Mitsubishi Electric PUZ-ZM100YKA Service Manual Download Page 106

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106

4. Disassembling the electrical parts box

(1) Disconnect all the connectors on the controller circuit

board.

[Disassembling the electrical parts box for V model]
(2) Remove the 3 screws, screw

and

, that fix the plate

equipped with the outdoor controller circuit board, and the
electrical parts box, screw

and

from the front of

the electrical parts box. (See Figure 4)

(3) Remove the plate equipped with the outdoor controller

circuit board from the electrical parts box.
(The plate is fixed to the cont base piece with hooks on the
left side.)

[Disassembling the electrical parts box for Y model]
(2) Remove the 3 screws, screw

and

, that fix the plate

equipped with the outdoor controller circuit board, and the
electrical parts box, screw

from the front and the screw

and

from the bottom of the electrical parts box. (See

Photo 6 and 7)

(3) Slide the plate in the direction of the arrow A and remove it.

(See Photo 6.)

(4) Remove the lead wires from the clamp on the bottom of the

electrical parts box. (See Photo 6)

(5) Remove the 3 screws, screw

and

, that fix the bottom

side of the electrical parts box and remove the bottom side
plate by sliding in the direction of the arrow B.
(See Photo 8 and 9)

(6) Remove the 2 screws, screw

and

, that fix the plate

equipped with the noise filter circuit board and converter
circuit board. (See Photo 10)

Note: When reassembling the electrical parts box, make

sure the wirings are correct.

PHOTOS & ILLUSTRATION

Photo 6

Figure 4

Electrical
parts box

Screw

Controller
circuit board
(C.B.)

Photo 7

Screw

Bottom plate of
electrical parts
box

Electrical parts
box

Photo 8

Screw

Bottom plate of electrical parts box

Clamp

Photo 9

Power circuit
board (P.B)

Noise filter
circuit board
(N.F.)

Photo 10

Screw

Noise filter circuit board (N.F.)

Electrical parts box

Heat sink

Screw

Controller
circuit board
(C.B)

Noise filter circuit
board (N.F.)

Screw

Controller
circuit board
(C.B.)

Cont base
piece

Converter
circuit board
(CONV.B)

OPERATING PROCEDURE

Screw

Electrical parts box

OCH654

Summary of Contents for PUZ-ZM100YKA

Page 1: ... CATALOG OCB654 CONTENTS 1 REFERENCE MANUAL 2 2 SAFETY PRECAUTION 2 3 FEATURES 12 4 SPECIFICATIONS 13 5 DATA 14 6 OUTLINES AND DIMENSIONS 17 7 WIRING DIAGRAM 18 8 WIRING SPECIFICATIONS 20 9 REFRIGERANT SYSTEM DIAGRAM 25 10 TROUBLESHOOTING 27 11 FUNCTION SETTING 84 12 MONITORING THE OPERATION DATABY THE REMOTE CONTROLLER 92 13 EASY MAINTENANCE FUNCTION 101 14 DISASSEMBLY PROCEDURE 104 Note This man...

Page 2: ...roper protectors Provide adequate ventilation After stopping the operation of the air conditioner turn off the power supply breaker Discharge the condenser before the work involving the electric parts Precautions during the repair service Do not perform the work involving the electric parts with wet hands Do not pour water into the electric parts Do not touch the refrigerant Do not touch the hot o...

Page 3: ... insides of the pipes are clean Change flare nut to the one provided with this product Use a newly flared pipe Avoid using thin pipes Do not use refrigerant other than R32 If other refrigerant R22 etc is used chlorine in refrige rant can cause deterioration of refrigerant oil etc Handle tools with care If dirt dust or moisture enters into refrigerant cycle that can cause deterioration of refrigera...

Page 4: ...nt leaks and accumulates it may ignite or poisonous gases may be released 11 Do not install the unit in places where refrigerant may build up or places with poor ventilation such as a semi base ment or a sunken place in outdoor Refrigerant is heavier than air and inclined to fall away from the leak source 12 Do not use means to accelerate the defrosting process or to clean other than those recomme...

Page 5: ...igeration Equipment Where electrical components are being changed they shall be fit for the purpose and to the correct specification At all times the manufacturer s maintenance and service guidelines shall be followed If in doubt consult the manufacturer s technical department for assistance The following checks shall be applied to installations using flammable refrigerants The charge size is in a...

Page 6: ...tional procedures shall be used However for flammable refrigerants it is important that best practice is followed since flammability is a considera tion The following procedure shall be adhered to remove refrigerant purge the circuit with inert gas evacuate purge again with inert gas open the circuit by cutting or brazing The refrigerant charge shall be recovered into the correct recovery cylinder...

Page 7: ...nders ensure that only appropriate refrig erant recovery cylinders are employed Ensure that the correct number of cylinders for holding the total system charge are available All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant i e special cylinders for the recovery of refrigerant Cylinders shall be complete with pressure relief valve and associate...

Page 8: ... flowchart below to determine if the existing pipes can be used and if it is necessary to use a filter drier If the diameter of the existing pipes is different from the specified diameter refer to technological data materials to confirm if the pipes can be used Measure the existing pipe thickness and check for damage The existing pipe thickness meets specifica tions and the pipes are not damaged C...

Page 9: ...2 0 24 0 27 0 36 0 Nominal dimensions in Flare nut dimensions Outside diameter Dimension B mm mm R32 R410a R22 36 00 mm for indoor unit of ZM100 125 and 140 Gauge manifold Charge hose Gas leak detector Refrigerant recovery equipment Refrigerant cylinder Safety charger Charge valve Vacuum pump Flare tool Bender Pipe cutter Welder and nitrogen gas cylinder Refrigerant charging scale Vacuum gauge or ...

Page 10: ...es is open and in a sufficiently large space with out depressions 2 5 Minimum installation area If you unavoidably install a unit in a space where all four sides are blocked or there are depressions confirm that one of these situations A B or C is satisfied Note These countermeasures are for keeping safety not for specification guarantee A Secure sufficient installation space minimum installation ...

