Mitsubishi Electric CITY MULTI P500YMF-C How to use

AIR CONDITIONERS CITY MULTI
Models PURY-P400, P500YMF-C
Service Handbook
Service Handbook PURY-P400, P500YMF-C
HEAD OFFICE MITSUBISHI DENKI BLDG. MARUNOUCHI TOKYO 100-0005 TELEX J24532 CABLE MELCO TOKYO
New publication effective Aug 2002
Specifications subject to change without notice.
Service Handbook PURY-P400, P500YMF-C
Issued in Aug 2002 F1105-214(MDOC)
Printed in Japan

Contents
1PRECAUTIONS FOR DEVICES THAT USE R407C REFRIGERANT..... 3
[1] Storage of Piping Material................................................................. 4
[2] Piping Machining............................................................................... 5
[3] Brazing.............................................................................................. 6
[4] Airtightness Test................................................................................ 7
[5] Vacuuming ........................................................................................ 7
[6] Charging of Refrigerant..................................................................... 8
[7] Dryer ................................................................................................. 8
2COMPONENT OF EQUIPMENT ............................................................. 9
[1] Appearance of Components ............................................................. 9
[2] Refrigerant Circuit Diagram and Thermal Sensor ........................... 17
[3] Electrical Wiring Diagram................................................................ 20
[4] Standard Operation Data ................................................................ 24
[5] Function of Dip SW and Rotary SW................................................ 26
3TEST RUN ............................................................................................. 29
[1] Before Test Run............................................................................... 29
[2] Test Run Method............................................................................. 33
4GROUPING REGISTRATION OF INDOOR UNITS WITH M-NET
REMOTE CONTROLLER ...................................................................... 34
5CONTROL.............................................................................................. 40
[1] Control of Outdoor Unit ................................................................... 40
[2] Control of BC Controller.................................................................. 49
[3] Operation Flow Chart...................................................................... 50
[4] List of Major Component Functions ................................................ 56
[5] Resistance of Temperature Sensor................................................. 59
6REFRIGERANT AMOUNT ADJUSTMENT............................................ 60
[1] Operating Characteristics and Refrigerant Amount ........................ 60
[2] Adjustment and Judgement of Refrigerant Amount ........................ 60
[3] Refrigerant VolumeAdjustment Mode Operation............................ 62
7TROUBLESHOOTING ........................................................................... 66
[1] Principal Parts................................................................................. 66
[2] BC Controller Disassembly Procedure............................................ 99
[3] Self-diagnosis and Countermeasures Depending on the Check
Code Displayed............................................................................. 104
[4] LED Monitor Display ..................................................................... 121
8PREPARATION, REPAIRSAND REFRIGERANT REFILLING WHEN
REPAIRING LEAKS .............................................................................141
[1] Location of leaks: Extension piping or indoor units (when cooling) ... 141
[2] Location of leaks: Outdoor unit (Cooling mode)............................ 142
[3] Location of leaks: Extension piping or indoor units (Heating mode).. 142
[4] Location of leaks: Outdoor unit (when heating)............................. 143
9CHECK THE COMPOSITION OF THE REFRIGERANT
(PURY-P200·250YMF-C only).................................................................144
–1–

