Mitsubishi Electric City Multi PUHY-P250YNW-A How to use

AIR CONDITIONER 2017
Service Handbook
PUHY-P250YNW-A
PUHY-P500YSNW-A
PFD-P250VM-E
PFD-P500VM-E
Model

i
Safety Precautions
Thoroughly read the following safety precautions prior to installation.
Observe these precautions carefully to ensure safety.
After reading this manual, pass the manual on to the end user to retain for future reference.
The user should keep this manual for future reference and refer to it as necessary. This manual should be made available to
those who repair or relocate the units. Make sure that the manual is passed on to any future user.
All electric work must be performed by qualified personnel.
Air-tightness test must be performed by qualified personnel.
Brazing work must be performed by qualified personnel in accordance with local
regulations.
[1] General Precautions
Incorrect handling can result in death or serious injury.
Incorrect handling can result in minor injury or structure
damage.
General Precautions
Do not use refrigerant other than the type in-
dicated in the manuals provided with the
unit and on the nameplate. Doing so may
cause the unit or pipes to burst, or result in
explosion or fire during use, during repair,
or at the time of disposal of the unit. It may
also be in violation of applicable laws. MIT-
SUBISHI ELECTRIC CORPORATION cannot
be held responsible for malfunctions or ac-
cidents resulting from the use of the wrong
type of refrigerant.
Do not install the unit in a place where large
amounts of oil, steam, organic solvents, or
corrosive gases, such as sulfuric gas, are
present or where acidic/alkaline solutions
or sprays containing sulfur are used fre-
quently. These substances can compro-
mise the performance of the unit or cause
certain components of the unit to corrode,
which can result in refrigerant leakage, wa-
ter leakage, injury, electric shock, malfunc-
tions, smoke, or fire.
Do not try to defeat the safety features of the
unit or make unauthorized setting changes.
Forcing the unit to operate the unit by de-
feating the safety features of the devices
such as the pressure switch or the tempera-
ture switch, making unauthorized changes
to the switch settings, or using accessories
other than the ones recommended by Mit-
subishi Electric may result in smoke, fire, or
explosion.
To prevent the risk of injury from falling
tools or work materials, before starting in-
stallation work, inspection, or repair work,
check the surroundings and make sure to
keep children away from the work area.
To reduce the risk of refrigerant leakage,
water leakage, injury, electric shock, or fire,
do not alter or modify the unit.
To reduce the risk of bursting, fire or explo-
sion, only use fuses with the specified
breaking capacity. Do not substitute wire or
copper wire for a fuse.
To reduce the risk of shorting, current leak-
age, electric shock, malfunctions, smoke, or
fire, do not wash the unit with water or any
other liquid.
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ii
To reduce the risk of shorting, current leak-
age, electric shock, malfunctions, smoke, or
fire, do not splash water on electric parts.
To reduce the risk of electric shock, mal-
functions, smoke or fire, do not operate the
switches/buttons or touch other electrical
parts with wet hands.
When cleaning or replacing filters or other
elements located at high places, use cau-
tion not to fall off a ladder or other device
used to extend your reach.
To prevent the risk of pipe bursts and explo-
sion, do not create a closed circuit in the re-
frigerant circuit with the refrigerant gas or
refrigerant oil left in the pipe line.
To reduce the risk of electric shock and in-
jury from the fan or other rotating parts,
stop the operation and turn off the main
power before cleaning, maintaining, or in-
specting the unit.
To reduce the risk of burns or frost bites, do
not touch the refrigerant pipes or refrigerant
circuit components with bare hands during
and immediately after operation.
Do not touch the electrical parts with bare
hands during and immediately after opera-
tion.
Keep the space well ventilated. Refrigerant
can displace air and cause oxygen starva-
tion. If leaked refrigerant comes in contact
with a heat source, toxic gas may be gener-
ated.
Properly install all required covers and pan-
els on the terminal box and control box to
keep moisture and dust out. Dust accumula-
tion and water may result in electric shock,
smoke, or fire.
Periodically check the unit base for dam-
age. If the damage is left uncorrected, the
unit will fall and cause injury.
