Mitsubishi Electric PLA-ZRP100BA Service Manual Download Page 2

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REFERENCE MANUAL

OUTDOOR UNIT’S SERVICE MANUAL

Service Ref.

Service Manual No.

PUHZ-ZRP100VKA

PUHZ-ZRP100YKA

OCH527/OCB527

OCH529

Summary of Contents for PLA-ZRP100BA

Page 1: ...TION 3 3 PART NAMES AND FUNCTIONS 4 4 SPECIFICATIONS 12 5 NOISE CRITERION CURVES 13 6 OUTLINES AND DIMENSIONS 14 7 WIRING DIAGRAM 15 8 REFRIGERANT SYSTEM DIAGRAM 16 9 TROUBLESHOOTING 17 10 SPECIAL FUNCTION 33 11 DISASSEMBLY PROCEDURE 43 Indoor unit Model names Service Ref WIRED REMOTE CONTROLLER WIRELESS REMOTE CONTROLLER ON OFF TEMP INDOOR UNIT Model name indication PARTS CATALOGUE OCB529 No OCH5...

Page 2: ...2 1 REFERENCE MANUAL OUTDOOR UNIT S SERVICE MANUAL Service Ref Service Manual No PUHZ ZRP100VKA PUHZ ZRP100YKA OCH527 OCB527 OCH529 ...

Page 3: ...ration 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 ...

Page 4: ... for R410A Use pressure performance of 5 09MPa G or over 3 Electronic scale 4 Gas leak detector Use the detector for R134a R407C or R410A 5 Adaptor for reverse flow check Attach on vacuum pump 6 Refrigerant charge base 7 Refrigerant cylinder Only for R410A Top of cylinder Pink Cylinder with syphon 8 Refrigerant recovery equipment 3 PART NAMES AND FUNCTIONS Drain pipe Filter Vane Gas pipe Liquid pi...

Page 5: ...Displays whether timer is on or off Buttons used to set the hour and minute of the current time and timer settings h and min buttons display display FAN SPEED display indicates which fan speed has been selected display The vertical direction of air flow is indicated display Blinks when model is selected display display CHECK and TEST RUN display indicate that the unit is being checked or test run ...

Page 6: ... 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 decrease temperature Main menu Press to move the cursor up Function button F2 Main display Press to increase temperature Main menu Press to go to the previous page Function button F3 Main display Press to change the fan speed Main menu Press to go to t...

Page 7: ...ON OFF operation is centrally controlled Appears when the operation mode is centrally controlled Appears when the preset temperature is centrally controlled Appears when the f lter reset function is centrally controlled Indicates when f lter needs maintenance Current room temperature appears here Room temperature See the Installation Manual Appears when the buttons are locked Appears when the On O...

Page 8: ...ver 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 Service menu Input maintenance info Function setting Lossnay City Multi only Check Self check Maintenance password Remote controller c...

Page 9: ...operate at the preset temperature after performing energy save operation for a specif ed time period Time can be set to a value from 30 and 120 in 10 minute increments This function will not be valid when the preset temperature ranges are restricted Schedule Set the start stop times to operate the units in the energy save mode for each day of the week and set the energy saving rate Up to four ener...

Page 10: ...ance Select Input maintenance Info from the Service menu to bring up the Maintenance information screen The following settings can be made from the Maintenance Information screen Model name input Serial No input Dealer information input Function setting Make the settings for the indoor unit functions via the remote controller as necessary LOSSNAY setting City Multi only This setting is required on...

Page 11: ...erature display range is 8 39 The display blinks if the temperature is less than 8 or 39 or more Louver display Indicates the action of the swing louver Does not appear if the louver is not running Power On indicator Indicates that the power is on Fan Speed indicator Shows the selected fan speed Ventilation indicator Appears when the unit is running in Ventilation mode Operation Section Temperatur...

Page 12: ... kg lbs W D H INDOOR UNIT PLA ZRP100BA Service Ref Mode Power supply phase cycle voltage Input Running current External finish Panel Heat exchanger Fan Fan drive No Fan motor output Airflow Low Medium2 Medium1 High External static pressure Booster heater Operation control Thermostat Noise level Low Medium2 Medium1 High Field drain pipe O D Dimensions Weight UNIT 840 33 1 16 PANEL 950 37 3 8 UNIT 8...

