Mitsubishi PURY-HP72TKMU-A, PURY-HP192T, PURY-HP72TKMU-A-H, PURY-HP72YKMU-A, PURY-HP72YKMU-A-H Service Handbook

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Safety Precautions
Please read the following safety precautions carefully before installing the unit to ensure safety.
Indicates a risk of death or serious injury.
Indicates a risk of serious injury or structural damage.
Make sure that this manual is passed on to the end user to retain for future reference.Retain this manual for future reference. When the unit is reinstalled or repaired, have this manual available to those who pro-
vide these services. Make sure that this manual is passed on to any future users.
All electric work must be performed by qualified personnel. Air tightness test must be performed by qualified personnel.
[1] General Precautions
General Precautions
Do not use refrigerant other than the type in­dicated in the manuals provided with the unit and on the nameplate. Doing so may cause the unit or pipes to burst, or result in explosion or fire during use, during repair, or at the time of disposal of the unit. It may also be in violation of applicable laws. MIT­SUBISHI ELECTRIC CORPORATION cannot be held responsible for malfunctions or ac­cidents resulting from the use of the wrong type of refrigerant.
Do not install the unit in a place where large amounts of oil, steam, organic solvents, or corrosive gases, such as sulfuric gas, are present or where acidic/alkaline solutions or sprays containing sulfur are used fre­quently. These substances can compro­mise the performance of the unit or cause certain components of the unit to corrode, which can result in refrigerant leakage, wa­ter leakage, injury, electric shock, malfunc­tions, smoke, or fire.
Do not try to defeat the safety features of the unit or make unauthorized setting changes. Forcing the unit to operate the unit by de­feating the safety features of the devices such as the pressure switch or the tempera­ture switch, making unauthorized changes to the switch settings, or using accessories other than the ones recommended by Mit­subishi Electric may result in smoke, fire, or explosion.
To reduce the risk of shorting, current leak­age, electric shock, malfunctions, smoke, or fire, do not splash water on electric parts.
To reduce the risk of electric shock, mal­functions, smoke or fire, do not operate the switches/buttons or touch other electrical parts with wet hands.
To reduce the risk of pipe burst and explo­sion, do not allow gas refrigerant and refrig­erant oil to be trapped in the refrigerant circuit.
To reduce the risk of burns or frost bites, do not touch the refrigerant pipes or refrigerant circuit components with bare hands during and immediately after operation.
To reduce the risk of burns, do not touch any electrical parts with bare hands during or immediately after stopping operation.
To reduce the risk of injury from falling tools, keep children away while installing, inspecting, or repairing the unit.
Keep the space well ventilated. Refrigerant can displace air and cause oxygen starva­tion. If leaked refrigerant comes in contact with a heat source, toxic gas may be gener­ated.
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Always replace a fuse with one with the cor­rect current rating. The use of improperly rated fuses or a substitution of fuses with steel or copper wire may result in bursting, fire or explosion.
To reduce the risk of electric shock, smoke, and fire due to infiltration of dust and water, properly install all required covers.
To reduce the risk of electric shock, smoke, and fire due to infiltration of dust and water, properly install all required terminal block covers and insulation sheets.
To reduce the risk of electric shock, smoke, and fire due to infiltration of dust and water, properly install all required covers and pan­els on the terminal box and control box.
To reduce the risk of injury from units falling or falling over, periodically check the instal­lation base for damage.
Consult an authorized agency for the proper disposal of the unit. Refrigerant oil and re­frigerant that may be left in the unit pose a risk of fire, explosion, or environmental pol­lution.
To reduce the risk of fire or explosion, do not place flammable materials or use flam­mable sprays around the unit.
To reduce the risk of being caught in rotat­ing parts, electric shock, and burns, do not operate the unit without all required panels and guards being installed.
To reduce the risk of injury, do not sit, stand, or place objects on the unit.
The unit described in this manual is not in­tended for use with food, animals, plants, precision instruments, or art work.
To reduce the risk of water leakage and mal­functions, do not turn off the power immedi­ately after stopping operation. Leave the unit turned on for at least 5 minutes before turning off the power.
Do not install the unit over things that are vulnerable to water damage from condensa­tion dripping.
To reduce the risk of injury, electric shock, and malfunctions, do not touch or allow ca­bles to come in contact with the edges of components.
[2] Transportation and Installa tion
To reduce the risk of injury, do not touch the heat exchanger fins or sharp edges of com­ponents with bare hands.
Always wear protective gears when touch­ing electrical components on the unit. Sev­eral minutes after the power is switched off, residual voltage may still cause electric shock.
To reduce the risk of electric shock and burns, always wear protective gear when working on units.
To reduce the risk of injury, do not insert fin­gers or foreign objects into air inlet/outlet grills. If the unit is left on a damaged base, it may fall and cause injury.
To reduce the risk of injury, always wear protective gear when working on units.
Do not release refrigerant into the atmo­sphere. Collect and reuse the refrigerant, or have it properly disposed of by an autho­rized agency. Refrigerant poses environ­mental hazards if released into the air.
Transportation and Installation
Lift the unit by placing the slings at desig­nated locations. Support the outdoor unit securely at four points to keep it from slip­ping and sliding. If the unit is not properly supported, it may fall and cause personal injury.
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To reduce the risk of injury, do not carry the product by the PP bands that are used on some packages.
[3] Installation
Installation
To reduce the risk of injury, products weigh­ing 20 kg or more should be carried by two or more people.
Do not install the unit where there is a risk of leaking flammable gas. If flammable gas accumulates around the unit, it may ignite and cause a fire or explo­sion.
To reduce the risk of injury from coming in contact with units, install units where they are not accessible to people other than maintenance personnel.
To reduce the risk of injury, properly dis­pose of the packing materials so that chil­dren will not play with them.
Properly dispose of the packing materials. Plastic bags pose suffocation hazard to children.
All drainage work should be performed by the dealer or qualified personnel according to the instructions detailed in the Installa­tion Manual. Improper drainage work may cause water leakage and resultant damage to the furnishings.
Consult your dealer and take appropriate measures to safeguard against refrigerant leakage and resultant oxygen starvation. An installation of a refrigerant gas detector is recommended.
Any additional parts must be installed by the dealer or qualified personnel. Only use the parts specified by Mitsubishi Electric. Installation by unauthorized personnel or use of unauthorized parts or accessories may result in water leakage, electric shock, or fire.
