Mitsubishi Electric PAC-MK50BC User manual

No. OCH574
September 2014
SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
TECHNICAL & SERVICE MANUAL
CONTENTS
1. SAFETY PRECAUTION ······································· 2
2. OVERVIEW OF UNIT ··········································· 5
3. SPECIFICATIONS ················································ 8
4. OUTLINES AND DIMENSIONS ··························· 9
5. WIRING DIAGRAM ············································· 10
6 . NECESSARY CONDITIONS FOR SYSTEM CONSTRUCTION·············· 11
7. TROUBLESHOOTING ········································ 15
8. DISASSEMBLY PROCEDURE ··························· 24
BRANCH BOX
HFC
utilized
R410A
Note:
•Thisservicemanual
describestechnicaldataof
branchbox.Asforindoor
unitsandoutdoorunit,
refertoitsservicemanual.
PARTS CATALOG (OCB574)
[Service Ref.]
PAC-MK50BC
PAC-MK30BC
[Model Name]
<Branch box>
PAC-MK50BC
PAC-MK30BC
(IndispensableoptionalpartsforPUMY-P112/125/140VKM1andPUMY-P112/125/140YKM1)

2
1SAFETY PRECAUTION
Cautions for units utilizing refrigerant R410A
1-1. ALWAYS OBSERVE FOR SAFETY
Use new refrigerant pipes.
Charge refrigerant from liquid phase of gas
cylinder.
If the refrigerant is charged from gas phase, composition
change may occur in refrigerant and the efficiency will be
lowered.
Do not use refrigerant other than R410A.
If other refrigerant (R22, etc.) is used, chlorine in refrige-
rant can cause deterioration of refrigerant oil, etc.
Use a vacuum pump with a reverse flow check
valve.
Vacuum pump oil may flow back into refrigerant cycle and
that can cause deterioration of refrigerant oil, etc.
Use the following tools specifically designed for
use with R410A refrigerant.
The following tools are necessary to use R410A refrigerant.
Handle tools with care.
If dirt, dust or moisture enters into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com-
pressor.
Do not use a charging cylinder.
If a charging cylinder is used, the composition of refrigera-
nt will change and the efficiency will be lowered.
Flare tool
Electronic refrigerant
charging scale
Vacuum pump adaptor
Size adjustment gauge
Gauge manifold
Torque wrench
Gas leak detector
Charge hose
Tools for R410A
Contamination inside refrigerant piping can cause deterio-
ration of refrigerant, oil etc.
If dirt, dust or moisture enters into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com-
pressor.
If large amount of mineral oil enters, that can cause deterio-
ration of refrigerant, oil etc.
Store the piping indoors, and both ends of the
piping sealed until just before brazing.
(Leave elbow joints, etc. in their packaging.)
Make sure that the inside and outside of refrige-
rant piping is clean and it has no contaminants
such as sulfur, oxides, dirt, shaving particles, etc,
which are hazard to refrigerant cycle.
In addition, use pipes with specified thickness.
The refrigerant oil applied to flare and flange
connections must be ester oil, ether oil or
alkylbenzene oil in a smalll amount.
Never use any refrigerant other than that specified.
Doing so may cause a burst, an explosion, or fire when the
unit is being used, serviced, or disposed of.
Correct refrigerant is specified in the manuals and on the
spec labels provided with our products.
We will not be held responsible for mechanical failure,
system malfunction, unit breakdown or accidents caused
by failure to follow the instructions.
Use the specified refrigerant only. Ventilate the room if refrigerant leaks during
operation. If refrigerant comes into contact with
a flame, poisonous gases will be released.
1-2. CAUTIONS RELATED TO NEW REFRIGERANT
Before obtaining access to terminal, all supply
circuit must be disconnected.
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Gravimeter
Unit
[3] Service tools
(1) Use the below service tools as exclusive tools for R410A refrigerant.
[2] Additional refrigerant charge
When charging directly from cylinder
·CheckthatcylinderforR410Aonthemarketisasyphontype.
·Chargingshouldbeperformedwiththecylinderofsyphonstoodvertically.(Refrigerantischargedfromliquidphase.)
[1] Cautions for service
(1) Perform service after recovering the refrigerant left in unit completely.
(2) Do not release refrigerant in the air.
(3) After completing service, charge the cycle with specified amount of refrigerant.
(4) When performing service, install a filter drier simultaneously.
Be sure to use a filter drier for new refrigerant.
