Text preview for : SH_PURY-P72_288(T)(Y)(S)KMU-A_HWE1116F.pdf part of Mitsubishi PURY-HP72 Service Handbook
PURY-P72, P96, P120, P144T(Y)KMU-A, P144YSKMU-A
PURY-P168, P192, P216, P240, P264, P288T(Y)SKMU-A
PURY-P72, P96, P120, P144T(Y)KMU-U, P144YSKMU-U
PURY-P168, P192, P216, P240, P264, P288T(Y)SKMU-U
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AIR CONDITIONER
2017
Service Handbook
Model
PURY-P72, P96, P120, P144T(Y)KMU-A, P144YSKMU-A
PURY-P168, P192, P216, P240, P264, P288T(Y)SKMU-A
PURY-P72, P96, P120, P144T(Y)KMU-U, P144YSKMU-U
PURY-P168, P192, P216, P240, P264, P288T(Y)SKMU-U
7th
Safety Precautions
Before installing the unit, thoroughly read the following safety precautions.
Observe these safety precautions for your safety.
WARNING
This symbol is intended to alert the user to the presence of important instructions that must be followed to avoid
the risk of serious injury or death.
CAUTION
This symbol is intended to alert the user to the presence of important instructions that must be followed to avoid
the risk of serious injury or damage to the unit.
After reading this manual, give it to the user to retain for future reference.
Keep this manual for easy reference. When the unit is moved or repaired, give this manual to those who provide these
services.
When the user changes, make sure that the new user receives this manual.
WARNING
Do not use refrigerant other than the type indicated in Do not make any modifications or alterations to the
the manuals provided with the unit and on the name- unit. Consult your dealer for repair.
plate.
Improper repair may result in water leakage, electric shock,
Doing so may cause the unit or pipes to burst, or result in smoke, and/or fire.
explosion or fire during use, during repair, or at the time of
disposal of the unit. Do not touch the heat exchanger fins.
It may also be in violation of applicable laws.
MITSUBISHI ELECTRIC CORPORATION cannot be held The fins are sharp and dangerous.
responsible for malfunctions or accidents resulting from the
use of the wrong type of refrigerant. In the event of a refrigerant leak, thoroughly ventilate
the room.
Ask your dealer or a qualified technician to install the If refrigerant gas leaks and comes in contact with an open
unit. flame, poisonous gases will be produced.
Improper installation by the user may result in water leak-
age, electric shock, smoke, and/or fire. When installing the All-Fresh type units, take it into
consideration that the outside air may be discharged
Properly install the unit on a surface that can with- directly into the room when the thermo is turned off.
stand the weight of the unit. Direct exposure to outdoor air may have an adverse effect
Unit installed on an unstable surface may fall and cause in- on health. It may also result in food spoilage.
jury.
Properly install the unit according to the instructions
Only use specified cables. Securely connect each ca- in the installation manual.
ble so that the terminals do not carry the weight of the Improper installation may result in water leakage, electric
cable. shock, smoke, and/or fire.
Improperly connected or fixed cables may produce heat
and start a fire. Have all electrical work performed by an authorized
electrician according to the local regulations and in-
Take appropriate safety measures against strong structions in this manual, and a dedicated circuit must
winds and earthquakes to prevent the unit from falling. be used.
If the unit is not installed properly, the unit may fall and Insufficient capacity of the power supply circuit or improper
cause serious injury to the person or damage to the unit. installation may result in malfunctions of the unit, electric
shock, smoke, and/or fire.
HWE1116F
i GB
WARNING
Securely attach the terminal block cover (panel) to the After completing the service work, check for a gas
unit. leak.
If the terminal block cover (panel) is not installed properly, If leaked refrigerant is exposed to a heat source, such as a
dust and/or water may infiltrate and pose a risk of electric fan heater, stove, or electric grill, poisonous gases may be
shock, smoke, and/or fire. produced.
Only use the type of refrigerant that is indicated on the Do not try to defeat the safety features of the unit.
unit when installing or reinstalling the unit.
Forced operation of the pressure switch or the temperature
Infiltration of any other type of refrigerant or air into the unit switch by defeating the safety features of these devices, or
may adversely affect the refrigerant cycle and may cause the use of accessories other than the ones that are recom-
the pipes to burst or explode. mended by MITSUBISHI may result in smoke, fire, and/or
explosion.
