CNS1, CNVCC3 INV board : CNAC2, CNVCC1, CNL2

3 Faulty power source circuit of outdoor unit.

• Faulty INV board,

• Blown fuse (F1 on INV board)

• Broken diode stack

• Broken resistor (R1) for rush current protection

2) Short circuit of transmission line.

3) Erroneous wiring of M-NET transmission line at outdoor unit. 1 Transmission line disconnection or slipping off from terminal

block.

2 Erroneous connection of indoor/outdoor transmission line to

TB7.

4) Disconnection of transmission wiring at remote controller.

5) Faulty remote controller.

The cause of 2) and 3) is displayed with self-diagnosis LED for 7102 error.

1) Power source is not fed to indoor unit from transformer.

1 2 3 4 5

Main power source of indoor unit is not turned on. Disconnection of connector (CND, CNT, CN3T) on indoor controller board. Blown fuse on indoor controller board. Faulty or disconnected transformer of indoor unit. Faulty indoor controller board.

2) Faulty outdoor control circuit board uncontrolled. As normal transmission is fails between indoor and outdoor units, outdoor unit model can not be recognized.

Checking method & countermeasure

a) Check transmission terminal block of

remote controller for voltage. i) In case of 17 ~ 30V

Faulty network remote controller

ii) In case of less than 17V

See “Transmission Power Circuit

(30V) Check Procedure”.

Check indoor LED3

Lighting?

Check for the change of LED display by operating dip switch SW1 for self-diagnosis.

Extinguishing or unable to confirm

Check indoor unit power source terminal block voltage

AC 220~240V?

Check fuse on circuit board

Blown?

Check connection of connector (CND, CNT , CN3T)

Disconnected

Check transformer resistance value

Within rated?

Check self-diagnosis function of outdoor unit

Changed?

Faulty indoor controller board

Check main power source of power source wiring.

Apply power source again.

Check 220V~240V circuit for short circuit and ground fault.

Improper connector connection

Check cause of transformer disconnection.

•Ground fault on circuit board

•Ground fault on sensor, LEV

Check self-diagnosis function after powering outdoor unit again.

Changed?

Accidental trouble

Faulty outdoor unit control circuit board

Repair faulty point.

YES

Lighting

❇

1 Check the transformer in accordance with the “TROUBLE SHOOTING” in the indoor unit’s service handbook.

❇

Page 72

- 66 -

Symptom Cause

3 “HO” display on re-

mote controller does not disappear and ON/OFF switch is ineffective.

(Without using MELANS)

1) Outdoor unit address is set to “00”.

2) Erroneous address. 1 Address setting of indoor unit to be coupled with remote controller incorrect.

(Indoor unit = remote controller - 100.)

2 Address setting of remote controller incorrect.

(Remote controller = indoor unit + 100.)

3) Faulty wiring of transmission terminal block TB5 of indoor unit in the same group with remote controller.

4) Centralized control SW2-1 of outdoor unit is turned ON.

5) Setting to interlocking system from indoor unit (Switch 3-1 = OFF), while Fresh Master is intended to be use by remote controller operation (indoor unit attribute).

6) Disconnection or faulty wiring of indoor unit transmission line.

7) Disconnection between indoor unit M-NET transmission line terminal block (TB5) and connector CN2M.

8) More than 2 sets of power supply connector (CN40) are inserted into centralized control transmission line of outdoor unit.

9) Faulty outdoor unit control circuit board.

10)Faulty indoor controller board.

11)Faulty remote controller.

(Interlocking control with MELANS)

12)No grouping registration from MELANS (Neglecting to set the relation between indoor unit and network remote controller).

13)Disconnection of centralized control transmission line (TB7) at outdoor unit.

14)At system connected with MELANS, power supply connector (CN40) is inserted to centralized control transmission line of outdoor unit.

Checking method & countermeasure

In case MELANS is not used

In case with MELANS used

When MELANS is used, “HO” display on the remote controller will disappear at the group registration of the indoor unit and local remote controller. If “HO” does not disappear after the registration, check the items 12) ~ 14) in the Cause column.

Same symptom for all units in a single refrigerant system?

Check outdoor unit address

51 ~ 100?

Check centralized control switch SW2-1 at outdoor unit

ON?

Faulty outdoor unit control circuit board

Outdoor unit address setting miss

Switch setting miss Change from ON to OFF

Address setting miss of remote controller

Indoor address setting miss

Transmission line wiring miss of indoor unit M-NET

Disconnection of CN2M connector

Setting miss of Fresh Master SW3-1

Repair spot in trouble

Confirm address of remote controller with “HO” displayed

Indoor unit + 100?

Check address of coupling indoor unit

Remote controller

-100?

Check voltage of indoor unit MNET transmission terminal block

17 ~ 30V?

Check connection between indoor unit M-NET transmission terminal block (TB5) and connector CN2M

Disconnection

Check Fresh Master SW3-1

Faulty indoor controller board or remote controller

ON?

YES

Page 73

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Symptom Cause Checking method & countermeasure

4 “88” appears on re-

mote controller at registration and access remote controller

a) Confirm the address of unit to be

coupled.

b) Check the connection of transmission

line.

c) Check the transmission terminal block

voltage of unit to be coupled. i) Normal if voltage is DC17 ~ 30V ii) Check the item d) in case other than i).

d) Confirm the power source of outdoor unit

to be coupled with the unit to be confirmed.

e) Confirm that the centralized control

transmission line (TB7) of outdoor unit is not disconnection.

f) Confirm the voltage of centralized control

transmission line. i) Normal in case of 10V ~ 30V ii) Check the items 7) ~ 10) left in case

other than i).

[Generates at registration and confirmation]

1) Erroneous address of unit to be coupled.

2) Disconnection of transmission line of unit to be coupled (No connection).

3) Faulty circuit board of unit to be coupled.

4) Installation miss of transmission line.

[Confirmation of different refrigerant system controller]

5) Disconnection of power source of outdoor unit to be confirmed.

6) Disconnection of centralized control transmission line (TB7) of outdoor unit.

7) Power supply connector (CN40) is not inserted into centralized control transmission line in grouping with different refrigerant system without using MELANS.

8) More than 2 sets of power supply connector are inserted into the centralized control transmission line of outdoor unit.

9) In the system connected with MELANS, power supply connector (CN40) is inserted into the centralized control transmission line of outdoor unit.

10)Short circuit of centralized control transmission line.

Page 74

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Transmission Power Circuit (30 V) Check Procedure If “” is not displayed by the remote control, investigate the points of the trouble by the following procedure and correct it.

No. Check Item Judgment Response

Disconnect the transmission line from TB3 and check the TB3 voltage.

Check if the following connectors are disconnected in the outdoor unit’s control box. MAIN Board: CNS1, CNVCC3, CNVCC4 INV Board: CNVCC2, CNVCC4, CNL2, CNR, CNAC2

Disconnect the wires from CNVCC3 on the Main board and check the voltage between pins 1 and 3 on the wire side of the CNVCC3.

Tester + ..... 1 pin

Tester - ..... 3 pin

Disconnect the wiring from CNVCC2 on the INV board and check the voltage between pins 1 and 3 of CNVCC2.

Tester ..... 1 pin

Tester ..... 3 pin

Disconnect the wiring from CNL2 on the INV board, and check the resistance at both ends of choke coil L2.

Disconnect the wiring from CNR on the INV board, and check the resistance at both ends of R7.

Check the resistance at both ends of F01 on the INV board.

Check the voltage between pins 1 and 3 of CNAC2 on the INV board.

Check the voltage between L2 and N on power supply terminal block TB1.

DC24~30 V

Except the above-mentioned Connector disconnected

Except the above-mentioned

DC24~30 V

Except the above-mentioned DC24~30 V

Except the above-mentioned

0.5~2.5Ω Except the above-mentioned 19~25Ω Except the above-mentioned 0Ω Except the above-mentioned AC198~264 V Except the above-mentioned AC198~264 V

Except the above-mentioned

Check the transmission line for the following, and correct any defects. Broken wire, short circuit, grounding, faulty contact.

to No. 2 Connect the connectors as shown on the electric

wiring diagram plate. to No. 3

Check the wiring between CNS1 and TB3 for the following, and correct any defects. Broken wire, short circuit, grounding, faulty contact. If there is no trouble, replace the Main board.

to No. 4 Check the wiring between CNVCC2 and

CNVCC3 for the following, and correct any defects. Broken wire, short circuit, grounding, faulty contact.

to No. 5 to No. 6 Replace choke coil L2. to No. 7 Replace R7. to No. 8 Replace F01 Replace the INV board. to No. 9 Check the wiring to CNAC2 for the following and

correct any defects. Broken wire, faulty contact.