Page 11: ...the spec nameplate or installation manual For the amount to be added locally refer to the installation manual Install the indoor unit so that the height from the floor to the bottom of the indoor unit is h0 for wall mounted 1 8 m or more for ceiling suspended cassette and ceiling concealed 2 2 m or more There are restrictions in installation height for each model so read the installation manual fo...

Page 12: ...al refrig erant level regardless of the length 30 m maximum and 5 m minimum of piping The additional refrigerant charging work during installation often causes problems It is completely eliminated by chargeless system This unique system improves the quality and reliability of the work done It also helps to speed up the installation time PUZ ZM100VKA PUZ ZM125VKA PUZ ZM140VKA PUZ ZM100YKA PUZ ZM125...

Page 13: ... REFRIGERANT PIPING 2 6 1 7 26 5 AVB33FADMT 50 52 116 256 118 260 110 3 880 120 4 230 A kW W kW K min CFM dB dB mm inch mm inch mm inch kg lb kg lb L mm inch mm inch Power supply phase cycle voltage Max current External finish Refrigerant control Compressor Model Motor output Starter type Protection devices Crankcase heater Heat exchanger Fan Fan drive o No Fan motor output Airflow Defrost method ...

Page 14: ...Winding Resistance Additional charge is required for pipes longer than 30 m Service Ref Piping length one way Initial charged 10 m 20 m 30 m 40 m 50 m 60 m 75 m 100 m PUZ ZM100VKA UK PUZ ZM100YKA UK 4 0 4 0 4 0 4 4 4 8 5 2 5 8 6 8 4 0 PUZ ZM125VKA UK PUZ ZM125YKA UK 4 0 4 0 4 0 4 4 4 8 5 2 5 8 6 8 4 0 PUZ ZM140VKA UK PUZ ZM140YKA UK 4 0 4 0 4 0 4 4 4 8 5 2 5 8 6 8 4 0 5 2 COMPRESSOR TECHNICAL DATA...

Page 15: ...ES Hz NC 60 NC 50 NC 40 NC 30 NC 20 NC 70 PUZ ZM100VKA UK PUZ ZM100YKA UK COOLING MODE HEATING 49 SPL dB 51 LINE 90 80 70 60 50 40 30 20 10 63 125 250 500 1000 2000 4000 8000 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE OCTAVE BAND SOUND PRESSURE LEVEL dB 0 dB 0 0002 µbar BAND CENTER FREQUENCIES Hz NC 60 NC 50 NC 40 NC 30 NC 20 NC 70 PUZ ZM125VKA UK PUZ ZM140VKA UK PUZ ZM125YKA UK PUZ ZM1...

Page 16: ...5 24 0 64 0 123 15 62 5 36 2 81 0 73 92 45 1 5 20 15 44 7 6 15 99 5 34 2 72 0 90 82 45 11 5 27 19 12 35 24 0 67 0 14 18 83 6 27 2 87 0 70 88 47 0 5 20 15 45 7 6 1 50 230 1 3 50 230 400 1 50 230 1 3 50 230 400 1 50 230 1 3 50 230 400 Phase Hz Voltage Current Outdoor unit Phase Hz Voltage Current Discharge pressure Suction pressure Discharge temperature Condensing temperature Suction temperature Ref...

Page 17: ...17 Unit mm PUZ ZM100VKA UK PUZ ZM125VKA UK PUZ ZM140VKA UK PUZ ZM100YKA UK PUZ ZM125YKA UK PUZ ZM140YKA UK 6 OUTLINES AND DIMENSIONS OCH654 ...

Page 18: ...tor Connect to Optional M NET Adapter Board LED Operation Inspection Indicators Fuse T6 3AL250V Relay SYMBOL TB1 MC MF1 MF2 21S4 63H TH3 TH4 TH6 TH7 TH8 TH33 LEV A LEV B LEV C DCL CY1 CY2 CX1 SYMBOL SYMBOL NAME NAME NAME P B W DCL L N S1 S2 S3 POWER SUPPLY N 230V 50Hz TB1 V U 2 RD WH BK MC CN2 RD CN4 WH 1 7 2 1 3 1 RD BU YE OG BN GNYE BK RD CNAC2 WH CNAC1 LI NI EI E3 CN52C RD 3 1 1 3 1 3 DCL1 DCL2...

Page 19: ... Adapter Board Connector Connect to Optional M NET Adapter Board LED Operation Inspection Indicators Fuse T6 3AL250V Relay TB U V W TB L1 L2 L3 SYMBOL TB1 TB2 MC MF1 MF2 21S4 63H TH3 TH4 TH6 TH7 TH8 TH33 LEV A LEV B LEV C ACL1 ACL2 ACL3 ACL4 CK RS CY1 CY2 P B SYMBOL SYMBOL NAME NAME NAME 1 2 3 4 5 6 7 8 OFF ON 1 2 3 4 5 6 7 8 OFF ON 1 2 3 4 5 6 7 8 OFF ON SW6 2 MODEL 100Y 125Y 140Y The black squar...

Page 20: ... the power cable or the indoor outdoor connection cable otherwise it may result in a smoke a fire or communication failure Outdoor unit model ZM100 125V ZM140V ZM100 125 140Y Outdoor unit power supply N single 50 Hz 230 V N single 50 Hz 230 V 3N 3 ph 4 wires 50 Hz 400 V Outdoor unit input capacity main switch Breaker 1 32 A 40 A 16 A Wiring Wire No size mm Outdoor unit power supply 3 Min 4 3 Min 6...

Page 21: ...nections when shipped from the factory are for indoor unit power supplied from outdoor unit Indoor unit power supplied from outdoor unit when shipped from factory If the indoor and outdoor units have separate power supplies change the connections of the connectors as shown in the following figure Connectors Indoor unit control board Separate indoor unit outdoor unit power supplies Electric heater ...