When installing the unit in a small room, exercise cau-
tion and take measures against leaked refrigerant Only use accessories recommended by MITSUBISHI.
reaching the limiting concentration.
Ask a qualified technician to install the unit. Improper instal-
Consult your dealer with any questions regarding limiting lation by the user may result in water leakage, electric
concentrations and for precautionary measures before in- shock, smoke, and/or fire.
stalling the unit. Leaked refrigerant gas exceeding the lim-
iting concentration causes oxygen deficiency. Control box houses high-voltage parts.
When opening or closing the front panel of the control box,
Consult your dealer or a specialist when moving or re-
do not let it come into contact with any of the internal com-
installing the unit.
ponents. Before inspecting the inside of the control box,
Improper installation may result in water leakage, electric turn off the power, keep the unit off for at least 10 minutes,
shock, and/or fire. and confirm that the voltage across the terminals of the in-
verter circuit main capacitor has dropped to DC20V or less.
To reduce the risk of burns, do not touch electrical (It takes about 10 minutes to discharge electricity after the
parts during or directly after operation. power supply is turned off.)
HWE1116F
ii GB
Precautions for handling units for use with R410A
CAUTION
Do not use the existing refrigerant piping. Use a vacuum pump with a reverse-flow check valve.
A large amount of chlorine that may be contained in the re- If a vacuum pump that is not equipped with a reverse-flow
sidual refrigerant and refrigerating machine oil in the exist- check valve is used, the vacuum pump oil may flow into the
ing piping may cause the refrigerating machine oil in the refrigerant cycle and cause the refrigerating machine oil to
new unit to deteriorate. deteriorate.
R410A is a high-pressure refrigerant and can cause the
existing pipes to burst. Prepare tools for exclusive use with R410A. Do not use
the following tools if they have been used with the con-
Use refrigerant pipes made of phosphorus deoxidized ventional refrigerant (gauge manifold, charging hose,
copper. Keep the inner and outer surfaces of the pipes gas leak detector, reverse-flow check valve, refrigerant
clean and free of such contaminants as sulfur, oxides, charge base, vacuum gauge, and refrigerant recovery
dust, dirt, shaving particles, oil, and water. equipment.).
These types of contaminants inside the refrigerant pipes If the refrigerant or the refrigerating machine oil left on
may cause the refrigerant oil to deteriorate. these tools are mixed in with R410A, it may cause the re-
frigerating machine oil to deteriorate.
Store the pipes to be installed indoors, and keep both Infiltration of water may cause the refrigerating machine
ends of the pipes sealed until immediately before braz- oil to deteriorate.
ing. (Keep elbows and other joints wrapped in plastic.) Gas leak detectors for conventional refrigerants will not
detect an R410A leak because R410A is free of chlorine.
Infiltration of dust, dirt, or water into the refrigerant system
may cause the refrigerating machine oil to deteriorate or
Do not use a charging cylinder.
cause the unit to malfunction.
If a charging cylinder is used, the composition of the refrig-
Use a small amount of ester oil, ether oil, or alkylben- erant will change, and the unit may experience power loss.
zene to coat flares and flanges.
Exercise special care when handling the tools for use
Infiltration of a large amount of mineral oil may cause the re-
with R410A.
frigerating machine oil to deteriorate.
Infiltration of dust, dirt, or water into the refrigerant system
Charge liquid refrigerant (as opposed to gaseous re- may cause the refrigerating machine oil to deteriorate.
frigerant) into the system.
If gaseous refrigerant is charged into the system, the com-
position of the refrigerant in the cylinder will change and
may result in performance loss.
HWE1116F
iii GB
Before installing the unit
WARNING
Do not install the unit where a gas leak may occur. When installing the unit in a hospital, take appropriate
measures to reduce noise interference.
If gaseous refrigerant leaks and piles up around the unit, it
may be ignited. High-frequency medical equipment may interfere with the
normal operation of the air conditioner or vice versa.The
Do not use the unit to keep food items, animals, plants, product may affect communication equipment. Visual inter-
artifacts, or for other special purposes. ruption to video images and noise may occur.
The unit is not designed to preserve food products.
Do not install the unit on or over things that cannot get
wet.
Do not use the unit in an unusual environment.
When the humidity level exceeds 80% or if the drainage
Do not install the unit where a large amount of oil or steam system is clogged, the indoor unit may drip water. Drain wa-
is present or where acidic or alkaline solutions or chemical ter is also discharged from the outdoor unit. Install a central-
sprays are used frequently. Doing so may lead to a re- ized drainage system if necessary.
markable drop in performance, electric shock, malfunc-
tions, smoke, and/or fire.