Page 13: ...ium2 34 Low 32 90 80 70 60 50 40 30 20 10 63 125 250 500 1000 2000 4000 8000 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE NC 60 NC 50 NC 40 NC 30 NC 20 NC 70 OCTAVE BAND SOUND PRESSURE LEVEL dB 0 dB 0 0002 μbar BAND CENTER FREQUENCIES Hz UNIT 1 5m MICROPHONE CEILING OCH529 ...

Page 14: ...e 9 52 Flared connection 3 8inch Refrigerant pipe 15 88 Flared connection 5 8inch PLA ZRP100BA Detail drawing of fresh air intake hole Detail connecting of branch duct Both aspects 3 2 8 14 2 8 150 100 Emergency operation switch Heating and Emergency Up Down switch Down In case of auto grille PLP 6BAJ Suspension bolt lower edge 170 Ceiling Air intake grille Max 4 0m L L Filter Ceiling Grille Indoo...

Page 15: ...DOOR CN01 BLK INDOOR OUTDOOR COMMUNICATION CN3C BLU REMOCON CN22 BLU RECTIFICATION VANE CNV WHT CN32 WHT CN51 WHT CN41 WHT CN2L FAN CNMF WHT ON SWE INTAKE CN20 RED FLOAT SW CN4F WHT LIQUID PIPE CN44 WHT Pair No J42 J41 SW2 SW1 Refer to tables 1 and 2 LED3 LED2 LED1 5 5 5 5 TH5 TH2 FS TH1 MV MV MV MV GRILLE TB5 DCL TRANSMISSION WIRES DC12V TO OUTDOOR UNIT 2 1 TB6 R B I B 1 6 1 3 3 1 5 LED2 LED1 RU ...

Page 16: ...r TH5 Cond Eva temperature Thermistor TH1 Room temperature Refrigerant flow in cooling Refrigerant flow in heating Strainer 50 Strainer 50 Heat exchanger Refrigerant GAS pipe connection Flare Refrigerant LIQUID pipe connection Flare PLA ZRP100BA 8 REFRIGERANT SYSTEM DIAGRAM OCH529 ...

Page 17: ...bleshooting of problems The trouble is not reoccurring Logged Not logged Consider the temporary defects such as the work of protection devices in the refrigerant circuit including compressor poor connection of wiring noise and etc Re check the symptom and check the installation environment refrigerant amount weather when the trouble occurred matters related to wiring and etc Reset error code logs ...

Page 18: ... is cancelled Procedure 1 Press the CHECK button twice 2 Press the temperature buttons 3 Point the remote controller at the sensor on the indoor unit and press the HOUR button 4 Point the remote controller at the sensor on the indoor unit and press the ON OFF button Malfunction diagnosis method at maintenance service 9 2 MALFUNCTION DIAGNOSIS METHOD BY REMOTE CONTROLLER In case of trouble during o...

Page 19: ...ber 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 PA Drain pump error Forced compressor stop due to water leakage abnormality 6 P6 Freezing Overheating protection operation 7 EE Communication error b...

Page 20: ...on device is not connected Reverse or open phase wiring for the outdoor unit s power terminal block L1 L2 L3 Incorrect wiring between indoor and outdoor units incorrect polarity of S1 S2 S3 Remote controller wire short Note Operation is not possible for about 30 seconds after cancellation of function selection Correct operation For description of each LED LED1 2 3 provided on the indoor controller...

Page 21: ... P1 above 2 Check contact failure of connector CN44 on the indoor controller board Refer to 9 7 Turn the power on and recheck operation after inserting connector again 4 Check pipe liquid temperature with remote controller in test run mode If pipe liquid temperature is extremely low in cooling mode or high in heating mode refrigerant circuit may have defects 5 Check pipe liquid temperature with re...

Page 22: ...nge 4 Defective indoor fan motor Fan motor is defective Indoor controller board is defec tive 5 Defective outdoor fan control 6 Overcharge of refrigerant 7 Defective refrigerant circuit clogs 8 Bypass circuit of outdoor unit is defective Cooling or drying mode 1 Check clogs of the filter 2 Remove the blockage 4 Refer to 9 6 5 Check outdoor fan motor 67 Check operating condition of refrigerant circ...

Page 23: ...onnecting remote control ler max 2 units When it is not the above mentioned problem of 1 3 4 Diagnose remote controllers a When RC OK is displayed Remote controllers have no problem Turn the power off and on again to check If abnormality generates again replace indoor controller board b When RC NG is displayed Replace remote controller c When RC E3 or ERC 00 66 is dis played noise may be causing a...