Page 22: ...d 1 o Min 2 5 Indoor unit Outdoor unit earth Wire No o Size mm Be sure to connect the indoor outdoor connecting cables directly to the units no intermediate connections Intermediate connections can lead to communication errors if water enters the cables and causes insufficient insulation to ground or a poor electrical contact at the intermediate connection point Indoor unit Outdoor unit Indoor Out...

Page 23: ... more than 2 earthing spots on the shield wire noise may enter into the shield wire because the earth wire and shield wire form 1 circuit and the electric potential difference occurs due to the impedance difference among earthing spots In case of single spot earthing noise does not enter into the shield wire because the earth wire and shield wire do not form 1 circuit To avoid communication errors...

Page 24: ...e OFF All refrigerant addresses are 00 1 23 4 5 6 7 8 9 0 1 23 4 5 6 7 8 9 0 1 23 4 5 6 7 8 9 0 1 23 4 5 6 7 8 9 0 1 23 4 5 6 7 8 9 0 1 23 4 5 6 7 8 9 0 1 2 50 M NET Address No Setting example Switch setting SW11 10s digit SW12 1s digit OFF ON 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 ...

Page 25: ...Distributor PUZ ZM100VKA UK PUZ ZM125VKA UK PUZ ZM100YKA UK PUZ ZM125YKA UK PUZ ZM140VKA UK PUZ ZM140YKA UK Refrigerant LIQUID pipe connection 9 52 3 8 Stop valve with service port Strainer 100 Power receiver Linear Heat interchange circuit expansion valve B Linear expansion valve C Linear expansion valve A Strainer 100 High pressure switch 63H Thermistor TH4 Discharge Thermistor TH33 Comp surface...

Page 26: ...minutes after the power circuit breaker is turned on 5 Perform the refrigerant collecting operation cooling test run Push the pump down SWP switch push button type on the control board of the outdoor unit The compressor and venti lators indoor and outdoor units start operating refrigerant collecting operation begins LED1 and LED2 on the control board of the outdoor unit are lit Only push the pump ...

Page 27: ...g service 3There is no abnormality in electrical component controller board remote controller etc 1Re check the abnormal symptom 2Conduct trouble shooting and ascertain the cause of the trouble according to 10 5 TROUBLESHOOTING OF PROBLEMS 3Continue to operate unit for the time being if the cause is not ascertained 4There is no abnormality concerning of parts such as electrical component controlle...

Page 28: ...ain Vane Cool mode Check the cold air blows out Heat mode Check the warm air blows out Press the F1 button to go through the operation modes in the order of Cool and Heat Check the auto vane with the F1 F2 buttons Press the button to return to Test run operation Press the button When the test run is completed the Test run menu screen will appear The test run will automatically stop after 2 hours T...

Page 29: ...ollowing screen will appear Check the error status stop the operation and consult your dealer Contact information dealer s phone number will appear if the information have been registered F1 F2 F3 F4 F1 F2 F3 F4 Error information Error reset Error reset Error code Error unit IU Ref address Unt Model name Serial No Reset Page Reset current error Error reset OK Cancel Main menu Reset error Reset but...

Page 30: ...dd mm yy Error history Cancel OK Delete error history Error history Check menu Error history deleted 2 Select Error history with the F1 or F2 button and press the button Select Check with the F1 or F2 button and press the button 3 Select Error history from the Check menu and press the button to view up to 16 error history records 4 records are shown per page and the top record on the first page in...

Page 31: ...ows out from the unit 5 Press the button and check whether strong air blows out from the unit 6 Press the button and check whether the auto vane operates properly 7 Press the ON OFF button to stop the test run Note Point the remote controller towards the indoor unit receiver while following steps 2 to 7 It is not possible to run in FAN DRY or AUTO mode MODE MODE COOL HEAT TEST RUN FAN VANE TEST RU...

Page 32: ...elf check with the F1 or F2 button and press the button 1 Select Service from the Main menu and press the button 3 Check code unit number attribute will appear will appear if no error history is available 4 Resetting the error history Press the F4 button Reset on the screen that shows the error history A confirmation screen will appear asking if you want to delete the error history Press the F4 bu...

Page 33: ... the remote controller display if the correct voltage 8 5 12 V DC is not supplied to the remote control ler If this is the case check the remote controller wiring and indoor units OK No problems are found with the remote controller Check other parts for problems E3 6832 There is noise on the transmission line or the indoor unit or another remote controller is faulty Check the transmission line and...

Page 34: ...indoor unit and press the ON OFF button Malfunction diagnosis method at maintenance service 10 3 3 Self diagnosis for wireless remote controller Type C When a malfunction occurs to air conditioner both indoor unit and outdoor unit will stop and operation lamp blinks to inform unusual stop ON OFF TEMP FAN VANE MODE CHECK LOUVER TEST RUN AUTO STOP AUTO START h min RESET SET CLOCK CHECK CHECK display...

Page 35: ...ptom Remark Number of times Wireless remote controller Wired remote controller Beeper sounds OPERATION INDICATOR lamp flashes Check code Number of times Wireless remote controller Wired remote controller 1 P1 Intake sensor error P9 Pipe TH5 sensor error 2 P2 Pipe TH2 sensor error 3 E6 E7 Indoor outdoor unit communication error 4 P4 Drain sensor error Float switch connector CN4F open 5 P5 Drain pum...

Page 36: ...n of power supply terminal block TB1 b Connection of terminal on outdoor power circuit board 3 Check connection of the connector CNDC on the outdoor controller circuit board Check connection of the connector CNDC on the outdoor power circuit board ZM100 140V noise filter circuit board ZM100 140Y Refer to 10 9 TEST POINT DIAGRAM 4 Check connection of reactor DCL ACL4 or ACL Refer to 7 WIRING DIAGRA...

Page 37: ...nit If EA is detected 4 6 Turn the power off once and on again to check Replace outdoor controller circuit board indoor controller board or indoor power board if abnormality occurs again 7 Check if refrigerant addresses SW1 3 to SW1 6 on outdoor controller circuit board are overlapping in case of group control system 8 Check transmission path and remove the cause Note The descriptions above 1 8 ar...