Contents
1PRECAUTIONS FOR DEVICES THAT USE R407C REFRIGERANT..... 3
[1] Storage of Piping Material................................................................. 4
[2] Piping Machining............................................................................... 5
[3] Brazing.............................................................................................. 6
[4] Airtightness Test................................................................................ 7
[5] Vacuuming ........................................................................................ 7
[6] Charging of Refrigerant..................................................................... 8
[7] Dryer ................................................................................................. 8
2COMPONENT OF EQUIPMENT ............................................................. 9
[1] Appearance of Components ............................................................. 9
[2] Refrigerant Circuit Diagram and Thermal Sensor ........................... 17
[3] Electrical Wiring Diagram................................................................ 20
[4] Standard Operation Data ................................................................ 24
[5] Function of Dip SW and Rotary SW................................................ 26
3TEST RUN ............................................................................................. 29
[1] Before Test Run............................................................................... 29
[2] Test Run Method............................................................................. 33
4GROUPING REGISTRATION OF INDOOR UNITS WITH M-NET
REMOTE CONTROLLER ...................................................................... 34
5CONTROL.............................................................................................. 40
[1] Control of Outdoor Unit ................................................................... 40
[2] Control of BC Controller.................................................................. 49
[3] Operation Flow Chart...................................................................... 50
[4] List of Major Component Functions ................................................ 56
[5] Resistance of Temperature Sensor................................................. 59
6REFRIGERANT AMOUNT ADJUSTMENT............................................ 60
[1] Operating Characteristics and Refrigerant Amount ........................ 60
[2] Adjustment and Judgement of Refrigerant Amount ........................ 60
[3] Refrigerant VolumeAdjustment Mode Operation............................ 62
7TROUBLESHOOTING ........................................................................... 66
[1] Principal Parts................................................................................. 66
[2] BC Controller Disassembly Procedure............................................ 99
[3] Self-diagnosis and Countermeasures Depending on the Check
Code Displayed............................................................................. 104
[4] LED Monitor Display ..................................................................... 121
8PREPARATION, REPAIRSAND REFRIGERANT REFILLING WHEN
REPAIRING LEAKS .............................................................................141
[1] Location of leaks: Extension piping or indoor units (when cooling) ... 141
[2] Location of leaks: Outdoor unit (Cooling mode)............................ 142
[3] Location of leaks: Extension piping or indoor units (Heating mode).. 142
[4] Location of leaks: Outdoor unit (when heating)............................. 143
9CHECK THE COMPOSITION OF THE REFRIGERANT
(PURY-P200·250YMF-C only).................................................................144
–1–

