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Mitsubishi Electric CITY MULTI PQRY-P200YMF-C Service Handbook
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Mitsubishi Electric CITY MULTI PQRY-P200YMF-C Service Handbook

Mitsubishi Electric CITY MULTI PQRY-P200YMF-C Service Handbook

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AIR CONDITIONERS CITY MULTI
PQRY-P200YMF-C, P250YMF-C
Models
CMB-P104, P105, P106, P108, P1010, P1013, P1016V-E
Service Handbook

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Summary of Contents for Mitsubishi Electric CITY MULTI PQRY-P200YMF-C

  • Page 1 AIR CONDITIONERS CITY MULTI PQRY-P200YMF-C, P250YMF-C Models CMB-P104, P105, P106, P108, P1010, P1013, P1016V-E Service Handbook...

  • Page 2: Table Of Contents

    Contents PRECAUTIONS FOR DEVICES THAT USE R407C REFRIGERANT ..3 [1] Storage of Piping Material ..............4 [2] Piping Machining ................5 [3] Necessary Apparatus and Materials and Notes on Their Handling .. 6 [4] Brazing ....................7 [5] Airtightness Test ................8 [6] Vacuuming ..................
  • Page 3 • Ask the dealer or an authorized technician to install the air device is shorted and operated forcibly, or parts other than conditioner. those specified by Mitsubishi Electric are used, fire or - Improper installation by the user may result in water leakage, explosion may result.

  • Page 4: Precautions For Devices That Use R407C Refrigerant

    1 1 1 1 1 PRECAUTIONS FOR DEVICES THAT USE R407C REFRIGERANT Caution Do not use the existing refrigerant piping. Use a vacuum pump with a reverse flow check valve. • The vacuum pump oil may flow back into the refriger- •...

  • Page 5: Storage Of Piping Material

    [1] Storage of Piping Material (1) Storage location Store the pipes to be used indoors. (Warehouse at site or owner’s warehouse) Storing them outdoors may cause dirt, waste, or water to infiltrate. (2) Pipe sealing before storage Both ends of the pipes should be sealed until immediately before brazing. Wrap elbows and T’s in plastic bags for storage.

  • Page 6: Piping Machining

    [2] Piping Machining Use ester oil, ether oil or alkylbenzene (small amount) as the refrigerator oil to coat flares and flange connections. Use only the necessary minimum quantity of oil ! Reason : 1. The refrigerator oil used for the equipment is highly hygroscopic and may introduce water inside. Notes : •...

  • Page 7: Necessary Apparatus And Materials And Notes On Their Handling

    [3] Necessary Apparatus and Materials and Notes on Their Handling The following tools should be marked as dedicated tools for R407C. <<Comparison of apparatus and materials used for R407C and for R22>> Apparatus Used R407C Gauge manifold Evacuating, refrigerant filling Current product Charging hose Operation check...

  • Page 8: Brazing

    [4] Brazing No changes from the conventional method, but special care is required so that foreign matter (ie. oxide scale, water, dirt, etc.) does not enter the refrigerant circuit. Example : Inner state of brazed section When non-oxide brazing was not used When non-oxide brazing was used Items to be strictly observed : 1.

  • Page 9: Airtightness Test

    [5] Airtightness Test No changes from the conventional method. Note that a refrigerant leakage detector for R22 cannot detect R407C leakage. Halide torch R22 leakage detector Items to be strictly observed : 1. Pressurize the equipment with nitrogen up to the design pressure and then judge the equipment’s airtightness, taking temperature variations into account.

  • Page 10: Charging Of Refrigerant

    [7] Charging of Refrigerant R407C must be in a liquid state when charging, because it is a non-azeotropic refrigerant. For a cylinder with a syphon attached For a cylinder without a syphon attached Cylin- Cylin- Cylinder color identification R407C-brown Charged with liquid refrigerant Valve Valve Liquid...

  • Page 11: Component Of Equipment

    2 2 2 2 2 COMPONENT OF EQUIPMENT [1] Appearance of Components Heat source unit Heatexchanger Control Box 4-way Valve Block Drier Block Compressor Accumulator –10–...
  • Page 12 INV board Control Box Front View Transformer (T01) RELAY board MAIN board Terminal block TB8 Terminal block TB7 Terminal block TB1A Terminal block UNIT ON/OFF, Transmission (Centralized Control) Power Source TB3 Transmission Pump inter lock Inner View Cooling fan DC reactor Choke coil (MF1) (DCL)
  • Page 13 MAIN board CNTR CNVCC4 CNS1 CNS2 CN40 CN41 Power source for control (5V) CNVCC3 Power source for control 1-2 30 V, 1-3 30 V, 4-6 12 V, 5-6 5 V CN51 CN3D Service LED CN20 SWU2 SWU1 –12–...
  • Page 14 INV board CNVDC DC-560V CN15V2 Power supply for IPM control CNVCC4 Power supply (5V) CNL2 Choke coil CNVCC2 Power supply 1-2 30V, 1-3 30V CN52C 4-6 12V, 5-6 5V Control for CNDR2 Out put to G/A board CNFAN Control CNTH for MF1 CNAC2 Power...
  • Page 15 RELAY board SNB board –14–...
  • Page 16 BC controller BC board CNTR CN12 Power supply CN02 1 EARTH M-NET transmission CN03 –15–...
  • Page 17 RELAY 10 board RELAY 4 board –16–...

  • Page 18: Refrigerant Circuit Diagram And Thermal Sensor

    [2] Refrigerant Circuit Diagram and Thermal Sensor Heat source unit –17–...
  • Page 19 BC controller, Indoor unit –18–...

