Mitsubishi Heavy Industries R410A User manual

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MITSUBISHI HEAVY INDUSTRIES - PAC SERVICE MANUAL
INDEX
MAINTENANCE DATA 2
ERROR CODES 4
PCB INDOOR UNITS 8
ERROR DISPLAY & REMEDY CHART 12
PCB OUTDOOR UNITS 22
ERROR DISPLAY – OUTDOOR UNIT 25
OPERATIONAL DATA CHECK – WIRED CONTROLLER 35
REMOTE CONTROL – WIRED 36
- SETTING FUNCTIONS 37
ERROR DISPLAY – WIRELESS CONTROL 43
REMOTE CONTROL WIRELESS 44

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1. MAINTENANCE DATA
1.1 Servicing
(1) Evacuation
The evacuation is a procedure to purge impurities, such as noncondensable gas, air, moisture from the refrigerant equipment by
using a vacuum pump. Since the refrigerant R410A is very insoluble in water, even a small amount of moisture left in the refriger-
ant equipment will freeze, causing what is called ice clogging.
Evacuation procedure
Make sure that the both service valves of gas and liquid line are fully opened.
(a) Check to ensure that there is no internal pres-
sure in the unit. If there is an internal pres-
sure, it should be relived through the service
port.
(b) Connect the charging hose of the gauge mani-
fold to the service port of the gas piping.
Close high pressure valve 2of gange mani-
fold.
(c) Connect the charging hose A to a vacuum
pump.
Repeat evacuation in the following sequence.
Notes (1) Do not use the refrigerant pressure to expel air.
Notes (2) Do not use the compressor for evacuation.
Notes (3) Do not operate the compressor in a vacuum condition.
Vacuuming begins
Vacuuming completed
Vacuum gauge check
When the vacuum gauge's needle pointer creeps up,
there is moisture left in the system or a leak. Pull air
again after you have checked the system for a leak and
rectified it. Use a reverse flow stop adapter to prevent
the vacuum pump's lubricant oil from flowing into the
refrigerant system.
Please run the
vacuum pump for at
least one hour after
the vacuum gauge
shows -101kPa or
lower. (-755mmHg or
lower)
No increase in the
reading of the
vacuum gauge's
needle pointer.
Liquid line
Indoor unit
Outdoor unit
Gus line
Charge hose
(for R410A only)
Refrigerant
cylinder
Handle Lo
3
Vacuum
pump
Gauge manifold
(for R410A only)
Handle Hi
Charge hose A
(for R410A only)
Charge valve
Vacuum adapter
(for R410A only)
Charge port
12
Notes (1) Refer to the exterior-view drawing for the position of the service valve.
Notes (2) When connecting of ther service valve, flare connection for both the
indoor and outdoor unit.

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3
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(2) Refrigerant charging
(a) After the evacuation shown in the above, change the connection of the charge hose A to the refrigerant cylinder.
(b) Purge air from the charge hose A .
First loosen the connecting portion of the charge hose at the gauge manifold side and open valve 3for a few seconds, and
then immediately retighten it after observing that gas has blown out from loosened connecting portion.
(c) Open valves 1and 3then gas refrigerant begins flowing from the cylinder into the unit.
When refrigerant has been charged into the unit to some extent, refrigerant flow becomes stagnant. When that happens, start
the compressor in cooling cycle until the system is filled with the specified amount of gas, then close valves 1and 3and
remove the gauge manifold. Cover the service port with caps and tighten them securely.
(d) Check for gas leakage by applying a gas leak detector around the piping connection.
(e) Start the air conditioner and make sure of its operating condition.
1.2 Trouble shooting for refrigerant circuit
(1) Judgement of operating condition by operation pressure and temperature difference
Making an accurate judgement requires a skill that is acquired only after years of experience, one trouble may lead to an another
trouble from a single trouble source and several other troubles may exist at the same time which comes from a undetected different
trouble source.
Filtering out the trouble sources can be done easier by comparing with daily operating conditions. Some good guides are to judge
the operating pressure and the temperature difference between suction air and delivery air.
Following are some pointers,
Pressure
Trouble cause
High side ¡
Low side ¡
High side ¡Ineffective compression
Low side ¡(defective compressor)
High side ¡
Low side ¡
High side ¡
Low side ¡
High side ¡
Low side ¡1) Too high temperature of room
1) Insufficient refrigerant in circuit
2) Clogging of strainer
3) Gas leakage
4) Clogging of air filter (in cooling)
5) Decrease in heat load (in cooling)
6) Locking of indoor fan (in cooling)
1) Locking of outdoor unit fan (in cooling)
2) Dirty outdoor heat exchanger (in cooling)
3) Mixture of non condensable gas (air etc.)
1) Excessive overcharging of refrigerant
2) Mixture of non condensable gas (air etc.)
Indi-
cation
Circuit
Too low
A little low
Normal
A little
high
Too high