–2–
Safety precautions
Before installation and electric work
Before installing the unit, make sure you read all
the “Safety precautions”.
The “Safety precautions” provide very important
points regarding safety. Make sure you follow
them.
This equipment may not be applicable to
EN61000-3-2: 1995 and EN61000-3-3: 1995.
This equipment may have an adverse effect on
equipment on the same electrical supply system.
Please report to or take consent by the supply
authority before connection to the system.
Symbols used in the text
Warning:
Describes precautions that should be observed to
prevent danger of injury or death to the user.
Caution:
Describes precautions that should be observed to
prevent damage to the unit.
Symbols used in the illustrations
: Indicates an action that must be avoided.
: Indicates that important instructions must be followed.
: Indicates a part which must be grounded.
: Beware of electric shock (This symbol is displayed on the
main unit label.) <Color: Yellow>
Warning:
Carefully read the labels affixed to the main unit.
Warning:
• Use the specified cables for wiring. Make the connections
securely so that the outside force of the cable is not
applied to the terminals.
- Inadequate connection and fastening may generate heat and
cause a fire.
• Have all electric work done by a licensed electrician
according to “Electric Facility Engineering Standard” and
“Interior Wire Regulations”and the instructions given in
this manual and always use a special circuit.
- If the power source capacity is inadequate or electric work is
performed improperly, electric shock and fire may result.
• Securely install the cover of control box and the panel.
- If the cover and panel are not installed properly, dust or water
may enter the outdoor unit and fire or electric shock may
result.
• After completing service work, make sure that refrigerant
gas is not leaking.
- If the refrigerant gas leaks and is exposed to a fan heater,
stove, oven, or other heat source, it may generate noxious
gases.
• Do not reconstruct or change the settings of the protection
devices.
- If the pressure switch, thermal switch, or other protection
device is shorted and operated forcibly, or parts other than
those specified by Mitsubishi Electric are used, fire or
explosion may result.
▲
▲
▲
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–3–
11
11
1PRECAUTIONS FOR DEVICES THAT USE R407C REFRIGERANT
Caution
Do not use the existing refrigerant piping.
• The old refrigerant and refrigerator oil in the existing
piping contains a large amount of chlorine which may
cause the refrigerator oil of the new unit to deterio-
rate.
Use refrigerant piping made of phosphorus deoxi-
dized copper and copper alloy seamless pipes and
tubes”. In addition, be sure that the inner and outer
surfaces of the pipes are clean and free of hazardous
sulphur, oxides, dust/dirt, shaving particles, oils,
moisture, or any other contaminant.
• Contaminants on the inside of the refrigerant piping
may cause the refrigerant residual oil to deteriorate.
Storethe piping to beusedduringinstallation indoors
and keep both ends of the piping sealed until just
before brazing. (Store elbows and other joints in a
plastic bag.)
• If dust, dirt, or water enters the refrigerant cycle,
deterioration of the oil and compressor trouble may
result.
Use ester oil, ether oil or alkylbenzene (small
amount) as the refrigerator oil to coat flares and
flange connections.
• The refrigerator oil will degrade if it is mixed with a
large amount of mineral oil.
Use liquid refrigerant to seal the system.
• If gas refrigerant is used to seal the system, the com-
position of the refrigerant in the cylinder will change
and performance may drop.
Do not use a refrigerant other than R407C.
• If another refrigerant (R22, etc.) is used, the chlorine
in the refrigerant may cause the refrigerator oil to de-
teriorate.
Use a vacuum pump with a reverse flow check valve.
• The vacuum pump oil may flow back into the refriger-
ant cycle and cause the refrigerator oil to deteriorate.
Do not use the following tools that have been used
with conventional refrigerants.
(Gauge manifold, charge hose, gas leak detector, re-
verse flow check valve, refrigerant charge base,
vacuum gauge, refrigerant recovery equipment)
• If the conventional refrigerant and refrigerator oil are
mixed in the R407C, the refrigerant may deterio-
rated.
• If water is mixed in the R407C, the refrigerator oil
may deteriorate.
• Since R407C does not contain any chlorine, gas
leak detectors for conventional refrigerants will not
react to it.
Do not use a charging cylinder.
• Using a charging cylinder may cause the refrigerant
to deteriorate.
Be especially careful when managing the tools.
• If dust, dirt, or water gets in the refrigerant cycle, the
refrigerant may deteriorate.
If the refrigerant leaks, recover the refrigerant in the
refrigerant cycle, then recharge the cycle with the
specified amount of the liquid refrigerant indicated
on the air conditioner.
• Since R407C is a nonazeotropic refrigerant, if addi-
tionallycharged whentherefrigerant leaked,the com-
position of the refrigerant in the refrigerant cycle will
change and result in a drop in performance or abnor-
mal stopping.

–4–
[1] Storage of Piping Material
(1) Storage location
Store the pipes to be used indoors. (Warehouse at site or owner’s warehouse)
Storing them outdoors may cause dirt, waste, or water to infiltrate.
(2) Pipe sealing before storage
Both ends of the pipes should be sealed until immediately before brazing.
Wrap elbows and T’s in plastic bags for storage.
* The new refrigerator oil is 10 times more hygroscopic than the conventional refrigerator oil (such as Suniso). Water
infiltration in the refrigerant circuit may deteriorate the oil or cause a compressor failure. Piping materials must be
stored with more care than with the conventional refrigerant pipes.

–5–
Use only the necessary minimum quantity of oil !
Reason :
1. The refrigerator oil used for the equipment is highly hygroscopic and may introduce water inside.
Notes :
•Introducing a great quantity of mineral oil into the refrigerant circuit may also cause a compressor failure.
•Do not use oils other than ester oil, ether oil or alkylbenzene.
[2] Piping Machining
Use ester oil, ether oil or alkylbenzene (small amount) as the refrigerator oil to coat flange connections.