  • Page 20: Electrical Wiring Diagram

    [3] Electrical Wiring Diagram • PQRY-P200·250YMF-C –19–...
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  • Page 28: Standard Operation Data

    [4] Standard Operation Data 1 Cooling operation Heat source unit PQRY-P200YMF-C PQRY-P250YMF-C Items Power source V/Hz 380-415V/50Hz • 60Hz 380-415V/50Hz • 60Hz Ambient temp. Indoor DB/WB 27.0/19.0 27.0/19.0 °C Circulated water temp. (Intet) Quantity Q’ty Indoor unit Quantity in operation Model –...
  • Page 29 2 Heating operation Heat source unit PQRY-P200YMF-C PQRY-P250YMF-C Items Power source V/Hz 380-415V/50Hz • 60Hz 380-415V/50Hz • 60Hz Ambient temp. Indoor DB/WB 20.0/– 20.0/– °C Circulated water temp. Quantity Q’ty Indoor unit Quantity in operation Model – Main pipe Piping Branch pipe Total piping length Indoor unit fan notch...

  • Page 30: Function Of Dip Sw And Rotary Sw

    [5] Function of Dip SW and Rotary SW (1) Heat source unit Function according to switch operation Switch set timing Switch Function When off When on When off When on Unit address setting Set on 51~100 with the dial switch. Before power is turned on.
  • Page 31 (2) Indoor unit DIP SW1, 3 Operation by SW Switch set timing Remarks Switch SW name Room temp. sensor position Indoor unit inlet Built in remote controller Clogged filter detect. None Provided Filter duration 100h 2500h OA intake Ineffective Effective Always ineffective for PKFY-P.VAM Remote display select.
  • Page 32 Setting of DIP SW4 Setting of DIP SW5 Model Circuit board used 220V 240V PMFY-P-VBM-A PLFY-P-VLMD-A – – – – PDFY-P20 ~ 80VM-A PLFY-P40 ~ 63VKM-A PLFY-P80 ~ 125VKM-A Phase control PCFY-P-VGM-A PKFY-P-VGM-A PKFY-P-VAM-A – – – – PEFY-P20 ~ 80VMM-A PFFY-P-VLEM-A, P-VLRM-A –...

  • Page 33: External Input/Output Specifications

    [6] External Input/Output Specifications (1) Output 1 Operation ON signal Terminal No. TB8-1, 2 Output Relay contacts output Rated voltage: L1 - N: 220 ~ 240 V Rated load: 1 A • When DIP switch 2-7 is OFF Operation The relay closes during compressor operation. •...

  • Page 34: Test Run

    3 3 3 3 3 TEST RUN [1] Before Test Run (1) Check points before test run Neither refrigerant leak nor loose power source/ transmission lines should be found. Confirm that the resistance between the power source terminal block and the ground exceeds 2MΩ by measur- ing it with a DC500V megger.
  • Page 35 (3) Check points for test run when mounting options Result Built-in optional parts Content of test run Check point Mounting of drain Release connector of pump circuit, Local remote controller displays code water lifting-up check error detection by pouring No. “2503”, and the mechanism stops. mechanism water into drain pan water inlet.
  • Page 36 (5) Check points for system structure ex. PQRY-P200YMF-B Check points from installation work to test run. Classification Portion Check item Trouble Installation and Instruction for selecting combination of heat source piping unit, and indoor unit followed? (Maximum number of Not operate. indoor units which can be connected, connecting model name, and total capacity.) Follow limitation of refrigerant piping length? For ex-...
  • Page 37 M-NET Remote Controller 1Hr. 1Hr. CENTRALLY CONTROLLED CENTRALLY CONTROLLED ˚C ˚C ON OFF ON OFF D A I L Y D A I L Y AUTO OFF CLOCK AUTO OFF CLOCK FILTER FILTER CHECK REMAINDER CHECK REMAINDER CHECK MODE CHECK MODE TEST RUN TEST RUN STAND BY...

  • Page 38: Address Setting

    [2] Address setting (1) Switch operation In order to constitute CITY MULTI in a complete system, switch Rotary switch operation for setting the unit address No. and connection No. is Connection Unit address No. setting required. No. setting 1 Unit address No. group No. and connection No. The unit address No.
  • Page 39 2 Branch number switch (Indoor Units and Fresh Master) Match the indoor unit’s refrigerant pipe with the BC controller’s end connection number. When combining branches, choose the smallest connection number in the series. The indoor unit capacity limit for connecting to a branch is 80. Max. 3sets for 1 connection. When selecting connection number 16, choose 0 as the setting for the branch number switch.
  • Page 40 (3) Examples of switch settings System diagram Description [Switch settings] 1 Individual operation (1) Address switch Unit Range Setting Heat source Indoor unit 01~50 – unit 101~150 Indoor unit Indoor unit Indoor unit Remote controller Indoor unit setting + 100 Note 1 Smallest address among 51~100...
  • Page 41 System diagram Description [Switch settings] System for operating with OA processing unit (Lossnay) This is the same as 1 Individual operation. However, keep the Fresh Master address within the 1 Heat source ~50 range to avoid duplication with other indoor units. unit Indoor unit Indoor unit...
  • Page 42 System diagram Description [Switch settings] PAC-SC30GR connection Address switch settings are the same as 1 Individual operation. Change This turns on the central manager switch (SW2-1) of Where a group remote controller is the outdoor unit. connected to a transfer line for indoor units. CN41 CN40 *Remote controllers for groups...

  • Page 43: Test Run Method

    [3] Test Run Method Operation procedure Turn on universal power supply at least 12 hours before getting started → Displaying “HO” on display panel for about two minutes 2 Press TEST RUN button twice → Displaying “TEST RUN’’ on display panel selection button →...