Check the power supply wiring and base power supply, and correct any defects.

Page 75

- 69 -

[3] Investigation of transmission wave shape/noise

Control is perf

(1) M-NET transmission

ormed by exchanging signals between outdoor unit, indoor unit and remote controller by M-NET transmission. If noise should enter into the transmission line, the normal transmission will be hindered causing erroneous operation.

1) Symptom caused by the noise entered into transmission line

Cause Erroneous operation Error code

Signal changes and is misjudged as the signal of other address.

Transmission wave shape changes to other signal due to noise.

Transmission wave shape changes due to noise, and can not be received normally thus providing no reply (ACK).

Transmission can not be made continuously due to the entry of fine noise.

Transmission can be made normally, but reply (ACK) or answer can not be issued normally due to noise.

2) Method to confirm wave shape

Check the wave shape of transmission line with an oscilloscope to confirm that the following conditions are being satisfied.

1 The figure should be 104µs/bit ± 1%. 2 No finer wave shape (noise) than the transmission signal (52µs ± 1%) should be allowed.

❇

3 The sectional voltage level of transmission signal should be as follows.

Noise entered into transmission line

6600

6602

6607

6603

6607 6608

No fine noise allowed

❇

No fine noise allowed

❇

Logic value Transmission line voltage level

0VHL = 2.0V or more 1V

BN = 1.3V or less

VBN

52 µs µs µs µs µs Logical

52 52

Logical

52 value “0”

52 value “1”

❇

1 However, minute noise from the DC-DC converter or inverter operation may be picked up.

Page 76

- 70 -

3) Checking and measures to be taken (a) Measures against noise

Check the items below when noise can be confirmed on wave shape or the error code in the item 1) is generated.

Items to be checked Measures to be taken

(b) When the wave height value of transmission wave shape is low, 6607 error is generated, or remote controller is

under the state of “HO.”

Items to be checked Measures to be taken

1 Wiring of transmission and power lines in

crossing.

2 Wiring of transmission line with that of other

system in bundle.

3 Use of shield wire for transmission line (for

both indoor unit control and centralized control).

4 Repeating of shield at the repeating of

transmission line with indoor unit.

5 Are the unit and transmission lines grounded

as instructed in the INSTALLATION MANUAL?

6 Earthing of the shield of transmission line (for

indoor unit control) to outdoor unit.

7 Arrangement for the shield of transmission line

(for centralized control).

Isolate transmission line from power line (5cm or more). Never put them in a same conduit.

Wire transmission line isolating from other transmission line. Wiring in bundle may cause erroneous operation like crosstalk.

Use specified transmission wire.

Type : Shield line CVVS/CPEVS Wire diameter : 1.25mm2 or more

The transmission line is wired with 2-jumper system. Wire the shield with jumper system as same for transmission line. When the jumper wiring is not applied to the shield, the effect against noise will be reduced.

Connect to ground as shown in the INSTALLATION MANUAL.

One point earthing should be made at outdoor unit. Without earthing, transmission signal may be changed as the noise on the transmission line has no way to escape.

For the shield earth of the transmission line for centralized control, the effect of noise can be minimized if it is from one of the outdoor units in case of the group operation with different refrigerant systems, and from the upper rank controller in case the upper rank controller is used. However, the environment against noise such as the distance of transmission line, the number of connecting sets, the type of connecting controller, and the place of installation, is different for the wiring for centralized control. Therefore, the state of the work should be checked as follows. a) No earthing

• Group operation with different refrigerant systems One point earthing at outdoor unit

• Upper rank controller is used Earthing at the upper rank controller

b) Error is generated even though one point earth is being con-

nected. Earth shield at all outdoor units.

Connect to ground as shown in the user’s manual.

Check for earthing

Checking for wiring method

8 The farthest distance of transmission line is

exceeding 200m.

9 The types of transmission lines are different.

No transmission power (30V) is being supplied to the indoor unit or the remote control.

Faulty indoor unit/remote controller.

Confirm that the farthest distance from outdoor unit to indoor unit/ remote controller is less than 200m.

Use the transmission wire specified.

Type of transmission line : Shield wire CVVS/CPEVS Wire dia. of transmission line : 1.25mm

or more

a) Check 30V on CNS1, CNS2. b)

Remove CNS1 and CNS2 and check resistance is 5-2, 6-2, if not this is a fault. Check main board R3 resistance is 1k±5%, if not this is a fault.

Replace outdoor unit circuit board or remote controller.

Page 77

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3) Treatment of Fan Motor Related Troubles

Condition Possible Cause Check Method and Treatment

1It won’t run for 20 minutes

or longer when the AK value is 10%. (When the MAIN board’s SW1 is set as shown below, the AK value is displayed by the service LED.)

2The f

SW1

an motor’s vibration

is large.

1) The power supply voltage is abnormal.

2) Wiring is faulty.

3) The motor is faulty.

4) A fuse (F1, F2, F3) is defective.

5) The transformer (T01) is defective.

6) The circuit board is faulty.

If there is an open phase condition before the breaker, after the breaker or at the power supply terminal blocks TB1A or TB1B, correct the connections.

If the power supply voltage deviates from the specified range, connect the specified power supply.

For the following wiring, 1 check the connections, 2 check the contact at the connectors, 3 check the tightening torque at parts where screws are tightened, 4 check the wiring polarity, 5 check for a broken wire and 6 check for grounding.

TB1A~NF~TB1B~CNTR1~T01~CNTR TB1B~CNPOW, CNFAN~CN04~CNMF CNFC1~CNFC2

❇

Check if the wiring polarity is as shown on the wiring diagram plate.

Measure the resistance of the motor’s coils: 20~60Ω Measure the motor’s insulation resistance with a megger: 10 MΩ (DC 500 V) or more

If a fuse is defective, replace it.

Judge that T01 is faulty. Go to “Individual Parts Failure Judgment Methods.”

If none of the items in 1) to 5) is applicable, and the trouble reappears even after the power is switched on again, replace the circuit board using the following procedure. (When replacing the circuit board, be sure to connect the connectors and ground wire, etc. securely.)

1 Replace the FANCON board only. If it recovers, the

FANCON board is defective.

2 Replace the FANCON board and replace the MAIN

board. If it recovers, the MAIN board is defective.

3 If the trouble continues even after 1 and 2 above, then

both boards are defective.

12345678910

(2) MA remote control transmission

The MA remote control and indoor unit communicate with the current tone burst method.

If noise, etc., infiltrates the transmission cable and the communication between the MA remote control and indoor unit is cut off for three consecutive minutes, a MA communication error (6831) will occur.

1) Symptoms caused by infiltration of noise on transmission cable

A1, B2: No polarity Across terminal No. 1-2

...

Power

supply (9V to 12VDC)

12msec/bit+5% must be satisfied Voltage across terminal No.1-2 must be within range shown on left.

2) Confirmation of transmission specifications and waveform

1 2

MA remote controller

Transmission waveform (Across terminal No. 1-2)

Logical 1 Logical 0 Logical 1 Logical 1

Indoor unit

Page 78

Check Code List

Check Code Check Content

0403 Serial transmission abnormality 0900 Test run (ventilation) 1102 Discharge temperature abnormality 1111 Low pressure saturation temperature sensor abnormality (TH2) 1301 Low pressure abnormality (OC) 1302 High pressure abnormality (OC) 1500 Overcharged refrigerant abnormality 2500 Leakage (water) abnormality 2502 Drain pump abnormality 2503 Drain sensor abnormality 4103 Reverse phase abnormality 4115 Power supply sync signal abnormality 4116 Fan speed abnormality (motor abnormality)

4220

4250

[108]

[101] [102] [103] [104] [105] [106] [107]

[115] [116] [117] [118] [119] [120]

Bus Voltage drop abnormality (S/W detect) [109] Bus Voltage rise abnormality (S/W detect) [110] Vdc abnormality (H/W detect) [111] Logic circuit for H/W error detect abnormality

4230

Heat sink overheating abnormality

Overload abnormality

IPM abnormality

ACCT overcurrent abnormality (H/W peak detect)

DCCT overcurrent abnormality (H/W peak detect)

IPM short/grounding abnormality

Load short abnormality

ACCT overcurrent abnormality (S/W detect peak current)

ACCT overcurrent abnormality (S/W detect effective current)

Cooling fan abnormality

4240

IAC sensor abnormality

IDC sensor abnormality

IAC sensor/circuit abnormality

IDC sensor/circuit abnormality

IPM-open/ACCT connection abnormality

ACCT miss-wiring abnormality

5301

4260

Air inlet (TH21:IC)

5101

Discharge (TH1:OC) Liquid pipe (TH22:IC)

5102

Low pressure saturation (TH2:OC)

5103 Gas pipe (TH23:IC)

Thermal sensor

5105

abnormality

Liquid pipe (TH5) 5106 Ambient temperature (TH6) 5107 SC coil outlet (TH7) 5108 SC coil bypass outlet (TH8) 5110 Heat sink (THHS)

5301 IAC sensor/circuit abnormality

5201 Pressure sensor abnormality (OC)

6600 Multiple address abnormality 6602 Transmission processor hardware abnormality 6603 Transmission circuit bus-busy abnormality

[4] Self-diagnosis and countermeasures depending on the check code displayed

[ ]: Error detail No.

