Mitsubishi Electric PUHZ-HRP200YKA Service Manual Download Page 52

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HEAD OFFICE : TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

Distributed in Nov. 2009 No. OCH466 PDF 7
Made in Japan

New publication, effective Nov. 2009
Specifications subject to change without notice

Summary of Contents for PUHZ-HRP200YKA

Page 1: ... SPECIFICATIONS 11 7 REFRIGERANT SYSTEM DIAGRAM 13 8 TROUBLESHOOTING 14 9 DISASSEMBLY PROCEDURE 47 November 2009 Note This manual describes only service data of the outdoor unit Refer to Technical manual of ATW I F and FTC RoHS compliant products have G mark on the spec name plate R410A PUHZ HRP200YKA PARTS CATALOG OCB466 Model name PUHZ HRP200YKA Service Ref PUHZ HRP200YKA ...

Page 2: ...eterioration of refrigerant oil or malfunction of compressor Do not use a charging cylinder If a charging cylinder is used the composition of refrigerant will change and the efficiency will be lowered Electronic refrigerant charging scale Vacuum pump adaptor Gauge manifold Torque wrench Gas leak detector Charge hose Tools for R410A Ventilate the room if refrigerant leaks during operation If refrig...

Page 3: ...s charged from liquid phase Gravimeter Unit 3 Service tools Use the below service tools as exclusive tools for R410A refrigerant No Tool name Specifications 1 Gauge manifold Only for R410A Use the existing fitting specifications UNF1 2 Use high tension side pressure of 5 3 MPa G or over 2 Charge hose Only for R410A Use pressure performance of 5 09 MPa G or over 3 Electronic scale 4 Gas leak detect...

Page 4: ...e 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 Tool exclusive for R410A Tool exclusive for R410A Tools for other refrigerants can be used if equipped with adap ter for reverse flow check Tools for othe...

Page 5: ... temperature inlet outlet 30 C 35 C Heating A7 W45 Outside air temperature Dry bulb 7 C Outside air temperature Wet bulb 6 C Water temperature inlet outlet 40 C 45 C Heating A7 W55 Outside air temperature Dry bulb 7 C Outside air temperature Wet bulb 6 C Water temperature inlet outlet 50 C 55 C Heating A 7 W35 Outside air temperature Dry bulb 7 C Outside air temperature Wet bulb Water temperature ...

Page 6: ...ner expansion valve Compressor Hermetic scroll Model ANB66FJHMT Motor output kW 4 7 Start type Inverter Protection devices HP switch LP switch Discharge thermo Oil Model L 1 7 FV50S Crankcase heater W Heat exchanger Air Plate fin coil Water Plate heat exchanger Fan Fan drive No Propeller fan 2 Fan motor output kW 0 150 2 Air flow m min 140 CFM 4 940 Defrost method Reverse cycle Noise level SPL Hea...

Page 7: ...ments Note If the calculation produces a negative number i e a minus charge of if calculation results in an amount that is less than the Additional charage amount for 50 m perform the additional charge using the amount shown in Additional charge amount for 50 m Amount of additional charge Main piping Liquid line size ø12 7 overall length 0 17 4 3 kg kg m 0 17 kg m Additional charge amount for 50 m...

Page 8: ...enser inlet temperature ºC 65 Condenser outlet temperature ºC 34 Water conditions Flow volume L min 57 3 65 9 Outlet water temperature ºC 7 35 Outdoor conditions Intake air temperature D B ºC 35 7 W B ºC 24 6 Piping length Main 2 5m Branch 2 5m 2 5m The unit of pressure has been changed to MPa based on international SI system The conversion factor is 1 MPa 10 2 kgf cm 3 4 CAPACITY CORRECTION Refri...

Page 9: ...Details Power supply wiring hole ø27Knockout Front piping hole Knockout Front trunking hole Knockout Power supply wiring hole ø40Knockout 60 55 63 73 55 27 26 75 92 60 ø 9 2 Power supply wiring hole ø27Knockout Right piping hole Knockout Right trunking hole Knockout Power supply wiring hole ø40Knockout 75 50 26 27 63 73 29 92 55 92 60 ø 9 2 Power supply wiring hole ø27Knockout Rear piping hole Kno...

Page 10: ...NAME SYMBOL NAME Connection Terminal TB P1 Connection Terminal TB P2 Switch Function Setup Switch Forced Defrost Defect History Record Reset Refrigerant Address Switch Test Operation Switch Function Switch Switch Model Select SW1 SW4 SW5 SW6 SW8 Switch SW9 Switch Pump Down SWP Connector Emergency Operation LED Operation Inspection Indicators CN31 F3 F4 CNMNT CNVMNT CNDM Connector Connected for Opt...