Take appropriate safety measures against wind gusts and earthquakes to prevent the unit from toppling over and causing injury.
To reduce the risk of injury from units falling or falling over, install the unit on a surface that is strong enough to support its weight.
To reduce the risk of injury from units falling or falling over, periodically check the instal­lation base for damage.
Remove packing materials from the unit be­fore operating the unit. Note that some ac­cessories may be taped to the unit. Properly install all accessories that are required. Fail­ing to remove the packing materials or fail­ing to install required accessories may result in refrigerant leakage, oxygen depri­vation, smoke, or fire.
Do not install the unit over things that are vulnerable to water damage. Provide an ad­equate collective drainage system for the drain water from unit as necessary.
Do not install the unit over things that are vulnerable to water damage. When the in­door humidity exceeds 80% or if the drain water outlet becomes clogged, condensa­tion may drip from the indoor unit onto the ceiling or floor.
To reduce the risk of damage to the unit and resultant electric leak and electric shock, keep small animals, snow, and rain water from entering the unit by closing the gap in the pipe and wire access holes.
To reduce the risk of rain water or drain wa­ter from entering the room and damaging the interior, drainage work must be per­formed by your dealer or qualified person­nel according to the instructions detailed in the Installation Manual.
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To reduce the risk of drain water overflow, install the unit horizontally, using a level.
[4] Piping Work
Piping Work
To reduce the risk of injury, including frost bites, that may result from being blasted with refrigerant, use caution when operat­ing the refrigerant service valve. If refriger­ant leaks out and comes in contact with an open flame, toxic gases may be generated.
To reduce the risk of refrigerant catching fire and causing burns, remove the refriger­ant gas and the residual refrigerant oil in the pipes before heating them.
To reduce the risk of pipe damage, refriger­ant leakage, and oxygen deprivation, use pipes that meet the pipe thickness specifi­cations, which vary by the type of refriger­ant used, pipe diameter, and pipe material.
To reduce the risk of pipe burst or explo­sion, evacuate the refrigerant circuit using a vacuum pump, and do not purge the system with refrigerant.
To reduce the risk of explosion and deterio­ration of refrigerant oil caused by chloride, do not use oxygen, flammable gas, or refrig­erant that contains chloride as a pressuriz­ing gas.
To prevent explosion, do not heat the unit with refrigerant gas in the refrigerant circuit.
To reduce the risk of refrigerant leakage and resultant oxygen deprivation, use the flare nut with holes that is supplied with the re­frigerant service valve.
To reduce the risk of refrigerant leakage and resultant oxygen deprivation, use the flare nut that is supplied with the unit or its equiv­alent that meets applicable standards.
To reduce the risk of damage to the unit, and resultant refrigerant leakage and oxy­gen deprivation, tighten flare nuts to a spec­ified torque.
To reduce the risk of oxygen deprivation and gas poisoning, check for gas leakage and keep fire sources away.
Insulate pipe connections after completing the air tightness test. Performing an air tightness test with the pipe being insulated may lead to failure to detect refrigerant leak­age and cause oxygen deprivation.
To reduce the risk of pipe damage and re­sultant refrigerant leakage and oxygen de­privation, keep the field-installed pipes out of contact with the edges of components.
To reduce the risk of pipe bursting and ex­plosion due to abnormal pressure rise, do not allow any substances other than R410A (such as air) to enter the refrigerant circuit.
[5] Wiring Work
Wiring Work
To reduce the risk of wire breakage, over­heating, smoke, and fire, keep undue force from being applied to the wires.
To reduce the risk of water leakage and re­sultant damage to the furnishings, drain piping work must be performed by your dealer or qualified personnel according to the instructions detailed in the Installation Manual.
To keep the ceiling and floor from getting wet due to condensation, properly insulate the pipes.
To reduce the risk of wire breakage, over­heating, smoke, or fire, properly secure the cables in place and provide adequate slack in the cables so as not to stress the termi­nals.
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To reduce the risk of injury or electric shock, switch off the main power before performing electrical work.
All electric work must be performed by a qualified electrician according to the local regulations, standards, and the instructions detailed in the Installation Manual. Capacity shortage to the power supply circuit or im­proper installation may result in malfunc­tion, electric shock, smoke, or fire.
To reduce the risk of electric shock, smoke, or fire, install an earth leakage breaker on the power supply to each unit.
To reduce the risk of electric shock, smoke, or fire, install an inverter circuit breaker on the power supply to each unit. (Applicable to inverter units only)
Use properly rated breakers and fuses (earth leakage breaker, local switch <switch + fuse>, no-fuse breaker). The use of a breaker with a breaking capacity greater than the specified capacity may cause elec­tric shock, malfunctions, smoke, or fire.
Use properly rated breakers and fuses (in­verter circuit breaker, local switch <switch + fuse>, no-fuse breaker). The use of a break­er with a breaking capacity greater than the specified capacity may cause electric shock, malfunctions, smoke, or fire. (Appli­cable to inverter units only)
To reduce the risk of current leakage, over­heating, smoke, or fire, use properly rated cables with adequate current carrying ca­pacity.
Proper grounding must be provided by a li­censed electrician. Do not connect the grounding wire to a gas pipe, water pipe, lightning rod, or telephone wire. Improper grounding may result in electric shock, smoke, fire, or malfunction due to electrical noise interference.
To reduce the risk of current leakage, wire breakage, smoke, or fire, keep the wiring out of contact with the refrigerant pipes and other parts, especially sharp edges.
[6] Relocation and Repairs
Relocation and Repairs
To reduce the risk of refrigerant leakage, water leakage, injury, electric shock, and fire, units should only be moved or repaired by your dealer or qualified personnel.
To reduce the risk of wire shorting, electric shock, malfunctions, or fire, keep circuit boards dust free, and do not touch them with your hands or tools.
[7] Additional Precautions
To reduce the risk of wire shorting, electric leak, electric shock, smoke, or fire, do not perform maintenance work in the rain.
To reduce the risk of injury, electric shock, and fire, properly reinstall all removed com­ponents after completing repair work.
To reduce the risk of refrigerant and water leakage, check the pipe supports and insu­lation for damage during inspection or re­pair, and replace or repair the ones that are found to be deteriorated.