- 72 -

Page 79

- 73 -

Check Code Check Content

6606 Communications with transmission processor abnormality 6607 No ACK abnormality 6608 No response abnor 6831 MA Communication no reception error

6834 MA Communication start bit error

6832 MA Communication synchronization recovery error 6833 MA Communication transmission/reception hardware error

mality

7100 Total capacity abnormality 7101 Capacity code abnormality 7102 Connected unit count over 7105 Address setting abnormality 7106 Characteristics setting abnormality 7107 Connection number setting abnormality 7110

7130

Intermittent fault check code

Preliminary error code Preliminary Error Content

1202 (1102)

Preliminary discharge temperature abnormality or preliminary discharge thermal sensor abnormality (TH1) 1205 (5105) Preliminary liquid pipe temperature sensor abnormality (TH5) 1211 (1111)

Preliminary low pressure saturation abnormality or preliminary low pressure saturation sensor abnormality (TH2) 1214 (5110) Preliminary THHS sensor/circuit abnormality 1216 (5107) Preliminary sub-cool coil outlet thermal sensor abnormality (TH7) 1217 (5108) Preliminary sub-cool coil bypass outlet thermal sensor abnormality (TH8)

1221 (5106) Preliminary ambient temperature thermal sensor abnormality (TH6) 1402 (1302) Preliminary high pressure abnormality or preliminary pressure sensor abnormality 1600 (1500) Preliminary overcharged refrigerant abnormality

1605

4330 (4230) 4340 (4240)

4360 (4260)

Preliminary suction pressure abnormality

1607 4300 (0403) [121] 4300 (5301)

4320 (4220)

4350 (4250)

[115] [116] [117] [118] [119] [120] [108]

[101] [102] [103] [104] [105] [106] [107]

[109] [110] [111]

CS circuit b Preliminary serial transmission abnormality Preliminary IAC sensor abnormality Preliminary IDC sensor abnormality Preliminary IAC sensor/circuit abnormality Preliminary IDC sensor/circuit abnormality Preliminary IPM-open/ACCT connection abnormality Preliminary ACCT miss-wiring abnormality Preliminary bus voltage drop abnormality (S/W detect) Preliminary bus voltage rise abnormality (S/W detect) Preliminary Vdc abnormality (H/W detect) Preliminary logic circuit for H/W error detect abnormality Preliminary heat sink overheating abnormality Preliminary overload abnormality Preliminary IPM abnormality Preliminary ACCT overcurrent abnormality (H/W peak detect) Preliminary DCCT overcurrent abnormality (H/W peak detect) Preliminary IPM short/grounding abnormality Preliminary load short abnormality Preliminary ACCT overcurrent abnormality (S/W detect peak current) Preliminary ACCT overcurrent abnormality (S/W detect effective current) Preliminary cooling fan abnormality

lock abnormality

❇

Please refer to ( ) check code. [ ] : Error detail No.

Different unit model error

Transmission line power failure 7111 7113

Remote control sensor abnormality

Functional restriction error

Page 80

- 74 -

Checking code Meaning, detecting method Cause Checking method & Countermeasure

Serial transmission abnormality

0403

If serial transmission cannot be established between the MAIN and INV boards.

1) Wiring is defective.

2) Switches are set wrong on the INV board.

3) The fuse (F01) on the INV board is defective.

4) The circuit board is defective.

Check 1, the connections, 2, contact at the connectors and 3, for broken wires in the following wiring.

CNRS2 - CNRS3 CNAC2 - TB1B

SW1-4 on the INV board should be OFF.

If the fuse is melted, (if the resistance between the both ends of fuse is ∞), replace the fuse.

If none of the items in 1) to 3) is applicable, and if the trouble reappears e ven after the power is switched on again, replace the circuit board by the following procedure (when replacing the circuit board, be sure to connect all the connectors, ground wires, etc. securely). 1 If serial transmission is restored af-

ter the INV board is replaced, then the INV board is defective.

2 If serial transmission is not restored,

reinstall the INV board and replace the MAIN board. If serial transmission is restored, the MAIN board is defective.

3 If serial transmission is not restored

by 1 and 2 above, replace both boards.

(1) Mechanical

Page 81

- 75 -

Checking code Meaning, detecting method Cause Checking method & Countermeasure

Discharge temperature abnormality (Outdoor unit)

1102

When 110˚C for 8HP and 120°C temper

for 10HP or more discharge

for 10Hp or more discharge

ature is detected during operations (the first time), outdoor unit stops once, mode is changed to restart mode after 3 minutes, then the outdoor unit restarts.

When 110˚C for 8Hp and 120°C

is detected again (the third time) within 30 minutes after previous stop of outdoor unit, emergency stop is observ

ed with

code No. “1102” displayed.

4. When

110˚C for 8Hp and 120°C

is detected 30 or more minutes after previous stop of outdoor unit, the stop is regarded as the first time and the process shown in 1 is observed.

5. 30 min2.utes after stop of outdoor unit is intermittent fault check period with LED displayed (1202).

See Refrigerant amount check. Check operating conditions and opera-

tion status of indoor/outdoor units. Check operation status by actually

performing cooling or heating operations.

See Trouble check of LEV and sole-

noid valve.

Confirm that ball valve is fully opened. Check outdoor fan.

See Trouble check of outdoor fan.

Check operation status of cooling-only or heating-only.

See Trouble check of solenoid

valve.

Check resistance of thermistor. Check inlet temperature of sensor

with LED monitor.

1) Gas leak, gas shortage.

2) Overload operations.

3) Poor operations of indoor LEV.

4) Poor operations of OC controller LEV:

5) Poor operations of ball valve.

6) Outdoor unit fan block, motor trouble, poor operations of fan controller Heating (Heating-only, Heating-main).

3) ~ 6) : Rise in discharge temp. by low pressure drawing.

7) Gas leak between low and high pressures. 4-way valve trouble, compressor trouble, solenoid valve SV1 trouble.

8) Poor operation of solenoid valve SV1. Bypass valve SV1 can not control rise in discharge temp.

9) Thermistor trouble. (TH1)

10)Thermistor input circuit trouble on control circuit board.

When 110°C for 8HP and 120 °C for 10HP or higher discharge is detected again (the second time) within 30 minutes after the first stop of outdoor unit, mode is changed to restart mode after 3 minutes, then the outdoor unit restarts.

Cooling : Indoor LEV

LEV1

Heating : Indoor LEV

Cooling : LEV1

Page 82

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Checking code Meaning, detecting method Cause Checking method & Countermeasure

Low pressure saturation temperature sensor abnormality (TH2)

1111

1. When saturation temperature sensor (TH2) detects -40˚C or

less (the first time) during operations, outdoor unit stops once, mode is changed to restart mode after 3 minutes, then the outdoor unit restarts.

4. When -40˚C or less temperature is detected 30 or more minutes after stop of outdoor unit, the stop is regarded as the first time and the process shown in

1. is observed.

5. 30 minutes after stop of outdoor unit is intermittent fault check period with LED displayed.

Note:

1. Low press. saturation tem-

perature trouble is not detected for 3 minutes after compressor start, and finish of defrosting operations, and during defrosting operations

2. In the case of short/open of

TH2 sensor before starting

of compressor or within

10 minutes after starting of compressor, “1111

”

is displayed, too.

See Refrigerant amount check. Check operating conditions and opera-

tion status of outdoor unit. Check operation status by actually per-

forming cooling-only or heating-only operations.

See T r oub le chec k of LEV and sole-

noid valve.

Confirm that ball valve is fully opened. Check indoor unit, and take measu-res

to troube.

Check outdoor unit, and take measures to trouble.

Check outdoor unit fan. See Trouble check of outdoor unit

fan.

See T r ouble check of solenoid v alve.