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4
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(1) Selfdiagnosis function
(a) Check Indicator Table
Whether a failure exists or not on the indoor unit and outdoor unit can be know by the contents of remote controller eroor code, indoor/outdoor unit green LED (power pilot lamp
and microcomputer normality pilot lamp) or red LED (check pilot lamp).
1) Indoor unit side
Outdoor unit LEDIndoor unit LED
Green
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Red
Stays OFF
Stays OFF
Stay OFF or Lights
continously
Green
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Stays OFF
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
*3 time flash
Stays OFF
Stay OFF
2 time flash
2 time flash
2 time flash
1 time flash
1 time flash
1 time flash
Stays OFF
Stays OFF
Stay OFF
Red
Stays OFF Normal
Indoor unit microcomputer failure
Indoor unit PCB fault
Outdoor unit microcomputer failure
Indoor unit heat exchanger thermistor failure
Indoor unit return air thermistor failure
The float SW operates (with FS only). Drain up kit wiring fault.
Indoor / outdoor transmission error.
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
2 time flash
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Remote
controller
error code
No-indication
LCD flashes
continuously
or is off.
E1
E5
E6
E7
E9
E10
E28
Cause
Keeps flashing Keeps flashing1 time flash Stays OFF
E8
Stays OFF Stays OFF Stays OFF Power OFF, L phase wiring is open, power source failure
Stays OFF
Remote controller wires X and Y are reversely connected. *For wire breaking at
power ON, the LED is OFF. Remote controller wire is open. (X wire breaking : A
beep is produced and no indication is made. Z wire breaking : No beep and no
indication) The remote controller wires Y and Z are reversely connected.
The remote controller wire Y is open. The remote controller wires X and Y are
reversely connected. Noise is penetrating the remote control lines. The remote
controller or indoor control PCB is faulty. (The communications circuit is faulty.)
Keeps flashing Keeps flashingStays OFF 2 time flash Poor connection or disconnection in wires connecting the indoor and outdoor
units.
When multiple remote controllers are used for control, the power supply to some
indoor units is OFF.
When multi-unit control by remote controller is performed, the number of units is
over (more than 17 units). Two remote controller are provided for one controller is
performed.
Outdoor unit control PCB is faulty when the power is turned on, or the inverter
parts are faulty (FDCVA 151~251 type).
Heating overload (indoor heat exchanger temperature is abnormally high) and
indoor heat exchanger thermistor is faulty.
Remote controller thermistor failure
Keeps flashing Keeps flashing
Stays OFF Stays OFF
E16 Fan motor is faulty (FDTA 501, 601 type, FDKN type).
1.3Diagnosing of microcomputer circuit
Note (1) The green LED in the outdoor unit is used in the FDCA301 ~ 601 models only.

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Outdoor unit LEDIndoor unit LED
Green
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Keeps flashing
Red Green
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
Stays OFF
1 time flash
1 time flash
1 time flash
1 time flash
1 time flash
1 time flash
1 time flash
1 time flash
1 time flash
1 time flash
Red
Wiring is open or reversal phase (FDCA 301~601 type)
Abnormal current cut of compressor (FDCA 301~601 type)
52C secondary side L3-phase wiring is open. (FDCA 301~601 type)
Discharge temperature abnormality.
Discharge pipe thermistor failure
63H1 operation (FDCA 301~601 type)
Outdoor air temperature thermistor failure
Inverter Over-voltage Trouble. (FDCVA 151~251 type)
DC fan motor abnormal. (FDCVA 151~251 type)
Remote
controller
error code
E32
E33
E34
E36
E37
E38
E39
E40
E47
E48
Cause
Keeps flashing Keeps flashing
Stays OFF 1 time flash
E35
Keeps flashing Stays OFF 1 time flash Current (Abnormalities in a compressor over current)
E42
Keeps flashing Keeps flashing
Stays OFF Lights contiously 52C abnormal. (FDCA 301~601 type)
E52
Keeps flashing
Keeps flashing
Stays OFF 1 time flash Power transistor thermistor is faulty or disconnection or connector
connections are poor. (FDCVA 151~251 type)
E56
Keeps flashing Stays OFF 1 time flash Insufficient refrigerant.
E57
1 time flash
Keeps flashing Stays OFF 2 time flash Compressor startup error (FDCVA 151~251 type)
E59
3 time flash
Keeps flashing Stays OFF 1 time flash Compressor loader position detection error. (FDCVA 151~251 type)
E60
Outdoor unit heat exchanger thermistor
failure
Outdoor heat exchanger temperature is high or outdoor heat exchanger thermistor
is faulty.
Inverter primary side current is abnormal. (FDCVA151~251 type)
2) Outdoor unit side
Note (1) The green LED in the outdoor unit is used in the FDCA301 ~ 601 models only.