Consult qualified personnel for the proper
disposal of the unit. The refrigerant oil and
the refrigerant in the unit will pose a risk of
environmental pollution, fire, or explosion.
To reduce the risk of fire or explosion, do
not place flammable materials or use flam-
mable sprays around the unit.
Do not operate the unit with the panels and
guards removed. Rotating, hot, or high-volt-
age parts may cause injury, electric shock,
or fire.
Do not sit, stand, or place objects on the
unit. The unit or the objects could fall, re-
sulting in injury.
Do not turn off the power immediately after
stopping operation. Wait for at least five
minutes after the unit has stopped before
turning off the power. Doing so may result
in unit malfunction or water leakage, and
may wet the surroundings.
To reduce the risk of injury, do not touch the
heat exchanger fins or sharp edges of com-
ponents with bare hands.
To prevent the risk of eye injury from dust,
wear goggle before removing the filter.
Always wear protective gears when touch-
ing electrical components on the unit. Sev-
eral minutes after the power is switched off,
residual voltage may still cause electric
shock.
Wear protective gear before touching elec-
trical parts. Coming in contact with high-
voltage or high-temperature parts may re-
sult in electric shock or burns.
To reduce the risk of injury, do not insert fin-
gers or foreign objects into air inlet/outlet
grills.
To reduce the risk of injury, wear protective
gear when working on the unit.
The filter must be inspected or cleaned by
qualified personnel. Improper inspection or
cleaning may result in injury.
Do not release refrigerant into the atmo-
sphere. Collect and reuse the refrigerant, or
have it properly disposed of by an autho-
rized agency. Refrigerant poses environ-
mental hazards if released into the air.
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iii
[2] Transportation a nd Installation
[3] Installation
The unit must be periodically inspected by a
dealer or qualified personnel. If dust or dirt
accumulates inside the unit, the drain pipes
may become clogged, and water leakage
from the pipes may wet the surroundings
and generate odours.
Transportation and Installation
Lift the unit by placing the slings at desig-
nated locations. Support the outdoor unit
securely at four points to keep it from slip-
ping and sliding. If the unit is not properly
supported, it may fall and cause personal
injury.
To reduce the risk of injury, do not lift the
unit with the PP bands that are used on
some products.
To reduce the risk of injury, observe the re-
strictions on the maximum weight that a
person can lift.
Installation
To reduce the risk of injury, properly dis-
pose of the packing materials.
Properly dispose of the packing materials.
Tear up the packing materials that potential-
ly pose suffocation hazards.
Remove packing materials from the unit be-
fore operating the unit. Note that some ac-
cessories may be taped to the unit. Properly
install all accessories that are required. Fail-
ing to remove the packing materials or fail-
ing to install required accessories may
result in refrigerant leakage, oxygen starva-
tion, smoke, or fire.
Consult your dealer and take appropriate
measures to safeguard against refrigerant
leakage and resultant oxygen starvation. An
installation of a refrigerant gas detector is
recommended.
Any additional parts must be installed by a
dealer or qualified personnel. To reduce the
risk of water leakage, electric shock, or fire,
only use the parts specified by Mitsubishi
Electric.
To reduce the risk of current leakage, elec-
tric shock, or damage to the unit, seal all
openings around pipes and wires to keep
out small animals, rainwater, or snow.
Units are heavy and pose a risk of injury.
Use caution not to get your fingers or hands
caught when disassembling or reassem-
bling units.
Drain piping must be installed by a dealer or
qualified personnel to ensure proper drain-
age. Improper drain piping may cause water
leakage, resulting in damage to furniture
and other surroundings.
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iv
[4] Piping Work
Piping Work
Operate the service valves carefully. Refrig-
erant may spurt out and cause frost bite or
other injuries. If leaked refrigerant comes in
contact with an open flame, toxic gas may
be generated.
Use pipes with adequate wall thickness. Re-
quirements for pipe wall thickness vary with
the refrigerant used, pipe diameter, and
pipe material. The use of the wrong type of
pipes may result in damage to the pipes, re-
frigerant leakage, and oxygen starvation.
Vacuum dry the refrigerant circuit using a
vacuum pump. Do not attempt to purge the
existing refrigerant out of the pipe with an-
other type of refrigerant. Doing so may re-
sult in pipe bursts and explosion.
To prevent explosion, do not use oxygen,
flammable gas, or a refrigerant containing
chlorine for pressurizing the system. Chlo-
rine will deteriorate the refrigerant oil.
To prevent explosion, do not heat the unit
with refrigerant gas in the refrigerant circuit.
To prevent refrigerant leakage that can pose
a risk of oxygen starvation, use the flare nut
with a hole (supplied with refrigerant ser-
vice valve) to make flare connections.
Check for refrigerant leaks. If the refrigerant
leaks, oxygen starvation may result. If the
leaked refrigerant comes in contact with a
heat source, toxic gas will be generated.
To prevent the risk of failure to detect refrig-
erant leakage that can lead to oxygen star-
vation, perform air tightness test before
insulating the pipe connections. Refrigerant
detector may not be able to properly detect
refrigerant leak from pipe connections cov-
ered with insulation.
Before brazing connecting pipes, make sure
to remove them from the service valve. Fail-
ure to do so may heat up the valve, resulting
in unit malfunctions, wire burn damages,
and refrigerant leakage that can pose oxy-
gen starvation.
To prevent damage to the piping and resul-
tant refrigerant leakage that can pose oxy-
gen starvation, do not let the edges of the
parts come in contact with the adjacent pip-
ing.
Any substance other than the specified re-
frigerant, such as air, may cause abnormal-
ly high pressure in the refrigerant lines,
resulting in bursting of the pipes or an ex-
plosion.
Drain piping must be installed by a dealer or
qualified personnel in accordance with the
Installation Manual to ensure proper drain-
age. Improper drain piping may cause water
leakage, resulting in damage to the furnish-
ings.
To prevent the risk of water damage to the
furnishings, provide a separate trap for the
backup drain piping, and do not connect the
main drain piping and the backup drain pip-
ing in the upstream of the trap for the back-
up drain piping.
Ensure proper drainage. Improper drain pip-
ing may cause water leakage, resulting in
damage to the furnishings.
Check if some water is retained in the drain
trap at periodic inspection. Water shortage
may cause water leakage, resulting in dam-
age to the furnishings.
To keep the ceiling and floor from getting
wet due to condensation, properly insulate
the pipes.
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v
[5] Wiring Work
[6] Relocation and Repairs
Wiring Work
To reduce the risk of wire breakage, over-
heating, smoke, and fire, keep undue force
from being applied to the wires.
Properly secure the cables in place and pro-
vide adequate slack in the cables so as not
to stress the terminals. Improperly connect-
ed cables may break, overheat, and cause
smoke or fire.
To reduce the risk of injury or electric
shock, switch off the main power before
performing electrical work.
Electrical work must be performed by quali-
fied personnel in accordance with local reg-
ulations and the instructions provided in
the Installation Manual. Only use the speci-
fied cables and dedicated circuits. Inade-
quate power source capacity or improper
electrical work will result in electric shock,
malfunction, smoke, or fire.
To reduce the risk of electric shock, smoke,
or fire, install an overcurrent breaker on the
power supply of each unit.
To reduce the risk of electric shock, smoke,
or fire, install an inverter circuit breaker on
the power supply of each unit.
Only use properly rated breakers (an earth
leakage breaker, local switch <a switch +
fuse that meets local electrical codes>, or
overcurrent breaker). The use of improperly
rated breakers or the substitution of fuses
with steel or copper wire may result in elec-
tric shock, malfunction, smoke, or fire.
Only use properly rated breakers (an invert-
er circuit breaker, local switch <a switch +
fuse that meets local electrical codes>, or
overcurrent breaker). The use of improperly
rated breakers or the substitution of fuses
with steel or copper wire may result in elec-
tric shock, malfunction, smoke, or fire.
To reduce the risk of current leakage, over-
heating, smoke, or fire, use properly rated
cables with adequate current carrying ca-
pacity.
Proper grounding must be provided by a li-
censed electrician.
Do not connect the grounding wire to a gas
pipe, water pipe, lightning rod, or telephone
wire. Improper grounding may result in
electric shock, smoke, fire, or malfunction
due to electrical noise interference.
To reduce the risk of current leakage, wire
breakage, smoke, or fire, keep the wiring
out of contact with the refrigerant pipes and
other parts, especially sharp edges.
Relocation and Repairs
The unit should be moved, disassembled,
or repaired only by a dealer or qualified per-
sonnel. Do not alter or modify the unit. Im-
proper repair or unauthorized modifications
may result in refrigerant leakage, water
leakage, injury, electric shock, or fire.
After disassembling the unit or making re-
pairs, replace all components as they were.
Failing to replace all components may re-
sult in injury, electric shock, or fire.
To reduce the risk of shorting, electric
shock, malfunctions, or fire, do not touch
the circuit board with tools or with your
hands, and do not allow dust to accumulate
on the circuit board.
To prevent the risk of refrigerant and water
leakage, inspect the pipe supports and in-
sulation for damage, and repair or replace
them as necessary at inspection and main-
tenance.
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vi
[7] Additional Precautions
Additional Precautions
Be sure to recover the refrigerant from the
unit in accordance with local regulations
before disposing of the unit.
Provide a maintenance access hole on the
piping in the ceiling and underground pip-
ing.
Take appropriate measures against electri-
cal noise interference when installing the
unit in hospitals or radio communication fa-
cilities. Inverter, high-frequency medical, or
wireless communication equipment as well
as power generators may cause the air con-
ditioning system to malfunction. The air
conditioning system may also adversely af-
fect the operation of these types of equip-
ment by creating electrical noise.
Use the tools specifically designed for use
with the specified refrigerant. If other tools
are used, refrigerant oil will deteriorate and
the compressor will malfunction.
Use refrigerant piping made of phosphorus
deoxidized copper (copper and copper alloy
seamless pipes) that meets local require-
ments. Pipe joints should also meet local re-
quirements. Keep the inner and outer
surfaces of the pipes clean and free of sul-
phur, oxides, dust/dirt, shaving particles,
oils, moisture, or any other contaminants.
Contaminants on the inside of the refriger-
ant piping will cause the refrigerant oil to
deteriorate and cause the compressor to
malfunction.
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CONTENTS
HWE17020 GB
Chapter 1 Check Before Servicing
1-1 Preparation for Piping Work.................................................................................................................. 1
1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ....................... 3
1-3 Working with Refrigerant Piping........................................................................................................... 8
1-4 Precautions for Wiring......................................................................................................................... 12
1-5 Cautionary notes on installation environment and maintenance.................................................... 14
Chapter 2 Restrictions
2-1 System Configurations .......................................................................................................................... 1
2-2 Types and Maximum Allowable Length of Cables .............................................................................. 2
2-3 Switch Settings....................................................................................................................................... 3
2-4 M-NET Address Settings ....................................................................................................................... 4
2-5 Demand Control Overview .................................................................................................................... 8
2-6 System Connection Example .............................................................................................................. 10
2-7 Example System with an MA Remote Controller .............................................................................. 11
2-8 Restrictions on Refrigerant Pipes ...................................................................................................... 19
Chapter 3 Major Components, Their Functions and Refrigerant Circuits
3-1 External Appearance and Refrigerant Circuit Components of Outdoor Unit ................................... 1
3-2 External Appearance and Internal Components of Indoor Unit......................................................... 3
3-3 Refrigerant Circuit Diagrams ................................................................................................................ 9
3-4 Functions of the Major Components of Outdoor Unit ...................................................................... 12
3-5 Functions of the Major Components of Indoor Unit ......................................................................... 15
3-6 Procedure of Separating the Indoor Unit ........................................................................................... 16
Chapter 4 Electrical Components and Wiring Diagrams
4-1 Circuit Board Arrangement ................................................................................................................... 1
4-2 Circuit Board Components.................................................................................................................... 5
4-3 Electrical Wiring Diagrams.................................................................................................................. 12
4-4 Transmission Booster Electrical Wiring Diagrams........................................................................... 15
Chapter 5 Control
5-1 Dipswitch Functions and Factory Settings.......................................................................................... 1
5-2 Outdoor Unit Control ............................................................................................................................. 9
5-3 Indoor Unit Control .............................................................................................................................. 20
5-4 Operation Flow Chart........................................................................................................................... 24
Chapter 6 Test Run
6-1 Read before Test Run ............................................................................................................................ 1
6-2 Operation Characteristics and Refrigerant Charge ............................................................................ 2
6-3 Evaluating and Adjusting Refrigerant Charge..................................................................................... 2
6-4 The Following Symptoms Are Normal ................................................................................................. 5
6-5 Initialization Procedure for System Rotation Settings ....................................................................... 6
Chapter 7 Troubleshooting Using Error Codes
7-1 Error Code and Preliminary Error Code Lists ..................................................................................... 1
7-2 Error Code Definitions and Solutions: Codes [0 - 999]....................................................................... 5
7-3 Error Code Definitions and Solutions: Codes [1000 - 1999]............................................................... 6
7-4 Error Code Definitions and Solutions: Codes [2000 - 2999]............................................................. 10
7-5 Error Code Definitions and Solutions: Codes [3000 - 3999]............................................................. 11
7-6 Error Code Definitions and Solutions: Codes [4000 - 4999]............................................................. 13
7-7 Error Code Definitions and Solutions: Codes [5000 - 5999]............................................................. 29
7-8 Error Code Definitions and Solutions: Codes [6000 - 6999]............................................................. 37
7-9 Error Code Definitions and Solutions: Codes [7000 - 7999]............................................................. 57
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CONTENTS
HWE17020 GB
Chapter 8 Troubleshooting Based on Observed Symptoms
8-1 MA Remote Controller Problems .......................................................................................................... 1
8-2 Refrigerant Control Problems ............................................................................................................... 5
8-3 External Input Problems (including operation mode)......................................................................... 8
8-4 Checking Transmission Waveform and for Electrical Noise Interference........................................ 9
8-5 Pressure Sensor Circuit Configuration and Troubleshooting Pressure Sensor Problems .......... 12
8-6 Troubleshooting Solenoid Valve Problems ....................................................................................... 16
8-7 Troubleshooting Outdoor Unit Fan Problems ...................................................................................18
8-8 Troubleshooting LEV Problems.......................................................................................................... 19
8-9 Troubleshooting Inverter Problems ................................................................................................... 25
8-10 Control Circuit ...................................................................................................................................... 40
8-11 Measures for Refrigerant Leakage ..................................................................................................... 43
8-12 Parts Replacement Instructions ......................................................................................................... 45
8-13 Troubleshooting Problems Using the LED Status Indicators on the Outdoor Unit....................... 70
8-14 Replacement Instructions for Motor and Bearing (Indoor Unit) ...................................................... 71
8-15 Maintenance/Inspection Schedule...................................................................................................... 77
Chapter 9 USB Function
9-1 Service Overview.................................................................................................................................... 1
9-2 Operation Data Collection and Storage Functions ............................................................................. 4
9-3 Software Rewrite Function on the USB................................................................................................ 8
9-4 Maintenance LED Display and Troubleshooting............................................................................... 10
Chapter 10 LED Status Indicators on the Outdoor Unit Circuit Board
10-1 LED Status Indicators ............................................................................................................................ 1
10-2 LED Status Indicators Table.................................................................................................................. 4
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GB_BS_01_C
Chapter 1 Check Before Servicing
1-1 Preparation for Piping Work ................................................................................................................ 1
1-1-1 Read before Servicing ............................................................................................................................ 1
1-1-2 Tool Preparation ..................................................................................................................................... 2
1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil...................... 3
1-2-1 Piping Materials ...................................................................................................................................... 3
1-2-2 Storage of Piping Materials..................................................................................................................... 5
1-2-3 Pipe Processing ...................................................................................................................................... 5
1-2-4 Characteristics of the New and Conventional Refrigerants .................................................................... 6
1-2-5 Refrigerant Oil......................................................................................................................................... 7
1-3 Working with Refrigerant Piping ......................................................................................................... 8
1-3-1 Pipe Brazing............................................................................................................................................ 8
1-3-2 Air Tightness Test................................................................................................................................... 9
1-3-3 Vacuum Drying ..................................................................................................................................... 10
1-3-4 Refrigerant Charging............................................................................................................................. 11
1-4 Precautions for Wiring ....................................................................................................................... 12
1-5 Cautionary notes on installation environment and maintenance .................................................. 14
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GB_BS_01_C
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[1-1 Preparation for Piping Work ]
BS_01_C chapter 1 - 1
1 Check Before Servicing
1 Check B efore Servicing
1-1 Preparation for Piping Work
1-1-1 Read before Servicing
1. Check the type of refrigerant used in the system to be serviced.
Refrigerant Type
Packaged air conditioner for computer room application PFD series: R410A
Note: The unit can be operated only in the cooling mode when combined with PFD series.
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 re-
frigerant.
For information about the correct use of tools, refer to the following page(s). [1-1-2 Tool Preparation]
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.
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[1-1 Preparation for Piping Work ]
2 - chapter 1 BS_01_C
1 Check Before Servicing
1-1-2 Tool Preparation
Prepare the following tools and materials necessary for installing and servicing the unit.
Tools for use with R410A (Adaptability of tools that are for use with R22 or R407C)
1. To be used exclusively with R410A (not to be used if used with R22 or R407C)
2. Tools and materials that may be used with R410A with some restrictions
3. Tools and materials that are used with R22 or R407C that may also be used with R410A
4. Tools and materials that must not be used with R410A
Tools for R410A must be handled with special care to keep moisture and dust from infiltrating the cycle.
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.
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 the following page(s). [1-2-1
Piping Materials]
Refrigerant Recovery Equipment Refrigerant recovery May be used if compatible with
R410A.
Tools/Materials Use Notes
Vacuum Pump with a Check Valve Vacuum drying
Bender Bending pipes
Torque Wrench Tightening flare nuts Only the flare processing dimensions
for pipes that have a diameter of
ø12.7 (1/2") and ø15.88 (5/8") have
been changed.
Pipe Cutter Cutting pipes
Welder and Nitrogen Cylinder Welding pipes
Refrigerant Charging Meter Refrigerant charging
Vacuum Gauge Vacuum level check
Tools/Materials Use Notes
Charging Cylinder Refrigerant charging Prohibited to use
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[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
BS_01_C chapter 1 - 3
1 Check Before Servicing
1-2 Handling and Characteristics of Piping Materials,
Refrigerant, and Refrigerant Oil
1-2-1 Piping Materials
1. Copper pipe materials
The distinction between O-materials (Annealed) and 1/2H-materials (Drawn) is made based on the strength of the pipes them-
selves.
O-materials (Annealed) can easily be bent with hands.
1/2H-materials (Drawn) are considerably stronger than O-material (Annealed) at the same thickness.
2. Types of copper pipes
3. Piping materials/Radial thickness
Use refrigerant pipes made of phosphorus deoxidized copper.
The operation pressure of the units that use R410A is higher than that of the units that use R22.
Use pipes that have at least the radial thickness specified in the chart below.
(Pipes with a radial thickness of 0.7 mm or less may not be used.)
Annealed pipes have been used for older model units when a diameter of the pipe is up to φ19.05 (3/4"). For a system that
uses R410A, use pipes that are made with 1/2H-material (Drawn). (Annealed pipes may be used for pipes with a diameter of
φ19.05 (3/4") and a radial thickness of 1.2 t).
The figures in the radial thickness column are based on the Japanese standards and provided only as a reference. Use pipes
that meet the local standards.
O-material (Annealed) Soft copper pipes (annealed copper pipes). They can easily be bent with hands.
1/2H-material (Drawn) Hard copper pipes (straight pipes). They are stronger than the O-material (Annealed)
at the same radial thickness.
Maximum working pressure Refrigerant type
3.45 MPa [500psi] R22, R407C etc.
4.30 MPa [624psi] R410A etc.
Pipe size (mm[in]) Radial thickness (mm) Type
ø6.35 [1/4"] 0.8t
O-material (Annealed)
ø9.52 [3/8"] 0.8t
ø12.7 [1/2"] 0.8t
ø15.88 [5/8"] 1.0t
ø19.05 [3/4"] 1.0t
1/2H-material,
H-material (Drawn)
ø22.2 [7/8"] 1.0t
ø25.4 [1"] 1.0t
ø28.58 [1-1/8"] 1.0t
ø31.75 [1-1/4"] 1.1t
ø34.93 [1-3/8"] 1.2t
ø41.28 [1-5/8"] 1.4t
Do not use the existing piping!
0000004491.BOOK 3 ページ ２０１７年１２月２６日 火曜日 午後１時１０分

[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
4 - chapter 1 BS_01_C
1 Check 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.
5. Flare processing (O-material (Annealed) and OL-material only)
The flare processing dimensions for the pipes that are used in the R410A system are larger than those in the R22 system.
If a clutch-type flare tool is used to flare the pipes in the system using R410A, the length of the pipes must be between 1.0
and 1.5 mm. For margin adjustment, a copper pipe gauge is necessary.
6. Flare nut
The flare nut type has been changed to increase the strength. The size of some of the flare nuts have also been changed.
The figures in the radial thickness column are based on the Japanese standards and provided only as a reference. Use pipes
that meet the local standards.
Flare processing dimensions (mm[in])
Pipe size (mm[in])
A dimension (mm)
R410A R22, R407C
ø6.35 [1/4"] 9.1 9.0
ø9.52 [3/8"] 13.2 13.0
ø12.7 [1/2"] 16.6 16.2
ø15.88 [5/8"] 19.7 19.4
ø19.05 [3/4"] 24.0 23.3
Flare nut dimensions (mm[in])
Pipe size (mm[in])
B dimension (mm)
R410A R22, R407C
ø6.35 [1/4"] 17.0 17.0
ø9.52 [3/8"] 22.0 22.0
ø12.7 [1/2"] 26.0 24.0
ø15.88 [5/8"] 29.0 27.0
ø19.05 [3/4"] 36.0 36.0
Dimension A
Dimension B
0000004491.BOOK 4 ページ ２０１７年１２月２６日 火曜日 午後１時１０分

[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
BS_01_C chapter 1 - 5
1 Check Before Servicing
1-2-2 Storage of Piping Materials
1. Storage location
Store the pipes to be used indoors. (Warehouse at site or owner's warehouse)
If they are left outdoors, dust, dirt, or moisture may infiltrate and contaminate the pipe.
2. Sealing the pipe ends
Both ends of the pipes should be sealed until just before brazing.
Keep elbow pipes and T-joints in plastic bags.
The new refrigerator oil is 10 times as hygroscopic as the conventional refrigerating machine oil (such as Suniso) and, if not
handled with care, could easily introduce moisture into the system. Keep moisture out of the pipes, for it will cause the oil to
deteriorate and cause a compressor failure.
1-2-3 Pipe Processing
Use a small amount of ester oil, ether oil, or alkylbenzene to coat flares and flanges.
Use a minimum amount of oil.
Use only ester oil, ether oil, and alkylbenzene.
0000004491.BOOK 5 ページ ２０１７年１２月２６日 火曜日 午後１時１０分

[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
6 - chapter 1 BS_01_C
1 Check Before Servicing
1-2-4 Characteristics of the New and Conventional Refrigerants
1. Chemical property
As with R22, the new refrigerant (R410A) is low in toxicity and chemically stable nonflammable refrigerant.
However, because the specific gravity of vapor refrigerant is greater than that of air, leaked refrigerant in a closed room will
accumulate at the bottom of the room and may cause hypoxia.
If exposed to an open flame, refrigerant will generate poisonous gases. Do not perform installation or service work in a con-
fined area.
*1 When CFC11 is used as a reference
*2 When CO2is 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.
3. Pressure characteristics
The pressure in the system using R410A is 1.6 times as great as that in the system using R22.
New Refrigerant (HFC type) Conventional Refriger-
ant (HCFC type)
R410A R407C R22
R32/R125 R32/R125/R134a R22
Composition (wt%) (50/50) (23/25/52) (100)
Type of Refrigerant Pseudo-azeotropic
Refrigerant
Non-azeotropic
Refrigerant
Single Refrigerant
Chloride Not included Not included Included
Safety Class A1/A1 A1/A1 A1
Molecular Weight 72.6 86.2 86.5
Boiling Point (°C/°F) -51.4/-60.5 -43.6/-46.4 -40.8/-41.4
Steam Pressure
(25°C,MPa/77°F,psi) (gauge)
1.557/226 0.9177/133 0.94/136
Saturated Steam Density
(25°C,kg/m3/77°F,psi)
64.0 42.5 44.4
Flammability Nonflammable Nonflammable Nonflammable
Ozone Depletion Coefficient (ODP)*1 0 0 0.055
Global Warming Coefficient (GWP)*2 2088 1774 1810
Refrigerant Charging Method Refrigerant charging in
the liquid state
Refrigerant charging in
the liquid state
Refrigerant charging in
the gaseous state
Replenishment of Refrigerant after a Refrigerant
Leak
Available Available Available
Temperature (°C/°F)
Pressure (gauge)
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
0000004491.BOOK 6 ページ ２０１７年１２月２６日 火曜日 午後１時１０分

[1-2 Handling and Characteristics of Piping Materials, Refrigerant, and Refrigerant Oil ]
BS_01_C chapter 1 - 7
1 Check Before Servicing
1-2-5 Refrigerant Oil
1. Refrigerating machine oil in the HFC refrigerant system
HFC type refrigerants use a refrigerating machine oil different from that used in the R22 system.
Note that the ester oil used in the system has properties that are different from commercially available ester oil.
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.
Refrigerant Refrigerating machine oil
R22 Mineral oil
R407C Ester oil
R410A Ester oil
*1. Contaminants is defined as moisture, air, processing oil, dust/dirt, wrong types of refrigerant, and refrigerating machine oil.
Cause Symptoms Effects on the refrigerant cycle
Water infiltration Frozen expansion valve
and capillary tubes
Clogged expansion valve and capillary tubes
Poor cooling performance
Compressor overheat
Motor insulation failure
Burnt motor
Coppering of the orbiting scroll
Lock
Burn-in on the orbiting scroll
Hydrolysis
Sludge formation and ad-
hesion
Acid generation
Oxidization
Oil degradation
Air infiltration Oxidization
Infiltration of
contaminants
Dust, dirt
Adhesion to expansion valve and capillary
tubes
Clogged expansion valve, capillary tubes, and
drier
Poor cooling performance
Compressor overheat
Infiltration of contaminants into the com-
pressor
Burn-in on the orbiting scroll
Mineral oil
etc.
Sludge formation and adhesion Clogged expansion valve and capillary tubes
Poor cooling performance
Compressor overheat
Oil degradation Burn-in on the orbiting scroll
0000004491.BOOK 7 ページ ２０１７年１２月２６日 火曜日 午後１時１０分

[1-3 Working with Refrigerant Piping ]
8 - chapter 1 BS_01_C
1 Check Before Servicing
1-3 Working with Refrigerant Piping
1-3-1 Pipe Brazing
No changes have been made in the brazing procedures. Perform brazing with special care to keep foreign objects (such as oxide
scale, water, and dust) out of the refrigerant system.
Example: Inside the brazed connection
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.
Use of no inert gas during brazing Use of inert gas during brazing
0000004491.BOOK 8 ページ ２０１７年１２月２６日 火曜日 午後１時１０分

[1-3 Working with Refrigerant Piping ]
BS_01_C chapter 1 - 9
1 Check Before Servicing
1-3-2 Air Tightness Test
No changes have been made in the detection method. Note that a refrigerant leak detector for R22 will not detect an R410A leak.
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.
Halide torch R22 leakage detector
0000004491.BOOK 9 ページ ２０１７年１２月２６日 火曜日 午後１時１０分