Check resistance of thermistor. See Trouble check of pressure sen-

sor.

Check inlet temp. and press. of sensor by LED monitor.

1) Gas leak, Gas shortage.

2) Insufficient load operations.

3) Poor operations of indoor LEV.

4) Poor operations of OC controller LEV:

5) Poor operations of ball valve.

6) Short cycle of indoor unit.

7) Clogging of indoor unit filter.

8) Fall in air volume caused by dust on indoor unit fan.

9) Dust on indoor unit heat exchanger.

10)Indoor unit block, Motor trouble.

5)~9) : Fall in low pressure caused by evaporating capacity in cooling-only cooling-principal operation.

11)Short cycle of outdoor unit.

12)Dust on outdoor heat exchanger.

13)Indoor unit fan block, motor trouble , and poor operations of fan controller.

14)~16) : F all in low press. caused by lowered evaporating capa-city in heating-only heating-principal operation.

14)Poor operations of solenoid valve SV1. Bypass valve (SV1) can not control low pressure drop.

15)Thermistor trouble (TH2~TH6).

16)Pressure sensor abnormality.

17)Control circuit board thermistor abnormality and pressure sensor input circuit abnormality.

18)Poor mounting of thermistor (TH2~TH6).

Low pressure satur

ation temperature trouble

When a temperature of -40°C or less is detected again (the second time) with in 30 minutes after the first stop of outdoor unit, mode is changed to restart mode after 3 minutes, then the outdoor unit restarts.

When -40˚C or less temp. is detected again (the third time) within 30 minutes after the second stop of outdoor unit, error stop is observed with code Nos “1111,” “1112,” or “1113” di splayed.

Cooling : Indoor LEV

LEV1

Heating : Indoor LEV

Cooling : LEV1

Page 83

- 77 -

Checking code Meaning, detecting method Cause Checking method & Countermeasure

1301

1302

Low pressure abnoramlity

High pressure abnoramlity 1 (Outdoor unit)

When starting from the stop mode for the first time, (if at the start of bind power transmission, the end of bind power transmission, and in the mode when the thermostat goes OFF immediately after the remote control goes ON, the following compressor start time is included), if the low pressure pressure sensor before starting is at 0.098MPa, operation

stops immediately.

1. When press. sensor detects oper ations (the first

time), outdoor unit stops once, mode is changed to restart mode after 3 minutes, then the outdoor unit restarts.

3. When

2.94MPa

or more pressure is detected again (the third time) within 30 minutes after stop of outdoor unit,error stop is observed with code No. “1302” displayed.

4. When

2.74MPa or more pressure is detected 30 or more minutes after stop of outdoor unit, the detection is regarded as the first time and the process shown in 1 is observed.

5. 30 minutes after stop of outdoor unit is intermittent fault check period with LED displayed.

Error stop is observed immediately when press. switch

(2.94 MPa)

operates in

addition to pressure sensor.

1) Internal pressure is dropping due to a gas leak.

2) The low pressure pressure sensor is defective.

3) Insulation is torn.

4) A pin is missing in the connector, or there is faulty contact.

5) A wire is disconnected.

6) The control board’s low pressure pressure sensor input circuit is defective.

1) Poor operations of indoor LEV.

2) Poor operations of outdoor LEV1

3) Poor operations of ball valve.

4) Short cycle of indoor unit.

5) Clogging of indoor unit filter.

6) Fall in air volume caused by dust on indoor unit fan.

7) Dust on indoor unit heat exchanger.

8) Indoor unit fan block, motor trouble.

8)~13) : Rise in high pressure caused by lowered condensing capacity in heating-only and heating-principal operation.

9) Short cycle of outdoor unit.

10)

Dust on outdoor unit heat exchanger .

11)

Outdoor unit fan block, motor trou-ble ,

poor operations of fan controller.

14)~16):Rise in high press. caused by lowered condensing capacity in cooling-only and cooling-pincipal operation.

12)Poor operations of solenoid valves SV1 (Bypass valv es (SV1) can not control rise in high pressure).

13)Thermistor trouble (TH2, TH5, TH6).

14)Pressure sensor trouble.

15)Control circuit board thermistor trouble, press. sensor input circuit trouble.

Refer to the item on judging low pressure pressure sensor failure.

Check operations status by actually performing cooling or heating operations.

Cooling : Indoor LEV

LEV1

Heating : Indoor LEV

See Trouble check of LEV and sole-

noid valve.

Confirm that ball valve is fully open-ed. Check indoor unit and take measures

to trouble.

Check outdoor unit and take measures to trouble.

Check outdoor unit fan See Trouble check of outdoor unit

fan.

See T r ouble check of solenoid v alve.

Check resistance of thermistor. Check Trouble check of pressure

sensor.

Check inlet temperature and press. of sensor with LED monitor.

-1.5

2.74MPa

or more during

When a pressure of 2.74MPa or more is detected again (the second time) within 30 minutes after first stop of outdoor unit, mode is changed to restart mode after 3 minutes, then the outdoor unit restarts.

Page 84

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Checking code Meaning, detecting method Cause Checking method & Countermeasure

1302 High pressure

abnoramlity 2 (Outdoor unit)

When press. sensor detects

0.098MPa

or less just before starting of operation, erro stop is observed with code No. “1302” displayed.

1) Fall in internal press. caused by gas leak.

2) Press. sensor trouble.

3) Film breakage.

4) Coming off of pin in connector portion, poor contact.

5) Broken wire.

6) Press. sensor input circuit trouble on control circuit board.

See Trouble check of pressure sen-

sor.

1500

Overcharged refrigerant abnormality

1) Excessive refrigerant charge.

Main circuit board thermistor input circuit trouble

Thermistor mounting trouble (TH1, TH2)

Refer to the section on judging the refrigerant volume.

Check the sensor detection temperature and pressure with the LED monitor.

If the discharge SH≤10K is detected during operation (at first detection), the outdoor unit stops at once. The 3minute restart prevention mode is entered. After three minutes, the outdoor unit starts up again.

If the discharge SH≤10K is detected again within 30 minutes after the outdoor unit stops (second detection), an abnormal stop is applied, and "1500" is displayed.

If discharge SH≤10K is detected more than 30 minutes after the outdoor unit stops, the state is the same as the first detection and the same operation as 1 above takes place.

The abnormal stop delay period is in effect for 30 minutes after the outdoor unit stops. The abnormal stop delay period LED turns ON during this time.

If the abnormality detection prohibit switch (SW2-4) is ON, the same operation as the first detection will apply for the second and following detections.

–

2500

2502

2503

Leakage (water) abnormality

Drain pump abnormality

Drain sensor abnormality

Operation of float switch

When drain sensor detects flooding during drain pump OFF.

When indirect heater of drain sensor is turned on, rise in temperature is 20 deg. or less (in water) f or 40 seconds, compared with the temperature detected before turning on the indirect heater.

Short/open is detected during drain pump operations. (Not detected when drain pump is not operating.) Short : 90˚C or more detected Open : -40˚C or less detected

When float switch operates (point of contact : OFF), error stop is observed with code No. “2503” displayed.

1) Water leak due to humidifier or the like in trouble.

1) Drain sensor sinks in water because drain water level rises due to drain water lifting-up mechanism trouble.

2) Broken wire of indirect heater of drain sensor.

3) Detecting circuit (circuit board) trouble.

1) Thermistor trouble.

2) Poor contact of connector. (insufficient insertion)

3) Full-broken of half-broken thermistor wire.

4) Indoor unit circuit board (detecting circuit) trouble.

Check water leaking of humidifier and clogging of drain pan.

Check operations of drain pump.

Measure resistance of indirect heater of drain sensor. (Normal: Approx. 82Ω between 1-3 of CN50)

Indoor board trouble if no other problems is detected.

Check resistance of thermistor.

0˚C : 15kΩ 10˚C : 9.7kΩ 20˚C : 6.4kΩ 40˚C : 3.1kΩ

30˚C : 4.3kΩ

Check contact of connector. Indoor port trouble if no other problem is detected.

Drain up input trouble. Poor contact of float switch circuit. Float switch trouble.

Check drain pump operations. Check connect contact. Check float switch operations.

Page 85

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Checking code Meaning, detecting method Cause Checking method & Countermeasure

4103

4115

Reverse phase abnormality

Power supply sync signal abnormality

Reverse phase (or open phase) in the power system is being detected, so operation cannot be started.

The frequency cannot be determined when the power is switched on. (The power supply’s frequency cannot be detected. The outdoor fan cannot be controlled by phase control.)

1) The phases of the power supply (L1, L2, L3) have been reversed.