Page 38: ...r TH33 TH5 Heating TH4 or TH33 TH6 increases All the conditions in A or B are detected simultaneously for 10 minutes continuous ly after 6 minutes past from compressor Startup including the thermostat indication or recovery from defrosting Condition A Heating mode When discharge superheat is less than 70 C When the TH6 temp is more than the value obtained by TH7 5 When the condensing temp of TH5 i...

Page 39: ...outdoor power circuit board 7 Replace outdoor controller circuit board U6 4250 Power module Check abnormality by driving power module in case overcurrent is detected UF or UP error condition 1 Outdoor stop valve is closed 2 Decrease of power supply voltage 3 Looseness disconnection or converse of compressor wiring connection 4 Defective compressor 5 Defective outdoor power circuit board 1 Open sto...

Page 40: ... outdoor converter circuit board ZM100 140Y 6 Check RS wiring ZM100 140Y 7 Replace RS ZM100 140Y 8 Check CN2 wiring ZM100 140V 9 Replace outdoor controller circuit board ZM100 140V 04 Input current sensor error L1 phase open error Decrease in input current through outdoor unit to 0 1A only if operation frequency is more than or equal to 40Hz or compressor current is more than or equal to 6A 1 L1 p...

Page 41: ...ayed follow the U4 processing direc tion The check code in the parenthesis indi cates PAR 3xMAA x represents 0 or later UF 4100 Compressor overcurrent interruption When compressor locked Abnormal if overcurrent of DC bus or compressor is detected within 30 seconds after compressor starts operating 1 Stop valve is closed 2 Decrease of power supply voltage 3 Looseness disconnection or con verse of c...

Page 42: ...d if voltage among phases U V V W and W U is same Make sure to perform the voltage check with same performing frequency 8Replace outdoor power circuit board 9Check the DIP switch setting of outdoor controller circuit board E0 or E4 Remote controller transmission error E0 signal receiving error E4 1 Abnormal if main or sub remote controller cannot receive normally any transmission from indoor unit ...

Page 43: ...3 minutes from outdoor controller circuit board a signal which allows outdoor controller circuit board to transmit signals 1 Contact failure short circuit or miswiring converse wiring of indoor outdoor unit connecting wire 2 Defective transmitting receiving circuit of outdoor controller circuit board 3 Defective transmitting receiving circuit of indoor controller board 4 Noise has entered into ind...

Page 44: ...inverter 12 Turn the power off and on again to check Replace indoor controller board or outdoor controller circuit board if abnormality is displayed again 3 Replace outdoor unit with power inverter type outdoor unit Ed 0403 Serial communication error 1 Abnormal if serial communication between outdoor controller circuit board and out door power circuit board is defective 1 Breaking of wire or conta...

Page 45: ... temperature display on remote controller and outdoor controller circuit board Pipe liquid or condenser evaporator temperature display is indicated by set ting SW2 of outdoor controller circuit board as follows Conduct temperature check with outdoor controller circuit board after connecting A Control Service Tool PAC SK52ST 1 2 3 4 5 6 ON OFF 1 2 3 4 5 6 ON OFF 1 2 3 4 5 6 ON OFF 1 2 3 4 5 6 ON OF...

Page 46: ...ision of transmission 2 Data could not reach transmission wire for 8 to10 minutes continuously because of noise etc Note The address and attribute displayed at remote controller indicate the controller that detected abnormality 1 Transmission processor could not transmit signal because short cycle voltage of noise and the like have entered into transmission wire continuously 2 Transmission quantit...

Page 47: ...r LOSSNAY at the same time for 2 minutes or more and turn the power on again If the cause of trouble is not in 1 5 above in single refrigerant system one outdoor unit controller of displayed address or attribute is defective If the cause of trouble is not in 1 5 above in different refrigerant system 2 or more outdoor units judge with 6 6 If address of abnormality source is the address that should ...

Page 48: ...or within 2 minutes of restart abnormality is detected 2 Contact failure of transmission wire of indoor unit or FRESH MASTER 3 Disconnection of transmission connector CN2M of indoor unit or FRESH MASTER 4 Defective transmitting receiving circuit of indoor unit or FRESH MASTER 6 If displayed address or attribute is LOSSNAY indoor unit detects abnormal ity when indoor unit transmits signal to LOSSNA...

Page 49: ...plied to remote controller however no display is indicated PLEASE WAIT is not displayed PLEASE WAIT is displayed 1Check LED2 on indoor controller board 1 When LED2 is lit Check the remote controller wiring for breaking or contact failure 2 When LED2 is blinking Check short circuit of remote controller wiring 3 When LED2 is not lit Refer to phenomena No 3 below 2Check the following Failure of remot...

Page 50: ...ck if heat exchanger is clogged by inspecting discharging pressure Clean the heat exchanger 4 Remove the blockage 7 Remote controller display works normally and the unit performs heating operation however the capacity cannot be fully obtained 1 Linear expansion valve fault Opening cannot be adjusted well due to linear expansion valve fault 2 Refrigerant shortage 3 Lack of insulation for refrigeran...

Page 51: ... after turning on the main power Normal The start up diagnosis will be over in around 2 minutes Miswiring of indoor outdoor connecting wire Breaking of indoor outdoor connecting wire S3 Defective indoor controller board Defective outdoor controller circuit board Refer to Self diagnosis action table in order to solve the trouble In case of communication errors the display of remote controller may n...

Page 52: ...re blown Check the wiring of the outdoor unit Check if the wiring is bad Check if the fuses are blown The fuses on the outdoor controller circuit board will be blown when the indoor outdoor connecting wire short circuits Bad wiring of the outdoor controller board The fuses on the outdoor controller circuit board are blown Check if miswiring breaking or poor contact is causing this problem Indoor o...

Page 53: ... controller circuit board Replace the outdoor controller circuit board Normal Only the unit which has the refrigerant address 0 supplies power to the remote controller Set the refrigerant address to 0 In case of the multiple grouping system recheck the refrigerant address again Defective indoor power board Replace the indoor power board Defective outdoor power circuit board Replace the outdoor pow...