The presence of organic solvents or corrosive gas (i.e.
ammonia, sulfur compounds, and acid) may cause gas
leakage or water leakage.
HWE1116F
iv GB
Before installing the unit (moving and reinstalling the unit) and performing
electrical work
CAUTION
Properly ground the unit. Periodically check the installation base for damage.
Do not connect the grounding wire to a gas pipe, water pipe, If the unit is left on a damaged platform, it may fall and
lightning rod, or grounding wire from a telephone pole. Im- cause injury.
proper grounding may result in electric shock, smoke, fire,
and/or malfunction due to noise interference. Properly install the drain pipes according to the in-
structions in the installation manual. Keep them insu-
Do not put tension on the power supply wires. lated to avoid dew condensation.
If tension is put on the wires, they may break and result in Improper plumbing work may result in water leakage and
excessive heat, smoke, and/or fire. damage to the furnishings.
Install an earth leakage breaker for the inverter circuit Exercise caution when transporting products.
to avoid the risk of electric shock.
Products weighing more than 20 kg should not be carried
Failure to install an earth leakage breaker for the inverter alone.
circuit may result in electric shock, smoke, and/or fire. Do not carry the product by the PP bands that are used on
some products.
Use the kind of power supply wires that are specified Do not touch the heat exchanger fins. They are sharp and
in the installation manual. dangerous.
When lifting the unit with a crane, secure all four corners
The use of wrong kind of power supply wires may result in to prevent the unit from falling.
current leak, electric shock, and/or fire.
Properly dispose of the packing materials.
Use breakers and fuses (current breaker, remote
switch , moulded case circuit Nails and wood pieces in the package may pose a risk of
breaker) with the proper current capacity. injury.
Plastic bags may pose a risk of choking hazard to chil-
The use of wrong capacity fuses, steel wires, or copper dren. Tear plastic bags into pieces before disposing of
wires may result in malfunctions, smoke, and/or fire. them.
Do not spray water on the air conditioner or immerse
the air conditioner in water.
Otherwise, electric shock and/or fire may result.
When handling units, always wear protective gloves to
protect your hands from metal parts and high-tempera-
ture parts.
To reduce the risk of burns, do not touch electrical
parts during or directly after operation.
HWE1116F
v GB
Before the test run
CAUTION
Turn on the unit at least 12 hours before the test run. Do not operate the unit without panels and safety
guards.
Keep the unit turned on throughout the season. If the unit is
turned off in the middle of a season, it may result in malfunc- Rotating, high-temperature, or high-voltage parts on the unit
tions. pose a risk of burns and/or electric shock.
To avoid the risk of electric shock or malfunction of the Do not turn off the power immediately after stopping
unit, do not operate switches with wet hands. the operation.
Keep the unit on for at least five minutes before turning off
Do not touch the refrigerant pipes with bare hands dur-
the power to prevent water leakage or malfunction.
ing and immediately after operation.
During or immediately after operation, certain parts of the Do not operate the unit without the air filter.
unit such as pipes and compressor may be either very cold
Dust particles may build up in the system and cause mal-
or hot, depending on the state of the refrigerant in the unit
functions.
at the time. To reduce the risk of frost bites and burns, do
not touch these parts with bare hands.