2) Open phase has occurred in the power supply (L1, L2, L3, N).

3) The wiring is faulty.

4) The fuse is faulty.

5) T01 is faulty.

6) The circuit board is faulty.

1) There is an open phase in the power supply (L1, L2, L3, N).

2) The power supply voltage is distorted.

3) A fuse is defective.

4) T01 is defective.

5) The circuit board is defective.

If there is reverse phase before the breaker, after the breaker or at the power supply terminal blocks TB1A, reconnect the wiring.

Check before the breaker, after the breaker or at the power supply terminal blocks TB1A, and if there is an open phase, correct the connections.

a) Check if a wire is disconnected. b) Check the voltage between each

of the wires.

Check 1 the connections, 2, the contact at the connector, 3, the tightening torque at screw tightening locations and 4 for wiring disconnections. TB1A~NF~TB1B~CNTR1~F3~ T01~CNTR Refer to the circuit number and the wiring diagram plate.

If F1 on the MAIN board, or F3 is melted, (Resistance between both ends of the fuse is ∞), replace the fuses.

To judge failure of the T01, go to “Indi- vidual Parts Failure Judgment Methods.”

If none of the items in 1) to 5) is applicable, and if the trouble reappears e ven after the power is switched on again, replace the MAIN board (when replacing the circuit board, be sure to connect all the connectors, etc. securely).

Check before the breaker, after the breaker or at the power supply terminal blocks TB1A, and if there is an open phase, correct the connections.

If the power supply voltage waveform is distorted from a sine wave, improve the power supply environment.

If F1 on the MAIN board, or F2 is melted, (Resistance between both ends of the fuse is ∞), replace the fuses.

To judge failure of the T01, go to “Indi- vidual Parts Failure Judgment Methods.”

If none of the items in 1) to 4) is applicable, and if the trouble reappears e ven after the power is switched on again, replace the MAIN board (when replacing the circuit board, be sure to connect all the connectors, ground wires, etc. securely).

Page 86

- 80 -

Checking code Meaning, detecting method Cause Checking method & Countermeasure

4116 Fan speed

abnormality (motor abnoramlity)

(Detects only for PKFY-VAM)

1. Detecting fan speed below 180rpm or over 2000rpm during fan operation at indoor unit (first detection) enters into the 3-minute restart prevention mode to stop fan for 30 seconds.

2. When detecting fan speed below 180rpm or over 2000rpm again at fan returning after 30 seconsd from fan stopping, error stop (fan also stops) will be commenced displaying 4116.

1) Disconnection of fan speed detecting connector (CN33) of indoor controller board.

2) Disconnection of fan output connector (FAN1) of indoor power board.

3) Disconnection of fan speed detecting connector (CN33) of indoor controller board, or that of fan output connector (FAN1) of indoor power board.

4) Filter cologging.

5) Trouble of indoor fan motor.

6) Faulty fan speed detecting circuit of indoor controller board, or faulty fan output circuit of indoor power board.

• Confirm disconnection of connector (CN33) on indoor controller board.

• Confirm disconnection of connector (FAN1) on indoor power board.

• Check wiring for disconnection.

• Check filter.

• Check indoor fan motor.

• When aboves have no trouble.

1) For trouble after operating fan. Replace indoor controller board. If not remedied, replace indoor power board.

2) For trouble without operating fan. Replace indoor power board.

Page 87

- 81 -

4220

Checking code

Meaning, detection procedure

Cause Check method & Countermeasure

Bus voltage drop protection (Error details No. 108.)

If Vdc 289V is detected during inverter operation.

Bus voltage rise protection (Error details No. 109.)

If Vdc 817V is detected during inverter operation.

1) Power environment Check if an instantaneous stop or power failure, etc. has occurred. Check if the power supply voltage 289V across all phases.

3) INV board failure Check that DC12V is being applied to the INV board connector CN52C during inverter operation.

4) 52C failure

Refer to VII.¢.5(4) -"52C coil resistance check" Check the voltage across the 52C points during inverter operation .

5) Diode stack failure

Refer to VII.¢.4(6). Check the diode stack resistance.

1) Abnormal voltage

connection

VDC error (Error details No. 110.)

Bus voltage error If Vdc 772V or Vdc 308V is detected.

Logic error (Error details No. 111.)

If only the H/W error logic circuit operates, and no identifiable error is detected.

1) Same as error details

No. 108 and 109 for 4220 error.

Check the voltage at the power terminal board (TB1).

Replace the INV board if there is no problem with the power supply.

Same as error details No. 108 and 109 for 4220 error.

2) INV board failure

1) External noise Refer to ¶ [1] (7) 1) [7] "Malfunction due to external noise".

Replace the INV board if the error detects even after turning on again.

2) INV board failure

Check the voltage between the G/A board P-N.

Go to 3) if there is no voltage drop. Check the G/A board CNDC1 voltage. Replace the G/A board if a

voltage drop is detected. Check the INV board connector CNDC2 voltage.

If there is a voltage drop, the

wiring connection is

defective. Check the INV board connector CNDC2 solder joints.

2) Voltage drop detected

Page 88

- 82 -

4230

4240

Checking code

Meaning, detection procedure

Cause Check method & Countermeasure

Heat sink overheat protection

If the cooling fan stays ON for 5 minutes or longer during inverter operation, and if THHS 95°C is detected.

Overload protection

The output current (Iac) Imax(Amps) or THHS 85°C is detected continuously for 10 minutes during operation of the inverter. Imax=27Amps

1) Power supply environment

Check the power supply voltage. Ensure that the power supply voltage 342V across all phases.

Check to make sure the air passage of the heat sink cooling is not blocked.

Check the cooling fan wiring.

Check the THHS sensor resistance.

3) Wiring defect

Ensure that the heat sink temperature is 55°C or more and that 220~240V is applied to the inverter PCB connector CNFAN when the inverter is on.

4) THHS failure

5) INV board fan output failure

6) Cooling fan failure

4) Wiring defect

5) THHS failure

6) INV board fan output failure

7) Cooling fan failure

8) Current sensor (ACCT) failure

9) Inverter circuit failure

10) Compressor failure

Check the cooling fan operation under the above operating conditions.

Ensure that the heat sink temperature is 55°C or more and that 220~240V is applied to the inverter PCB connector CNFAN when the inverter is on.

Check the cooling fan operation under the above operating conditions.

Refer to ¶ [1] (7) 4) "Current sensor ACCT"

Refer to ¶ [1] (7) 2) [4] "Inverter damage check"

Check that the compressor has not overheated during operation.

Check the refrigerant circuit (oil return section). Replace the compressor if there are no problems with the refrigerant circuit.

7) IPM failure Refer to ¶ [1] (7) 2)

[2] "Check for compressor ground fault or coil error" [5] "Check for inverter circuit trouble"

1) Air passage short cycle Ensure that a short cycle has

not occurred at the unit fan exhaust.

Check to make sure the air passage of the heat sink cooling is not blocked.

2) Air passage blockage

Check if the power supply voltage 342V.

3) Power supply

2) Air passage blockage

Page 89

- 83 -

4250

4260

Checking code

Meaning, detection procedure

Cause Check method & Countermeasure

IPM error (Error details No. 101)

IPM error signal detected

ACCT overcurrent break error (Error details No. 102) DCCT overcurrent break error (Error details No. 103) Overcurrent break error (Error details No. 106, 107)

Overcurrent break (94Apeak or 35Amps) detected by the current sensor.

IPM short/grounding fault (Error details No. 104)

IPM short damage or grounding at the load side detected just before starting the inverter.

Load short error (Error details No. 105)

Shorting at the load (compressor) side detected just before starting the inverter.

Cooling fan error

If the heat sink temperature (THHS) 95°C for 10 minutes or over when the inverter starts.

1) Inverter output related VII ¢ 5 (2) inverter output related trouble processing Refer to [1] - [5].

¶ [1] (7) 2) inverter output related trouble processing Refer to [1] - [5].

Same as 4230 error

1) Inverter output related

1) Compressor grounded Refer to ¶ [1] (7) 2) [2] "Check for compressor ground fault or coil error".

2) Inverter output related Refer to ¶ [1] (7) 2) [5] "Check for inverter circuit trouble".

1) Compressor grounded Refer to ¶ [1] (7) 2) [2] "Check for compressor ground fault or coil error".

Short circuit check

2) Output wiring

Check if the power supply voltage 342V.