No. Toolname Specifications
1Gaugemanifold
·OnlyforR410A
·Usetheexistingfittingspecifications.(UNF1/2)
·Usehigh-tensionsidepressureof5.3MPa·Gorover.
2Chargehose ·OnlyforR410A
·Usepressureperformanceof5.09MPa·Gorover.
3Electronicscale
4Gasleakdetector ·UsethedetectorforR134a,R407CorR410A.
5Adaptorforreverseflowcheck ·Attachonvacuumpump.
6Refrigerantchargebase
7Refrigerantcylinder ·OnlyforR410A·Topofcylinder(Pink)
·Cylinderwithsyphon
8Refrigerantrecoveryequipment
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4
(2) Cautions for refrigerant piping work
NewrefrigerantR410Aisadoptedforreplacementinverterseries.AlthoughtherefrigerantpipingworkforR410Aissame
asforR22,exclusivetoolsarenecessarysoasnottomixwithdifferentkindofrefrigerant.Furthermoreastheworking
pressureofR410Ais1.6timeshigherthanthatofR22,theirsizesofflaredsectionsandflarenutsaredifferent.
1Thicknessofpipes
BecausetheworkingpressureofR410AishighercomparedtoR22,besuretouserefrigerantpipingwiththickness
shownbelow.(Neverusepipesof0.7mmorbelow.)
2Dimensionsofflarecuttingandflarenut
ThecomponentmoleculesinHFCrefrigerantaresmallercomparedtoconventionalrefrigerants.Inadditiontothat,
R410Aisarefrigerant,whichhashigherriskofleakagebecauseofitsworkingpressurehigherthanthatofotherrefriger-
ants.Therefore,toenhanceairtightnessandstrength,flarecuttingdimensionofcopperpipeforR410Ahasbeenspeci-
fiedseparatelyfromthedimensionsforotherrefrigerantsasshownbelow.ThedimensionBofflarenutforR410Aalso
haspartlybeenchangedtoincreasestrengthasshownbelow.Setcopperpipecorrectlyreferringtocopperpipeflaring
dimensionsforR410Abelow.For1/2”and5/8”inchpipes,thedimensionBchanges.
Usetorquewrenchcorrespondingtoeachdimension.
3ToolsforR410A(Thefollowingtableshowswhetherconventionaltoolscanbeusedornot.)
1/4
3/8
1/2
5/8
3/4
6.35
9.52
12.70
15.88
19.05
0.8
0.8
0.8
1.0
—
0.8
0.8
0.8
1.0
1.0
Nominal
dimensions (in)
Diagram below: Piping diameter and thickness
Outside
diameter (mm)
Thickness (mm)
R410A R22
1/4
3/8
1/2
5/8
3/4
6.35
9.52
12.70
15.88
19.05
9.1
13.2
16.6
19.7
—
9.0
13.0
16.2
19.4
23.3
Nominal
dimensions (in)
Flare cutting dimensions
Outside
diameter (mm)
Dimension A ( )
+0
-0.4 (mm)
R410A R22
1/4
3/8
1/2
5/8
3/4
6.35
9.52
12.70
15.88
19.05
17.0
22.0
26.0
29.0
—
17.0
22.0
24.0
27.0
36.0
Nominal
dimensions (in)
Flare nut dimensions
Outside
diameter (mm
)
Dimension B (mm)
R410A R22
Gauge manifold
Charge hose
Gas leak detector
Refrigerant recovery equipment
Refrigerant cylinder
Applied oil
Safety charger
Charge valve
Vacuum pump
Flare tool
Bender
Pipe cutter
Welder and nitrogen gas cylinder
Refrigerant charging scale
Vacuum gauge or thermis-
tor vacuum gauge and
vacuum valve
Charging cylinder
Air purge, refrigerant charge
and operation check
Gas leak check
Refrigerant recovery
Refrigerant charge
Apply to flared section
Prevent compressor malfunction
when charging refrigerant by
spraying liquid refrigerant
Prevent gas from blowing out
when detaching charge hose
Vacuum drying and air
purge
Flaring work of piping
Bend the pipes
Cut the pipes
Weld the pipes
Refrigerant charge
Check the degree of vacuum. (Vacuum
valve prevents back flow of oil and refri-
gerant to thermistor vacuum gauge)
Refrigerant charge
Tool exclusive for R410A
Tool exclusive for R410A
Tool for HFC refrigerant
Tool exclusive for R410A
Tool exclusive for R410A
Ester oil and alkylbenzene
oil (minimum amount)
Tool exclusive for R410A
Tool exclusive for R410A
Tools for other refrigerants can
be used if equipped with adop-
ter for reverse flow check
Tools for other refrigerants
can be used by adjusting
flaring dimension
Tools for other refrigerants can be used
Tools for other refrigerants can be used
Tools for other refrigerants can be used
Tools for other refrigerants can be used
Tools for other refrigerants
can be used
Tool exclusive for R410A
Tools and materials Use R410A tools Can R22 tools be used?