Page 24: ... board to transmit signals Indoor controller board Abnormal if data cannot be read normally from the nonvolatile memory of the indoor controller board 1 Defective indoor controller board 1 Replace indoor controller board Remote controller control board 1 Abnormal if data cannot be read nor mally from the nonvolatile memory of the remote controller control board Error code E1 2 Abnormal if the cloc...

Page 25: ...on of 4 way valve 2 Disconnection of or leakage in refrigerant pipes 3 Air into refrigerant piping 4 Abnormal operation no rotation of indoor fan Defective fan motor Defective indoor control board 5 Defective refrigerant circuit clogging 1 When this error occurs be sure to replace the 4 way valve 2 Check refrigerant pipes for disconnection or leakage 3 After the recovery of refrigerant vacuum dry ...

Page 26: ...ck S1 and S2 When AC 220 240V is not detected check indoor outdoor unit connecting wire for miswiring When AC 220 240V is detected check 4 below 4 Check the fuse on indoor controller board Check the wiring connection If no problem are found indoor controller board is defective 1 Check the voltage of indoor power supply terminal block L N When AC220 240V is not detected check the power supply wirin...

Page 27: ...oller Check indoor outdoor unit connecting wire for connection failure 1 Check the connection of remote control ler wires in case of twin triple indoor unit system When 2 or more indoor units are wired in one refrigerant system connect remote controller wires to one of those units 2 Check the setting of refrigerant address in case of grouping control system If there are some units whose refrigeran...

Page 28: ...unction it is possible to activate Emergency Operation by using the indoor unit Emergency operation switch SW1 SW2 of the wireless signal receiver board However if the indoor unit microprocessor has failed it is necessary to proceed with points 2 and 3 below as in the case of the wired remote control 2 When you activate Emergency operation of the cooling or heating you have to set the switch SWE o...

Page 29: ...r i see sensor Option Abnormal Open or short Red Yellow Red Blue Red Orange Red White Connector Normal 300 Measure the resistance between the terminals with a tester At the ambient temperature of 20 30 Abnormal Open or short Red Yellow Red Blue Red Orange Red White Connector Normal 250 MV MV Normal Do not disassemble corner panel with i see sensor Black plastic tape Turn on the indoor unit with th...

Page 30: ... of the indoor controller circuit board and fan motor Self check Symptom The indoor fan cannot rotate Wiring contact check Contact of fan motor connector CNMF No No NG Power supply check Remove the connector CNMF Measure the voltage in the indoor controller circuit board TEST POINT VDC between 1 and 4 of the fan connector VDC DC 310 340 V TEST POINT VCC between 5 and 4 of the fan connector VCC DC ...

Page 31: ... 24V DC SW2 Capacity setting SW1 Model selection CN2L Connector LOSSNAY CN41 Connector HA terminal A CN22 Connect to the terminal block TB5 Remote controller con necting wire 10 4 14 6V DC LED3 Transmission Indoor outdoor CN01 Connect to the Terminal Block TB4 Indoor outdoor connecting line Between 3 and 5 220 240V AC CN3G Connect to the auto grille controller board CN3G 13V pulse output CNV Vane ...

Page 32: ... table on the left in the table indicates the jumper wire is dis connected There is no jumper JP1 because these models have the cond eva temperature thermistor TH5 Marks in the table below Jumper wire Short Open Without TH5 With TH5 Model JP1 For product Service parts Indoor controller board type JP3 MODELS PLA ZRP100BA SETTING MODELS PLA ZRP100BA SETTING ON OFF 1 2 3 4 5 ON OFF 1 2 3 4 5 9 8 FUNC...

Page 33: ...Electric Box of the decorative panel You can set up 8 different stages of lowering distance for the air intake grille according to the set up location if desired As a factory default the decorative panel will automatically stop at 1 6 m from the ceiling level The distance is a rough indication check by actually lowering it 1 Take the cover off the electric box of the decorative panel 2 screws 2 Se...

Page 34: ... cause an injury or a failure Warning F1 F2 F3 F4 F1 F2 F3 F4 All Auto descending panel Auto descending panel Input display All Cur Address Check Down Up Cur Address Check Down Up Ref address Unit No Operation Keep clear panel descending Press Check for Unit No Ref address Unit No Operation Panel will stop in 30 sec Keep clear panel descending F1 F2 F3 F4 Maintenance menu Main menu Cursor Auto des...