3) Power supply

2) Same as 4230 error

Same as 4230 error1) Same as 4230 error

Page 90

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Checking code Meaning, detecting method Cause Checking method & Countermeasure

5101

5102

5105

5106

5107

5108

5110

<Other than THHS> 1 A short in the thermistor or an

open circuit was sensed. The outdoor unit switches to the temporary stop mode with restarting after 3 minutes, then if the temperature detected by the thermistor just before restarting is in the normal range, restarting takes place.

2 If a short or open circuit in the

thermistor is detected just before restarting, error code

“5101”, “5102”, “5103”, “5104”, “5105”, “5106”, “5108”, “5109” or “5112” is displayed.

3 In the 3 minute restar t mode,

the abnormal stop delay LED is displayed.

4 The above short or open circuit

is not detected for 10 minutes after the compressor starts, or for 3 minutes during defrosting or after recovery following de-

frosting. <THHS> If a heat sink (THHS) temperature of -40°C is detected just after the inverter starts or during inverter operation.

Discharge (TH1)

Low pressure saturation (TH2)

Heat exchanger inlet pipe (TH5)

Ambient temperature (TH6)

Heat exchanger outlet pipe (TH7)

SC coil bypass outlet (TH8)

Radiator panel (THHS)

Thermal sensor abnormality (Outdoor Unit)

Check the thermistor’s resistance. Check if the lead wires are pinched. Check for tearing of the insulation. Check if a pin is missing on the con-

nector. Check if a wire is disconnected. Check the temperature picked up by

the sensor using the LED monitor. If the deviation from the actual temperature is great, replace the MAIN circuit board. (In the case of the THHS, replace the INV board.)

1) Thermistor

2) Lead wires are being pinched.

3) Insulation is torn.

4) A connector pin is missing, or there is faulty contact.

5) A wire is disconnected.

6) The thermistor input circuit on the MAIN circuit board is faulty. (In the case of the THHS, replace the INV board.)

Short Circuit Detection Open Circuit Detection

TH1 240°C or higher (0.57 kΩ)15°C or lower (321 kΩ) TH2 70°C or higher (1.71 kΩ) -40°C or lower (130 kΩ) TH5 110°C or higher (0.4 kΩ) -40°C or lower (130 kΩ) TH6 110°C or higher (0.4 kΩ) -40°C or lower (130 kΩ) TH7 110°C or higher (1.14 kΩ) -40°C or lower (130 kΩ) TH8 70˚C or higher (1.14 kΩ) -40°C or lower (130 kΩ) THHS – -40°C or lower (2.5 MΩ)

Page 91

- 85 -

Checking code Meaning, detecting method Cause Checking method & Countermeasure

5201

5301

Pressure sensor abnormality (outdoor unit)

ACCT sensor error (Error details No. 115)

DCCT sensor error (Error details No. 116)

When pressue sensor detects

0.098MP

a or less during operation, outdoor unit once stops with 3 min ut es re st ar tin g mode, and restarts if the detected pressure of pressure sensor exceeds 0.098 MPa imediately before restarting.

2 If the detected pressure of sen-

sor is less than

0.098MPa immediately before restarting, error stop is commenced displaying 5201.

3 Under 3 minutes restar ting

mode, LED displays intermittent fault check.

4 Dur ing 3 minutes after com-

pressor start, defrosting and 3 minutes after defrosting operations, trouble detection is ignored.

1) Pressutre sensor trouble.

2) Inner pressure drop due to a leakage.

3) Broken cover.

4) Coming off of pin at connector portion, poor contact.

5) Broken wire.

6) Faulty thermistor input circuit of MAIN board.

See Troubleshooting of pressure sensor.

1.5Amps output current's effective value 1.5Amps was detected during inverter operation.

Check the INV board CNCT2 (ACCT) contact, CNDR2 and G/A Board CNDR1.

1) Contact is faulty.

The start current detected by DCCT is too low

Check the connector connection on the INV board CNCT (DCCT), DCCT side.

1) Contact is faulty.

Check DCCT installation direction

2) DCCT sensor incorrectly installed Replace the DCCT sensor

3) DCCT sensor is faulty. Replace the INV board

4) INV board fault

Replace the ACCT sensor

2) ACCT sensor is faulty.

ACCT sensor circuit error (Error details No. 117)

An abnormal value was detected with the ACCT detection circuit just before the INV started.

Refer to¶ [1] (7) 2) [1]. [Check INV board error detection circuit]

1) INV board fault

Refer to ¶ [1] (7) 2) [2]. "Check compressor ground fault" and winding error". Refer to ¶ [1] (7) 2) [5]. "Check inverter circuit fault".

2) Compressor ground fault and IPM fault.

Page 92

- 86 -

Checking code Meaning, detecting method Cause Checking method & Countermeasure

IPM open/CNCT2 dislocation error (Error details No. 119)

IPM open damage or CNCT2 dislocation was detected just before INV started. (Sufficient current was not detected during self-diagnosis just before starting.)

Check CNCT2 sensor connection (Check ACCT installation state)

Refer to

¶ [1] (7) 4)

Check "current

sensor ACCT" resistance value

1) ACCT sensor is dislocated

Incorrect wiring detection error (Error details No. 120)

Improper installation of the ACCT sensor was detected.

Refer to ¶ [1] (7) 4). "Current sensor ACCT"

1) ACCT sensor incorrectly installed.

2) Wire connection is faulty.

Check CNDR2 connection on INV board, or CNDR1 connection on G/A board

2) INV board fault

3) ACCT is faulty.

Refer to ¶ [1] (7) 2) [5]. "Check inverter circuit fault".

5) Inverter circuit is faulty.

Refer to ¶ [1] (7) 2) [2]. "Check compressor ground fault" and winding error"

4) Compressor is disconnected

DCCT sensor circuit error (Error details No. 118)

An abnormal value was detected with the DCCT detection circuit just before the INV started.

Check the contacts around the INV board connector CNCT and DCCT side connector

If there is no problem up to step 2), replace DCCT and check the DCCT polarity.

1) Contact is faulty.

Refer to¶ [1] (7) 2) [1]. [Check INV board error detection circuit]

3) DCCT is faulty.

Refer to ¶ [1] (7) 2) [2]. "Check compressor ground fault" and winding error" Refer to ¶ [1] (7) 2) [5]. "Check inverter circuit fault".

5) Compressor ground fault and IMP

fault.

Refer to ¶ [1] (7) 2) [2]. "Check compressor ground fault" and winding error" Refer to ¶ [1] (7) 2) [5]. "Check inverter circuit fault".

4) Compressor is faulty.

Inverter circuit is fault.

5301

ACCT_U

ACCT_W

IPM-output phase U

IPM-output phase W

Compressor-input phase U

Compressor-input phase W

Red wire

Black wire

Page 93

- 87 -

(2) Communication/system

Checking

code

6600

6602

Multiple address error Transmission from units with the

same address is detected.

Note:

The address/attribute shown on remote controller indicates the controller which has detected error.

T ransmission processor hardw are error

Though transmission processor intends to transmit “0”, “1” is displayed on transmission line.

Note:

The address/attribute shown on remote controller indicates the controller which has detected error.

Meaning, detecting method Cause Checking method & Countermeasure

At the genration of 6600 error, release the error by remote controller (with stop key) and start again. a) If the error occures again within 5 minutes.

Search f

or the unit which has the same address

with that of the source of the trouble.

When the same address is found, turn off the power source of outdoor unit, BC controller, and indoor unit for 5 min utes or more after modifying the address, and then turn on it again.

b)When no trouble is generated even continuing

operation over 5 minutes.

The transmission wave shape/noise on the transmission line should be investigated in accordance with <Investigation method of transmission wave shape/noise>.

1) Two or more controllers of outdoor unit, indoor unit, remote controller, BC controller, etc. have the same address.

2) In the case that signal has changed due to noise entered into the transmission signal.

1) At the collision of mutual transmission data generated during the wiring work or polarity change of the transmission line of indoor or outdoor unit while turning the power source on, the wave shape is changed and the error is detected.

2) 100V power source connection to indoor unit or BC controller.

3) Ground fault of transmission line.

4) Insertion of power supply connector (CN40) of plural outdoor units at the grouping of plural refrigerant systems.

5) Insertion of power supply connector (CN40) of plural outdoor units in the connection system with MELANS.

6) Faulty controller of unit in trouble.

7) Change of transmission data due to the noise in transmission.

8) Connection system with plural refrigerant systems or MELANS for which voltage is not applied on the transmission line for central control.

Page 94

- 88 -

T ransmission processor hardw are error

Transmission circuit bus-busy error 1 Collision of data transmission:

Transmission can not be performed for 4~10 consecutive minutes due to collision of data transmission.