Additional Precautions
To avoid damage to the unit, use appropri­ate tools to install, inspect, or repair the unit.
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To reduce the risk or malfunction, turn on the power at least 12 hours before starting operation, and leave the power turned on throughout the operating season.
To reduce the risk of the vacuum pump oil backflowing into the refrigerant cycle and causing the refrigerant oil to deteriorate, use a vacuum pump with a check valve.
Recover all refrigerant in the units, and dis­pose of it properly according to any applica­ble laws and regulations.
To reduce the risk of deterioration of refrig­erant oil and compressor malfunctions caused by a refrigerant that contains chlo­ride, such as R22, only use R410A.
Provide a maintenance access to allow for the inspection of pipes above the ceiling or the buried pipes.
Take appropriate measures against electri­cal noise interference when installing the air conditioners in hospitals or facilities with radio communication capabilities. Inverter, high-frequency medical, or wireless com­munication equipment as well as power generators may cause the air conditioning system to malfunction. Air conditioning system may also adversely affect the opera­tion of these types of equipment by creating electrical noise.
To reduce the risk of damage to the unit, leave the valves on the unit closed until re­frigerant charging is completed.
Have a set of tools for exclusive use with R410A. Consult your nearest Mitsubishi Electric Dealer.
Keep dust, dirt, and water off charging hose and flare tool. Infiltration of dust, dirt, or wa­ter into the refrigerant circuit may cause the refrigerant oil to deteriorate or damage the compressor.
Use refrigerant piping and couplings that meet the applicable standards. For refriger­ant pipes, use pipes made of phosphorus deoxidized copper. Keep the inner and out­er surfaces of pipes and couplings clean and free of such contaminants as sulfur, ox­ides, dust, dirt, shaving particles, oil, and moisture. Failure to follow these directions may result in the deterioration of refrigerant oil or compressor damage.
Store the piping materials indoors, and keep both ends of the pipes sealed until im­mediately before brazing. Keep elbows and other joints in plastic bags. Infiltration of dust, dirt, or water into the refrigerant cir­cuit may cause the refrigerant oil to deterio­rate or damage the compressor.
Place a wet towel on the refrigerant service valve before brazing the pipes to keep its temperature from rising above 120ºC and damaging the surrounding equipment.
Direct the blazing torch flame away from the adjacent cables and sheet metal to keep them from being overheated and damaged.
Prepare tools for exclusive use with R410A. Do not use the following tools if they have been used with the conventional refrigerant (R22): gauge manifold, charging hose, re­frigerant leak detector, check valve, refrig­erant charge spout, vacuum gauge, and refrigerant recovery equipment. R410A does not contain chloride, so leak detectors for use with older types of refrigerants will not detect an R410A leak. Infiltration of the residual refrigerant, refrigerant oil, or water on these tools may cause the refrigerant oil in the new system to deteriorate or damage the compressor.
Apply ester oil, ether oil, or a small amount of alkyl benzene to flares and flanges. The use and accidental infiltration of mineral oil into the system may cause the refrigerant oil to deteriorate or damage the compres­sor.
To reduce the risk of oxidized film from en­tering the refrigerant pipe and causing the refrigerant oil to deteriorate or damaging the compressor, braze pipes under nitrogen purge.
Do not use the existing refrigerant piping. A large amount of chloride that is contained in the residual refrigerant and refrigerant oil in the existing piping may cause the refriger­ant oil in the new unit to deteriorate or dam­age the compressor.
Charge refrigerant in the liquid state. If re­frigerant is charged in the gas phase, the composition of the refrigerant in the cylin­der will change, compromising the unit's performance.
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Do not use a charging cylinder. The use of a charging cylinder will change the composi­tion of the refrigerant, compromising the unit's performance.
Charge the system with an appropriate amount of refrigerant in the liquid phase. Refer to the relevant sections in the manu­als to calculate the appropriate amount of refrigerant to be charged. Refrigerant over­charge or undercharge may result in perfor­mance drop or abnormal stop of operation.
To reduce the risk of power capacity short­age, always use a dedicated power supply circuit.
To reduce the risk of both the breaker on the product side and the upstream breaker from tripping and causing problems, split the power supply system or provide protection coordination between the earth leakage breaker and no-fuse breaker.
Have a backup system, if failure of the unit has a potential for causing significant prob­lems or damages.
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CONTENTS
Chapter 1 Check Before Servicing
1-1 Preparation for Piping Work..................................................................................................................3
1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ....................... 5
1-3 Working with Refrigerant Piping.........................................................................................................10
1-4 Precautions for Wiring......................................................................................................................... 15
Chapter 2 Restrictions
2-1 System Configurations ........................................................................................................................ 19
2-2 Types and Maximum Allowable Length of Cables............................................................................ 20
2-3 Switch Settings.....................................................................................................................................21
2-4 M-NET Address Settings .....................................................................................................................22
2-5 Demand Control Overview ..................................................................................................................29
2-6 System Connection Example ..............................................................................................................30
2-7 Example System with an MA Remote Controller .............................................................................. 32
2-8 Example System with an ME Remote Controller...............................................................................46
2-9 Example System with an MA and an ME Remote Controller............................................................48
2-10 Restrictions on Refrigerant Pipes ......................................................................................................51
Chapter 3 Major Components, Their Functions and Refrigerant Circuits
3-1 External Appearance and Refrigerant Circuit Components of Outdoor Unit ................................. 65
3-2 Outdoor Unit Refrigerant Circuit Diagrams ....................................................................................... 67
3-3 Functions of the Major Components of Outdoor Unit ...................................................................... 69
3-4 Functions of the Major Components of Indoor Unit .........................................................................72
3-5 External Appearance and Refrigerant Circuit Components of BC Controller ................................ 73
3-6 BC Controller Refrigerant Circuit Diagrams ......................................................................................76
3-7 Functions of the Major Components of BC Controller ..................................................................... 79
Chapter 4 Electrical Components and Wiring Diagrams
4-1 Outdoor Unit Circuit Board Arrangement ..........................................................................................87
4-2 Outdoor Unit Circuit Board Components .......................................................................................... 90
4-3 Outdoor Unit Electrical Wiring Diagrams........................................................................................... 98
4-4 Transmission Booster Electrical Wiring Diagrams......................................................................... 100
4-5 BC Controller Circuit Board Arrangement....................................................................................... 101
4-6 BC Controller Circuit Board Components .......................................................................................102
4-7 BC Controller Electrical Wiring Diagrams ....................................................................................... 104
Chapter 5 Control
5-1 Dipswitch Functions and Factory Settings...................................................................................... 117
5-2 Outdoor Unit Control ......................................................................................................................... 124