  • Page 44: Grouping Registration Of Indoor Units With Remote Controller

    4 GROUPING REGISTRATION OF INDOOR UNITS WITH M-NET REMOTE CONTROLLER (1) Switch function • The switch operation to register with the remote controller is shown below: CENTRALLY CONTROLLED ˚C ON OFF D A I L Y AUTO OFF CLOCK FILTER CHECK REMAINDER CHECK MODE...
  • Page 45 (2) Attribute display of unit • At the group registration and the confirmation/deletion of registration/connection information, the type (attribute) of the unit is displayed with two English characters. Display Type (Attribute) of unit/controller Indoor unit connectable to remote controller Outdoor unit Local remote controller System controller (MJ) [Description of registration/deletion/retrieval]...
  • Page 46 (3) Group registration of indoor unit Registration method • Group registration of indoor unit ................ 1 The indoor unit to be controlled by a remote controller is registered on the remote controller. [Registration procedure] 1 With the remote controller under stopping or at the display of “HO”, continuously press the switch FILTER (A + B) at the same time for 2 seconds to change to the registration mode.
  • Page 47 Method of retrieval/confirmation • Retrieval/confirmation of group registration information on indoor unit ....2 The address of the indoor unit being registered on the remote controller is displayed. [Operation procedure] 1 With the remote controller under stopping or at the display of “HO”, continuously press the switch (A FILTER + B) at the same time for 2 seconds to change to the registration mode.
  • Page 48 • Registered ˚C (Alternative display) ˚C TEMP ON/OFF CLOCK ON OFF FILTER CHECK TEST PAR-F27MEA TIMER SET ˚C 1 + 2 (Alternative display) 2 Press the switch for 1 Set the address confirmation (E) ˚C ˚C INDOOR UNIT ERROR CODE ADDRESS NO OA UNIT ADDRESS NO * Same display will appear when...
  • Page 49 Deletion of information on address not existing • Deletion of information on address not existing ........... 5 This operation is to be conducted when “6607” error (No ACK error) is displayed on the remote controller caused by the miss setting at test run, or due to the old memory remained at the alteration/modification of group composition, and the address not existing will be deleted.

  • Page 50: Control

    5 5 5 5 5 CONTROL [1] Control of Heat Source Unit (1) Initial processing • When turning on power source, initial processing of microcomputer is given top priority. • During initial processing, control processing corresponding to operation signal is suspended. The control process- ing is resumed after initial processing is completed.
  • Page 51 Pressure limit The upper limit of high pressure (Pd) is set for each frequency. When the limit is exceeded, frequency is reduced every 10 seconds. (Frequency decrease rate (Hz) : 22% of the present value) <P200YMF-C> <P250YMF-C> Discharge temperature limit Discharge temperature (Td) of compressor is detected during operation.
  • Page 52 (6) Judgement of refrigerant amount Cooling Mode AL=0 AL=1 AL=2 F(Hz) Heating Mode AL=0 AL=1 AL=2 Te(°C) –51–...
  • Page 53 (7) Control of heat source unit fan and heat source unit heat exchanger capacity Control system Depending on capacity required, control SV3~6, SV71~73, for maintaining evaporation temperature (0˚C) in cooling operations, and high pressure saturated temperature (52˚C) in heating operations. Heat exchanger pattern Heat Exchanger Switching Mode...

  • Page 54: Control Box Cooling System

    [2] Control box cooling system In PQRY, in order to cool the parts in the control box which emit heat, a refrigerant evaporator has been placed in the bottom of the control box (unit frame side). (See the figure.) The control box is also mounted in the frame and when the inverter operates, it operates the control box internal cooling fan as well as supplying refrigerant to the evaporator, thus creating air passages in the direction shown by the arrows.

  • Page 55: Control Of Bc Controller

    [3] Control of BC Controller (1) Control of SVA, SVB and SVC SVA, SVB and SVC are turned on and off depending on connection mode. Mode Cooling Heating Stop Defrost Connection (2) Control of LEV LEV opening (sj) is controlled corresponding to operation mode as follows: (Number of pulse) Operation mode Cooling-only...

  • Page 56: Operation Flow Chart

    [4] Operation Flow Chart (1) Heat source unit Start Normal operations Breaker turned on Trouble observed Stop “HO” blinks on the remote controller Note : 1 Set indoor ad- dress No. to remote controller Operation command Oil return LEV (SLEV), INV cooling LEV (LEV2) fully closed Operation mode...
  • Page 57 (2) BC controller Start Normal operations Breaker turned on Trouble observed Stop Operation command 1. Operation mode judgement (cooling-only, heating-only, cooling/heating mixed) 2. Transmission to heat source unit Receiving operation mode command from heat source unit Note : 1 Error mode Error stop Cooling/heating mixed Operation mode...
  • Page 58 (3) Indoor unit Start Normal operations Trouble observed Breaker turned on Stop Operation SW turned on Note :1 1. Protection function self-holding cancelled. 2. Indoor unit LEV fully closed. Note :2 Remove controller display extinguished Error mode Operation mode Error stop Error code blinks on Heating Cooling/heating...
  • Page 59 (4) Cooling operation Cooling operation Normal operations 4-way valve OFF Test run Stop Indoor unit fan operations Test run start Thermostat ON 3-minute restart prevention 1. Inverter output 0Hz 1. Inverter frequency control 2. Indoor unit LEV, oil return LEV 2.
  • Page 60 (5) Heating operation Normal operations Heating operation Stop Test run 4-way valve ON Test run start Thermostat ON 3-minute restart prevention 1. Indoor unit fan very low speed 1. Indoor and heat source unit fan operations control 2. Inverter output 0Hz 2.
  • Page 61 (6) Dry operation Dry operations Normal operations Thermostat ON 4-way valve OFF Stop Test run start Note : 2 Thermostat ON Inlet temp. 18˚C Note : 1 1. Indoor unit fan stop 1. Heat source unit (Compressor) 2. Inverter output 0Hz intermittent operations 3.