2 Data can not be transmitted on

transmission line due to noise for 4~10 consecutive minutes.

Note:

The address/attribute shown on remote controller indicates the controller which has detected error.

Checking method and processing

1) As the voltage of short frequency like noise is mixed in transmission line continuously , transmission processor can not transmit.

2) Faulty controller of generating unit.

a) Check transmission wav e shape/noise on trans-

mission line by following <Investigation method of transmission wave shape/noise>. No noise indicates faulty controller of generating unit. Noise if existed, check the noise.

Checking

code

6602

6603

Meaning, detecting method Cause Checking method & Countermeasure

Transmission line

installed while turning

power source on?

Check power source of indoor unit.

220V ~ 240V?

Shut off the power source of outdoor/indoor units/BC controller and make it again.

Erroneous power source work

Erroneous transmission work

Check transmission line work and shield

Ground fault or shield

contacted with transmission

line?

System composition?

Single refrigerant system

Investigation of transmission line noise

Modification of faulty point

Replace insertion of CN40 to CN41

CN40 inserted?

Confirm supply power connector CN40 of outdoor unit

MELANS connected system

Investigation of the cause of noise

❇

For the investigation method, follow <Investigation method of transmission wave shape/noise>

Modification of CN40 insertion method.

Only 1 set with

CN40 inserted?

Noise exist?

Faulty controller of generating unit

Plural refrigerant system

Confirm supply power connector CN40 of outdoor unit

YES

Page 95

- 89 -

Checking

code

6606

Meaning, detecting method Cause Checking method & Countermeasure

1) Data is not properly transmitted due to casual errouneous operation of the generating controller.

2) Faulty generating controller.

Communications with transmission processor error

Communication trouble between apparatus processor and transmission processor.

Note:

The address/attribute shown on remote controller indicates the controller which has detected error.

Turn off power sources of indoor unit, BC controller and outdoor unit.

When power sources are turned off separately, microcomputer is not reset and normal operations can not be restored.

Controller trouble is the source of the trouble when the same trouble is observed again.

Checking

code

6607

Meaning, detecting method

No ACK error When no ACK signal is detected in 6 continuous times with 30 second interval by

transmission side controller, the transmission side detects error.

Note: The address/attribute shown on remote controller indicates the controller

not providing the answer (ACK).

1 Outdoor

unit (OC)

2 BC

controller (BC)

3 Indoor

unit (IC)

4 Remote

controller (RC)

(1) Single refrigerant system

Remote controller (RC)

System compo-

sition

Generating

unit address

Display of

trouble

Detecting

method

Cause Checking method & countermeasure

No reply (ACK) at BC transmission to OC

No reply (ACK) at IC transmission to BC

No reply (ACK) at RC transmission to IC

No reply (ACK) at IC transmission to RC

1) Poor contact of transmission line of OC or BC.

2) Damping of transmission line voltage/signal by acceptable range of transmission wiring exceeded.

Farthest : Less than 200m Remote controller wiring : Less than 10m

3) Erroneous sizing of transmission line (Not within the range below). Wire diameter : 1.25mm

or more

4) Faulty control circuit board of OC.

1) When Fresh Master address is changed or modified during operation.

2) Faulty or disconnection of transmission wiring of BC controller.

3) Disconnection of BC unit connector (CN02).

4) Faulty BC controller circuit board.

1) When IC unit address is changed or modified during operation.

2) Faulty or disconnection of transmission wiring of IC.

3) Disconnection of IC unit connector (CN2M).

4) Faulty IC unit controller.

5) Faulty remote controller.

1) Faulty transmission wiring at IC unit side.

2) Faulty transmission wiring of RC.

3) When remote controller address is changed or modified during operation.

4) Faulty remote controller.

Shut down OC unit power source, and make it again. It will return to normal state at an accidental case. When normal state can not be recovered, check for the 1) ~ 4) of the cause.

Shut down both OC and BC power sources simultaneously for 5 minutes or more, and make them again. It will return to normal state at an accidental case. When normal state can not be recovered, check for the 1) ~ 4) of the cause.

Shut down OC power sources f or 5 minutes or more, and make it again. It will return to normal state at an accidental case. When normal state can not be recovered, check for the 1) ~ 4) of the cause.

Page 96

- 90 -

Checking

code

6607

(continued)

Meaning, detecting method

System compo-

sition

Generating

unit address

Display of

trouble

Detecting

method

Cause Checking method & countermeasure

No ACK error When no ACK signal is detected in 6 continuous times with 30 second

interval by transmission side controller, the transmission side detects error.

Note: The address/attribute shown on remote controller indicates the

controller not providing the answer (ACK).

1 Outdoor

unit (OC)

2 BC

controller (BC)

3 Indoor

unit (IC)

4 Remote

controller (RC)

Remote controller (RC)

No reply (ACK) at BC transmission to OC

No replay (ACK) at IC transmission to BC

No reply (ACK) at RC transmission to IC

No reply (ACK) at IC transmission to RC

As same that for single refrigerant system.

1) Cause of 1) ~ 5) of “Cause for single refrigerant system”.

2) Disconnection or short circuit of transmission line of OC t e r minal block for centralized control(TB7).

3) Shut down of OC unit power source of one re-frigerant system.

4) Neglecting insertion of OC unit power supply connector (CN40).

5) Inserting more than 2 sets of power supply connector (CN40) for centralized control use .

For generation after normal operation conducted once, the following causes can be considered.

• Total capacity error (7100)

• Capacity code setting error (7101)

• Connecting set number error (7102)

• Address setting error (7105)

1) Cause of 1) ~ 3) of “Cause for single refrigerant system”.

2) Disconnection or short circuit of transmission line of OC te rminal block for centralized control(TB7).

3) Shut down of OC unit power source of one refrigerant system.

4) Neglecting insertion of OC unit power supply connector (CN40).

5) Inserting more than 2 sets of power supply connector(CN40) for centralized control use.

At generation after normal operation conducted once, the following causes can be considered.

• Total capacity error (7100)

• Capacity code setting error (7101)

• Connecting set number error (7102)

• Address setting error (7105)

Same as measure for single refrigerant system.

a) Shut down the power source of both

IC and OC for over 5 minutes simultaneously, and make them again. Normal state will be returned incase of accidental trouble.

b) Check for 1) ~ 5) of causes. If cause

is found, remedy it.

c) Check other remote controller or OC

unit LED for troubleshooting for trouble.

Trouble

Modify the trouble according to the content of check code.

No trouble Faulty indoor con-

troller

a) Shut down the power source of OC

for over 5 minute, and make it again. Normal state will be returned in case of accidental trouble.

b) Check for 1) ~ 5) of causes. If cause

is found, remedy it. When normal state can not be obtained, check 1) ~ 5) of causes.

(2) Group oper

ation system using plur

al refrigerants

Page 97

- 91 -

Checking

code

6607

(continued)

Meaning, detecting method

System compo-

sition

Generating

unit address

Display of

trouble

Detecting

method

Cause Checking method & countermeasure

No ACK error When no ACK signal is detected in 6 continuous times with 30 second

interval by transmission side controller, the transmission side detects error.

Note: The address/attribute shown on remote controller indicates the

controller not providing the answer (ACK).

(3) Connecting system with system controller (MELANS)

1 Outdoor

unit (OC)

2 BC

controller (BC)

3 Indoor

unit (IC)

4 Remote

controller (RC)

Remote controller (RC)

No reply (ACK) at BC transmission to OC

No reply (ACK) at RC transmission to IC

No reply (ACK) at transmission of SC to IC

No reply (ACK) at transmission of IC to RC

No reply (ACK) at transmission of MELANS to RC

As same that for single refrigerant system.

Same cause of that for grouping from plural refrigerants.

Trouble of partial IC units:

1) Same cause as that for single refrigerant system.

Trouble of all IC in one refrigerant system:

1) Cause of total capacity error. (7100)

Cause of capacity code setting error. (7101)

3) Cause of connecting number error. (7102)

4) Cause of address setting error. (7105)

5) Disconnection or short circuit of transmission line of OC unit terminal block for central control(TB7).

6) Power source shut down of OC unit.

7) Trouble of OC unit electrical system.

Trouble of all IC:

1) As same that for single refrigerant system.

2) Insertion of power supply connector (CN40) into OC unit transmission line for centralized control.

3) Disconnection or p ower source shut down of power supply unit for transmission line.

4) Faulty system controller (MELANS).

Same cause as that for plural refrigerant system.

Trouble of partial IC units:

1) Same cause of that for single refrigerant system.