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Section Display section
Error code of remote controller
Inspection LED (red) of indoor unit PCB
Inspection LED (red) of outdoor unit PCB
• Displays the error of higher priority (When plural errors are persisting)
• Displays the present errors.
(When a new error has occurred after the former error was reset.)
Error detail Error code Timing of error detection
Wrong connection between the indoor and
outdoor units. “ Wait ”
Normally, 30 seconds after the power is turned ON.
Normally after the power is turned ON (during communications).
Broken wire of heat exchanger thermistor
Drain error (float switch motion)
No communications even once with the outdoor unit.
After 1 or more communications of the indoor unit with the remote controller
following power on, transmission errors cause an interruption for 2 minutes.
After communications with the outdoor unit 1 or more times, communications
are abnormal continuously for 2 minutes.
When an input temperature of –50°C or lower is measured by the return air
thermistor is measured for 5 seconds or longer within 60 minutes after the
first detection.
When an input temperature of –50°C or lower is measured by the heat
exchanger thermistor is measured for 5 seconds or longer within 60 minutes
after the first detection.
Transmission error of remote controller
indoor unit
Transmission error between indoor/outdoor
units
The number of connected indoor units
exceeds the connection limit (when
multiple units are control by a single remote
controller).
Broken wire of indoor unit return air
thermistor
······················
Error detail Error code Timing of error detection
Broken wire of heat exchanger thermister
Broken wire of discharge pipe thermistor
Broken wire of outdoor air temperature
thermistor
Broken wire of power transistor
thermistor
When a thermistor input temperature of –30°C or lower is measured for 5
seconds or longer 3 times within 40 (60) minutes after the 1st detection
between 2 minutes and 2 minutes 20 seconds after compressor operation
starts.
When a thermistor input temperature of –30°C or lower is measured for 5
seconds or longer 3 times within 40 (60) minutes after the 1st detection
between 2 minutes and 2 minutes 20 seconds after compressor operation
starts.
When a thermistor input temperature of –10°C or lower is measured for 5
seconds or longer 3 times within 40 (60) minutes after the 1st detection
between 10 minutes and 10 minutes 20 seconds (between 2 minutes and 2
minutes 20 seconds) after compressor operation starts.
When the under-dome thermistor input temperature of –10°C is measured for
5 seconds or longer 3 times within 40 minutes after the 1st detection between
10 minutes and 10 minutes 20 seconds after compressor operation starts.
(b) Display sequence of error, inspection display lamp
1) One kind error
Display corresponding to the error is shown.
2) More than one errors.
3) Timing of error detection
●Indoor unit side.
Notes (1) Values in ( ) show for the FDCA301~601 models.
(2) The power transistor temperature sensor is used in the FDCVA151~251 models only.
●Outdoor unit side.

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4) Recording and reset of error
Notes (1) Priority is in the order of E1 > ... > E10 > ... > E60.
(2) Procedures of trouble diagnosis
When any error occurs, inspect in following sequence. Detailed explanation on each step is given later in this text.
Note (1) It means the operation to turn off the power and back on again more than 1 min. later in order to reset the malfunction of microcomputer due to the
effect of power supply conditions or accidental noise.
Error display Memory Reset
Error code of remote
controller
Indoor unit inspection lamp
(red)
• Saves in memory the mode (1) of higher
priority
• Stop the unit operation by pressing the ON/OFF switch of remote
controller.
• Operation can be started again if the error has been reset.
• Saves in memory the mode (1) of higher
priority
• Cannot save in memory
Outdoor unit inspection lamp
(red)
Error Power supply reset
(1)
Check of inspection display [In-
door/outdoor unit PCB, remote
controller or Indication board]
Check of inspection display [In-
door/outdoor unit PCB, remote
controller or Indication board]
Power supply check
(indoor/outdoor unit)
Replacement or repair of defective
parts Test run/adjustment
Check of unit
controller
Indoor unit
Outdoor unit
: Press the ON/OFF button on the remote controller. Or disconnect and reconnect the power supply connector
(CNW1 or CNW0) on the indoor unit control PCB or turn the main power supply OFF.
: Turn the main power supply OFF.
(3) Error diagnosis procedures at the indoor unit side
To diagnose the error, measure the voltage (AC, DC), resistance, etc. at each connector around the circuit board of indoor unit
based on the inspection display or the operation state of unit (no operation of compressor or blower, no switching of 4-way valve,
etc.) If any defective parts are discoverd, replace with the assembly of parts as shown below.
(a) Single-unit replacement parts for circuit board of indoor unit. (Peripheral electric parts for circuit board.)
Indoor unit printed circuit board, thermistor (return, heat exchanger), operating switches, limit switches, transformers, fuses.
Note (1) Use normal inspection methods to determine the condition of strong electrical circuits and frozen cycle parts.
(b) Replacement procedure of indoor unit microcomputer printed circuit board
Microcomputer printed circuit board can be replaced with following procedure.
(i) Confirm the parts numbers. (Refer to the following parts layout drawing for the location of parts number.)
PJA505A122ZD
PJA505A122ZC
PJA505A128ZF
Parts number
FDTA 151~401
FDTA 501, 601
FDE
Model
FDKA 151~251
FDKA 301
FDUR
Model
PHA505A018ZF
PHA505A018ZG
PJA505A131ZC
Parts number