  • Page 62: List Of Major Component Functions

    [5] List of Major Component Functions Name Symbol (function) Application Specification Check method Compressor Adjust refrigerant circulation by control- Low pressure shell scroll type with ling operating frequency and capacity capacity control mechanism control valve with operating pressure. Winding resistance: Each phase 0.388Ω...
  • Page 63 Name Symbol (function) Application Specification Check method Thermistor TH10 1) Detects the compressor shell =7.465kΩ temperature. =4057 25/120 2) Provides compressor shell overheat- Rt = ing protection. 7.465exp {4057( 273+t 273+120 20˚C : 250kΩ 70˚C : 34kΩ 30˚C : 160kΩ 80˚C : 24kΩ...
  • Page 64 Name Symbol (function) Application Specification Check method Pressure 1) Liquid pressure (high-pressure) sensor detection PS1/PS3 Pressure 2) LEV control 0~30 kg/cm (0~2.94MPa) Vout 0.5~3.5 V Con- nector Gnd (black) 1) Intermediate pressure detection Vout (white) 2) LEV control Vc (DC5V) (red) Thermistor TH11 LEV control (liquid refrigerant control)

  • Page 65: Resistance Of Temperature Sensor

    [6] Resistance of Temperature Sensor Thermistor for low temperature = 15kΩ ± 3% (TH3 ~ 9, THINV) = 7.465kΩ ± 2% (TH1, 10) Thermistor R Thermistor R = 15exp {3460 ( = 7.465exp {4057 ( 273+t 273+120 273+t 273+0 –20 –10 Temperature (˚C) Temperature (˚C) = 33kΩ...

  • Page 66: Refrigerant Amount Adjustment

    6 6 6 6 6 REFRIGERANT AMOUNT ADJUSTMENT Clarify relationship between the refrigerant amount and operating characteristics of CITY MULTI, and perform service activities such as decision and adjustment of refrigerant amount on the market. [1] Refrigerant Amount and Operating Characteristics The followings are refrigerant amount and operating characteristics which draw special attention.
  • Page 67 (2) Refrigerant amount 1 Checking the operating condition Operate all the indoor units on cooling or on heating, checking the discharge temperature, sub-cooling (BC control- ler), low pressure saturation temperature, inlet temperature, shell bottom temperature, liquid level, liquid step, etc. and rendering an overall judgment.
  • Page 68 (α Calculation Table) Total capacity of α Connected indoor units P200 P250 100~160 125~160 161~300 161~375 Caution : When charging with refrigerant, be sure to charge from the liquid side. If charging from the gas side, it will cause the refrigerant composition to change inside the unit and the composition of the refrigerant remaining in the canister will also change.
  • Page 69 (3) Refrigerant amount adjustment Adjustment starts. Start cooling operation of all indoor units in a test run mode. Note 1 Note 1) As the refrigerant volume can not be adjusted in the heating mode, retrieve the refrigerant, evacuate air and then fill the specified volume of refrigerant if it is necessary to adjust the refrigerant Has the volume in the winter season.
  • Page 70 Time required for recovering refrigerant from low pressure service port (minute) Low pressure (kg/cm G) (MPa) 3.5~4.5 4.5~5.5 5.5 ~ 7.5 Refrigerant amount (0.34~0.44) (0.44~0.54) (0.54~0.74) to be drawn out (kg) 12.0 10.5 10.0 16.0 14.0 13.0 20.0 18.0 16.5 24.0 21.5 19.5...