Page 54: ...k TB5 of the indoor unit Defective remote controller Replace the remote controller Breaking or poor contact of the remote controller wire Check if there is breaking or poor contact of the remote controller wire Check the voltage of the terminal block TB5 connecting the remote controller wire If it is not between 10 and 16 V DC the indoor controller board must be defective The remote controller wir...

Page 55: ... clear FILTER from the display See the operation manual that came with the product for how to clean the filters 3 STANDBY is displayed on the screen 3 This is displayed when the unit starts HEAT operation when the thermostat puts the compressor in operation mode or when the outdoor unit ends DEFROST operation and returns to HEAT operation The display will automatically disappear around 10 minutes ...

Page 56: ...tdoor unit is controlling the airflow amount in order to keep the optimum operating condition 5 A sound similar to water flowing is heard from the unit 5 This is not a malfunction This is the sound which is heard when the refrigerant is flowing inside the indoor unit 2 The fan speed does not match the setting of the remote controller in HEAT operation The up down vane will be automatically set to ...

Page 57: ...The airflow direction does not change Up down vane left right louver 3 1 Check if the vane is set to a fixed position Check if the vane motor connector is removed 2 Check if the air conditioner has a function for switching the air direction 3 If the air conditioner does not have that function NOT AVAILABLE will be displayed on the remote controller when AIR DIRECTION or LOUVER button is pressed So...

Page 58: ...down HEAT water drips down from the heat exchanger Note Make use of optional parts Drain Socket and Drain pan if these water needs to be collected and drained out for once Water or moisture is expelled from the outdoor unit Batteries are being exhausted Replace them and press the reset button of remote controller The display of wireless remote controller gets dim or does not come on The indoor uni...

Page 59: ... TH3 TH6 TH7 TH8 Abnormal Open or short Measure the resistance between the terminals with a tester At the ambient temperature 20 C Solenoid valve coil 4 way valve 21S4 Motor for compressor MC Linear expansion valve LEV A LEV B LEV C 2 Normal Abnormal Open or short Abnormal Open or short Refer to 5 2 COMPRESSOR TECHNICAL DATA Disconnect the connector then measure the resistance with a tester Windin...

Page 60: ...he fuse F5 on outdoor controller circuit board Power supply check Remove the connector CNF1 2 Measure the voltage in the outdoor controller circuit board TEST POINT 1 VDC between 1 and 4 of the fan connector VDC 250 330 V DC TEST POINT 2 VCC between 5 and 4 of the fan connector VCC 15 V DC Recover wiring Replace the outdoor controller circuit board Replace the fan motor Replace the outdoor control...

Page 61: ...nt 4150 3 Rt 17exp 4150 273 t 323 1 1 Thermistor R120 7 465 k 2 B constant 4057 2 Rt 7 465exp 4057 273 t 393 1 1 Medium temperature thermistor Thermistor Heat sink TH8 ZM100 140Y only 20 250 k 30 160 k 40 104 k 50 70 k 60 48 k 70 34 k 80 24 k 90 17 5 k 100 13 0 k 110 9 8 k High temperature thermistor Thermistor Discharge TH4 Thermistor Comp Surface TH33 0 10 20 30 40 50 20 10 0 10 20 30 40 50 Temp...

Page 62: ...ocked more sound can be heard No sound is heard when the pulse number moves from B to A in case coil is burnt out or motor is locked by open phase Sound can be detected by placing the ear against the screw driv er handle while putting the screw driver to the linear expansion valve LEV M 1 6 4 4 3 2 1 1 Gray Orange Red Yellow Black 2 3 4 5 Connector LEV A LEV B LEV C 12 V DC Outdoor controller boar...

Page 63: ...pipes can bend due to stress How to attach the coil Hold the lower part of the main body shown as A firmly so that the main body does not move and attach the coil by inserting it downward into the main body Then securely attach the coil stop per to main body At this time be careful that stress is not added to lead wire and main body is not wound by lead wire If the stopper is not firmly attached t...

Page 64: ...rgency operation the air conditioner will continuously be operated by supplying power and stopping it It can not be turned on or off by remote control and temperature control is not possible 4 Do not perform emergency heating operation for an extended period of time If the outdoor unit starts defrosting during this period cold air will blow out from the indoor unit 5 Do not perform emergency cooli...

Page 65: ...35 5 30 5 HEAT 20 5 45 50 22 5 80 5 7 5 30 5 1 1 1 1 2 2 Remarks 1 If the thermistor temperature data is normal not open short that data is loaded into the control as valid data When the unit enters emergency operation and TH values are mismatched set the thermistors to open short And the unit runs emergency operation with the values listed above 2 If one thermistor is set to open short the values...

Page 66: ...efrigerant address CNDM 1 to 2 Input of low level sound priority mode 1 to 3 Input of external contact point SW7 Demand control setting 63H High pressure switch SW4 Test operation SW6 Model select SW5 Function switch TH4 Thermistor Discharge TH3 Thermistor Liquid TH7 6 Thermistor Ambient 2 phase pipe VFG Voltage between right pins of PC5C and PC5D pin 3 and pin 4 Same as CNF17 4 VSP Voltage betwee...

Page 67: ...arth CNAC1 CNAC2 230 V AC Connect to the outdoor controller circuit board CNAC CNDC Connect to the outdoor controller circuit board CNDC LO1 LO2 LO3 POWER SUPPLY LO1 LO2 LO2 LO3 LO3 LO1 400 V AC OUTPUT Connect to the outdoor converter circuit board L1 IN ACL2 ACL3 CNCT Primary current Connect to the outdoor power circuit board CN5 CNL Connect to the ACL4 GD3 Connect to the earth NO Connect to the ...

Page 68: ...e outdoor controller circuit board CN2 1 5 Transmitting signal to outdoor controller circuit board 0 5 V DC 2 5 Zero cross signal 0 5 V DC 3 4 18 V DC 6 5 16 V DC 7 5 16 V DC CN4 Connect to the outdoor controller circuit board CN4 Brief Check of POWER MODULE Usually they are in a state of being short circuited if they are broken Measure the resistance in the following points connectors etc If they...