Page 11: ...omply with the applicable local and national code 2 Power supply cords and Indoor Outdoor unit connecting cords shall not be lighter than polychloroprene sheathed flexible cord Design 60245 IEC 57 3 Use an earth wire which is longer than the other cords so that it will not become disconnected when tension is applied Caution Be sure to install N line Without N line it could cause damage to the unit...

Page 12: ...e with stripe of yellow and green is available 3 In case of regular polarity connection S1 S2 S3 wire size is 1 5 mm2 4 In case of regular polarity connection S1 S2 S3 5 In the flat cables are connected as this picture they can be used up to 30 m 6 Mentioned cable length is just a reference value It may be different depending on the condition of installation humidity or materials etc 3C Flat cable...

Page 13: ...ection OFF 0 03MPa REV V Reversing 4 way valve 21S4 Change the refrigerant circuit Heating Cooling and for Defrosting Charge plug Charge plug High pressure Low pressure For production test use P Sensor Pressure sensor 63HS For calculation of the condensing temperature from high pressure LEV A Linear expansion valve A Heating Secondary LEV Cooling Primary LEV LEV B Linear expansion valve B Heating ...

Page 14: ...ct troubleshooting and ascertain the cause of the trouble The trouble is not reoccurring Logged 1 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 e...

Page 15: ...de Symptom P1 Flow water TH1 sensor error P2 Refrigerant liquid Pipe TH2 sensor error P6 Freezing Overheating protection operation P9 Actual tank temp TH5 sensor error Fb FTC unit control system error memory error etc E0 E5 Signal transmission failure between remote controller and FTC E6 EF Signal transmission failure between outdoor unit and FTC No trouble generated in the past FFFF No correspond...

Page 16: ... 3 minutes continuously after power sup ply 63H High pressure switch 1 Disconnection or contact failure of 63H connector on outdoor controller circuit board 2 Disconnection or contact failure of 63H 3 63H is working due to defective parts 4 Defective outdoor controller circuit board 1 Check connection of 63H connector on outdoor controller circuit board Refer to 8 7 2 Check the 63H side of connect...

Page 17: ...ed Interface unit Flow temp con troller Abnormal if the number cannot be checked automatically due to miswiring of Interface unit Flow temp controller outdoor unit connecting wire and etc after power is turned on for 4 minutes 2 Abnormal if outdoor controller circuit board recognizes excessive number of Interface unit Flow temp controller Check disconnection or looseness or polarity of Interface u...

Page 18: ... more is detected during compressor operation Detection is inoperative for 10 minutes of compressor starting process and for 10 minutes after and during defrosting 1 Disconnection or contact failure of connector TH4 on the outdoor controller circuit board 2 Defective thermistor 3 Defective outdoor controller circuit board 1 Check connection of connector TH4 on the outdoor controller circuit board ...

Page 19: ...2 on A Control Service Tool Refer to 8 8 3 Replace outdoor controller circuit board 1 Disconnection or contact failure of connectors Outdoor controller circuit board TH3 TH32 TH7 6 Outdoor power circuit board CN3 2 Defective thermistor 3 Defective outdoor controller circuit board U6 Power module Check abnormality by driving power module in case overcurrent is detected UF or UP error condition 1 Ou...

Page 20: ...power circuit board Refer to 8 7 4 Check CN2 wiring on the outdoor power circuit board Refer to 8 7 UF 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 converse of compressor wiring connectio...

Page 21: ...ility of power supply 3 Correct the wiring U V W phase to compressor Refer to 8 7 Outdoor power cir cuit board 4 Check indoor outdoor fan 5 Solve short cycle 6 Replace outdoor controller circuit board W Before the replacement of the outdoor con troller circuit board disconnect the wiring to compressor from the outdoor power circuit board and check the output voltage among phases U V W during test ...

Page 22: ...n error E3 signal receiving error E5 1 Abnormal if remote controller could not find blank of transmission path for 6 seconds and could not transmit Error code E3 2 When remote controller receives the transmitted data same time and com pares these data Abnormal if the data is judged to be different for 30 continuous times Error code E3 1 Abnormal if Interface unit Flow temp controller could not fin...

Page 23: ...rcuit board and outdoor power circuit board is defective 1 Wire disconnection or contact failure of connector CN2 be tween the outdoor controller circuit board and the outdoor power circuit board 2 Wire disconnection or contact failure of connector CN4 be tween the outdoor controller circuit board and the outdoor power circuit board 3 Defective communication circuit of outdoor power circuit board ...