(Usable if equipped
with adopter for rever-
se flow)
(Usable by adjusting
flaring dimension)
Can R407C tools be used?
Ester oil:
Alkylbenzene oil: minimum amount
(Usable if equipped
with adopter for rever-
se flow)
(Usable by adjusting
flaring dimension)
: Prepare a new tool. (Use the new tool as the tool exclusive for R410A.)
: Tools for other refrigerants can be used under certain conditions.
: Tools for other refrigerants can be used.
DimensionA
DimensionB
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2OVERVIEW OF UNIT
Indoor unit (Ceiling concealed type)
Indoor unit
(Wall mounted type)
Outdoor unit Branch Box
2-1. SYSTEM OUTLINE
TheadditionalconnectionoftheBranchBoxtogetherwithemploymentofthecompacttrunk-lookingoutdoorunitcan
successfullyrealizesalongdistancepipingforbighouses.Equippedwithamicroprocessor,theBranchBoxcantrans-
latethetransmissionsignalofindoorunitstoachievetheoptimumcontrol.
2-1-1. System example
2-1-2. Method for identifying
■ Outdoor unit
PU M Y - P 125 Y K M 1 - BS
Refrigerant
R410A
Indicates equivalent
to Cooling capacity
Power supply
V: Single phase
220/230/240 V, 50 Hz
Y: 3-phase
380/400/415 V, 50 Hz
Outdoor unit
model type
M-NET control
Frequency
conversion
controller
Outdoor unit
MULTI-S
(k cal/ h)
Salt proof
type
Sub number
Branch box (Controller)
Number of branches
5 : 5 branches
3 : 3 branches
Model type
Symbol of factory
P A C – MK 5 0 BC
(Indispensable)
Optional parts
■ Branch box
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2-2. INSTALLATION
2-2-1. Space required for Installation and servicing for Branch box.
(1) Front View (Fig. 2-1)
A Branchbox
B Onthesideofpiping
(2) Side View (Fig. 2-2, Fig. 2-3)
C Forindoorinstallations
D Ceilingboard
E Maintenancehole
*1: Aminimum350mmisrequiredfor90°bendsinrefrigerantpiping.
*2: Ais“Min.200mm”.
Inthecaseoflessthan200mm(forexampleAis100mm),theexchangeworkofBranchboxfromamaintenancehole
 becomesdifficult(OnlyexchangeworkofaPCB,linearexpansionvalvecoilsandsensorsispossible).
*3: Bis“□600”.
 Inthecaseof“□450”,prepareamaintenanceholeataPCBsideasitisshowninFig.2-3,and“Min.300mm”isneeded
asdistanceA.
 Inthecaseoflessthan300mm(forexampleAis100mm),theexchangeworkofBranchbox,linearexpansion
 valvecoilsandsensorsfromamaintenanceholebecomesdifficult.OnlyexchangeworkofaPCBispossible.
(3) Top View (Fig. 2-4)
G Refrigerantpiping
NOTE1:Thebranchboxisonlyforindooruse.
NOTE2:Pleaseattachthespecialoptionalcover(PAC-AK350CVR-E)toinstallbranchboxintheoutdoors.
Fig. 2-4
Fig. 2-3
Fig. 2-2Fig. 2-1
unit : mm
(3)
G
Min. 250
(1) (2)
50 450
450
250 250 250
170 30
278
180-200
A
C
B
D E
*1
*3
*2
E D
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A
B B B B B
Branch box
■Incaseofusing1-branchbox
Flareconnectionemployed(Nobrazing)
AA
A
B B B B B
2 branches pipe (joint)
: optional parts
Branch box #1
Branch box #2
■Incaseofusing2-branchboxes
■Installationprocedure(2branchpipe(joint))
RefertotheinstallationmanualsofMSDD-50AR-EandMSDD-50BR-E.
2-3. SIMPLIFIED PIPING SYSTEM
Piping connection size
Liquid (mm)
Gas (mm)
{9.52
{15.88
The piping connection size differs according to the type and capacity of indoor units.