Page 69: ...ent Connect to the outdoor noise filter circuit board CNCT CN4 Connect to the outdoor controller circuit board CN4 CN2 Connect to the outdoor controller circuit board CN2 1 5 Power circuit board Transmitting signal to the controller board 0 5 V DC 2 5 Zero cross signal 0 5 V DC 3 4 Not used 6 5 16 V DC 7 5 16 V DC 5 1 2 6 7 CN7 Connect to the outdoor con verter circuit board CN7 TB U TB V TB W Con...

Page 70: ...2 A2 L3 A2 Connect to the ACL1 ACL2 ACL3 CN7 Connect to the outdoor power circuit board CN7 CK OU Connect to the CK capacitor L1 IN N IN Connect to the noise filter circuit board LO1 NO L1 A1 Connect to the ACL1 L1 OU L2 OU L3 OU Connect to the outdoor power circuit board TB L1 L2 L3 OCH654 ...

Page 71: ...t will start by the above operation 1 if all these conditions written below are satisfied Heat mode setting 10 minutes have passed since compressor started operating or previous manual defrost is finished Pipe temperature is less than or equal to 8 C Manual defrost will finish if certain conditions are satisfied Manual defrost can be done if above conditions are satisfied when DIP SW1 1 is changed...

Page 72: ... ON OFF DIP switch SW5 1 No function 2 Power failure automatic recovery 2 Auto recovery No auto recovery When power supply ON 3 4 5 No function 6 No function SW7 4 1 Mode select 3 Demand function Low noise mode Always 2 No function 3 Max Hz setting cooling Max Hz cooling o 0 8 Normal Always 4 Max Hz setting heating Max Hz heating o 0 8 Normal Always 5 Breaker capacity setting 5 Decrease capacity N...

Page 73: ...ode B On site arrangement C External input adapter PAC SC36NA E X Relay D Outdoor unit control board E Maximum 10 m F Power supply for relay A SW1 Orange 1 3 Brown Red E B F CNDM X X C D A Circuit diagram example Demand function B On site arrangement X Y Relay C External input adapter PAC SC36NA E D Outdoor unit control board E Maximum 10 m F Power supply for relay By performing the following modi...

Page 74: ...ard 4Re check error by turning off power and on again P 43 Indoor outdoor unit communication error transmitting error is detected by indoor unit E7 P 43 Indoor outdoor unit communication error signal receiving error is detected by outdoor unit P 43 E8 Indoor outdoor unit communication error transmitting error is detected by outdoor unit P 44 E9 3 blinking Remote controller signal receiving error i...

Page 75: ...r units have a short cycle on their air ducts 2Measure resistance value of outdoor thermistor TH8 P 39 7 blinking Abnormality of voltage U9 1Check looseness disconnection and converse connection of compressor wiring 2Measure resistance value among terminals on compressor using a tester 3Check if power supply voltage decreases 4Check the wiring of CN52C P 40 4 blinking 1 blinking Abnormality of roo...

Page 76: ...3 When the display blinks Inspection code is displayed when compressor stops due to the work of protection devices Display Contents to be inspected When power is turned on F5 E8 E9 EA Eb EC E0 E7 63H connector yellow is open Indoor outdoor communication error Signal receiving error Outdoor unit Indoor outdoor communication error Transmitting error Outdoor unit Miswiring of indoor outdoor unit conn...

Page 77: ...dreds digit tens digit and ones digit are displayed by turns Example When 2450 hours 245 10 hours 0 5 s 0 5 s 2 s 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 Compressor operating current 0 to 50 LEV A opening pulse 0 to 480 0 to 50 Omit the figures after the decimal fractions 0 to 480 When it is 100 pulse or more hundreds digit tens digit and ones digit are displayed by turns Example When 150 pul...

Page 78: ...er and code 52 to 221 When the temperature is 100 or more the hundreds digit tens digit and ones digit are displayed by turns Example When 130 0 5 s 0 5 s 2 s A Code display Code display 0 to 50 When no error history 0 and are displayed by turns When no error history 0 and are displayed by turns 1 ON 2 3 4 5 6 Thermostat ON time 0 to 999 Test run elapsed time 0 to 120 0 to 999 When it is 100 minut...

Page 79: ...oling only 0 Single phase 2 3 phase Setting details Defrosting switch Display details 0 Normal 1 For high humidity Example When heat pump 3 phase and defrosting normal are set up 20 is displayed 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 Indoor pipe temperature Cond Eva TH5 1 Indoor 1 39 to 88 39 to 88 When the temperature is 0 or less and temperature are displayed by turns 39 to 88 When the temperature is 0 o...

Page 80: ...d by turns 40 to 200 When the temperature is 0 or less and temperature are displayed by turns When the thermistor detects 100 or more hundreds digit tens digit and ones digit are displayed by turns Outdoor Ambient temperature TH7 60 to 91 60 to 91 When the temperature is 0 or less and temperature are displayed by turns Normal Overvoltage error Undervoltage error Input current sensor error L1 phase...

Page 81: ...ase of no postponement Code display Error history 3 Oldest Alternate display of abnormal unit num ber and code When no error history 0 and are displayed by turns 3 Outdoor pipe temperature Liquid TH3 6 Outdoor pipe temperature 2 phase TH6 7 Outdoor ambient temperature TH7 8 Outdoor heat sink TH8 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 Error thermistor display When there is no e...

Page 82: ... to 91 When the temperature is 0 C or less and temperature are displayed by turns Example When 15 C 0 5 s 0 5 s 2 s Outdoor temperature Ambient TH7 on error occurring 60 to 91 60 to 91 When the temperature is 0 C or less and temperature are displayed by turns Example When 15 C 0 5 s 0 5 s 2 s Outdoor temperature Heat sink TH8 on error occurring 40 to 200 40 to 200 When the temperature is 0 C or le...