Page 24: ...perature with remote controller in test run mode If there is ex tremely difference with actual pipe liquid temperature replace PCB of Interface unit Flow temp controller Turn the power off and on again to operate after check P6 Freezing overheating protection is working 1 Freezing protection Cooling mode The unit is in 6 minute resume preven tion mode if pipe temperature stays under 15 for 3 minut...

Page 25: ...re timer settings invalid If the timer can be set WEEKLY SIMPLE or AUTO OFF appears in the remote controller display PLEASE WAIT appears in the remote controller display The initial settings are being performed Wait approximately 3 minutes If the remote controller is not only for FTC change it An error code appears in the remote controller display The protection devices have operated to protect th...

Page 26: ...stance between the terminals with a tester At the ambient temperature 20 Solenoid valve coil 4 way valve 21S4 Motor for compressor MC Linear expansion valve LEV A LEV B LEV C Normal Abnormal Open or short Abnormal Open or short 0 37 Disconnect the connector then measure the resistance with a tester Winding temperature 20 Normal Gray Black Gray Red Gray Yellow Gray Orange Abnormal 46 3 Open or shor...

Page 27: ...or CNF1 2 Fuse check Check the fuse F5 on outdoor controller board Power supply check Remove the connector CNF1 2 Measure the voltage in the outdoor controller circuit board TEST POINT VDC between 1 and 4 of the fan connector VDC DC250 330V TEST POINT VCC between 5 and 4 of the fan connector VCC DC15V Recover wiring Replace outdoor controller board Replace the fan motor Replace outdoor controller ...

Page 28: ... 1 Thermistor R120 7 465k 2 B constant 4057 2 Rt 7 465exp 4057 273 t 393 1 1 20 250k 30 160k 40 104k 50 70k 60 48k 70 34k 80 24k 90 17 5k 100 13 0k 110 9 8k High temperature thermistor Thermistor Discharge pipe TH4 0 10 20 30 40 50 20 10 0 10 20 30 40 50 Temperature Resistance k 500 400 300 200 100 0 25 50 75 100 120 Temperature Resistance k 1 0 5 2 5 5 2 5 4 5 Vout V PRESSURE MPa 3 2 1 WHT BLU BL...

Page 29: ...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 3 4 5 6 Connector LEV A LEV B LEV C DC12V Outdoor controller board ...

Page 30: ...ure Be sure to attach the stopper A 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 att...

Page 31: ... of external con tact point TH4 Thermistor Discharge TH3 Thermistor Liquid pipe TH7 6 Thermistor Outdoor 2 phase pipe CNDC 280V DC 1 3 Noise filter circuit board VFG Voltage between right pins of PC5C and PC5D pin 3 and pin 4 Same as CNF17 4 VSP Voltage between pins of C5A C5B DC 0V when stopped DC 1 6 5V when operated SW7 Demand control setting CN51 External signal output Compressor operat ing si...

Page 32: ...1 Connect to the earth CNAC1 CNAC2 AC220 230 240V 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 AC380 400 415V OUTPUT Connect to the outdoor power circuit board TB1 L1 L2 L3 CNCT Primary current Connect to the outdoor power circuit board CN5 CNL Connect to the ACL4 GD3 Connect to the e...

Page 33: ...moothing capacitor CB1 TB U TB V TB W Connect to the compressor MC Voltage among phases 10V 400V AC TB L1 TB L2 TB L3 Connect to the outdoor noise filter circuit board LO1 LO2 LO3 380V 415V AC TB N1 Connect to the smoothing capacitor CB2 CN7 Connect to the outdoor converter circuit board CN7 Brief Check of POWER MODULE W Usually they are in a state of being short circuited if they are broken Measu...

Page 34: ...tch Type of switch Dip switch Push switch SW1 1 2 No Function Effective timing Action by the switch operation Forced defrost 1 Start Normal When compressor is working in heating operation 1 Abnormal history clear Refrigerant address setting When power supply ON Clear Normal off or operating SWP 6 5 4 3 Under suspension Pump down Start Normal SW4 SW8 1 2 1 2 3 Test run Operating OFF Under suspensio...

Page 35: ... Always Always Always Always Always Setting of demand control 3 1 2 SW7 1 SW7 2 OFF 0 Operation stop 75 50 OFF ON OFF OFF ON Power consumption Demand switch ON SW9 3 SW9 4 OFF 3 C Initial setting 0 C 3 C 6 C ON ON OFF OFF OFF ON ON Ambient temp Model select Following SW5 6 reference w2 Power failure automatic recovery can be set by either remote controller or this DIP SW If one of them is set to O...

Page 36: ...or Low level sound priority mode Turn SW1 to off to release Low level sound priority mode and normal operation b On demand control Local wiring Demand control is available by external input In this mode power consumption is decreased within the range of usual 0 100 How to wire Basically the wiring is same with a Connect an SW 1 which is procured locally between Orange and Red 1 and 3 of the adapte...