Match the piping connection size of branch box with indoor unit.
If the piping connection size of branch box does not match the piping connection size of
indoor unit, use optional different-diameter (deformed) joints to the branch box side.
(Connect deformed joint directly to the branch box side.)
A B
Flareconnectionemployed.(Nobrazing!)
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3 SPECIFICATIONS
kW
A
mm
mm
mm
kg
mm
mm
mm
mm
Model Name
Connectable number of indoor units
Power supply (from outdoor unit)
Input
Running current
External finish
Dimensions
Weight
Piping
connection
(Flare)
Width
Depth
Height
Branch (indoor side)*
Main (outdoor side)
Liquid
Gas
Liquid
Gas
Maximum 3
6.7
[6.35 O 3 {A,B,C}
[9.52 O 3 {A,B,C}
Maximum 5
7.4
[6.35 O 5 {A,B,C,D,E}
[9.52 O 4 {A,B,C,D}, [12.7 o1{E}
PAC-MK50BC PAC-MK30BC
Single phase, 220/230/240V, 50Hz, Single phase, 220V, 60Hz
0.003
0.05 (Max. 6)
Galvanized sheets
450
280
170
[9.52
[15.88
PAC-MK50BC PAC-MK30BC
* Thepipingconnectionsizediffersaccordingtothetypeandcapacityofindoorunits.Matchthepipingconnectionsizeforindoor
andbranchbox.Ifthepipingconnectionsizeofbranchboxdoesnotmatchthepipingconnectionsizeofindoorunits,use
optionaldifferent-diameter(deformed)jointstothebranchboxside.(Connectdeformedjointdirectlytothebranchboxside.)
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4OUTLINES AND DIMENSIONS
unit: mm
PAC-MK50BC
PAC-MK30BC
SUSPENSION BOLT PITCH
SUSPENSION BOLT PITCH
402
24
12
320
TO INDOOR UNIT
ABCDE ABCDE
170
4765
25 25 25 25 25
70 70
72
67
450 90
70
70
TO OUTDOOR UNIT
SERVICE PANEL
(for LEV,THERMISTOR)
CONTROL COVER
BUSH
5-ELECTRIC WIRE INLET
87 70
112
96
83
280 40
TB3B TB3D
TB3A TB3C TB3E
TB5 TB2B
TERMINAL BLOCK
TO OUTDOOR UNIT
TERMINAL BLOCK
TO INDOOR UNIT
TERMINAL BLOCK
TO M-NET UNIT
SUSPENSION BOLT : W3/8(M10)
GAS PIPE
REFRIGERANT PIPE FLARED CONNECTION
1/4F 1/4F 1/4F 1/4F 1/4F 3/8F
3/8F 3/8F 3/8F 3/8F 1/2F 5/8F
TO OUTDOOR UNIT
LIQUID PIPE
A B C D E
TO INDOOR UNIT
A
A
B
C
BC
CAP
CAP
72
90
25 25
209
170
4765
25
70 70
452
SERVICE PANEL
(for LEV.THERMISTOR)
TO OUTDOOR UNIT
CONTROL COVER
BUSH
5-ELECTRIC WIRE INLET
112
7087
280 40 96
83
TERMINAL BLOCK
TO M-NET UNIT
TERMINAL BLOCK
TO INDOOR UNIT
TERMINAL BLOCK
TO OUTDOOR UNIT
TB2B
TB5
TB3B
TB3CTB3A
SUSPENSION BOLT PITCH
SUSPENSION BOLT PITCH
320
402
12
24
CBA
LIQUID PIPE
TO OUTDOOR UNIT
5/8F3/8F
3/8F
3/8F
3/8F1/4F1/4F1/4F
REFRIGERANT PIPE FLARED CONNECTION
GAS PIPE
SUSPENSION BOLT : W3/8(M10)
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BLU
RED
TO OUTDOOR UNIT
LEV-E
LEV-D
LEV-C
LEV-B
LEV-A
TH-E
tº
TH-D
tº
TH-C
tº
TH-B
tº
TH-A
tº
1 2 3 4 5 6
SW5
ON
OFF
10ths
DIGIT
1s
DIGIT
TO
INDOOR UNIT-E
TO
INDOOR UNIT-D
TO
INDOOR UNIT-C
TO
INDOOR UNI T-B
TO
INDOOR UNIT-A
L
N
S3
S2
S1
S3
S2
S1
S3
S2
S1
S3
S2
S1
S3
S2
S1
M1
M2
S
TO OUTDOOR UNIT
DC24-30V
TB3E
TB3C
TB3A
TB3D
TB3B
TB1
F4
10A 250V
F3
10A 250V
F2
10A 250V
TB2B
TB5
(SHIELD)
(SHIELD)
CND
(BLK)
F1
6.3A 250V
+–
3
1
M-NET
CN3M
(BLU)
1 2 3
5
LEV-E
(GRN)
1
5
LEV-D
(BLK)
1
5
LEV-C
(BLU)
1
5
LEV-B
(RED)
1
5
LEV-A
(WHT)
1
2 TH-E
1 (GRN)
2 TH-D
1 (BLK)
2 TH-C
1 (BLU)
2 TH-B
1 (RED)
2 TH-A
1 (WHT)
M
M
M
M
M
(PAC-MK50BC only)
(PAC-MK50BC only)
0
1
2
3
4
5
6
7
8
9
SW12
0
1
2
3
4
5
6
7
8
9
SW11
ON
OFF
1 2 3 4 5 6 7 8 9 10
SW4
1 2 3 4 5 6
SW1
ON
OFF
LED1
LED2 CNM
(WHT)
114
B.C.