Page 83: ...tion 1 ON 2 3 4 5 6 Outdoor temperature Comp Surface TH33 52 to 221 52 to 221 When the comp surface thermistor detects 100 C or more hundreds digit tens digit and ones digit are displayed by turns Example When 105 C 0 5 s 0 5 s 2 s 05 1 Controlling status of compressor operating frequency 1 ON 2 3 4 5 6 Code display The following code will be a help to know the operating status of unit Display Com...

Page 84: ... detecting No Indoor temperature ta No 1 Average data of the sensor on all the indoor units Initial setting ta A B 2 ta A B 2 ta A ta A No 2 The data of the sensor on the indoor unit that connected with remote controller ta A ta B ta A ta A No 3 The data of the sensor on main remote controller ta C ta C ta C ta C OUTDOOR INDOOR REMOTE MAIN REMOTE SUB INDOOR OUTDOOR INDOOR REMOTE MAIN REMOTE SUB OU...

Page 85: ...to make the maintenance setting Maintenance password is required Note The initial maintenance password is 9999 Change the default password as necessary to prevent unauthorized access Have the password available for those who need it If you forget your maintenance password you can initialize the password to the default password 9999 by pressing and holding the F1 and F2 buttons simultaneously for t...

Page 86: ...e setting number with the F3 or F4 button 1 Select Service from the Main menu and press the button Checking the indoor unit No When the button is pressed the target indoor unit will start fan operation If the unit is common or when running all units all indoor units for the selected refrigerant address will start fan operation Function setting Ref address Sending data Grp 5 When the settings are c...

Page 87: ...e wireless remote controller toward the receiver of the indoor unit and press the button 3 Set the unit number Press the TEMP button to set the unit number Press 01 to specify the indoor unit whose unit number is 01 Direct the wireless remote controller toward the receiver of the indoor unit and press the button Notes 1 If a unit number that cannot be recognized by the unit is entered 3 beeps of 0...

Page 88: ...ver of the indoor unit and press the button Current setting number 1 1 beep 1 second 2 2 beep 1 second each 3 3 beep 1 second each 4 Selecting the setting number Use the button to change the Setting number C Fig 11 4 Direct the wireless remote controller toward the receiver of the indoor unit and press the button 5 To select multiple functions continuously Repeat select 3 and 4 to change multiple ...

Page 89: ...ton turns the backlight on and it will stay lit for a certain period of time depending on the screen Backlit LCD This lamp lights up in green while the unit is in operation It blinks while the remote controller is starting up or when there is an error ON OFF lamp Main display Press to change the operation mode Main menu Press to move the cursor down Function button F1 Main display Press to decreas...

Page 90: ...er Vent Lossnay High power Weekly timer Restriction Maintenance Initial setting ON OFF timer Auto Off timer Temp range Operation lock Manual vane angle Main Sub Timer Main display Contrast Display details Auto mode Administrator password Language selection Service Input maintenance info Function setting Check Self check Maintenance password Remote controller check Test run Clock Auto descending pa...

Page 91: ...tenance Auto descending panel Auto descending panel Optional parts Up Down you can do Manual vane angle Use to set the vane angle for each vane to a fixed position 3D i see sensor Use to set the following functions for 3D i see Sensor Air distribution Energy saving option Seasonal airflow Initial setting Main Sub When connecting 2 remote controllers one of them needs to be designated as a sub cont...

Page 92: ...th the F1 or F2 button and press the button 2 Set the Refrigerant address and Request code Select the item to be changed with the F1 or F2 button Select the required setting with the F3 or F4 button Ref address setting 0 15 Request code setting Press the button Data will be collected and displayed F1 F2 F3 F4 Request code Request Request Request code Ref address Request code Cursor Ref address Req...

Page 93: ... No 1 Heat mode 4 deg correction Indoor unit Intake air temperature Unit No 2 Heat mode 4 deg correction Indoor unit Intake air temperature Unit No 3 Heat mode 4 deg correction Indoor unit Intake air temperature Unit No 4 Heat mode 4 deg correction Indoor unit Liquid pipe temperature Unit No 1 Indoor unit Liquid pipe temperature Unit No 2 Indoor unit Liquid pipe temperature Unit No 3 Indoor unit L...

Page 94: ...history 1 latest Outdoor unit Error postponement history 2 previous Outdoor unit Error postponement history 3 last but one 0 255 0000 Not connected Examples Ver 5 01 Auxiliary information displayed after version information Examples Ver 5 01 A000 Displays postponement code is displayed if no postponement code is present Displays postponement code is displayed if no postponement code is present Dis...

Page 95: ...ror history 3 third to last Abnormal thermistor display TH3 TH6 TH7 TH8 Operation mode at time of error Compressor Operating current at time of error Compressor Accumulated operating time at time of error Compressor Number of operation times at time of error Discharge temperature TH4 or comp surface temperature TH33 at time of error Outdoorunit Liquidpipe1temperature TH3 attimeoferror Outdoor unit...

Page 96: ...mation Examples Ver 5 01 A000 A000 1 hour 10 hours Ver For indoor fan phase control For indoor fan pulsation control For indoor DC brushless motor control Indoor Fan operating time After filter is reset Indoor Total operating time Fan motor ON time Indoor fan output value Sj value Indoor fan output value Pulsation ON OFF Indoor fan output value duty value Indoor unit Capacity setting information I...

Page 97: ...play Operation mode 0 STOP FAN C COOL DRY H HEAT d DEFROST Relay output state Display Power currently Compressor 4 way valve Solenoid valve supplied to compressor Unit No 4 state Unit No 3 state Unit No 2 state Unit No 1 state Display State 0 Normal 1 Preparing for heat operation 2 3 4 Heater is ON 5 Anti freeze protection is ON 6 Overheat protection is ON 7 RequestingcompressortoturnOFF F There a...

Page 98: ...SV1 4 way valve Compressor 0 1 2 3 4 5 6 7 8 9 A b C d E F ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON Actuator output state 2 Display 52C SV2 SS 0 1 2 3 4 5 6 7 ON ON ON ON ON ON ON ON ON ON ON ON Error content U9 Request code 55 Data display Error content 1 Error content 2 0 0 Error content 1 Detected Display Overvoltage Undervoltage L1 phase P...