5-3 BC Controller Control ........................................................................................................................139
5-4 Operation Flowcharts ........................................................................................................................ 140
Chapter 6 Test Run
6-1 Read before Test Run ........................................................................................................................149
6-2 MA and ME Remote Controller Functions and Specifications....................................................... 150
6-3 Making the Group and Interlock Settings from an ME Remote Controller ...................................151
6-4 Selecting Remote Controller Functions from an ME Remote Controller...................................... 155
6-5 Making Interlock Settings from an MA Remote Controller............................................................. 157
6-6 Changing the Room Temperature Detection Position.................................................................... 159
6-7 Test Run Method ................................................................................................................................ 160
6-8 Operation Characteristics and Refrigerant Charge ........................................................................161
6-9 Evaluating and Adjusting Refrigerant Charge................................................................................. 161
6-10 The Following Symptoms Are Normal ............................................................................................. 166
6-11 Standard Operation Data (Reference Data) .....................................................................................167
Chapter 7 Troubleshooting Using Error Codes
7-1 Error Code and Preliminary Error Code Lists .................................................................................175
7-2 Error Code Definitions and Solutions: Codes [0 - 999]...................................................................179
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CONTENTS
7-3 Error Code Definitions and Solutions: Codes [1000 - 1999]........................................................... 180
7-4 Error Code Definitions and Solutions: Codes [2000 - 2999]........................................................... 184
7-5 Error Code Definitions and Solutions: Codes [3000 - 3999]........................................................... 191
7-6 Error Code Definitions and Solutions: Codes [4000 - 4999]........................................................... 192
7-7 Error Code Definitions and Solutions: Codes [5000 - 5999]........................................................... 210
7-8 Error Code Definitions and Solutions: Codes [6000 - 6999]........................................................... 223
7-9 Error Code Definitions and Solutions: Codes [7000 - 7999]........................................................... 239
Chapter 8 Troubleshooting Based on Observed Symptoms
8-1 MA Remote Controller Problems......................................................................................................251
8-2 ME remote Controller Problems .......................................................................................................255
8-3 Refrigerant Control Problems ...........................................................................................................259
8-4 Checking Transmission Waveform and for Electrical Noise Interference .................................... 264
8-5 Pressure Sensor Circuit Configuration and Troubleshooting Pressure Sensor Problems ........ 267
8-6 Troubleshooting Solenoid Valve Problems .....................................................................................269
8-7 Troubleshooting Outdoor Unit Fan Problems ................................................................................. 272
8-8 Troubleshooting LEV Problems........................................................................................................273
8-9 Troubleshooting Problems with Major Components on BC Controller ........................................ 277
8-10 Troubleshooting Inverter Problems (TKMU).................................................................................... 288
8-11 Troubleshooting Inverter Problems (YKMU) ...................................................................................298
8-12 Control Circuit (TKMU) ...................................................................................................................... 307
8-13 Control Circuit (YKMU) ......................................................................................................................309
8-14 Measures for Refrigerant Leakage ................................................................................................... 311
8-15 Compressor Replacement Instructions ........................................................................................... 313
8-16 Solenoid Valve Block and Check Valve Replacement Instructions .............................................. 315
8-17 BC Controller Maintenance Instructions..........................................................................................319
8-18 Troubleshooting Problems Using the LED Status Indicators on the Outdoor Unit..................... 322
Chapter 9 LED Status Indicators on the Outdoor Unit Circuit Board
9-1 LED Status Indicators ........................................................................................................................ 325
9-2 LED Status Indicators Table .............................................................................................................328
HWE13080 GB
Chapter 1 Check Before Servicing
1-1 Preparation for Piping Work ................................................................................................................ 3
1-1-1 Read before Servicing ............................................................................................................................ 3
1-1-2 Tool Preparation ..................................................................................................................................... 4
1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil...................... 5
1-2-1 Piping Materials ...................................................................................................................................... 5
1-2-2 Storage of Piping Materials..................................................................................................................... 7
1-2-3 Pipe Processing ...................................................................................................................................... 7
1-2-4 Characteristics of the New and Conventional Refrigerants .................................................................... 8
1-2-5 Refrigerant Oil......................................................................................................................................... 9
1-3 Working with Refrigerant Piping ....................................................................................................... 10
1-3-1 Pipe Brazing.......................................................................................................................................... 10
1-3-2 Air Tightness Test ................................................................................................................................. 11
1-3-3 Vacuum Drying ..................................................................................................................................... 12
1-3-4 Refrigerant Charging............................................................................................................................. 14
1-4 Precautions for Wiring ....................................................................................................................... 15
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[1-1 Preparation for Piping Work ]
CAUTION
1 Check Before Servicing
1-1 Preparation for Piping Work
1-1-1 Read before Servicing
1. Check the type of refrigerant used in the system to be serviced. Refrigerant Type
Multi air conditioner for building application CITY MULTI H2i (Hyper Heating Inverter) R2 TKMU-A-H, YKMU-A series : R410A
2. Check the symptoms exhibited by the unit to be serviced.
Refer to this service handbook for symptoms relating to the refrigerant cycle.
3. Thoroughly read the safety precautions at the beginning of this manual.
4. Preparing necessary tools: Prepare a set of tools to be used exclusively with each type of refrigerant.
For information about the correct use of tools, refer to the following page(s). [1-1-2 Tool Preparation](page 4)
5. Verification of the connecting pipes: Verify the type of refrigerant used for the unit to be moved or replaced.
Use refrigerant pipes made of phosphorus deoxidized copper. Keep the inner and outer surfaces of the pipes clean and free
of such contaminants as sulfur, oxides, dust, dirt, shaving particles, oil, and water.
These types of contaminants inside the refrigerant pipes may cause the refrigerant oil to deteriorate.
6. If there is a leak of gaseous refrigerant and the remaining refrigerant is exposed to an open flame, a poisonous gas hydrofluoric acid may form. Keep workplace well ventilated.