  • Page 71: Troubleshooting

    7 7 7 7 7 TROUBLESHOOTING [1] Principal Parts Pressure sensor (1) Judging failure 1) Check for failure by comparing the sensing pressure according to the high pressure/low pressure pressure sensor and the pressure gauge pressure. Turn on switches 1, 3, 5, 6 (High) and 2, 4, 5, 6 (Low) of the digital display select switch (SW1) as shown below, and the sensor pressure of the high pressure/low pressure sensors is displayed digitally by the light emitting diode LD1.
  • Page 72 * Connector connection specifications on the pressure sensor body side. The connector’s pin numbers on the pressure sensor body side differ from the pin numbers on the main circuit board side. Sensor body side MAIN board side Pin 1 Pin 3 Vout Pin 2 Pin 2...
  • Page 73 (d) The refrigerant flow is as following figure. Hot gas (high pressured) flows in cooling mode and cool gas/liquid (low pressured) flows in heating mode. Please refer to the Refrigerant Circuit Diagram. And, ON/OFF of Solenoid valve is depends on the amount of running indoor units, ambient temperature and so on.
  • Page 74 LEV for heat source unit The valve opening angle changes in proportion to the number of pulses. (Connections between the heat source unit’s MAIN board and SLEV, LEV2) Pulse signal output and valve operation Output pulses change in the following orders when the Output states Output (phase) Valve is Closed...
  • Page 75 LEV for BC controller and indoor unit 1 LEV receives pulse signal from microcomputer, and operates valve with stepping motor. 2 Valve opening changes in proportion to the number of pulses. Connection of microcomputer circuit board and LEV Microcomputer circuit boad Intermediate connector (mounted on outdoor unit only) Brown...
  • Page 76 Judgment methods and likely failure mode Caution: The specifications of the heat source unit (heat source LEV) and indoor unit (indoor LEV) differ. For this reason, there are cases where the treatment contents differ, so follow the treatment specified for the appropriate LEV as indicated in the right column.
  • Page 77 Heat source LEV (SLEV) coil removal procedure (configuration) As shown in the figure, the heat source LEV is made in such a way that the coils and the body can be separated. Body Coils Stopper Indentation for Stopper (12 places around the circumference) Lead wires <Removing the coils>...
  • Page 78 Check valves block (PQRY-P200·250YMF-C) The refrigerant flow in the pipe 6, 7, 8 and 9 are depend on ON/OFF of the SV3, 4, 5 and 6. Please confirm by LED monitor display. You can open the cap of valve A, B and C, but 3 types of hexagon socket screw keys. The size is as follows. Distributor HEXA HEXB HEXC HEXD HEXE...
  • Page 79 Intelligent Power Module (IPM) Measure resistances between each terminal of IPM with tester, and use the results for troubleshooting. Specified resistance value is dependent on tester type to be used for resistance measurement, because diode inside IPM has non-linearity, thus difference of impedance and voltage in tester being influential. As the internal impedance of resistance range of analog tester equals to the center value of meter indication, the affect of internal impedance can be minimized if the tester having close center value of resistance range.
  • Page 80 (5) Trouble and remedy of remote controller Symptom Cause Checking method & countermeasure Despite pressing of 1) M-NET transmission power source is not supplied a) Check transmission terminal block of remote controller from heat source unit. remote controller for voltage. switch, operation 1 Main power source of heat source unit is not i) In case of 17 ~ 30V...
  • Page 81 Symptom Cause “HO” display on re- (Without using MELANS) mote controller does 1) Heat source unit address is set to “000.” not disappear and 2) Erroneous address. switch is ineffective. 1 Address setting miss of indoor unit to be coupled with remote controller. (Indoor unit = remote controller - 100.) 2 Address setting miss of remote controller.
  • Page 82 Symptom Cause Checking method & countermeasure “88” appears on re- [Generates at registration and confirmation] a) Confirm the address of unit to be mote controller at the 1) Erroneous address of unit to be coupled. coupled. registration and 2) Slipping off of transmission line of unit to be coupled b) Check the connection of transmission access remote (No connection).
  • Page 83 Transmission Power Circuit (30 V) Check Procedure If “ ” is not displayed by the remote control, investigate the points of the trouble by the following procedure and correct it. Check Item Judgment Response Disconnect the transmission line from TB3 DC24~30 V Check the transmission line for the following, and and check the TB3 voltage.
  • Page 84 (6) Investigation of transmission wave shape/noise Control is performed by exchanging signals between heat source unit, indoor unit and remote controller by M-NET transmission. If noise should enter into the transmission line, the normal transmission will be hindered causing erroneous operation. 1) Symptom caused by the noise entered into transmission line Cause Erroneous operation...
  • Page 85 3) Checking and measures to be taken (a) Measures against noise Check the items below when noise can be confirmed on wave shape or the error code in the item 1) is generated. Items to be checked Measures to be taken 1 Wiring of transmission and power lines in Isolate transmission line from power line (5cm or more).
  • Page 86 4) Treatment of Inverter and Compressor Troubles If the compressor does not work when error codes 4240, 4250, 4340 or 4350 are detected, determine the point of malfunction by following the steps in the LED monitor display and countermeasures depending on the check code displayed, then perform the procedures below.
  • Page 87 5) Troubleshooting at breaker tripping Check items Measures to be taken 1 Check the breaker capacity. The breaker’s capacity should be proper. 2 Check the a short circuit or grounding in the electrical Correct any defects. system other than the inverter. 3 Check the resistance between terminals on the terminal Check each part inside the inverter power circuit block TB1A for power source.
  • Page 88 Individual Parts Failure Judgment Methods. Part Name Judgment Method Diode Stack (DS) Refer to “Judging Diode Stack Failure.” Intelligent Power Module(IPM) Refer to “Judging IPM Failure.” Electromagnetic Contactor (52C) Measure the resistance value at each terminal. 1/L1 3/L2 5/L3 Check Location Judgment Value A1-A2 0.1k~1.3kΩ...
  • Page 89 Motor (Compressor) White Black Black Capacitor (C2,C3) G/A board –88–...
  • Page 90 (8) Troubleshooting the major components of the BC controller 1) Pressure sensor Pressure sensor troubleshooting flow START Note 1 Check pressure sensor, PS1, PS3, connectors for discon- nection, looseness, or incor- rect attachment. Take corrective action. Unit running? Note 2 Check on the LED monitor dis- play.
  • Page 91 Note 1 : • Symptoms of incorrect connection of BC controller pressure sensor to the board Symptom Cooling-only Cooling-principal Heating-only Heating-principal Insufficient SC11 large Warm indoor SC SC11 small Insufficient heating SC11 large cooling. SC16 small small. Warm in- SC16 small Warm indoor SC small SC16 small Normal...
  • Page 92 2) Temperature sensor Thermistor troubleshooting flow Start Note 1 Disconnect applicable thermistor connector from the board. Note 2 Measure temperature of applicable thermistor (actual measured value). Note 3 Check thermistor resistance value. Compare temperature for thermistor resistance value with actual mea- sured valued.
  • Page 93 Note 1 : • Board connector CN10 corresponds to TH11 through TH12, while connector CN11 corresponds to TH15 through TH16. Remove the applicable connector and check the sensor for each number. Note 2, 3 : 1. Pull the sensor connector from the I/O board. Do not pull on the lead wire. 2.
  • Page 94 3) LEV, solenoid valve troubleshooting flow No cooling No heating Note 1 Check disconnection or looseness of connectors. Is there a problem? Correct the problem. Operate in cooling or heating (1 system only when there are plural systems) Heating operation Cooling or heating operation? Cooling operation...
  • Page 95 1 LEV Note 1 : • Symptoms of incorrect connection to BC controller LEV board LEV No. Cooling-only Cooling-main Heating-only Heating-main ← ← ← Normal Insufficient cooling Insufficient cooling, insuf- Heating indoor SC small Insufficient cooling SH12 small, ficient heating PHM large Heating indoor SC small SC11 small...
  • Page 96 (Self-diagnostic monitor) Measured data Signal Heat source unit MAIN board SW1 setting 2 3 4 5 6 7 8 9 10 LEV 1 pulse – 2 3 4 5 6 7 8 9 10 – LEV 3 pulse 2 3 4 5 6 7 8 9 10 BC controller bypass SH12 output superheat...
  • Page 97 2 Solenoid Valve Solenoid valve troubleshooting Operation OFF? Check solenoid valve wiring for incorrect connection, and connector disconnection or looseness. No problem. Correct the problem. Operate cooler and heater for the applicable solenoid valve’s refrigerant system only. Note 1 Clicking noise produced when working timing? Remove the coil and check for...
  • Page 98 Solenoid valves (SVA, SVB, SVC) Coordination signals output from the board and solenoid valve operations. Note 1 : (SVA, SVB, SVC) SVA, SVB and SVC are turned on and off in accordance with operation mode. Mode Cooling Heating Stopped Defrosting Branch port Note 2 : (SVA, SVB, SVC) Measure temperature of piping on either side of SVA 1-A...