Trouble of all IC in one refrigerant system:

1) Error detected by OC unit. Total capacity error. (7100) Capacity code setting error.(7101) Connecting number error. (7102) Address setting error. (7105)

2) Disconnection or short circuit of transmission line of OC unit terminal block for central control(TB7).

3) Power source shut down of OC unit.

4) Trouble of OC unit electrical system.

Trouble of all IC:

1) As same that for single refrigerant system.

2) Insertion of power supply connector (CN40) into OC unit transmission line for central-ized control.

3) Disconnection or power shutdown of po wer supply unit for transmission line.

4) Faulty MELANS.

Same countermeasure as that for single refrigerant system.

Same countermeasure as that for IC unit error in plural refrigerant system.

Same countermeasure as that for single refrigerant system.

Confirm OC trouble diagnosis LED.

At trouble generation, check for the content according to check code.

Check the content of 5)~7) shown left.

Confirm voltage of transmission line for centralized control.

• More than 20V Confirm 1) 2) left.

• Less than 20V Confirm 3) left.

Same countermeasure as that for plural refrigerant system.

Same countermeasure as that for single refrigerant system.

Confirm OC trouble diagnosis LED.

At trouble generation, check for the content according to check code.

Check the content of 2)~4) shown left.

Check the causes of 1) ~ 4) left.

Page 98

- 92 -

Checking

code 6607

(continued)

Meaning, detecting method

System compo-

sition

Generating

unit address

Display of

trouble

Detecting

method

Cause Checking method & countermeasure

No ACK error When no ACK signal is detected in 6 continuous times with 30 second

interval by transmission side controller, the transmission side detects error.

Note: The address/attribute shown on remote controller indicates the

controller not providing the answer (ACK).

(3) Connecting system with system controller (MELANS)

5 System

controller (SC)

Address which should not be existed

Remote controller (RC)

Trouble of partial remote controller:

1) Faulty wiring of RC transmission line.

2) Disconnection or poor contact of RC trans

-mission connector.

3) Faulty RC. Trouble of all IC in one refrigerant system.

1) Error detected by OC unit. Total capacity error (7100) Capacity code setting error (7101) Connecting number error (7102) Address setting error (7105)

2) Disconnection or short circuit of transmission

line of OC unit terminal block for central control(TB7).

3) Power source shut down of OC unit.

4) Trouble of OC unit electrical system.

Trouble of all RC:

1) As same that for single refrigerant system.

2) Inserting supply power connector (CN40) to

OC transmission line for centralized control.

3) Disconnection or power shutdown of power

supply unit for transmission line.

4) Faulty MELANS.

1) IC unit is keeping the memory of the original

group setting with RC although the RC address was changed later.

The same symptom will appear for the regis-

tration with SC.

2) IC unit is keeping the memory of the original

interlocking registration with Fresh Master with RC although the Fresh Master address was changed later.

No reply (ACK) at transmission of IC to SC

Check 1) ~ 3) left.

Confirm OC trouble diagnosis LED.

At trouble generation, check for the content according to check code.

Check the content of 2) ~ 4) shown left.

Check the causes 1)~4) left.

As some IC units are keeping the memory of the address not existing, delete the information. Employ one of the deleting method among two below.

1) Deletion by remote controller. Delete unnecessary information by the manual setting function of remote controller.

2) Deletion by connecting information deleting switch of OC unit.

Be careful that the use of this method will delete all the group information set with RC and all the interlocking information of Fresh Master and IC unit.

1 Shut down OC unit power source,

and wait for 5 minutes.

2 Turn on the dip switch SW2-2 pro-

vided on OC unit control circuit board.

3 Make OC unit power source, and

wait for 5 minutes.

4 Shut down OC unit power source,

and wait for 5 minutes.

5 Turn off the dip switch SW2-2 pro-

vided on OC unit control circuit board.

6 Make OC unit power source.

No relation with system

Page 99

- 93 -

7105 Address setting error

• Erroneous setting of OC unit address

Trouble source : Outdoor unit

2) The Outdoor unit address is being set to 51~100 under automatic address mode (Remote controller displays “HO”).

3) Disconnection of transmission wiring at Outdoor unit.

4) Short circuit of transmission line in case of 3) & 4), remote controller displays “HO”.

1) Setting error of Outdoor unit address. The address of Outdoor unit is not being set to 51~100.

d) Check for the model total (capacity code total)

of indoor units connected.

Check that the address of OC unit is being set to 51~100. Reset the address if it stays out of the range, while shutting the power source off.

1) Total capacity of indoor units in the same refrigerant system exceeds the following:

2) Erroneous setting of OC model selector switch (SW3-10).

1) The Indoor unit model name (model code) connected is not connectable.

Connectable range.....20~250

2) Erroneous setting of the switch (SW2) for setting of model name of Indoor unit connected.

1) Number of unit connected to terminal block (TB3) for outdoor/indoor transmission line exceeds limitations given be-lows:

Item Limitation

Total of 200:1~13 Indoor unit 250:1~16

Total of Indoor unit & RC

1~35

(3) System error

Checking

code 7100

7101

7102

Meaning, detecting method Cause Checking method & Countermeasure

Total capacity error

Total capacity of indoor units in the same refrigerant system exceeds limitations.

Trouble source: Outdoor unit

Capacity code error

Error display at erroneous connection of Indoor unit of which model name can not be connected.

Trouble source : Outdoor unit Indoor unit

Connected unit count over

Number of units connected in the same refrigerant system exceeds limitations.

Trouble source: Outdoor unit

a) Check for the model total (capacity cord total) of

indoor units connected.

b) Check whether indoor unit capacity code (SW2)

is wrongly set. For erroneous switch setting, modify it, turn off

power source of outdoor unit, and indoor unit simultaneously for 5 minutes or more to modify the switch for setting the model name (capacity coad).

Check for the model selector switch (Dip switches SW3-10 on outdoor unit control circuit) of OC.

a) Check for the model name of the Indoor unit

connected.

b) Check for the switch (SW2 if indoor controller

for setting of Indoor unit model name of generating address. When it is not agreed to the model name, modify the capacity code while shutting off the power source of Indoor unit.

❇

The capacity of Indoor unit can be confirmed by

the self-diagnosios function (SW1 operation) of Indoor unit.

a) Check whether the connection of units to the

terminal block for indoor/outdoor transmission wiring (TB3) of outdoor unit is not exceeding the

limitation. b) Check for 2), 3), and 4). c) Check for the connection of transmission wiring

to the terminal block for centralized control is

erroneously connected to the indoor/outdoor

transmission wiring terminal block (TB3).

Model Total capacity code

200

250

ON 250 OFF 200

2345

SW3

678910

.....

...

Page 100

- 94 -

Different unit model error

An exclusive R22 refrigerant indoor unit was connected to a R407C refrigerant outdoor unit.

7111 Remote control sensor error

Error not providing the temperature designed to remote controller sensor.

Trouble source : Indoor unit

1) In case when the old type remote

1) Transmission booster is faulty.

2) Power supply of transmission booster has been cut.

controller for M-NET is used and the remote controller sensor is designed on indoor unit. (SW1-1 turned ON)

a) Replace the old remote controller by the new

remote controller.

7110 Transmission line power failure. Check transmission booster and power supply.

Disconnection of plug on main board.

7113

7130

Main board connection failure. Check all main board connectors and rectify faulty

connection.

Checking

code

Meaning, detecting method Cause Checking method & Countermeasure

If the model name plate on the outdoor unit says that it is an exclusive R22 model, and if error “7130” has occurred, the MAIN board for the outdoor unit is a R407C model circuit board, so replace it with the MAIN board for the R22 model.

An error was made in the MAIN board of the outdoor unit (replaced with the wrong circuit board).

If the model name plate for the indoor unit is an exclusive R22 model, install a unit which can also operate with R407C

An error was made in selecting the indoor unit (installation error).

If the model name plate on the indoor unit indicates that it is also capable of operating with R407C, and error “7130” occurs , the indoor unit’s circuit board is for an exclusive R22 model, so replace it with the circuit board for a unit which is also capable of using R407C

If the refrigerant type shown on the model name plate on the outdoor unit and the settings shown in the refrigerant model recognition table do not match, change the settings so that they match.

The relation of the SWU3 and TH2 settings on the outdoor unit's main board establish the following errors.

An error was made in the indoor unit’s circuit board (replaced with the wrong circuit board).

SWU3

Exist

R407C

Refrigerant model recognition table

Different unit

model error

(7130)

Not exist

R407C

TH2

R22

Different unit

model error

(7130)

R22

Mitsubishi PUHY-P200YREM-A, PUHY-P250YREM-A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual