Mitsubishi Electric Mr. SLIM PU-2NJA Operating manual

TECHNICAL & SERVICE MANUAL
CONTENTS
1. COMBINATION OF INDOOR AND OUTDOOR UNITS ···2
2. PART NAMES AND FUNCTIONS ··················2
3. DATA ·······························································3
4. OUTLINES AND DIMENSIONS······················5
5. WIRING DIAGRAM·········································9
6. REFRIGERANT SYSTEM DIAGRAM···········11
7. TROUBLESHOOTING ··································12
8. DISASSEMBLY PROCEDURE·····················16
9. PARTS LIST··················································18
10. OPTIONAL PARTS ·······································27
Outdoor unit
[Model names] [Service Ref.]
PU-2NJA PU-2NJA.TH
PU-2.5NJA PU-2.5NJA.TH
PU-3NJA PU-3NJA.TH
PU-4TJSA PU-4TJSA.TH
PU-5TJSA PU-5TJSA.TH
PU-5XJSA PU-5XJSA.TH
PU-6TJSA PU-6TJSA.TH
PU-6XJSA PU-6XJSA.TH
No.OC353
Outdoor unit
SPLIT-TYPE, AIR CONDITIONERS
Model name
indication
August 2005
OC353.qxq 05.8.9 9:27 AM Page 1

2
1COMBINATION OF INDOOR AND OUTDOOR UNITS
2PART NAMES AND FUNCTIONS
Indoor unit Outdoor unit
Model Service PU-2.TH PU-2.5.TH PU-3.TH PU-4.TH PU-5.TH PU-6.TH
Manual No. NJA NJA NJA TJSA TJSA XJSA TJSA XJSA
PL-AK(S)D
PL-AK(S)COC227 ——
PL-KJD OC233 ——————
PC-GJ(S)D OC215
PE-EJH(S)A OC131 —— ————
PE-EJ(S)A OC155 ——
PS-GJ(S)OC143 —— ————
PK-FL(S)D OC232 —————
PK-2GKLD OC228 ———————
wUnit of pressure is based on ISO (International Standardization Organization)
[kgf/cm2]➝[MPa] (1MPa=10.2kgf/cm2)
●Outdoor Unit
Air intake
Air outlet
(Expels warm air during cooling)
Air intake
Air outlet
Air intake
Air outlet
Air intake
Air outlet
PU-5XJSA.TH
PU-5TJSA.TH
PU-6XJSA.TH
PU-6TJSA.TH
PU-2NJA.TH
PU-4TJSA.TH
PU-2.5NJA.TH
PU-3NJA.TH
OC353.qxq 05.8.9 9:27 AM Page 2

3
3DATA
1. ELECTRICAL SPECIFICATIONS
(1) Rating conditions
2.POWER SUPPLY & MODEL NAMES
3.COMPRESSOR TECHNICAL DATA
●JIS B8616 Indoor 27:(80°F)D.B.,19:(66°F)W.B.
Outdoor 35:(115°F)D.B.,24:(75°F)W.B.
Power supply N:220V(1phase) 60Hz T:220V(3phase) 60Hz
Service Ref PU-2NJA.TH PU-2.5NJA.TH PU-3NJA.TH PU-4TJSA.TH PU-5TJSA.TH PU-6TJSA.TH
Current A 11.4 13.4 17.6 12.2 16.83 18.7
Input kW 2.45 2.91 3.44 4.27 5.63 6.15
Starting current A 54 58 80 69 135 140
Power supply X:380V(3phase) 60Hz
Service Ref PU-5XJSA.TH PU-6XJSA.TH
Current A 8.69 9.35
Input kW 5.12 5.71
Starting current A 64 70
●SSA 385,386 Indoor 29:(84°F)D.B.,19:(66°F)W.B
Outdoor 46:(115°F)D.B.,24:(75°F)W.B.
Power supply N:220V(1phase) 60Hz T:220V(3phase) 60Hz
Service Ref PU-2NJA.TH PU-2.5NJA.TH PU-3NJA.TH PU-4TJSA.TH PU-5TJSA.TH PU-6TJSA.TH
Current A 13.6 15.8 20.9 14.0 19.61 21.45
Input kW 2.97 3.44 4.09 4.97 6.68 7.28
Starting current A 54 58 80 69 135 140
Power supply Service Ref.(inddor unit)Model name (Outdoor unit)/Service Ref.
PU-2 PU-2.5 PU-3 PU-4 PU-5 PU-6
60Hz 1ph 220V PU-2NJA.TH PU-2.5NJA.TH PU-3NJA.TH — — —
3ph 220V — — — PU-4TJSA.TH PU-5TJSA.TH PU-6TJSA.TH
380/220V — — — — PU-5XJSA.TH PU-6XJSA.TH
Notes:1.Powert supply key N····1ph, 220V, 60Hz
T···· 3ph, 220V, 60Hz
X···· 3ph, 380/220V, 60Hz, 4 wires
Compressor Winding resistance(")at20:Outdoor unit
R-C/U-V S-C/V-W W-U Service Ref.
NHJ33NBDT 0.92 1.93 — PU-2NJA.TH
NHJ38NBDT 0.83 1.83 — PU-2.5NJA.TH
NHJ47NADT 0.55 1.24 — PU-3NJA.TH
NHJ56TKAT 0.87 0.87 0.87 PU-4TJSA.TH
Compressor Winding resistance(")at20:Outdoor unit
T1-T2 T2-T3 T3-T1 Service Ref.
ZR-61KC-TF5 0.628-0.722 0.628-0.722 0.628-0.722 PU-5TJSA.TH
ZR-61KC-TF7 2.23 2.23 2.23 PU-5XJSA.TH
ZR-68KC-TF5 0.517 0.517 0.517 PU-6TJSA.TH
ZR-68KC-TF7 1.92 1.92 1.92 PU-6XJSA.TH
OC353.qxq 05.8.9 9:27 AM Page 3

4
4. ADDITIONAL REFRIGERANT CHARGE (R-22……kg (lbs))
Outdoor unit
precharged (kg)
(up to 20m)
Service Ref. Refrigerant piping length (one way)
PU-2NJA.TH
PU-2.5NJA.TH
PU-3NJA.TH
PU-4TJSA.TH
1.9
2.4
3.5
4.6
20m (66ft) 25m (82ft) 30m (98ft) 35m (115ft) 40m (131ft)
0
0
0
0
0.06 (0.13)
0.06 (0.13)
0.06 (0.13)
0.15 (0.33)
––
––
––
0.45 (0.99) 0.6 (1.32)
45m (148ft)
–
–
–
–
50m (164ft)
–
–
–
–
0.12 (0.26)
0.12 (0.26)
0.12 (0.26)
0.30 (0.66)
PU-5XJSA.TH
5.1 0 0.15 (0.33) 0.45 (0.99) 0.6 (1.32) 0.75 (1.65) 0.9 (1.98)0.30 (0.66)
PU-5TJSA.TH
5.1 0 0.15 (0.33) 0.45 (0.99) 0.6 (1.32) 0.75 (1.65) 0.9 (1.98)0.30 (0.66)
PU-6XJSA.TH
5.7 0 0.15 (0.33) 0.45 (0.99) 0.6 (1.32) 0.75 (1.65) 0.9 (1.98)0.30 (0.66)
PU-6TJSA.TH
5.7 0 0.15 (0.33) 0.45 (0.99) 0.6 (1.32) 0.75 (1.65) 0.9 (1.98)0.30 (0.66)
OC353.qxq 05.8.9 9:27 AM Page 4

5
4OUTLINES AND DIMENSIONS
PU-2NJA.TH Unit : mm (inch)
100 10
1000For 10 units or less
200
Outdoor Unit-necessary surrounding clearance (Concentrated installation) The upper side must be open.
Outdoor Unit-necessary surrounding clearance
200
10
10
10Note:Allow adequate
upper clearance
150
500
500 Service space
Front opening
Handle for moving
138
95 Rear piping hole
23
33
Rear fresh air intake
Side air intake
7 24(1)295(11-5/8) Outlet guide
installation hole
302
Air intake
Air intake
Air outlet
870(34-1/4)
185
(7-9/32) 185
(7-9/32)
500(19-11/16)
330(13)
362(14-1/4) 1715 39.5 27.5
Terminal block for indoor and outdoor unit connection
Terminal block for power line
Handle for moving
77 524
339
282
297
444
650 (25-5/8)
40 60524
Service panel
(Ground terminal)
Refrigerant-pipe flared connection [15.88 3/8F Refrigerant-pipe flared connection [9.52 3/8F
Knock out hole for front piping (refrigerant,drainage and wiring)
Knock out hole for front piping (refrigerant,drainage and wiring)
R20
R20
60
120
4553
25 max.
Knock out holes for power line 2-[27
Standard bolt length
65
Front right piping holes- detail figures
80
17
42
45
12
R6
104 33
Bottom piping hole
2-U-shaped notched holes
Drain hole
Drain hole
2-12o23 Oval holes
(standard bolt M10)
Handle for moving
OC353.qxq 05.8.9 9:27 AM Page 5

6
PU-2.5NJA.TH
PU-3NJA.TH Unit : mm (inch)
100 10
1000For 10 units or less
200
Outdoor Unit-necessary surrounding clearance (Concentrated installation) The upper side must be open.
Outdoor Unit-necessary surrounding clearance
200
10
10
10Note:Allow adequate
upper clearance
150
500
500 Service space
Front opening
Handle for moving
138
95 Rear piping hole
23
33
Rear fresh air intake
Side air intake
7 24(1)295(11-5/8)
Outlet guide installation hole
302
Air intake
Air intake
Air outlet
870(34-1/4)
185
(7-9/32) 185
(7-9/32)
500(19-11/16)
330(13)
362(14-1/4) 1715 39.5 27.5
Terminal block for indoor and outdoor unit connection
Terminal block for power line
Handle for moving
179 524
441
337
352
403
553
850(33-7/16)
40 60524
Service panel
(Ground terminal)
Refrigerant-pipe flared connection [15.88 5/8F
Refrigerant-pipe flared connection [9.52 3/8F
Knock out hole for front piping (refrigerant,drainage and wiring)
Knock out hole for front piping (refrigerant,drainage and wiring)
R20
R20
60
120
4553
25 max.
Knock out holes for power line 2-[27
Standard bolt length
65
Front right piping holes- detail figures
80
17
42
45
12
R6
104 33
Bottom piping hole
2-U-shaped notched holes
Drain hole
Drain hole
2-12o23 Oval holes
(standard bolt M10)
Handle for moving
OC353.qxq 05.8.9 9:27 AM Page 6

7
150 10
1000For 10 units or less
300
Outdoor Unit-necessary surrounding clearance (Concentrated installation) Outdoor Unit-necessary surrounding clearance
The upper side must be open.
Handle for moving
138
95 Rear piping hole
23
33
Rear fresh air intake
Side air intake
7 24(1)295(11-5/8) Outlet guide
installation hole
302
Air intake
Air intake
Air outlet 870(34-1/4)
185
(7-9/32) 185
(7-9/32)
500(19-11/16)
330(13)
362(14-1/4) 1715 39.5 27.5
Terminal block for indoor and outdoor unit connection
Terminal block for power line
300
10
10
10 Note:Allow adequate
upper clearance
150
500
500 Service space
Handle for moving
52461
585
83 524
345
382
403
959
1258(49-1/2)
40 60524
Service panel
(Ground terminal)
Handle for moving
Refrigerant-pipe flared connection [19.05 3/4F
Refrigerant-pipe flared connection [9.52 3/8F
Knock out hole for front piping (refrigerant,drainage and wiring)
Knock out hole for front piping (refrigerant, drainage and wiring)
R20
R20
60
120
4553
25 max.
Knock out holes for power line 2-[27
Standard bolt length
65
Front right piping holes- detail figures
80
17
52
57
12
R6
104 39
Bottom piping hole
2-U-shaped notched holes
Drain hole
Drain hole
2-12o23 Oval holes
(standard bolt M10)
Front opening
Unit : mm (inch)
PU-4TJSA.TH
OC353.qxq 05.8.9 9:27 AM Page 7

8
PU-5TJSA.TH PU-6TJSA.TH
PU-5XJSA.TH PU-6XJSA.TH Unit : mm (inch)
150 10
1000For 10 units or less
300
Outdoor Unit-Necessary surrounding clearance (Concentrated installation) Outdoor Unit-Necessary surrounding clearance
The upper side must be open.
Handle for moving
138
95 Rear piping hole
23
33
Rear fresh air intake
Side air intake
7 24(1)345(13-9/16) Outlet guide
installation hole
352
Air intake
Air intake
Air outlet 970(38-3/16)
185
(7-9/32) 185
(7-9/32)
600(23-5/8)
380(14-31/32)
412(16-1/4) 1715 39.5 27.5
Terminal block for indoor and outdoor unit connection
Terminal block for power line
300
10
10
10 Note:Allow adequate
upper clearance
150
500
500 Service space
Handle for moving
52461
585
83 524
345
382
403
959
1258(49-1/2)
90 60524
Service panel
(Ground terminal)
Handle for moving
Refrigerant-pipe flared connection [19.05 3/4F Refrigerant-pipe flared connection [9.52 3/8F
Knock out hole for front piping (refrigerant,drainage and wiring)
Knock out hole for right piping (refrigerant, drainage and wiring)
R20
R20
60
120
4553
25 max.
Knock out holes for power line 2-[27
Standard bolt length
65
Front right piping holes- detail figures
80
17
52
57
12
R6
104 39
Bottom piping hole
2-U-shaped notched holes
Drain hole
Drain hole
2-12o23 Oval holes (standard bolt M10)
Front opening
OC353.qxq 05.8.9 9:27 AM Page 8

BLU
WHT
ORN
BLU
MC
MF3
WHT
ORN
REDRED
3
1
2
4
63H 63L
A1
A2
A
WHT
RED
TB3 1
12
2
BP1 P3 P3
X17
X6
X6
X17X14
X14
CP
P2
52C 52C
52
C
F3
(5A)
GRY
GRY
BLU
RED
ORN
YLW
WHT WHT
WHT
BLU
RED
49C
49F3
C3
C
BLU
RED
TB1
C
CP
C3
F3
MC
MF3
TB1
TB3
49C
49F3
52C
63H
63L
COMPRESSOR RUN CAPACITOR
COMPRESSOR PROTECTOR
FAN MOTOR CAPACITOR
FUSE(5A)
COMPRESSOR
FAN MOTOR
POWER SUPPLY TERMINAL BLOCK
INDOOR/OUTDOOR CONNECTING LINE TERMINAL BLOCK
COMPRESSOR INTERNAL THERMOSTAT
FAN MOTOR INTERNAL THERMOSTAT
COMPRESSOR CONTACTOR
HIGH PRESSURE SWITCH
LOW PRESSURE SWITCH
NOTES:1.THE DOTTED LINES SHOW FIELD WIRING.
2. TO INDOOR UNIT TERMINAL BLOCK.
POWER
SUPPLY
~/N
220V 60z
L
N
GRN/YLW
T1/2
BLUT3/6
L3/5
L1/1 52C
SC
R
PU-2NJA.TH PU-2.5NJA.TH
9
5WIRING DIAGRAM
WHT
BLU
RED
WHT
MC
MF3
BLU
RED
ORNORN
4
2
1
3
63H
52C
63L
A1
A2
A
WHT
RED
TB3 1
12
2
BP1 P3 P3
X17
X6
X6
X17X14
X14
CP
P2
52C 52C
52
C
F3
(5A)
GRY
GRY GRY
GRY
BLU
RED
ORN
YLW
WHT WHT
WHT
BLU
RED
49C
49F3
C3
C
BLU
WHT
TB1
POWER
SUPPLY
~/N
220V 60Hz
N
T1/2 BLU
T3/6
L3/5
L1/1 52C
SR
C
13 14
VLT VLT
22
21
52C
HC
GRN/YLW
L
C
CP
C3
F3
HC
MC
MF3
TB1
TB3
49C
49F3
52C
63H
COMPRESSOR RUN CAPACITOR
COMPRESSOR PROTECTOR
FAN MOTOR CAPACITOR
FUSE(5A)
CRANKCASE HEATER
COMPRESSOR
FAN MOTOR
POWER SUPPLY TERMINAL BLOCK
INDOOR/OUTDOOR CONNECTING LINE TERMINAL BLOCK
COMPRESSOR INTERNAL THERMOSTAT
FAN MOTOR INTERNAL THERMOSTAT
COMPRESSOR CONTACTOR
HIGH PRESSURE SWITCH
63L LOW PRESSURE SWITCH
NOTES:1.THE DOTTED LINES SHOW FIELD WIRING.
2. TO INDOOR UNIT TERMINAL BLOCK.
PU-3NJA.TH
WHT
BLU
BRN
YLW WHT
49F4
MF4
MF3
MC
BLU
RED
ORN
4
2
1
3
WHT
YLW
YLW
GRY
GRY C
HC
9695
47
51C
52C
13
32
31
14 63L
26C
63H
A1
A2
A
WHT
REDTB3 1
12
2
BP1 P3P3
X17
X6
X6
X17X14
X14
CP
P2 52C 52C
52C
52
C
F3
(5A)
WHT
WHT BRN VLT VLT GRY
GRY
RED
ORN YLW WHT
BLU
RED
ORN
WHT
BLU
BLU
C3
C4
RED
WHT
BLK
GRY RED WHT BLU
RED
TB1
TB1
26C
47
49F3,4
51C
52C
63H
63L
CP
C3,4
F3
HC
MC
MF3,4
POWER SUPPLY TERMINAL BLOCK
LINE TERMINAL BLOCK
TB3 INDOOR/OUTDOOR CONNECTING
THERMAL SWITCH
ANTI-PHASE PROTECTOR
FAN MOTOR INTERNAL THERMOSTAT
THERMAL RELAY
COMPRESSOR CONTACTOR
HIGH PRESSURE SWITCH
LOW PRESSURE SWITCH
COMPRESSOR PROTECTOR
FAN MOTOR CAPACITOR
FUSE(5A)
CRANKCASE HEATER
COMPRESSOR
FAN MOTOR
NOTES:1.THE DOTTED LINES SHOW FIELD WIRING.
2. TO INDOOR UNIT TERMINAL BLOCK.
POWER SUPPLY
3~
220V 60Hz
L1
L2
L3
GRN/
YLW
T3/6
T2/4
T1/2
L3/5
RST 47
L2/3
L1/1 51C
52C
WHT
49F3
BLU
RED
ORN
4
U
2
1
3
V
W
A
PU-4TJSA.TH
OC353.qxq 05.8.9 9:27 AM Page 9

10
PHASE PROTECTOR47
TERMINAL BLOCK
(CONNECTING WIRES INDOOR/OUTDOOR)
CP
TERMINAL BLOCK(POWER SUPPLY)
COMPRESSOR
FAN MOTOR
FUSE(5A)
FAN MOTOR CAPACITOR
COMPRESSOR PROTECTOR
THERMAL RELAY51C LOW PRESSURE SWITCH63L
INTERNAL THERMOSTAT FOR MC49C
2.* TO INDOOR UNIT TERMINAL BLOCK.
NOTES: 1.THE DOTTED LINES SHOW FIELD WIRING.
HIGH PRESSURE SWITCH
COMPRESSOR CONTACTOR
INTERNAL THERMOSTAT FOR MF3,4
THERMAL SWITCH
63H
52C
49F3,4
26C
TB3
TB1
MF3,4
MC
F3
C3,4
96
95
TB1
51C
51C
T2/4
T1/2
T3/6
63H
BLK
CIRCUIT
BREAKER
WHT
49C
49C
49C
GRY
26C
GRN/YLW
3~ (3PHASE)
220V 60Hz
POWER SUPPLY
L1
L2
L3 BLK
WHT
RED
(5A)
F3
WHT RED
A1
A2
GRY
A
C
1413 63L
47
52C
GRY
RED
WHT
GRY RED BLK
YLW
47
RTS
RED WHT BLK
L3/5
L2/3
L1/1
52C
C
52
BLU
T3
T2
T1
BLK
WHT
RED
MF4
49F4
WHT
ORN
RED
BLU
WHT
ORN
RED
BLU
MC
MF3
49F3
C4
C3
WHT
ORN
RED
BLU BLU
RED
ORN
WHT
3
1
2
4
3
1
2
4
CP
X17
X6
X14
52C P2P3P3 52C P1BA
WHT
RED
TB3
X6
2
1
*
*1
2X17X14
PU-5TJSA.TH PU-6TJSA.TH
PU-5XJSA.TH PU-6XJSA.TH
96
95
51C A
C
47
51C
T1/2
T2/4
T3/6
TB1
26C
63H
GRY
63L GRY
BLK
WHT
CIRCUIT
BREAKER
BLU
49C
49C
49C
GRN/YLW
N
POWER SUPPLY
3N~(3PHASE 4WIRES)
380V 60Hz
L1
L2
L3 BLK
WHT
RED
F3
(5A)
BLU
RED
A1
A2 14
1352C
GRY
RED
WHT
GRY
RED BLK
YLW
47
RTS
RED
WHT
BLK
L3/5
L2/3
L1/1 52C
52
C
T3
T2
T1
BLK
WHT
RED
MF4
49F4
WHT
ORN
RED
BLU
WHT
ORN
RED
BLU
MC
MF3
49F3
C4
C3 WHT
ORN
RED
BLU BLU
RED
ORN
WHT
3
1
2
4
3
1
2
4
CP
X17
X6
X14
P2P3P3
52C
52C
P1
BA
WHT
RED
TB3 X6
2
1
1
2
X17
X14
THERMAL RELAY51C LOW PRESSURE SWITCH63L
PHASE PROTECTOR47
INTERNAL THERMOSTAT FOR MC49C
NOTES: 1.THE DOTTED LINES SHOW FIELD WIRING.
2. TO INDOOR UNIT TERMINAL BLOCK.
TERMINAL BLOCK (CONNECTING WIRES INDOOR/OUTDOOR)
CP
TERMINAL BLOCK (POWER SUPPLY)
COMPRESSOR
FAN MOTOR
FUSE (5A)
FAN MOTOR CAPACITOR
HIGH PRESSURE SWITCH
COMPRESSOR CONTACTOR
INTERNAL THERMOSTAT FOR MF3,4
THERMAL SWITCH
COMPRESSOR PROTECTOR
63H
52C
49F3,4
26C
TB3
TB1
MF3,4
MC
F3
C3,4
OC353.qxq 05.8.9 9:27 AM Page 10

11
6REFRIGERANT SYSTEM DIAGRAM
PU-2NJA.TH
Low pressure
switch
Charge
plug
Ball
valve
[15.88
(5/8)
Ball valve
(with service port)
Accumulator
[9.52
(3/8)
O.D.3.2oI.D.2.0-L430
Check
plug
Compressor
Capillary tube
O.D.3.2oI.D.1.2
-L1000
Capillary tube
for injection
Strainer
#100
Outdoor heat
exchanger
High pressure
switch
flow of refrigerant
PU-2.5NJA.TH
PU-3NJA.TH
Charge
plug
Ball
valve
Ball valve
(with service port)
Accumulator
[9.52
(3/8)
Compressor
Capillary tube for
injection
#100
Strainer
Outdoor heat
exchanger
Check
plug
flow of refrigerant
Low pressure
switch High pressure
switch
[15.88
(5/8)
w
Capillary
tube
PU-2.5
(O.D.3.2oI.D.1.6
-L760)o2pcs
PU-3
( O.D.3.2oI.D.1.8
-
L800)o2pcs
PU-2.5 (O.D.3.2oI.D.1.2- L 1000)
PU-3 (O.D.3.2oI.D.1.6-
L500 )
PU-4TJSA.TH
Charge
plug
Ball
valve
[19.05
(3/4)
Ball valve
(with service port)
Accumulator
[9.52
(3/8)
Compressor
Capillary tube for
injection
Strainer
#100
Outdoor heat
exchanger
Check
plug
flow of refrigerant
Low pressure
switch High pressure
switch
w
Capillary
tube
O.D.3.2oI.D.2.0
-L840o2pcs
O.D.3.2oI.D.1.2-L500
PU-5TJSA.TH PU-6TJSA.TH
PU-5XJSA.TH PU-6XJSA.TH
Outdoor heat
exchanger
Ball
valve
Ball valve
(with service port)
High pressure
switch
Compressor
Accumulator
DPR
Capillary tube
PU-5 (O.D. 4.0 oI.D. 2.4 oL400)
PU-6 (O.D. 4.0 oI.D. 2.4 oL200)
Capillary tube
PU-5
(O.D. 4.0 oI.D. 2.4 oL840)o2pcs
PU-6
(O.D. 4.0 oI.D. 2.4 oL740)o2pcs
[9.52
(3/8)
[19.05
(3/4)
Check plug
Charge
plug
: flow of refrigerant
Strainer #100
Low pressure
switch
Strainer
#50
DPR : Discharge pressure
regulator
OC353.qxq 05.8.9 9:27 AM Page 11

12
7TROUBLE SHOOTING
12
11
10
9
8
7
6
5
1
2
3
4
29
28
27
26
25
24
23
22
18
19
20
21
7-1. SELF-DIAGNOSTIC FUNCTION
7-1-1. Wired remote controller (1)
!When trouble occurs during operation, the unit stops and enters the self-diagnostic mode, and displays the trouble loca-
tion with the timer lamps on the remote controller. All the other lamps are OFF.
@To activate the self-diagnostic function for service, press the UP and DOWN buttons simultaneously for more than two
seconds during operation with lamp ON.
#The timer lamps show the latest trouble. Trouble data is memorized until the next trouble occurs, even when the breaker
turns OFF. To clear the memory, press the UP and DOWN buttons simultaneously for more than two seconds during the
test run.
$All buttons except the POWER ON/OFF button are unavailable during the self-diagnostic mode.
%To release the self-diagnostic mode, press the POWER ON/OFF button.
Unit Trouble location
Transmission error
in twin control
Cause
●Wrong wiring between No. 1
and No. 2 units
●Poor connector contact
Measures
●Check dip switch setting
●Check wiring
Outdoor unit
●Wrong wiring between
indoor/outdoor units
●Outdoor unit abnormality
detection
●Malfunction of outdoor coil
thermistor
●Reversed phase detected
●Check wiring
●Check outdoor unit
●Check outdoor coil thermistor
Unit
No.1
Unit
No.2
Room
temperature
thermistor
(RT1)
●Poor connector contact
●Thermistor malfunction
●Check connector
●Check thermistor
➔ No trouble ➔replace indoor
controller
board.
Unit
No.1
Unit
No.2
Indoor coil
thermistor
(RT2)
●Poor connector contact
●Thermistor malfunction
●Check connector
●Check thermistor
➔ No trouble ➔replace indoor
controller
board.
Unit
No.1
Unit
No.2
Drain sensor
(DS) ●Poor connector contact
●Thermistor malfunction
●Check connector
●Check thermistor
➔ No trouble ➔replace indoor
controller
board.
Unit
No.1
Unit
No.2
Drain
overflow
protection
●Drain pump malfunction
●Drain sensor improperly
mounted
●Check drain pump
●Check drain sensor
➔ No trouble ➔replace indoor
controller
board.
Unit
No.1
Unit
No.2
Coil frost
or overheat
prevention
●Air passage short cycle
●Air filter clogged
●Indoor fan malfunction
●Remove blockage
●Check air filter
●Check indoor fan
(Indicates that the unit is in self-diagnostic mode)
}
}
}
}
TEMP.
▲
12
11
10
9
8
7
6
5
1
2
3
4
TEMP.
▲
TIMER
▲
29
28
27
26
25
24
23
22
18
19
20
21
OC353.qxq 05.8.9 9:27 AM Page 12

13
7-1-2. WIRED REMOTE CONTROLLER(2)
1) When malfunction occurs during operation
When a malfunction occurs, the indoor and outdoor units stop and the malfunction is displayed on the LCD of the remote
controller.
(1) ON the set temperature display part, “CHECK” appears, and the unit
address and the check code are displayed alternately at one-second
intervals. (Check mode)
2) How to use the self diagnostic function for service
A. For normal control with one unit and one remote controller
(1) Pressing the CHECK button on the remote controller twice starts the self diagnostic function.
(2) During the self diagnostic function, “CHECK MODE” appears at two positions on the remote controller display. Then, at
least 10 seconds later, the unit address and the check code is alternately displayed at one-second intervals.
(3) Check and repair the unit according to the check code.
B. For group control using one remote controller
(1) Pressing the CHECK button on the remote controller twice starts the self diagnostic function.
(2) Press the TEMP. button or TEMP. button on the remote controller to advance or go back to the unit address.
Each time TEMP. button is pressed, the unit address advances by one. Each time TEMP. button is pressed,
the unit address goes back by one.
The check code and the unit address, appear alternately.
(3) The check code “U8” means no malfunction has occurred since installation.
The check code “EO” means the following conditions:
● The unit address displayed on the remote controller does not apply to any unit.
● power is not supplied to the unit.
● Signal transmitting/receiving circuit is abnormal.
(4) Check and repair the unit according to the check code.
(2) When one remote controller controls several units in the group con-
trol, the LCD shows the unit address and check code of the first mal-
functioning unit.
(3) To cancel the check mode, press the ON/OFF button. In remote
ON/OFF control, press the remote ON/OFF switch. In centralized
control, turn OFF the ON/OFF button of centralized controller.
NOTE: The latest check code is memorized, even if the check mode is cancelled by the way mentioned above. It takes
60 seconds maximum to display the memorized check code.
▲▼
▲ ▼
Example
Check
code Unit
address
CHECK mode
Check button
OC353.qxq 05.8.9 9:27 AM Page 13

14
Check
code Diagnosis of malfunction Cause Check points
(P4) Abnormality of drain sensor 1) Bad contact of transmission
wire
2) Damaged thermistor
1) Check the connector.
2) Measure the resistance of the thermistor 4~
5.
As for the normal resistance, refer to the case
of P1.
If the resistance is normal, replace the indoor con-
troller board.
(P5) Malfunction of drain pump 1) Malfunction of drain pump
2) Damaged drain sensor 1) Check the drain pump. 2) ●Check the drain sensor.
●Check the drain sensor heater. Normal resis-
tance should be 82Ω.
If the resistance is normal, replace the indoor con-
troller board.
(P6) Coil frost protection is work-
ing. 1) Short cycle of air cycle 2) Dirty air filter
3) Damaged fan
4) Abnormal refrigerant
1) Clear obstructions from the air cycle.
2) Clean the air filter
3) Check the fan.
4) Check the refrigerant temperature.
(P8) Abnormality in outdoor unit 1) Wrong wiring of indoor/outdoor
connecting wire
2) Reversed phase
3) Protection device is working
4) Damaged outdoor coil thermis-
tor
1) Check the indoor/outdoor connecting wire.
2) Change the connection of electric wiring.
3) Check the protection device.
4) Measure the resistance of the outdoor coil ther-
mistor. If the resistance is normal, replace the
outdoor controller board.
(P1)
(P2)
Abnormality of room temper-
ature thermistor (RT1)
Abnormality of indoor coil
thermistor (RT2)
1) Bad contact of thermistor
2) Damaged thermistor 1) Check the thermistor. 2) Measure the resistance of the thermistor.
Normal resistance should be as follows.
0°C···15kΩ30°C ····4.3kΩ
10°C·····9.6kΩ40°C·····3.0kΩ
20°C·····6.3kΩ
If the resistance is normal, replace the indoor
controller board.
OC353.qxq 05.8.9 9:27 AM Page 14

15
7-2. HOW TO CHECK THE PARTS
PU-2NJA.TH
PU-2.5NJA.TH
PU-3NJA.TH
PU-4TJSA.TH
PU-5TJSA.TH PU-5XJSA.TH
PU-6TJSA.TH PU-6XJSA.TH
Check points
FAN MOTOR
Parts name Measure the resistance between the terminals using a tester.
(MF3,MF4)(Surrounding temperature20:)
Motor lead wire Normal Abnormal
2,2.5,3N 4T 5,6T,X
White-Blue 68.8"74.6"91.3"Open or short
Blue-Red(Brown)88.4"122.0"96.0"
Protector
OPEN:145I8:
CLOSE:90I15:
CRANK CASE Measure the resistance between the terminals using a tester.
HEATER(HC)Normal Abnormal
3N 4T
1274"1274"Open or short
COMPRESSOR 1Winding resistance
(
"
)
(MC)Measure the resistance between the terminals using a tester.
(Surrounding temperature20:)
Terminals Normal Abnormal
2N 2.5N 3N 4T
R-C(U-V)0.92"0.83"0.55"0.87"Open or short
S-C(V-W)1.933"1.83"1.24"0.87"
W-U — — — 0.87"
Terminals Normal Abnormal
5T 5X 6T 6X
T1-T2 0.628-0.722"2.23"0.517"1.92"Open or short
T2-T3 0.628-0.722"2.23"0.517"1.92"
T3-T1 0.628-0.722"2.23"0.517"1.92"
2
Internal thermostat motor protection (49C)
Internal
thermostat
motor protection
PU-4T PU-5T PU-5X PU-6T PU-6X
NH56TKAT TF5
ZR-61KC- TF7 ZR-61KC- TF5 ZR-68KC- F7 ZR-68KC-T
Opening temp. 125I5:120I5:120I5:120I5:120I5:
Closing temp. 90I7:90I15:90I15:90I15:90I15:
OC353.qxq 05.8.9 9:27 AM Page 15

16
8DISASSEMBLY PROCEDURE
OPERATING PROCEDURE PHOTOS
1. Removing the electrical parts
(1)Remove the 5 screws and the top panel. (3 screws in
front and 2 screws in rear)
(2)Remove the screw of the cover panel. To remove the
cover panel, pull it toward you and unhook the catch-
es from the side panel.
(3)Remove the screw of the service panel. To remove the
service panel, pull it down toward you and unhook the
catches on the both sides.
2. Removing the fan motor
(1)Remove the 3 screws of the front panel. Open the
front panel to a 45-degree angle. Then lift it and
unhook the 3 catches to remove.
(2)Remove the propeller nut and the propeller.
(3)Remove the 3 screws and the fan motor.
Disconnect the lead connectors.
OUTDOOR UNIT PU-3NJA.TH
Photo 1
Photo 2
Photo 3
Top panel
Service panel
Panel cover
Front panel
Propeller nut Crankcase heater
Valve bed
Lead
connectors
High-pressure control
switch
Separator support plate
Motor support
Propeller
Compressor
protector Capacitor
Contactor
Terminal blockScrews
Screws
OC353.qxq 05.8.9 9:27 AM Page 16

17
OPERATING PROCEDURE PHOTOS
3. Removing the heat exchanger and the compressor
(1)Remove the rear panel (2 screws in front, 1 screw on
the side, 3 screws in the rear). Remove the valve bed,
and open the rear panel to the rear to remove.
NOTE :
All panels are fixed by catches, and must be removed by
shifting up and down.
(2)Remove the 4 screws of the right side panel and
remove it.
(3)Remove the 3 screws of the rear guard and remove
the rear guard.
(4)Remove the 4 screws of the separator support plate
and remove the separator support plate .
(5)Remove the 2 screws of the motor support and
remove the motor support.
(6)Remove the 5 screws of the valve bed.
The valve bed is fixed by the catches on the right and
left sides.
Lift it to remove.
(7)Remove the electrical parts box.
Disconnect the connectors from the high pressure
switch, crank case heater, shell thermo, and fan motor
lead.
(8)Remove the 2 screws of the separator and remove the
separator.
(9)Remove the 2 screws of the heat exchanger and
remove the heat exchanger.
Detach the welded point of pipe.
(
10
)Remove the 3 nuts of the compressor and remove the
compressor.
Detach the welded points of the compressor suction
pipe and discharge pipe.
Photo 4
Photo 5
Photo 6
Compressor
Ball valve
Charge plug
Heat exchanger
Accumulator
Screws
Screws
OC353.qxq 05.8.9 9:27 AM Page 17

18
9PARTS LIST
STRUCTURAL PARTS
PU-2NJA.TH
1
2
3
4
5
6
7
8
9
10
11
12
13
Part No. Part Name
SpecificationNo.
Q,ty/set
Wiring
Diagram
Symbol
Recom-
mended
Q,ty
Price
Unit Amount
SCREW
LEFT SIDE PANEL
HANDLE
FRONT PANEL
FAN GUARD
MOTOR SUPPORT
BASE
SERVICE PANEL
PANEL COVER
REAR PANEL
LABEL
REAR GUARD
TOP PANEL
13
1
3
1
1
1
1
1
1
1
1
1
1
Remarks
(BG00N264G06)
(JG79C180H02)
(5o10)
NJA.TH
PU-2
—
E07 001 249
E07 001 009
E07 001 232
E07 001 521
—
E07 003 290
E07 001 245
E07 001 006
E07 001 522
—
E07 001 523
E02 214 297
(Z004M203H10)
13Pcs/set
13 12
1
2
7689
3
4
5
11 103
OC353.qxq 05.8.9 9:27 AM Page 18

19
STRUCTURAL PARTS
PU-2.5NJA.TH
PU-3NJA.TH
1
2
3
4
5
6
7
8
9
10
11
12
13
Part No. Part Name
SpecificationNo. Wiring
Diagram
Symbol
Recom-
mended
Q,ty
Price
Unit Amount
SCREW
LEFT SIDE PANEL
FRONT PANEL
HANDLE
FAN GUARD
BASE
MOTOR SUPPORT
SERVICE PANEL
PANEL COVER
REAR PANEL
LABEL
REAR GUARD
TOP PANEL
13
1
1
3
1
1
1
1
1
1
1
1
1
Remarks
(5o10)
NJA.TH
PU-2.5, 3
—
E02 214 249
E07 003 232
E07 001 009
E02 527 521
E07 003 290
—
E07 003 245
E07 001 006
E07 003 522
—
E07 003 523
E02 214 297
(SU02Y704G04)
(JG79C180H02)
(Z004M203H10)
13Pcs/set
Q,ty/set
13 12
1
2
67 89
4
3
5
11
10
4
OC353.qxq 05.8.9 9:27 AM Page 19

20
STRUCTURAL PARTS
PU-4TJSA.TH
Part No. Part Name SpecificationNo.
Q,ty/set
Wiring
Diagram
Symbol
Recom-
mended
Q,ty
Price
Unit Amount
SCREW
LEFT SIDE PANEL
FAN GUARD
FRONT PANEL
HANDLE
BASE
SERVICE PANEL
PANEL COVER
REAR PANEL
LABEL
REAR GUARD
TOP PANEL
MOTOR SUPPORT
1
2
3
4
5
6
7
8
9
10
11
12
13
13
1
2
1
3
1
1
1
1
1
1
1
1
Remarks
(5o10)
TJSA.TH
PU-4
—
E07 005 249
E02 527 521
E07 005 232
E07 001 009
E07 005 290
E07 005 245
E07 001 006
E07 005 522
—
E07 005 523
E02 214 297
—
(JG79C180H02)
(BG00N264G08)
(Z004M203H10)
13Pcs/set
12 1113
8
1
2
67
4
5
3
10 9
5
3
OC353.qxq 05.8.9 9:27 AM Page 20