1 Check Before Servicing
Install new pipes immediately after removing old ones to keep moisture out of the refrigerant circuit.The use of refrigerant that contains chloride, such as R22, will cause the refrigerating machine oil to deteriorate.
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[1-1 Preparation for Piping Work ]
1-1-2 Tool Preparation
Prepare the following tools and materials necessary for installing and servicing the unit.
Tools for use with R410A (Adaptability of tools that are for use with R22 or R407C)
1. To be used exclusively with R410A (not to be used if used with R22 or R407C)
Tools/Materials Use Notes
Gauge Manifold Evacuation and refrigerant charging Higher than 5.09MPa[738psi] on the
Charging Hose Evacuation and refrigerant charging The hose diameter is larger than the
Refrigerant Recovery Cylinder Refrigerant recovery
Refrigerant Cylinder Refrigerant charging The refrigerant type is indicated. The
Charging Port on the Refrigerant Cylinder Refrigerant charging The charge port diameter is larger
Flare Nut Connection of the unit with the pipes Use Type-2 Flare nuts.
2. Tools and materials that may be used with R410A with some restrictions
high-pressure side
conventional model.
cylinder is pink.
than that of the current port.
Tools/Materials Use Notes
Gas Leak Detector Gas leak detection The ones for use with HFC refrigerant
may be used.
Vacuum Pump Vacuum drying May be used if a check valve adapter
is attached.
Flare Tool Flare processing Flare processing dimensions for the
piping in the system using the new re­frigerant differ from those of R22. Re­fer to the following page(s). [1-2-1 Piping Materials](page 5)
Refrigerant Recovery Equipment Refrigerant recovery May be used if compatible with
R410A.
3. Tools and materials that are used with R22 or R407C that may also be used with R410A
Tools/Materials Use Notes
Vacuum Pump with a Check Valve Vacuum drying
Bender Bending pipes
Torque Wrench Tightening flare nuts Only the flare processing dimensions
for pipes that have a diameter of ø12.7 (1/2") and ø15.88 (5/8") have been changed.
Pipe Cutter Cutting pipes
Welder and Nitrogen Cylinder Welding pipes
Refrigerant Charging Meter Refrigerant charging
Vacuum Gauge Vacuum level check
4. Tools and materials that must not be used with R410A
Tools/Materials Use Notes
Charging Cylinder Refrigerant charging Prohibited to use
Tools for R410A must be handled with special care to keep moisture and dust from infiltrating the cycle.
HWE13080 GB
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[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
1-2 Handling and Characteristics of Piping Materials,
Refrigerant, and Refrigerant Oil
1-2-1 Piping Materials
Do not use the existing piping!
1. Copper pipe materials
O-material (Annealed) Soft copper pipes (annealed copper pipes). They can easily be bent with hands.
1/2H-material (Drawn) Hard copper pipes (straight pipes). They are stronger than the O-material (Annealed)
at the same radial thickness.
The distinction between O-materials (Annealed) and 1/2H-materials (Drawn) is made based on the strength of the pipes them-
selves.
O-materials (Annealed) can easily be bent with hands. 1/2H-materials (Drawn) are considerably stronger than O-material (Annealed) at the same thickness.
2. Types of copper pipes
Maximum working pressure Refrigerant type
3.45 MPa [500psi] R22, R407C etc.
4.30 MPa [624psi] R410A etc.
1 Check Before Servicing
3. Piping materials/Radial thickness
Use refrigerant pipes made of phosphorus deoxidized copper. The operation pressure of the units that use R410A is higher than that of the units that use R22. Use pipes that have at least the radial thickness specified in the chart below. (Pipes with a radial thickness of 0.7 mm or less may not be used.)
Pipe size (mm[in]) Radial thickness (mm) Type
ø6.35 [1/4"] 0.8t
ø9.52 [3/8"] 0.8t
ø12.7 [1/2"] 0.8t
ø15.88 [5/8"] 1.0t
ø19.05 [3/4"] 1.0t
ø22.2 [7/8"] 1.0t
ø25.4 [1"] 1.0t
ø28.58 [1-1/8"] 1.0t
ø31.75 [1-1/4"] 1.1t
ø34.93 [1-3/8"] 1.1t
ø41.28 [1-5/8"] 1.2t
The pipes in the system that uses the refrigerant currently on the market are made with O-material (Annealed), even if the
pipe diameter is less than ø19.05 (3/4"). For a system that uses R410A, use pipes that are made with 1/2H-material (Drawn) unless the pipe diameter is at least ø19.05 (3/4") and the radial thickness is at least 1.2t.
The figures in the radial thickness column are based on the Japanese standards and provided only as a reference. Use pipes
that meet the local standards.
O-material (Annealed)
1/2H-material,
H-material (Drawn)
HWE13080 GB
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[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
4. Thickness and refrigerant type indicated on the piping materials
Ask the pipe manufacturer for the symbols indicated on the piping material for new refrigerant.
5. Flare processing (O-material (Annealed) and OL-material only)
The flare processing dimensions for the pipes that are used in the R410A system are larger than those in the R22 system.
Flare processing dimensions (mm[in])
A dimension (mm)
Pipe size (mm[in])
R410A R22, R407C
ø6.35 [1/4"] 9.1 9.0
ø9.52 [3/8"] 13.2 13.0
ø12.7 [1/2"] 16.6 16.2
Dimension A
ø15.88 [5/8"] 19.7 19.4
ø19.05 [3/4"] 24.0 23.3
If a clutch-type flare tool is used to flare the pipes in the system using R410A, the length of the pipes must be between 1.0 and 1.5 mm. For margin adjustment, a copper pipe gauge is necessary.
6. Flare nut
The flare nut type has been changed to increase the strength. The size of some of the flare nuts have also been changed.
Flare nut dimensions (mm[in])
B dimension (mm)
Pipe size (mm[in])
R410A R22, R407C
ø6.35 [1/4"] 17.0 17.0
ø9.52 [3/8"] 22.0 22.0
ø12.7 [1/2"] 26.0 24.0
Dimension B
ø15.88 [5/8"] 29.0 27.0
ø19.05 [3/4"] 36.0 36.0
The figures in the radial thickness column are based on the Japanese standards and provided only as a reference. Use pipes that meet the local standards.