Page 99: ...setting display Request code 70 Data display Capacity 10 50 9 35 11 60 14 71 20 100 25 125 28 140 40 200 50 250 Outdoor unit Setting information Request code 71 Data display Setting information 1 Setting information 2 0 0 Setting information 1 Display Defrost mode 0 Standard 1 For high humidity Setting information 2 Display Single Heat pump 3 phase cooling only 0 Single phase Heat pump 1 Cooling o...

Page 100: ...125 02 22 12 140 03 25 13 160 04 28 14 200 05 32 15 224 06 35 36 16 250 07 40 17 280 08 45 18 09 50 19 0A 56 1A 0b 63 1b 0C 71 1C 0d 80 1d 0E 90 1E 0F 100 1F Display Pair No setting state 00 No 0 01 No 1 J41 disconnected 02 No 2 J42 disconnected 03 No 3 J41 J42disconnected Wireless pair No indoor control board side setting Request code 165 Data display 0 0 See the table on the right OCH654 ...

Page 101: ...5 Stable mode setting Cool Heat Normal Press the button Fixed operation will start Stable mode will take approx 20 minutes 1 2 13 EASY MAINTENANCE FUNCTION Smooth maintenance Return Page Ref address Cool Sub cool OU TH4 temp OU TH6 temp OU TH7 temp Reduces maintenance work drastically Enables you to check operation data of the indoor and outdoor units by remote controller Furthermore use of mainte...

Page 102: ...ll appear 1 1 Refrigerant address 00 Twin Refrigerant address 00 Outdoor unit Indoor unit 02 Indoor unit 01 Outdoor unit Remote controller Remote controller Indoor unit 01 Refrigerant address Single refrigerant system In the case of single refrigerant system the refrigerant address is 00 and no operation is required Simultaneoustwin tripleunitsbelongtothiscategory single refrigerant system Multi r...

Page 103: ...xchanger temperature 7 Indoor intake air temperature Cool Classification Item Result Inspection Temperature difference Heat Inspection Temperature difference Stable Unstable Stable Unstable Notes Fixed Hz operation may not be possible under the following tempera ture ranges A In cool mode outdoor intake air temperature is 40 or higher or indoor intake air temperature is 23 or lower B In heat mode ...

Page 104: ...n top and under 6 Disconnect the connectors CNF1 WH and CNF2 WH on the controller circuit board in the electrical parts box See Photo 4 or 5 7 Loosen the clamp for the lead wire on motor support and separator 8 Release the lead wire from the hole on separator 9 Remove the fan motor fixing screws 4 for front 5 x 20 to remove the fan motor For the each fan motor on top and under Note1 Tighten the pr...

Page 105: ...Loosen the lead wires fixed to the pipes with bands 8 Remove the terminal cover to disconnect the COMP lead wire 9 Remove the electrical parts box fixing screws then slide the electrical parts box upward to remove it Note that number of the electrical parts box fixing screw is different on each model V or Y V model 2 for front 4 x 10 Y model 3 for front 4 x 10 The electrical parts box is fixed to ...

Page 106: ...hoto 6 4 Remove the lead wires from the clamp on the bottom of the electrical parts box See Photo 6 5 Remove the 3 screws screw 4 and 5 that fix the bottom side of the electrical parts box and remove the bottom side plate by sliding in the direction of the arrow B See Photo 8 and 9 6 Remove the 2 screws screw 6 and 7 that fix the plate equipped with the noise filter circuit board and converter cir...

Page 107: ...ent TH7 since they are combined together Refer to procedure No 6 on the next page to remove the thermistor Ambient TH7 6 Removing the thermistor Ambient TH7 1 Remove the service panel See Photo 1 2 Remove the top panel See Photo 1 3 Disconnect the connector TH7 6 RD on the controller circuit board in the electrical parts box See Photo 4 or 5 4 Loosen the fastener for the lead wire in the electrica...

Page 108: ... Disconnect the connector TH3 WH TH4 WH and TH33 BK on the controller circuit board in the electrical parts box See Photo 4 or 5 4 Loosen the fastener for the lead wire on the controller circuit board in the electrical parts box 5 Loosen the clamp for the lead wire on separator 6 Pull out the thermistor Liquid TH3 from thermistor clip 7 Pull out the thermistor Discharge TH4 from thermistor holder ...

Page 109: ...3 for front 5 x 12 and the ball valve and stop valve fixing screws 4 for front 5 x 16 to remove the valve bed 5 Remove the side panel R fixing screws 3 for rear 5 x 12 then slide the side panel R upward to remove it The side panel R is fixed to the side plate with hooks on the rear side 6 Recover refrigerant Removing the 4 way valve 7 Remove the 4 way valve coil See Photo 15 or 16 8 Remove the wel...

Page 110: ...o hooks of the side plate 11 Remove the band and the damper See Figure 5 12 Recover refrigerant 13 Remove the welded part of compressor 2 positions 14 Remove the 3 compressor fixing nuts M6 to remove the compressor Note 1 Recover refrigerant without spreading it in the air Note 2 The compressor can be easily removed by removing separator Note 3 When replacing the compressor ensure that the surroun...

Page 111: ...Screws Screws Electrical parts box Photo 20 Reactor box fixing screws Reactor fixing screws Reactor 4 way valve OPERATING PROCEDURE PHOTOS 13 Removing the reactor ACL Y model only 1 Remove the service panel See Photo 1 2 Loosen the clamp for the lead wire on separator 3 Disconnect the lead wires from the reactor ACL 4 Remove the reactor box fixing screws 4 for right side 4x10 to remove the reactor...

Page 112: ...ICE TOKYO BUILDING 2 7 3 MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN CCopyright 2017 MITSUBISHI ELECTRIC CORPORATION Published Apr 2017 No OCH654 Made in Japan Specifications are subject to change without notice ...

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Mitsubishi Electric PUZ-ZM100YKA, Service Manual

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