–6–
[3] 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. Do not conduct refrigerant piping work outdoors on a rainy day.
2. Apply non-oxide brazing.
3. Usea brazingmaterial (Bcup-3) whichrequires no fluxwhen brazingbetweencopper pipesor between acopper pipe
and copper coupling.
4. If installed refrigerant pipes are not immediately connected to the equipment, then braze and seal both ends of them.
Reasons :
1. The new refrigerant oil is 10 times more hygroscopic than the conventional oil. The probability of a machine failure if
water infiltrates is higher than with conventional refrigerant oil.
2. A flux generally contains chlorine.A residual flux in the refrigerant circuit may generate sludge.
Note :
•Commercially available antioxidants may have adverse effects on the equipment due to its residue, etc. When
applying non-oxide brazing, use oxygen free nitrogen (OFN).

–7–
[4] Airtightness Test
No changes from the conventional method. Note that a refrigerant leakage detector for R22 cannot detect R407C
leakage.
Halide torch R22 leakage detector
Items to be strictly observed :
1. Pressurize the equipment with nitrogen up to the design pressure and then judge the equipment’s airtightness, taking
temperature variations into account.
2. When investigating leakage locations using a refrigerant, be sure to use R407C.
3. Ensure that R407C is in a liquid state when charging.
Reasons :
1. Use of oxygen as the pressurized gas may cause an explosion.
2. Charging with R407C gas will lead the composition of the remaining refrigerant in the cylinder to change and this
refrigerant can then not be used.
Note :
•A leakage detector for R407C is sold commercially and it should be purchased.
[5] Vacuuming
1. Vacuum pump with check valve
Avacuum pump with a check valve is required to prevent the vacuum pump oil from flowing back into the refrigerant
circuit when the vacuum pump power is turned off (power failure).
It is also possible to attach a check valve to the actual vacuum pump afterwards.
2. Standard degree of vacuum for the vacuum pump
Use a pump which reaches 0.5 Torr (500 MICRON) or below after 5 minutes of operation.
In addition, be sure to use a vacuum pump that has been properly maintained and oiled using the specified oil. If the
vacuum pump is not properly maintained, the degree of vacuum may be too low.
3. Required accuracy of the vacuum gauge
Use a vacuum gauge that can measure up to 5 Torr. Do not use a general gauge manifold since it cannot measure a
vacuum of 5 Torr.
4. Evacuating time
•Evacuate the equipment for 1 hour after –755 mmHg (5 Torr) has been reached.
•After envacuating, leave the equipment for 1 hour and make sure that the vacuum is not lost.
5. Operating procedure when the vacuum pump is stopped
In order to prevent a backflow of the vacuum pump oil, open the relief valve on the vacuum pump side or loosen the
charge hose to drawn in air before stopping operation.
The same operating procedure should be used when using a vacuum pump with a check valve.

–8–
Cylin-
der
Cylin-
der
Valve Valve
Liquid Liquid
[6] Charging of Refrigerant
R407C must be in a liquid state when charging, because it is a non-azeotropic refrigerant.
For a cylinder with a syphon attached For a cylinder without a syphon attached
Cylinder color identification R407C-Gray Charged with liquid refrigerant
R410A-Pink
Reasons :
1. R407C is a mixture of 3 refrigerants, each with a different evaporation temperature. Therefore, if the equipment is
charged with R407C gas, then the refrigerant whose evaporation temperature is closest to the outside temperature is
charged first while the rest of refrigerants remain in the cylinder.
Note :
•In the case of a cylinder with a syphon, liquid R407C is charged without turning the cylinder up side down. Check the
type of cylinder before charging.
[7] Dryer
1. Replace the dryer when the refrigerant circuit is opened (Ex. Change the compressor, full gas leakage). Be sure to
replace the dryer with a CITY MULTI Series Y (For use with R407C).
If any other product is used, the unit will be damaged.
2. Opening the refrigerant circuit after changing to a new dryer is less than 1 hour. The replacement of the dryer should
be the last operation performed.

–9–
•PURY-P400·500YMF-C
22
22
2COMPONENT OF EQUIPMENT
[1] Appearance of Components
Outdoor unit
Propeller fan
Heat exchanger(front)
Compressor
Propeller fan
Fan motor
Fan motor
Heat exchanger(rear)
SV block 1
SV block 2
4–way
valve
4–way valveCS circuit
Drier
CV
block 1
CV block 2
Control box
Compressor
Compressor
P500 TYPEP400 TYPE
Accumulator

–10–
Controller Box
RELAY board
FANCON board
(for MF3)
INV boardMAIN board
Choke coil (L2)
Inteligent Power
Module (IPM)
G/A board
Y-C board
SNB board Diode stack (DS) Magnetic contactor (52C2)
Magnetic contactor (52C1)Magnetic contactor
(52F)
Overload relay
(51C2)
FANCON board
(for MF2)
Capacitor (C2, C3)
(Smoothing capacitor)
Noise filter
(NP)

–11–
MAIN board
•PUHY / PURY
CN51
Indication distance
3-4Compressor
ON/OFF
3-5Trouble
CNRS3
Serial transmission to
INV board
CN3D
SW1
CNTR CNFC1
CNVCC4
Power source
for control(5V)
CN20
Powersupply
3L1
1N
SW3SW4 SW2 SWU2 SWU1
CNS1 CNS2 CN40 CNVCC3
Power Source
for control
1-230V
1-330V
4-612V
5-65V
CN3S
CN3N
LD1
Service LED
CN41

–12–
INV board
CNDR2
Out put to
G/A board
CNTH
CN15V2
Power supply
for IPM control
CNACCT
CNAC2
Power
source
1L2
3N
5G
CN52C
Control for
52C
CNFAN
Control
for MF1
CNR
CNRS2
Serial transmission
to MAIN board
SW1
CNVDC
1-4
DC-560V
CNVCC4
Power supply (5V)
CNL2
Choke coil
CNVCC2
Power supply
1-230V, 1-330V
4-612V, 5-65V

–13–
CNFAN CNPOW
CNFC2
CN15V1
CNDR1
CNIPM1
CNE CNDC1
FANCON board
G/A board

–14–
Y-C board
SNB board

–15–
BC controller
CNTR
CN02
M-NET
transmission
CN03
CN12
Power
supply
1EARTH
3N
5L
SW4 SW2 SW1SW5

–16–
RELAY 10 board
RELAY 4 board

–17–
[2] Refrigerant Circuit Diagram and Thermal Sensor
PURY-P400, 500YMF-C
: Solenoid valve
: Orifice
: Capillary
: Check valve
: Thermal sensor
: Strainer
SP : Service port
ACC : Accumulator
CV3b
BV1
BV2
ST1
TH5
CV2b
ST15
TH7
TH6
CJ2
MA
SA
CJ3
CJ1
63HS
63H1
O/S
63H2
SLEV Comp2
Comp1
CV1b
CV1a
SV32
SV22
CP3a
TH12
TH2
TH9
Drier CP2
TH11
ST9
ST5
ST6
ST2
21S4a
21S4b
ST3
ST4
ST8
TH3
TH4
63LS
HEXf1
HEXf3
HEXb1
HEXf2
ST14
ST13
ST12
ST11
CV5b
CV7b
SV8
SV6
SV5
SV4
SV3
SV7
SV Block 2
SV Block 1 HEXf4
HEXb2
CV4b
CV4a
CV10a
Orifice
CV9a
CV8a CV3a
CV2a
CV5a
CV6a
CV7a
CV6b
CV Block 2
CV Block 1
*SV22, 32: P500 only
CP3b
SV4a
SV6a
SV1
CP1
CS Circuit

–18–
CMB-P108, 1010, 1013, 1016V-FA
SVM2
TH16
TH11
TH12
SVM1 PS3
PS1
Check valve block
Solenoid valve block
LEV3
LEV1
TH15
Gas/liquid separator
: Solenoid valve
: Orifice
: Capillary
: Check valve
: Thermal sensor
: Strainer