HWE13080 GB
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[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
1-2-2 Storage of Piping Materials
1. Storage location
Store the pipes to be used indoors. (Warehouse at site or owner's warehouse) If they are left outdoors, dust, dirt, or moisture may infiltrate and contaminate the pipe.
2. Sealing the pipe ends
1 Check Before Servicing
Both ends of the pipes should be sealed until just before brazing. Keep elbow pipes and T-joints in plastic bags.
The new refrigerator oil is 10 times as hygroscopic as the conventional refrigerating machine oil (such as Suniso) and, if not handled with care, could easily introduce moisture into the system. Keep moisture out of the pipes, for it will cause the oil to deteriorate and cause a compressor failure.
1-2-3 Pipe Processing
Use a small amount of ester oil, ether oil, or alkylbenzene to coat flares and flanges.
Use a minimum amount of oil. Use only ester oil, ether oil, and alkylbenzene.
HWE13080 GB
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[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
1-2-4 Characteristics of the New and Conventional Refrigerants
1. Chemical property
As with R22, the new refrigerant (R410A) is low in toxicity and chemically stable nonflammable refrigerant. However, because the specific gravity of vapor refrigerant is greater than that of air, leaked refrigerant in a closed room will accumulate at the bottom of the room and may cause hypoxia. If exposed to an open flame, refrigerant will generate poisonous gases. Do not perform installation or service work in a con­fined area.
New Refrigerant (HFC type) Conventional Refriger-
ant (HCFC type)
R410A R407C R22
R32/R125 R32/R125/R134a R22
Composition (wt%) (50/50) (23/25/52) (100)
Type of Refrigerant Pseudo-azeotropic
Refrigerant
Non-azeotropic
Refrigerant
Single Refrigerant
Chloride Not included Not included Included
Safety Class A1/A1 A1/A1 A1
Molecular Weight 72.6 86.2 86.5
Boiling Point (°C/°F) -51.4/-60.5 -43.6/-46.4 -40.8/-41.4
Steam Pressure
1.557/226 0.9177/133 0.94/136
(25°C,MPa/77°F,psi) (gauge)
Saturated Steam Density (25°C,kg/m
3
/77°F,psi)
64.0 42.5 44.4
Flammability Nonflammable Nonflammable Nonflammable
Ozone Depletion Coefficient (ODP)
Global Warming Coefficient (GWP)
*1
*2
Refrigerant Charging Method Refrigerant charging in
Replenishment of Refrigerant after a Refrigerant
0 0 0.055
1730 1530 1700
the liquid state
Refrigerant charging in
the liquid state
Refrigerant charging in
the gaseous state
Available Available Available
Leak
*1 When CFC11 is used as a reference *2 When CO
is used as a reference
2
2. Refrigerant composition
R410A is a pseudo-azeotropic HFC blend and can almost be handled the same way as a single refrigerant, such as R22. To be safe, however, draw out the refrigerant from the cylinder in the liquid phase. If the refrigerant in the gaseous phase is drawn out, the composition of the remaining refrigerant will change and become unsuitable for use. If the refrigerant leaks out, it may be replenished. The entire refrigerant does not need to be replaced.
3. Pressure characteristics
The pressure in the system using R410A is 1.6 times as great as that in the system using R22.
Pressure (gauge)
Temperature (°C/°F)
R410A R407C R22
MPa/psi MPa/psi MPa/psi
-20/-4 0.30/44 0.18/26 0.14/20
0/32 0.70/102 0.47/68 0.40/58
20/68 1.34/194 0.94/136 0.81/117
40/104 2.31/335 1.44/209 1.44/209
60/140 3.73/541 2.44/354 2.33/338
65/149 4.17/605 2.75/399 2.60/377
HWE13080 GB
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[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
1-2-5 Refrigerant Oil
1. Refrigerating machine oil in the HFC refrigerant system
HFC type refrigerants use a refrigerating machine oil different from that used in the R22 system. Note that the ester oil used in the system has properties that are different from commercially available ester oil.
Refrigerant Refrigerating machine oil
R22 Mineral oil
R407C Ester oil
R410A Ester oil
2. Effects of contaminants
*1
Refrigerating machine oil used in the HFC system must be handled with special care to keep contaminants out. The table below shows the effect of contaminants in the refrigerating machine oil on the refrigeration cycle.
3. The effects of contaminants in the refrigerating machine oil on the refrigeration cycle.
Cause Symptoms Effects on the refrigerant cycle
Water infiltration Frozen expansion valve
and capillary tubes
Clogged expansion valve and capillary tubes Poor cooling performance Compressor overheat Motor insulation failure Burnt motor Coppering of the orbiting scroll Lock Burn-in on the orbiting scroll
Clogged expansion valve, capillary tubes, and drier
Hydrolysis
Air infiltration Oxidization
Adhesion to expansion valve and capillary tubes
Sludge formation and ad­hesion Acid generation Oxidization Oil degradation
Poor cooling performance
Infiltration of contaminants
Dust, dirt
Infiltration of contaminants into the com­pressor
Compressor overheat
Burn-in on the orbiting scroll
Sludge formation and adhesion Clogged expansion valve and capillary tubes
Mineral oil etc.
Poor cooling performance Compressor overheat
Oil degradation Burn-in on the orbiting scroll
1 Check Before Servicing
*1. Contaminants is defined as moisture, air, processing oil, dust/dirt, wrong types of refrigerant, and refrigerating machine oil.
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[1-3 Working with Refrigerant Piping ]
1-3 Working with Refrigerant Piping
1-3-1 Pipe Brazing
No changes have been made in the brazing procedures. Perform brazing with special care to keep foreign objects (such as oxide scale, water, and dust) out of the refrigerant system.
Example: Inside the brazed connection
Use of no inert gas during brazing Use of inert gas during brazing
1. Items to be strictly observed
Do not conduct refrigerant piping work outdoors if raining.Use inert gas during brazing.Use a brazing material (BCuP-3) that requires no flux when brazing between copper pipes or between a copper pipe and
copper coupling.
If installed refrigerant pipes are not immediately connected to the equipment, then braze and seal both ends.
2. Reasons
The new refrigerating machine oil is 10 times as hygroscopic as the conventional oil and is more likely to cause unit failure if
water infiltrates into the system.
Flux generally contains chloride. Residual flux in the refrigerant circuit will cause sludge to form.