HWE1116F
vi GB
CONTENTS
I Read Before Servicing
[1] Read Before Servicing.............................................................................................................. 3
[2] Necessary Tools and Materials ................................................................................................ 4
[3] Piping Materials ........................................................................................................................ 5
[4] Storage of Piping ...................................................................................................................... 7
[5] Pipe Processing........................................................................................................................ 7
[6] Brazing...................................................................................................................................... 8
[7] Air Tightness Test..................................................................................................................... 9
[8] Vacuum Drying (Evacuation) .................................................................................................. 10
[9] Refrigerant Charging .............................................................................................................. 12
[10] Remedies to be taken in case of a Refrigerant Leak............................................................ 12
[11] Characteristics of the Conventional and the New Refrigerants ............................................ 13
[12] Notes on Refrigerating Machine Oil ...................................................................................... 14
II Restrictions
[1] System configuration .............................................................................................................. 17
[2] Types and Maximum allowable Length of Cables .................................................................. 18
[3] Switch Settings and Address Settings .................................................................................... 19
[4] Sample System Connection ................................................................................................... 26
[5] An Example of a System to which an MA Remote Controller is connected ........................... 28
[6] An Example of a System to which an ME Remote Controller is connected ........................... 42
[7] An Example of a System to which both MA Remote Controller and ME Remote Controller are con-
nected ..................................................................................................................................... 44
[8] Restrictions on Pipe Length.................................................................................................... 47
III Outdoor Unit Components
[1] Outdoor Unit Components and Refrigerant Circuit ................................................................. 61
[2] Control Box of the Outdoor Unit.............................................................................................. 65
[3] Outdoor Unit Circuit Board...................................................................................................... 70
[4] BC Controller Components ..................................................................................................... 81
[5] Control Box of the BC Controller ............................................................................................ 84
[6] BC Controller Circuit Board .................................................................................................... 85
IV Remote Controller
[1] Functions and Specifications of MA and ME Remote Controllers .......................................... 89
[2] Group Settings and Interlock Settings via the ME Remote Controller .................................... 90
[3] Interlock Settings via the MA Remote Controller .................................................................... 94
[4] Using the built-in Temperature Sensor on the Remote Controller.......................................... 95
V Electrical Wiring Diagram
[1] Electrical Wiring Diagram of the Outdoor Unit ........................................................................ 99
[2] Electrical Wiring Diagram of the BC Controller ..................................................................... 104
[3] Electrical Wiring Diagram of Transmission Booster.............................................................. 114
VI Refrigerant Circuit
[1] Refrigerant Circuit Diagram .................................................................................................. 117
[2] Principal Parts and Functions ............................................................................................... 125
VII Control
[1] Functions and Factory Settings of the Dipswitches .............................................................. 137
[2] Controlling the Outdoor Unit ................................................................................................. 144
[3] Controlling BC Controller ...................................................................................................... 158
[4] Operation Flow Chart............................................................................................................ 159
VIII Test Run Mode
[1] Items to be checked before a Test Run................................................................................ 167
[2] Test Run Method .................................................................................................................. 168
[3] Operating Characteristic and Refrigerant Amount ................................................................ 169
[4] Adjusting the Refrigerant Amount......................................................................................... 169
[5] Refrigerant Amount Adjust Mode.......................................................................................... 172
[6] The following symptoms are normal. .................................................................................... 174
[7] Standard Operation Data (Reference Data) ......................................................................... 175
IX Troubleshooting
[1] Error Code Lists.................................................................................................................... 195
[2] Responding to Error Display on the Remote Controller........................................................ 199
[3] Investigation of Transmission Wave Shape/Noise ............................................................... 286
[4] Troubleshooting Principal Parts ............................................................................................ 289
[5] Refrigerant Leak ................................................................................................................... 338
[6] Compressor Replacement Instructions................................................................................. 340
HWE1116F GB
[7] Servicing the BC controller ................................................................................................... 350
[8] Troubleshooting Using the Outdoor Unit LED Error Display................................................. 353
[9] Cleaning the outdoor unit heat exchanger............................................................................ 353
X LED Monitor Display on the Outdoor Unit Board
[1] How to Read the LED on the Service Monitor ...................................................................... 357
HWE1116F GB
I Read Before Servicing
[1] Read Before Servicing ....................................................................................................... 3
[2] Necessary Tools and Materials.......................................................................................... 4
[3] Piping Materials ................................................................................................................. 5
[4] Storage of Piping ............................................................................................................... 7
[5] Pipe Processing ................................................................................................................. 7
[6] Brazing............................................................................................................................... 8
[7] Air Tightness Test .............................................................................................................. 9
[8] Vacuum Drying (Evacuation) ........................................................................................... 10
[9] Refrigerant Charging........................................................................................................ 12
[10] Remedies to be taken in case of a Refrigerant Leak ....................................................... 12
[11] Characteristics of the Conventional and the New Refrigerants ....................................... 13
[12] Notes on Refrigerating Machine Oil ................................................................................. 14
HWE1116F -1- GB
HWE1116F -2- GB
[ I Read Before Servicing ]
[1] Read Before Servicing
I 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 R2 TKMU, YKMU 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.
Refer to "Necessary Tools and Materials" for information on the use of tools.(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.
CAUTION
Install new pipes immediately after removing old ones to keep moisture out of the refrigerant circuit.
The use of refrigerant that contains chloride, such as R22, will cause the refrigerating machine oil to deteriorate.
HWE1116F -3- GB
[ I Read Before Servicing ]
[2] Necessary Tools and Materials
Prepare the following tools and materials necessary for installing and servicing the unit.
Tools for use with R410A (Adaptability of tools that are for use with R22 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
high-pressure side
Charging Hose Evacuation and refrigerant charging The hose diameter is larger than the
conventional model.
Refrigerant Recovery Cylinder Refrigerant recovery
Refrigerant Cylinder Refrigerant charging The refrigerant type is indicated. The
cylinder is pink.
Charging Port on the Refrigerant Cylinder Refrigerant charging The charge port diameter is larger
than that of the current port.
Flare Nut Connection of the unit with the pipes Use Type-2 Flare nuts.
2. Tools and materials that may be used with R410A with some restrictions
Tools/Materials Use Notes
Gas Leak Detector Gas leak detection The ones for use with HFC refrigerant
may be used.
Vacuum Pump Vacuum drying May be used if a check valve adapter
is attached.
Flare Tool Flare processing Flare processing dimensions for the
piping in the system using the new re-
frigerant differ from those of R22. Re-
fer to I [3] Piping Materials.
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
ø12.70 (1/2") and ø15.88 (5/8") have
been changed.
Pipe Cutter Cutting pipes
Welder and Nitrogen Cylinder Welding pipes
Refrigerant Charging Meter Refrigerant charging
Vacuum Gauge Vacuum level check
4. Tools and materials that must not be used with R410A
Tools/Materials Use Notes
Charging Cylinder Refrigerant charging Prohibited to use
Tools for R410A must be handled with special care to keep moisture and dust from infiltrating the cycle.
HWE1116F -4- GB
[ I Read Before Servicing ]
[3] Piping Materials
Do not use the existing piping!
1. Copper pipe materials
Annealed Soft copper pipes (annealed copper pipes). They can easily be bent with hands.
Drawn Hard copper pipes (straight pipes). They are stronger than the Annealed at the same
radial thickness.
The distinction between Annealed and Drawn is made based on the strength of the pipes themselves.
Annealed can easily be bent with hands.
Drawn are considerably stronger than Annealed at the same thickness.
2. Types of copper pipes
Maximum working pressure Refrigerant type
3.45 MPa [500psi] R22, R407C etc.
4.30 MPa [624psi] R410A etc.
3. Piping materials/Radial thickness
Select piping materials that meet the requirements set forth in ASTM B280.
HWE1116F -5- GB
[ I Read Before Servicing ]
4. Thickness and refrigerant type indicated on the piping materials
Ask the pipe manufacturer for the symbols indicated on the piping material for new refrigerant (R410A).
5. Flare processing
Select piping materials that meet the requirements set forth in ASTM.
6. Flare nut
Select piping materials that meet the requirements set forth in ASTM.
HWE1116F -6- GB
[ I Read Before Servicing ]
[4] Storage of Piping
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
Both ends of the pipes should be sealed until just before brazing.
Keep elbow pipes and T-joints in plastic bags.
The new refrigerator oil is 10 times as hygroscopic as the conventional refrigerating machine oil (such as Suniso) and, if not
handled with care, could easily introduce moisture into the system. Keep moisture out of the pipes, for it will cause the oil to
deteriorate and cause a compressor failure.
[5] Pipe Processing
Use a small amount of ester oil, ether oil, or alkylbenzene to coat flares and flanges.
Use a minimum amount of oil.
Use only ester oil, ether oil, and alkylbenzene.
HWE1116F -7- GB
[ I Read Before Servicing ]
[6] Brazing
No changes have been made in the brazing procedures. Perform brazing with special care to keep foreign objects (such as oxide
scale, water, and dust) out of the refrigerant system.
Example: Inside the brazed connection
Use of 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.
HWE1116F -8- GB
[ I Read Before Servicing ]
[7] Air Tightness Test
No changes have been made in the detection method. Note that a refrigerant leak detector for R22 will not detect an R410A leak.
Halide torch R22 leakage detector
1. Items to be strictly observed
Pressurize the equipment with nitrogen up to the design pressure (4.15MPa[601psi]), and then judge the equipment's air tight-
ness, taking temperature variations into account.
Refrigerant R410A must be charged in its liquid state (vs. gaseous state).
2. Reasons
Oxygen, if used for an air tightness test, poses a risk of explosion. (Only use nitrogen to check air tightness.)