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8
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CNM3
52X6 52X1 52X2 52X3
52X4
52X8-2
PC3
IC2
C2
X1
CNE
F2 F1
Z2D Z3D Z4D Z5D
R16
ZD1
CNJ
D2
IC7
TVS1
CNM2
CNW8
CNT
IC9
J8
1234
J10 J11 J12
CNR
IC12
CNG
LED2 LED1
CNW9
C13
PC5
C12
C1
L1
C58
IC3
C4
C3
CNY CNI
CNH CNN1
SW2
SW10 SW5
1234
SW7
J5 J6 J7 J8
SW8
J1 J2 J3 J4
SW9
IC11
IC8
CNB
C11
C41
KN1
CNV
52X7
52X8-1
CNW7
TM1
PC2 PC1
R17
C23
L2
ON
ON
C5
Fan motor
(501, 601)
Power supply PCB
(CNW8)
Connector
(CNT)
Address switch
(SW2)
Heat exchanger thermistor,
Return air thermistor
(Thi-R1, Thi-A)
Heat exchanger
thermistor
(Thi-R2)
J9~J11
(SW10)
DIP switch
(SW5)
J5~J6
(SW8)
DIP switch
(SW9)
J1~J4
(SW7)
Remote
controller
Louver motor
To power supply
(CNW7)
To power supply PCB
(501, 601) (CNW9)
Fan motor
(151~401)
Parts layout on the indoor unit PCB
Model: FDT series
Input signal - Reverse invalid
Input signal - Rus stop
Heating thermostat OFF-Lo
Heating thermostat OFF-Stop, Lo
Normal operation operable
Operation permission prohibited
Normal
Heating temp. +3
Louver free stop control - Invalid
Louver free stop control - Effective
Freeze prevention fan control activated.
Freeze prevention fan control deactivated.
J1 (SW7-1)
J2 (SW7-2)
J3 (SW7-3)
J4 (SW7-4)
J5 (SW8-1)
J6 (SW8-2)
With
None
(1)
With
None
(1)
With
None
(1)
With
None
(1)
With
None
(1)
With
None
(1)
Name Function
Note (1)
(2)
“None”means that jumper wire is not provided on the PCB or the
connection is cut
The replacement board is not equipped with jumpers J1 ~ J6. Instead,
SW7 and 8, with the same functions as jumpers J1~J6, are used in the
position where the jumpers were previously. Set SW7 and 8 locally in
accordance with the above table.
Note (1) It is normally ON only in the case of SW9-4.
Setting time : 1000hrs. (Unit stop)
Setting time : 1000hrs. (Display)
Setting time : 600hrs. (Display)
Setting time : 180hrs. (when shipped from factory)
SW5-4SW5-3 ON
OFF
ON
OFF
ON
OFF
Switch Function
Emergency operation
Normal
Fan control : Powerful mode
Fan control : Mild mode
SW9-3
SW9-4
SW10-1 (J9)
Switch Function
Auto swing fanction - None
Auto swing function - With
Remote controller air flow –
Remote controller air flow 1 speed
Remote controller air flow 2 speed
Remote controller air flow 3 speed
SW10-3
(J11)
SW10-2
(J10)
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
OFF
ON
OFF
Switch Function
●Control change switch (SW5, SW9, SW10)
Function of DIP switch SW5 (Usually all turned OFF)
Function of DIP switch SW9 (Usually all turned OFF)
●Change by the jumper wire
Function of DIP switch SW10 (Usually all turned OFF)