3. Notes
Do not use commercially available antioxidants because they may cause the pipes to corrode or refrigerating machine oil to deteriorate.
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[1-3 Working with Refrigerant Piping ]
1-3-2 Air Tightness Test
No changes have been made in the detection method. Note that a refrigerant leak detector for R22 will not detect an R410A leak.
Halide torch R22 leakage detector
1 Check Before Servicing
1. Items to be strictly observed
Pressurize the equipment with nitrogen up to the design pressure (4.15MPa[601psi]), and then judge the equipment's air tight-
ness, taking temperature variations into account.
Refrigerant R410A must be charged in its liquid state (vs. gaseous state).
2. Reasons
Oxygen, if used for an air tightness test, poses a risk of explosion. (Only use nitrogen to check air tightness.)Refrigerant R410A must be charged in its liquid state. If gaseous refrigerant in the cylinder is drawn out first, the composition
of the remaining refrigerant in the cylinder will change and become unsuitable for use.
3. Notes
Procure a leak detector that is specifically designed to detect an HFC leak. A leak detector for R22 will not detect an HFC(R410A) leak.
HWE13080 GB
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[1-3 Working with Refrigerant Piping ]
1-3-3 Vacuum Drying
(Photo1) 15010H (Photo2) 14010
Recommended vacuum gauge: ROBINAIR 14010 Thermistor Vacuum Gauge
1. Vacuum pump with a reverse-flow check valve (Photo1)
To prevent the vacuum pump oil from flowing into the refrigerant circuit during power OFF or power failure, use a vacuum pump with a reverse-flow check valve. A reverse-flow check valve may also be added to the vacuum pump currently in use.
2. Standard of vacuum degree (Photo 2)
Use a vacuum pump that attains 0.5Torr(65Pa) or lower degree of vacuum after 5 minutes of operation, and connect it directly to the vacuum gauge. Use a pump well-maintained with an appropriate lubricant. A poorly maintained vacuum pump may not be able to attain the desired degree of vacuum.
3. Required precision of vacuum gauge
Use a vacuum gauge that registers a vacuum degree of 5Torr(650Pa) and measures at intervals of 1Torr(130Pa). (A recom­mended vacuum gauge is shown in Photo2.) Do not use a commonly used gauge manifold because it cannot register a vacuum degree of 5Torr(650Pa).
4. Evacuation time
After the degree of vacuum has reached 5Torr(650Pa), evacuate for an additional 1 hour. (A thorough vacuum drying re-
moves moisture in the pipes.)
Verify that the vacuum degree has not risen by more than 1Torr(130Pa) 1hour after evacuation. A rise by less than
1Torr(130Pa) is acceptable.
If the vacuum is lost by more than 1Torr(130Pa), conduct evacuation, following the instructions in section 6. Special vacuum
drying.
5. Procedures for stopping vacuum pump
To prevent the reverse flow of vacuum pump oil, open the relief valve on the vacuum pump side, or draw in air by loosening the charge hose, and then stop the operation. The same procedures should be followed when stopping a vacuum pump with a reverse-flow check valve.
6. Special vacuum drying
When 5Torr(650Pa) or lower degree of vacuum cannot be attained after 3 hours of evacuation, it is likely that water has pen-
etrated the system or that there is a leak.
If water infiltrates the system, break the vacuum with nitrogen. Pressurize the system with nitrogen gas to
0.5kgf/cm
2
G(0.05MPa) and evacuate again. Repeat this cycle of pressurizing and evacuation either until the degree of vac-
uum below 5Torr(650Pa) is attained or until the pressure stops rising.
Only use nitrogen gas for vacuum breaking. (The use of oxygen may result in an explosion.)
HWE13080 GB
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[1-3 Working with Refrigerant Piping ]
7. Triple Evacuation
The method below can also be used to evacuate the system.
Evacuate the system to 4,000 microns from both service valves. System manifold gauges must not be used to measure vac-
uum. A micron gauge must be used at all times. Break the vacuum with Nitrogen (N2) into the discharge service valve to 0 PSIG.
Evacuate the system to 1,500 microns from the suction service valve. Break the vacuum with Nitrogen (N2) into the discharge
service valve to 0 PSIG.
Evacuate the system to 500 microns. System must hold the vacuum at 500 microns for a minimum of 1 hour.Conduct a rise test for a minimum of 30 minutes
8. Notes
To evacuate air from the entire system
Applying a vacuum through the check joints at the refrigerant service valve on the high and low pressure sides (BV1 and 2) is not enough to attain the desired vacuum pressure. Be sure to apply a vacuum through the check joints at the refrigerant service valve on the high and low pressure sides (BV1 and 2) and also through the check joints on the high and low pressure sides (CJ1 and 2).
To evacuate air only from the outdoor units
Apply a vacuum through the check joints on the high and low pressure sides (CJ1, and 2).
To evacuate air from the indoor units and extension pipes
Apply a vacuum through the check joints at the refrigerant service valve on the high and low pressure sides (BV1 and 2).
1 Check Before Servicing
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[1-3 Working with Refrigerant Piping ]
1-3-4 Refrigerant Charging
Cylinder with a siphon
Cylinder without a siphon
Cylin-
Cylin-
der
der
Cylinder color R410A is pink. Refrigerant charging in the liquid state
Valve Valve
liquid
liquid
1. Reasons
R410A is a pseudo-azeotropic HFC blend (boiling point R32=-52°C[-62°F], R125=-49°C[-52°F]) and can almost be handled the same way as a single refrigerant, such as R22. To be safe, however, draw out the refrigerant from the cylinder in the liquid phase. If the refrigerant in the gaseous phase is drawn out, the composition of the remaining refrigerant will change and be­come unsuitable for use.
2. Notes
When using a cylinder with a siphon, refrigerant is charged in the liquid state without the need for turning it upside down. Check the type of the cylinder on the label before use.
If the refrigerant leaks out, it may be replenished. The entire refrigerant does not need to be replaced. (Charge refrigerant in the liquid state.) Refer to the following page(s).[8-14 Measures for Refrigerant Leakage](page 311)
HWE13080 GB
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[1-4 Precautions for Wiring ]
1-4 Precautions for Wiring
Control boxes house high-voltage and high-temperature electrical parts.They may still remain energized or hot after the power is turned off. When opening or closing the front cover of the control box, keep out of contact with the internal parts.