Refrigerant R410A must be charged in its liquid state. If gaseous refrigerant in the cylinder is drawn out first, the composition
of the remaining refrigerant in the cylinder will change and become unsuitable for use.
3. Notes
Procure a leak detector that is specifically designed to detect an HFC leak. A leak detector for R22 will not detect an
HFC(R410A) leak.
HWE1116F -9- GB
[ I Read Before Servicing ]
[8] Vacuum Drying (Evacuation)
(Photo1) 15010H (Photo2) 14010
Recommended vacuum gauge:
ROBINAIR 14010 Thermistor Vacuum Gauge
1. Vacuum pump with a reverse-flow check valve (Photo1)
To prevent the vacuum pump oil from flowing into the refrigerant circuit during power OFF or power failure, use a vacuum
pump with a reverse-flow check valve.
A reverse-flow check valve may also be added to the vacuum pump currently in use.
2. Standard of vacuum degree (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 recom-
mended 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/cm2G(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.)
HWE1116F - 10 - GB
[ I Read Before Servicing ]
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).
HWE1116F - 11 - GB
[ I Read Before Servicing ]
[9] 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 be-
come unsuitable for use.
2. Notes
When using a cylinder with a siphon, refrigerant is charged in the liquid state without the need for turning it upside down. Check
the type of the cylinder on the label before use.
[10] Remedies to be taken in case of a Refrigerant Leak
If the refrigerant leaks out, it may be replenished. The entire refrigerant does not need to be replaced. (Charge refrigerant in the
liquid state.)
Refer to "IX [5] Refrigerant Leak."(page 338)
HWE1116F - 12 - GB
[ I Read Before Servicing ]
[11] Characteristics of the Conventional and the New Refrigerants
1. Chemical property
As with R22, the new refrigerant (R410A) is low in toxicity and chemically stable nonflammable refrigerant.
However, because the specific gravity of vapor refrigerant is greater than that of air, leaked refrigerant in a closed room will
accumulate at the bottom of the room and may cause hypoxia.
If exposed to an open flame, refrigerant will generate poisonous gases. Do not perform installation or service work in a con-
fined area.
New Refrigerant (HFC type) Conventional 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 Non-azeotropic Single Refrigerant
Refrigerant 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 64.0 42.5 44.4
(25°C,kg/m3/77°F,psi)
Flammability Nonflammable Nonflammable Nonflammable
Ozone Depletion Coefficient (ODP)*1 0 0 0.055
Global Warming Coefficient (GWP)*2 1730 1530 1700
Refrigerant Charging Method Refrigerant charging in Refrigerant charging in Refrigerant charging in
the liquid state the liquid state the gaseous state
Replenishment of Refrigerant after a Refrigerant Available Available Available
Leak
*1 When CFC11 is used as a reference
*2 When CO2 is used as a reference
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
HWE1116F - 13 - GB
[ I Read Before Servicing ]
[12] Notes on Refrigerating Machine Oil
1. Refrigerating machine oil in the HFC refrigerant system
HFC type refrigerants use a refrigerating machine oil different from that used in the R22 system.
Note that the ester oil used in the system has properties that are different from commercially available ester oil.
Refrigerant Refrigerating machine oil
R22 Mineral oil
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 Clogged expansion valve and capillary tubes
and capillary tubes Poor cooling performance
Compressor overheat
Motor insulation failure
Sludge formation and ad-
Burnt motor
Hydrolysis hesion
Coppering of the orbiting scroll
Acid generation
Lock
Oxidization
Burn-in on the orbiting scroll
Oil degradation
Air infiltration Oxidization
Adhesion to expansion valve and capillary Clogged expansion valve, capillary tubes, and
tubes drier
Poor cooling performance
Dust, dirt Compressor overheat
Infiltration of Infiltration of contaminants into the com- Burn-in on the orbiting scroll
contaminants pressor
Sludge formation and adhesion Clogged expansion valve and capillary tubes
Mineral oil Poor cooling performance
etc. Compressor overheat
Oil degradation Burn-in on the orbiting scroll
*1. Contaminants is defined as moisture, air, processing oil, dust/dirt, wrong types of refrigerant, and refrigerating machine oil.