  • Page 99: Bc Controller Disassembly Procedure

    [2] BC Controller Disassembly Procedure (1) Service panel Be careful on removing heavy parts. Procedure Photos & Illustrations 1. Remove the two screws securing the electric panel box, and then remove the box. 2. Remove the four screws securing the front panel and then remove the panel.
  • Page 100 (2) Control box Be careful on removing heavy parts. Procedure Photos <CMB-P104, 105, 106V-E> 1. Removing the single screw that secures the elec- tric panel box cover provides access to the box con- tents for checking. 1 Check electrical lead wires and transmission lead terminal connections.
  • Page 101 (3) Thermistor (Liquid and gas piping temperature detection) Be careful when removing heavy parts. Procedure Photos 1. Remove the service panel 1 Use the procedure under (1)-1.2 to check TH11, TH12, and TH15. 2. Disconnect the piping sensor lead from the control- ler panel.
  • Page 102 (5) LEV Be careful on removing heavy parts. Procedure Photos 1. Remove the service panel. See (1)-1.2.3.4. 2. Replace the applicable LEV. Important! 1 When performing the above procedure, be sure to LEV1 allow for enough service space in the ceiling area for welding.
  • Page 103 Check code list Check code Check content 0403 Serial transmission abnormality 0900 Trial operation 1102 Discharge temperature abnormality 1111 Low pressure saturation temperature sensor abnormality (TH2) 1301 Low pressure abnormality (OC) 1302 High pressure abnormality (OC) 1500 Overcharged refrigerant abnormality 1501 Low refrigerant abnormality 1505...
  • Page 104 Check code Check content 6606 Communications with transmission processor abnormality 6607 No ACK abnormality 6608 No response abnormality 7100 Total capacity abnormality 7101 Capacity code abnormality 7102 Connected unit count over 7105 Address setting abnormality 7106 Characteristics setting abnormality 7107 Connection number setting abnormality 7111 Remote control sensor abnormality...

  • Page 105: Self-Diagnosis And Countermeasures Depending On The Check Code Displayed

    [3] Self-diagnosis and Countermeasures Depending on the Check Code Displayed (1) Mechanical Checking code Meaning, detecting method Cause Checking method & Countermeasure 0403 Serial If serial transmission cannot be 1) Wiring is defective. Check 1, the connections, 2, contact transmission established between the MAIN and at the connectors and 3, for broken abnormality...
  • Page 106 Checking code Meaning, detecting method Cause Checking method & Countermeasure 1102 Discharge 1. When 140˚C or more discharge 1) Gas leak, gas shortage. See Refrigerant amount check. temperature temperature is detected during abnormality operations (the first time), heat 2) Overload operations. Check operating conditions and opera- (Heat source source unit stops once, mode...
  • Page 107 Checking code Meaning, detecting method Cause Checking method & Countermeasure 1111 1. When saturation temperature 1) Gas leak, Gas shortage. See Refrigerant amount check. pressure sensor (TH2) detects -40˚C or saturation less (the first time) during op- 2) Insufficient load operations. Check operating conditions and opera- tempera- erations, heat source unit stops...
  • Page 108 Checking code Meaning, detecting method Cause Checking method & Countermeasure 1301 Low pressure When starting from the stop mode 1) Internal pressure is dropping due Refer to the item on judging low pres- abnoramlity for the first time, (if at the start of bind to a gas leak.
  • Page 109 Checking code Meaning, detecting method Cause Checking method & Countermeasure 1302 High pressure When press. sensor detects 1kg/ 1) Fall in internal press. caused by See Trouble check of pressure sen- abnoramlity 2 G (0.098MPa) or less just be- gas leak. sor.
  • Page 110 Checking code Meaning, detecting method Cause Checking method & Countermeasure 1505 Suction Judging that the state when the • Operation while neglecting to open Once vacuum operation protection is pressure suction pressure reaches 0kg/ ball valve. Especially for the ball commenced, do not attempt to abnormality G (0MPa) during compressor...
  • Page 111 Checking code Meaning, detecting method Cause Checking method & Countermeasure 2135 Freezing of 1. If the water heat exchanger 1) Failure of the heat source water cir- the water heat freeze prevention thermostat op- culating pump to operate. exchanger. erates (OFF at 3±1°C) (the first 2) Heating equipment out of order time) the heat source unit stops 3) Clogged or dirty water heat ex-...
  • Page 112 Checking code Meaning, detecting method Cause Checking method & Countermeasure 4103 Reverse phase Reverse phase (or open phase) in 1) The phases of the power supply (L1, If there is reverse phase before the abnormality the power system is being de- L2, L3) have been reversed.
  • Page 113 Checking code Meaning, detecting method Cause Checking method & Countermeasure 4116 Fan speed (Detects only for PKFY-VAM) 1) Slipping off of fan speed detect- • Confirm slipping off of connector abnormality 1. Detecting fan speed below ing connector (CN33) of indoor (CN33) on indoor controller (motor 180rpm or over 2000rpm dur-...
  • Page 114 Checking code Meaning, detecting method Cause Checking method & Countermeasure 4220 1 If VDC 400 V is de- 1) The power supply voltage • Check if an instantaneous stop or power failure, etc. voltage tected during inverter is abnormal. has occurred. abnormality operation.
  • Page 115 Checking code Meaning, detecting method Cause Checking method & Countermeasure 4240 Over loard If IAC 32 Arms is detected con- 1) Air passage short cycle. Is the unit’s exhaust short cycling? protection tinuously for 10 minutes during op- eration of the inverter after 5 or 2) The heat exchanger is clogged.
  • Page 116 Checking code Meaning, detecting method Cause Checking method & Countermeasure 4260 Cooling fan If the heat sink temperature (THHS) 1) Same as “4230.” Same as “4230.” abnormality 60°C for 20 minutes or longer just before the inverter starts. 5101 Discharge <Other than THHS>...
  • Page 117 Checking code Meaning, detecting method Cause Checking method & Countermeasure 5201 Pressure 1. When pressue sensor detects 1kg/ 1) Pressutre sensor trouble. See Troubleshooting of pressure sensor G (0.098MPa) or less during sensor. abnormality operation, heat source unit once (heat source stops with 3 minutes restarting 2) Inner pressure drop due to a leak- unit)
  • Page 118 Checking code Meaning, detecting method Cause Checking method & Countermeasure 5301 IAC sensor/ 1 If IAC 3 Arms is detected just 6) The circuit board is defective. If none of the items in 1) to 5) is appli- circuit before the inverter starts, or cable, and if the trouble reappears abnormality If IAC...
  • Page 119 (2) Communication/system Checking Meaning, detecting method Cause Checking method & Countermeasure code 1) Two or more controllers of heat At the genration of 6600 error, release the error by 6600 Multiple address error source unit, indoor unit, remote con- remote controller (with stop key) and start again. troller, BC controller, etc.
  • Page 120 Checking Meaning, detecting method Cause Checking method & Countermeasure code 6602 Transmission processor hardware Checking method and processing error Transmission line Shut off the power source of heat source/ installed while turning indoor units/BC controller and make it again. power source on? Check power source of indoor unit.
  • Page 121 Checking Meaning, detecting method Cause Checking method & Countermeasure code 6606 Communications with transmis- 1) Data is not properly transmitted due Turn off power sources of indoor unit, BC controller sion processor error to casual errouneous operation of and heat source unit. the generating controller.
  • Page 122 Checking Meaning, detecting method code 6607 No ACK error When no ACK signal is detected in 6 continuous times with 30 second interval by transmission side controller, the transmission side detects error. Note: The address/attribute shown on remote controller indicates the controller not providing the answer (ACK).
  • Page 123 Checking Meaning, detecting method code 6607 No ACK error When no ACK signal is detected in 6 continuous times with 30 second (continued) interval by transmission side controller, the transmission side detects error. Note: The address/attribute shown on remote controller indicates the controller not providing the answer (ACK).
  • Page 124 Checking Meaning, detecting method code 6607 No ACK error When no ACK signal is detected in 6 continuous times with 30 second (continued) interval by transmission side controller, the transmission side detects error. Note: The address/attribute shown on remote controller indicates the controller not providing the answer (ACK).
  • Page 125 Checking Meaning, detecting method code 6607 No ACK error When no ACK signal is detected in 6 continuous times with 30 second (continued) interval by transmission side controller, the transmission side detects error. Note: The address/attribute shown on remote controller indicates the controller not providing the answer (ACK).
  • Page 126 Checking Meaning, detecting method Cause Checking method & Countermeasure code 6608 No response error 1) At the collision of mutual transmis- a) Generation at test run. sion data when transmission wiring Turn off the power sources of OC unit, IC unit Though acknowledgement of re- is modified or the polarity is and Fresh Master for more than 5 minutes si-...
  • Page 127 Checking Meaning, detecting method Cause Checking method & Countermeasure code 7102 Connected unit count over 2) The heat source unit address is be- a) Check for the model total (capacity code total) ing set to 51~100 under automatic of indoor units connected. address mode (Remote controller displays “HO”).

  • Page 128: Led Monitor Display

    [4] LED Monitor Display (1) How to read LED for service monitor By setting of DIP SW1-1 ~ 1-8, the unit operating condition can be observed with the service LED on the control circuit board. (For the relation of each DIP SW to the content, see the table provided.) As shown in the figure below, the LED consist of 7 segments is put in 4 sets side by side for numerical and graphic display.
  • Page 129 E: E2 Contents stored in the E2PROM; M: Monitored by the IC through communications; E*: Stored in service memory. Item Display Remarks 12345678910 0000000000 Relay Output COMP Crankcase 21S4 Lights for LD8 is a relay output indicator which Display 1 (Lights Operat- Heater ON Normal...
  • Page 130 Item Display Remarks 12345678910 1010100000 Heat Source Unit High Discharge Overcur- Heat Sink Overcur- Over- Lights up if an error Preliminary Error Pressure Pressure Tempera- rent Thermostat rent charged delay has occurred History Error 1, 2 Error 1 ture Error Protection Operation Break...
  • Page 131 Item Display Remarks 12345678910 0010110000 THHS Data –99.9 ~ 999.9 ↑ 1010110000 HPS Data ↑ 0110110000 THINV Data 1110110000 0001110000 TH9 Data –99.9 ~ 999.9 ↑ 1001110000 TH10 Data ↑ 0101110000 LPS Data α OC 1101110000 0 ~ 9.999 α OC* ↑...
  • Page 132 When there is an error stop with No95-121,the data on error stops or the data immediately before the error postpone- ment stop, which is stored in service memory, are displayed. Item Display Remarks 12345678910 1100101000 IC7 Address/ 0 ~ 99 0 ~ 99 Capacity Code ↑...
  • Page 133 When there is an error stop with No95-121,the data on error stops or the data immediately before the error postpone- ment stop, which is stored in service memory, are displayed. Item Display Remarks 12345678910 α OC* 0000111000 0 ~ 9.999 1000111000 –99.9 ~ 999.9 ↑...
  • Page 134 Item Display Remarks 12345678910 0011000100 BC LEV 1 Data –99.9 ~ 999.9 ↑ 1011000100 BC LEV 3 Data 0111000100 1111000100 0000100100 IC1 liquid Pipe –99.9 ~ 999.9 Temperature ↑ 1000100100 IC2 liquid Pipe Temperature ↑ 0100100100 IC3 liquid Pipe Temperature ↑...
  • Page 135 Item Display Remarks 12345678910 0110010100 IC7 Gas Pipe –99.9 ~ 999.9 Temperature ↑ 1110010100 IC8 Gas Pipe Temperature ↑ 0001010100 IC9 Gas Pipe Temperature ↑ 1001010100 IC10 Gas Pipe Temperature ↑ 0101010100 IC11 Gas Pipe Temperature ↑ 1101010100 IC12 Gas Pipe Temperature ↑...
  • Page 136 Item Display Remarks 12345678910 0001001100 IC9 SC –99.9 ~ 999.9 ↑ 1001001100 IC10 SC ↑ 0101001100 IC11 SC ↑ 1101001100 IC12 SC ↑ 0011001100 IC13 SC ↑ 1011001100 IC14 SC ↑ 0111001100 IC15 SC ↑ 1111001100 IC16 SC 0000101100 IC1 LEV Opening 0 ~ 9999 pulse ↑...
  • Page 137 Item Display Remarks 12345678910 10100111000 IC6 Operation Mode/ Branch Number On the left 0110011100 IC7 Operation Mode/ (LD1~LD4), the IC Branch Number address, and on the right (LD5~LD8), the 11100111000 IC8 Operation Mode/ capacity code is Branch Number displayed (displayed alternately every 5 0001011100 IC9 Operation Mode/...

  • Page 138: Preparation, Repairs And Refrigerant Refilling When Repairing Leaks

    8 8 8 8 8 PREPARATION, REPAIRS AND REFRIGERANT REFILLING WHEN REPAIRING LEAKS [1] Location of leaks: Extension piping or indoor units (when cooling) 1 Attach a pressure gage to the low-pressure servicing check joint (CJ2). 2 Stop all of the indoor units. When the compressor has stopped, shut off the liquid ball valve (BV2) for the heat source unit.

  • Page 139: Location Of Leaks: Extension Piping Or Indoor Units (Heating Mode)

    [3] Location of Leaks: Extension Piping or Indoor Units (Heating mode) 1 Test run all indoor units in heating mode. 1. With SW3-1 on the MAIN board of the heat source unit set to ON and SW3-2 OFF → ON to test run all indoor units.

  • Page 140: Check The Composition Of The Refrigerant

    9 9 9 9 9 CHECK THE COMPOSITION OF THE REFRIGERANT Start Test run all indoor units. Are all units operating stably? (Note 1) Is the refrigerant composition of αOC correct? (Note 2) Check TH2, TH9, LPS and the CS Finished checking the circuit block and correct any malfunc- composition.
  • Page 141 Note 1 Wait until the units stabilize as described in the refrigerant amount adjustment procedure in “Chapter 6”. Note 2 After the units are operating stably, check that the refrigerant composition of αOC is within the following ranges, indicating that the composition check is finished. αOC = 0.20 ~ 0.26 If the accumulator liquid level AL = 0 when cooling: αOC = 0.23 ~ 0.34...

  • Page 142: Differences Between The Previous Refrigerant And The New Refrigerant

    0 0 0 0 0 DIFFERENCES BETWEEN THE PREVIOUS REFRIGERANT AND THE NEW RE- FRIGERANT [1] Chemical Characteristics The new refrigerant (R407C) is a chemically stable non-combustible refrigerant with few of the same characteristics as R22. However, the vapor specific gravity is heavier than the specific gravity of air, so if the refrigerant leaks out in a closed room, it remains on the bottom near the floor and there is danger of accidents occurring due to lack of oxygen, so always handle it in an atmosphere with good ventilation where the refrigerant won’t accumulate.

  • Page 143: Pressure Characteristics

    [3] Pressure Characteristics Compared to the previous refrigerant (R22), the pressure of the new refrigerant (R407C) is higher. Pressure (Gauge) R407C Temperature (°C) MPa (Gauge)/kgf/cm (Gauge) MPa (Gauge)/kgf/cm (Gauge) 0.18/1.8 0.14/1.4 0.47/4.8 0.40/4.1 0.94/9.6 0.81/8.3 1.44/14.7 1.44/14.7 2.44/24.9 2.33/23.8 2.75/28.0 2.60/26.5 Data source: Japan refrigeration and air conditioning association thermal characteristics chart NIST REFROP V5.10.

  • Page 144: Refrigerator Oil

    A A A A A REFRIGERATOR OIL [1] Refrigerator Oil with HFC Based Refrigerants A different refrigerator oil is used with the new refrigerant than with R22. Note: Since the type of refrigerator oil used with R22 is different from that used with R407C, the different types of refrigerant oil should not be mixed and used together.
  • Page 145 MEMO...
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  • Page 147 Service Handbook PQRY-P200YMF-C, P250YMF-C CMB-P104, P105, P106, P108, P1010, P1013, P1016V-E HEAD OFFICE MITSUBISHI DENKI BLDG. MARUNOUCHI TOKYO 100-0005 TELEX J24532 CABLE MELCO TOKYO Issued in Jun.2002 MDOC F1105-179 New publication effective Jun.2002 Printed in Japan Specifications subject to change without notice.

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