Before inspecting the inside of the control box, turn off the power, leave the unit turned off for at least 10 minutes, and check that the voltage of the electrolytic capacitor (inverter main circuit) has dropped to 20 VDC or less.
It will take approximately 10 minutes until the voltage is discharged after power off.
Disconnect the outdoor unit fan board connector (CNINV) before performing maintenance work.
Before connecting or disconnecting the connector, check that the outdoor unit fan is stopped and that the voltage of the main circuit capacitor has dropped to 20 VDC or below.
If the outdoor unit fan is rotated by external forces such as strong winds, the main circuit capacitor can be charged and cause an electric shock.
Refer to the wiring nameplate for details. Reconnect the connector (CNINV) to the fan board after completion of maintenance work.
When the unit is turned on, the compressor will remain energized even when it is stopped to vaporize the liquid refrigerant
that accumulates in the compressor.
Before connecting wiring to TB7, check that the voltage has dropped below 20 VDC.When a system controller is connected to the centralized control transmission cable to which power is supplied from the out-
door unit (power jumper on the outdoor unit is connected to CN40), be aware that power can be supplied to the centralized control transmission and the system controller may detect an error and send an error notice if the outdoor unit fan is rotated by external forces, such as strong winds, even when power to the outdoor unit is turned off.
When replacing the internal electrical components of the control box, tighten the screws to the recommended tightening
torque as specified below. Recommended tightening torque for the internal electrical components of the control box
1 Check Before Servicing
Screw Recommended tightening torque (N·m)
M3 0.69
M4 1.47
M5 2.55
M6 2.75
M8 6.20
1 When replacing semiconductor modules (e.g., diode stack, IPM, INV board (with IPM), fan board (with IPM)), apply heat-
sink silicone evenly to the mounting surface of the semiconductor module (or the semiconductor module on the back of the circuit board). Next, tighten the screws holding the semiconductor module to one-third of the specified torque, and then tighten the screws to the specified torque.
2 Deviating from the recommended tightening torque may cause damage to the unit or its parts.
Take the following steps to ensure that the screws are properly tightened.
1) Ensure that the spring washers are parallel to the terminal block.
Even if the tightening torque is observed, if the washers are not parallel to the terminal block, then the semiconductor module is not installed properly.
Loose screws
Proper installation
Spring washers are parallel to the terminal block
HWE13080 GB
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[1-4 Precautions for Wiring ]
2) Check the wires are securely fastened to the screw terminals.
Screw the screws straight down so as not to damage the screw threads.
Hold the two round terminals back to back to ensure that the screw will screw down straight.
After tightening the screw, mark a line through the screw head, washer, and terminals with a permanent marker.
Example
Mark a line.
Daisy-chain
Power wires, transmission lines, centralized transmission lines
Place the round terminals back to back.
Power supply terminal block, indoor-outdoor transmission line terminal block, and centralized controller transmission line
Poor contact caused by loose screws may result in overheating and fire. Continued use of the damaged circuit board may cause overheating and fire.
HWE13080 GB
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Chapter 2 Restrictions
2-1 System Configurations....................................................................................................................... 19
2-2 Types and Maximum Allowable Length of Cables........................................................................... 20
2-3 Switch Settings ................................................................................................................................... 21
2-4 M-NET Address Settings .................................................................................................................... 22
2-4-1 Address Settings List ............................................................................................................................ 22
2-4-2 Outdoor Unit Power Jumper Connector Connection.............................................................................24
2-4-3 Outdoor Unit Centralized Controller Switch Setting .............................................................................. 24
2-4-4 Room Temperature Detection Position Selection ................................................................................. 24
2-4-5 Start/Stop Control of Indoor Units ......................................................................................................... 25
2-4-6 Miscellaneous Settings ......................................................................................................................... 25
2-4-7 Various Control Methods Using the Signal Input/Output Connector on Outdoor Unit .......................... 26
2-5 Demand Control Overview ................................................................................................................. 29
2-6 System Connection Example............................................................................................................. 30
2-7 Example System with an MA Remote Controller ............................................................................. 32
2-7-1 Single Refrigerant System (Automatic Indoor/Outdoor Address Startup)............................................. 32
2-7-2 Single Refrigerant System with Two or More LOSSNAY Units ............................................................ 34
2-7-3 Grouped Operation of Units in Separate Refrigerant Circuits ............................................................... 36
2-7-4 System with a Connection of System Controller to Centralized Control Transmission Line................. 38
2-7-5 System with a Connection of System Controller to Indoor-Outdoor Transmission Line ....................... 40
2-7-6 System with Multiple BC Controllers..................................................................................................... 42
2-8 Example System with an ME Remote Controller ............................................................................. 46
2-8-1 System with a Connection of System Controller to Centralized Control Transmission Line................. 46
2-9 Example System with an MA and an ME Remote Controller .......................................................... 48
2-9-1 System with a Connection of System Controller to Centralized Control Transmission Line................. 48
2-10 Restrictions on Refrigerant Pipes ..................................................................................................... 51
2-10-1 Restrictions on Refrigerant Pipe Length ............................................................................................... 51
2-10-2 Restrictions on Refrigerant Pipe Size ................................................................................................... 57
2-10-3 BC Controller Connection Method ........................................................................................................ 58
HWE13080 GB
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HWE13080 GB
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[2-1 System Configurations ]
2 Restrictions
2-1 System Configurations
1. Table of compatible indoor units
The table below summarizes the types of indoor units that are compatible with different types of outdoor units.
Outdoor
units
Composing units Maximum total capacity
of connectable indoor
units
Maximum number of connectable in-
door units
Types of connectable in-
door units
72 - - 36 - 108 18 P06 - P96 models
96 - - 48 - 144 24
R410A series indoor units
144 72 72 72 - 216 36
192 96 96 96 - 288 48
1) "Maximum total capacity of connectable indoor units" refers to the sum of the numeric values in the indoor unit model names.
2) If the total capacity of the indoor units that are connected to a given outdoor unit exceeds the capacity of the outdoor unit, the indoor units will not be able to perform at the rated capacity when they are operated simultaneously. Select a combination of units so that the total capacity of the connected indoor units is at or below the capacity of the outdoor unit whenever possible.
2 Restrictions
HWE13080 GB
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