BLU
BLU
(PAC-MK50BC only)
TO ANOTHER
BRANCH BOX
TO ANOTHER
BRANCH BOX
BLU
RED
POWER SUPPLY
220/ 230/ 240V 50Hz
220V 60Hz
L
N
TB2B
TO ANOTHER
BRANCH BOX
CIRCUIT
BREAKER
Fig. 1
PULL BOX
<Note>
1. At servicing for outdoor unit,
always follow the wiring diagram
of outdoor unit.
2. When work to supply power
separately to Branch box and outdoor
units are applied, refer to Fig. 1.
3. For the connection method, please
refer to the Branch box Installation
Manual.
<Combination of indoor units>
Enter the location of combined indoor units with model name in each
blank below because it is necessary for service and maintenance.
SYMBOL
B.C.
F1 <B.C.>
F2~F4 <B.C.>
SW1 <B.C.>
SW4 <B.C.>
SW5 <B.C.>
CNM <B.C.>
LED1,2 <B.C.>
LEV-A~E
TH-A~E
TB2B
TB5
TB3A~E <B.C.>
SW11 <B.C.>
SW12 <B.C.>
Branch box controller board
Fuse <T6.3AL 250V>
Fuse <T10AL 250V>
Switch for indoor unit connection *1
Switch for mode selection
Not in use
Connector <Connection for service>
Light emitting diode *2
Linear expansion valve *3
Thermistor <Gas pipe> *3
Terminal block <To Power Supply>
Terminal block <Transmission>
Terminal block To indoor unit-A~E *3
Address Setting 1s DIGIT
Address Setting 10ths DIGIT
NAME
Indoor unit-A Indoor unit-B Indoor unit-C Indoor unit-D Indoor unit-E
<Symbols used in wiring diagram>
: Terminal block, : Connector
: Dip switch (■(black square) indicates
a switch position)
After each indoor unit is connected to the outdoor unit, turn on
the switch corresponding to each indoor unit. For example,
when the indoor units are connected to INDOOR UNIT-A
and C, turn SW1-1 and SW1-3 to on.
*2 LED on Branch box controller board for service
*3 D and E for PAC-MK50BC only.
•start-up
Mark
LED 1
LED 2
Main power supply
Meaning
Main power supply (220/230/240V)
Power on →Lamps are lit
Function
Mark
LED 2 Total number of
indoor units
Meaning
Blink depend on the total number
<example> The total number is 2
1Blink 2 times.
2Turn off for three sec.
3Repeat 1to 2.
LED 1 Main power supply Lamp is lit
Function
• normal operating
PAC-MK
50BC only
INDOOR UNIT-A
INDOOR UNIT-B
INDOOR UNIT-C
INDOOR UNIT-D
INDOOR UNIT-E
NO USE
SW1-1
SW1-2
SW1-3
SW1-4
SW1-5
SW1-6
NOT CONNECT
NOT CONNECT
NOT CONNECT
NOT CONNECT
NOT CONNECT
CONNECT
CONNECT
CONNECT
CONNECT
CONNECT
*1 SW1 setting
OFF ON
Note : " PAC -MK30 .50BC " is only for R410A.
5WIRING DIAGRAM
PAC-MK50BC PAC-MK30BC
OCH574