HWE1116F - 14 - GB
II Restrictions
[1] System configuration ....................................................................................................... 17
[2] Types and Maximum allowable Length of Cables ........................................................... 18
[3] Switch Settings and Address Settings ............................................................................. 19
[4] Sample System Connection............................................................................................. 26
[5] An Example of a System to which an MA Remote Controller is connected..................... 28
[6] An Example of a System to which an ME Remote Controller is connected..................... 42
[7] An Example of a System to which both MA Remote Controller and ME Remote
Controller are connected.................................................................................................. 44
[8] Restrictions on Pipe Length ............................................................................................. 47
HWE1116F - 15 - GB
HWE1116F - 16 - GB
[ II Restrictions ]
[1] System configuration
II Restrictions
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 Composing units Maximum total capacity Maximum number Types of connectable in-
units of connectable indoor of connectable in- door units
units door units
72 - - 36 - 108 18 P06 - P96 models
R410A series indoor units
96 - - 48 - 144 24
120 - - 60 - 180 30
144 - - 72 - 216 36
144 72 72 72 - 216 36
168 96 72 84 - 252 42
192 96 96 96 - 288 48
216 120 96 108 - 324 50
240 120 120 120 - 360 50
264 144 120 132 - 396 50
288 144 144 144 - 432 50
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.
3) There is no P144 that consists of two P72 units in the TKMU series.
HWE1116F - 17 - GB
[ II Restrictions ]
[2] Types and Maximum allowable Length of Cables
1. Wiring work
(1) Notes
1) Have all electrical work performed by an authorized electrician according to the local regulations and instructions in this man-
ual.
2) Install external transmission cables at least 5cm [1-31/32"] away from the power supply cable to avoid noise interference.
(Do not put the control cable and power supply cable in the same conduit tube.)
3) Provide grounding for the outdoor unit as required.
4) Run the cable from the electric box of the indoor or outdoor unit in such way that the box is accessible for servicing.
5) Do not connect power supply wiring to the terminal block for transmission line. Doing so will damage the electronic compo-
nents on the terminal block.
6) Use 2-core shielded cables as transmission cables.
Use a separate 2-core control cable for each refrigerant system. Do not use a single multiple-core cable to connect indoor
units that belong to different refrigerant systems. The use of a multiple-core cable may result in signal transmission errors and
malfunctions.
Outdoor unit Outdoor unit
BC Controller Indoor unit BC Controller Indoor unit
TB TB TB TB TB TB TB TB
3 7 3 7 3 7 3 7
multiple-core cable
2-core shielded cable
Remote Controller Remote Controller
TB TB TB TB TB TB TB TB
3 7 3 7 3 7 3 7
2-core shielded cable
TB3: Terminal block for indoor-outdoor transmission line TB7: Terminal block for centralized control
7) When extending the transmission cable, be sure to extend the shield wire.
(2) Control wiring
Different types of control wiring are used for different systems.
Refer to section "[5] An Example of a System to which an MA Remote Controller is connected - [7] An Example of a System
to which both MA Remote Controller and ME Remote Controller are connected" before performing wiring work.
Types and maximum allowable length of cables
Control lines are categorized into 2 types: transmission line and remote controller line.
Use the appropriate type of cables and observe the maximum allowable length specified for a given system. If a given system
has a long transmission line or if a noise source is located near the unit, place the unit away from the noise source to reduce
noise interference.
1) M-NET transmission line
Facility
All facility types
type
Type Shielded cable CVVS, CPEVS, MVVS
Cable type
Number of
2-core cable
cores
Cable size Larger than 1.25mm2 [AWG16]
Maximum transmission
line distance between the
200 m [656ft] max.
outdoor unit and the far-
thest indoor unit
Maximum transmission
line distance for central-
500 m [1640ft] max.
ized control and Indoor/
*The maximum overall line length from the power supply unit on the transmission lines for
outdoor transmission line
centralized control to each outdoor unit or to the system controller is 200m [656ft] max.
(Maximum line distance
via outdoor unit)
HWE1116F - 18 - GB
[ II Restrictions ]
2) Remote controller wiring
MA remote controller*1 ME remote controller*5
Type CVV CVV
Number of
2-core cable 2-core cable
cores
Cable type
0.3 to 1.25mm2 *2 *4 0.3 to 1.25mm2 *2
[AWG22 to 16] [AWG22 to 16]
Cable size
(0.75 to 1.25mm2 ) *3 (0.75 to 1.25mm2 ) *3
[AWG18 to 16] [AWG18 to 16]
The section of the cable that exceeds 10m
Maximum overall line
200 m [656ft] max. [32ft] must be included in the maximum in-
length
door-outdoor