Page 35: ... 2 m 3 6 m and 4 0 m These should be used only as a guide You should lower the air intake grille yourself to check the exact distance You cannot stop the operation while the air intake grille is rising If you press the button while the air intake grille is moving up the air intake grille maystop rising but it will not stop immediately Stand by for raising display Raising display blinking Stopped d...

Page 36: ...t address No can be changed by using the TEMP buttons when the panel displays a or b Every time you press the Mode selection button the target of operation will change as illustrated below 6 Continue to press the Mode selection button until Waiting for up down operation is displayed The following steps are the same as steps 3 6 described in the General Operation section Refer to that section In St...

Page 37: ...ke grille has been raised the set distance but the storage detection switch is not engaged In this case the operation below will be repeated up to 4 times 10 cm down 30 cm up 10 cm down 30 cm up No load detection Case UP DOWN commands with no grille suspended When both wire 1b and wire 2b are not loaded the wires will not move Obstacle detection Case Making contact with something while lowering Sh...

Page 38: ...switch heating down UK1 Up down machine SW2 Emergency switch cooling up MU1 Motor Up down LS1 Limit switch storage detection LS21 Limit switch tension detection R B Wired remote controller I B Indoor controller board SW22 10 3 2 Dip SW 2 type SW2 SYMBOL NAME SYMBOL NAME U B CONTROLLER BOARD UK1 I B W B UP DOWN MACHINE FUSE FUSE T3 15AL250V M MOTOR FOR GRILLE UP DOWN LS21 LIMIT SWITCH TENSION DETEC...

Page 39: ...e grille Lower the air intake grille again and check whether the filter is installed in the correct position Lower the air intake grille again and hook on the air intake grille This is normal This is normal Power failure Batteries are not inserted into the wireless remote controller Or battery power is running low There is something on the air intake grille Or something is stuck in the air intake ...

Page 40: ... with the 1st unit Once the actual room temperature goes down to 4 degrees C below set point the 2nd unit stops operation automatically set point set temperature by R C remote controller 4 6 8 C selectable Number of operating units is determined according to the room temperature and set point When room temperature becomes higher than set point standby unit starts 2 units operation When room temper...

Page 41: ...ial setting 2nd unit cut in setting Setting contents Setting No Request code No 7 316 No 8 317 No 9 318 Rotation and Back up OFF Normal group control operation Monitoring the request code of current setting Setting No Request code No 1 310 No 2 311 No 3 312 No 4 313 No 5 314 No 6 315 Cut in function OFF Monitoring the request code of current setting Setting contents Rotation ON Alternating interva...

Page 42: ... with the F3 or F4 button 8 Press the F3 or F4 button to set the Refrigerant address 0 9 Press the F3 or F4 button to set the desired request code No Rotation Back up operation Please match request code with 311 318 either 2nd stage cut in operation Please match request code with 321 324 either 0 Press the button Data will be collected and displayed 1 Press the F3 or F4 button to set the Refrigera...

Page 43: ...reactor 4 Removing the indoor controller board I B 1 Remove the air intake grille and the filter See Figure 1 2 Remove the 2 screws from the electrical box cover 3 Disconnect the connectors CNMF White 7P for fan motor CN44 White 4P for thermistor TH2 TH5 CNP Blue 3P for drain pump CN4F White 4P for float switch CN01 Black 5P for earth and reactor CNV White 20P for vane motor 4 Remove the 6 support...

Page 44: ...the bell mouth 3 screws See Photo 2 3 Remove the turbo fan nut 4 Pull out the turbo fan 5 Remove the wire cover 3 screws 6 Remove 2 wiring clamps 7 Disconnect the connector of the fan motor CNMF 8 Remove the 3 nuts and washers and rubber mounts of the fan motor 8 Removing the drain pan 1 Remove the air intake grille and the filter See Figure 1 2 Remove the 2 screws from the electrical box cover 3 ...

Page 45: ...rain pump Hose band Float switch Drain pump assembly fixing screw Drain pump fixing screw Float switch fixing screw 11 Removing the heat exchanger 1 Remove the drain pan See Photo 6 2 Remove the 3 screws of the piping cover and pull out piping cover 3 Remove the 2 screws of coil plate 4 Remove the 2 screws of the coil 5 Remove the screw of the coil support 6 Pull out the heat exchanger Photo 9 Coi...

Page 46: ... MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN CCopyright 2012 MITSUBISHI ELECTRIC CORPORATION Distributed in Oct 2012 No OCH529 Made in Japan New publication effective Oct 2012 Specifications are subject to change without notice TM ...

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