Page 37: ...ignal receiving error is detected by outdoor unit I F or FTC or outdoor unit communication error transmitting error is detected by outdoor unit Remote controller signal receiving error is detected by remote controller Remote controller transmitting error is detected by remote controller Remote controller signal receiving error is detected by I F or FTC unit Remote controller transmitting error is ...

Page 38: ...ng terminals on compressor using a tester Check if outdoor unit has a short cycle on its air duct Compressor overcurrent breaking Start up locked Compressor overcurrent breaking Abnormality of current sensor P B Abnormality of power module Open short of discharge thermistor TH4 Open short of outdoor thermistors TH3 TH32 TH6 TH7 and TH8 Check if connectors TH3 TH32 TH4 and TH7 6 on outdoor controll...

Page 39: ...d w C5 is displayed during replacement operation 3 When the display blinks Inspection code is displayed when compressor stops due to the work of protection devices Display Inspection unit 0 Outdoor unit 1 Interface or FTC Display Contents to be inspected During operation U1 Abnormal high pressure 63H operated U2 Abnormal high discharging temperature shortage of refrigerant U3 Open short circuit of...

Page 40: ... hours or more hundreds digit tens digit and ones digit are displayed by turns Example When 2450 hours 245 10 hours 0 5 secs 0 5secs 2 secs 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 50 LEV A opening pulse 0 480 0 50 w Omit the figures after the decimal fractions 0 480 When it is 100 pulse or more hundreds digit tens digit and ones digit are displayed by turns Exam...

Page 41: ...tory 2 Alternate display of error unit number and code 3 217 When the temperature is 100 or more the hundreds digit tens digit and ones digit are displayed by turns Example When 130 0 5 secs 0 5secs 2 secs A Code display Code display 0 20 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 Thermo ON time 0 999 Test run elapsed time 0...

Page 42: ...urns 1 ON 2 3 4 5 6 Actual flow water temperature TH1 8 39 Setting details The tens digit Total display for applied setting The ones digit H P Cooling only Single phase 3 phase Display details 0 H P 1 Cooling 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 8 ...

Page 43: ... 255 0 255 When it is 100Hz or more hundreds digit tens digit and ones digit are displayed by turns DC bus voltage 180 370 180 370 When it is 100V or more hundreds digit tens digit and ones digit are displayed by turns V 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 1 ON 2 3 4 5 6 SW2 setting Display detail Explanation for display Unit 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 Pre...

Page 44: ...r and code When no error history 0 and are displayed by turns 3 Liquid pipe thermistor TH3 6 2 phase pipe thermistor TH6 7 Ambient temp thermistor TH7 8 Heatsink thermistor TH8 32 Suction pipe thermistor TH32 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 error thermistor is displayed Code display Operation frequency on error occurring 0 255 0...

Page 45: ...ture is 0 C or less and temperature are displayed by turns Example When 15 C 0 5 secs 0 5secs 2 secs Outdoor heatsink temperature TH8 on error occurring 40 200 40 200 When the temperature is 0 C or less and temperature are displayed by turns When the temperature is 100 C or more hundreds digit tens digit and ones digit are displayed by turns 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 ...

Page 46: ...rcuit board Description Detection point Display 00 01 02 04 08 U9 Error status during the Error postponement period Code display 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 Compressor operating frequency control Display Compressor operating frequency control Primary current control S...

Page 47: ...ce panel fixing screws 5 10 and slide the hook on the right downward to remove the service panel 2 Remove screws 3 for front 3 for rear 5 10 of the top panel and remove it 2 Removing the fan motor MF1 MF2 1 Remove the service panel See Photo 1 2 Remove the top panel See Photo 1 3 Remove 4 fan grille fixing screws 5 10 to detach the fan grille See Photo 1 4 Remove a nut for right handed screw of M6...

Page 48: ...ase of replacing thermistor Outdoor TH7 replace it together with thermistor Outdoor 2 phase pipe TH6 since they are combined together Refer to No 5 above to remove thermistor Outdoor 2 phase pipe Photo 7 Clamp Thermistor Outdoor 2 phase pipe TH6 6 Removing the thermistor Liquid pipe TH3 thermistor Discharge TH4 and thermistor Suction pipe TH32 1 Remove the service panel See Photo 1 2 Disconnect th...

Page 49: ...e right side panel 6 Remove the 4 way valve coil 7 Recover refrigerant 8 Remove the welded part of 4 way valve 9 Removing the linear expansion valve 1 Remove the service panel See Photo 1 2 Remove the top panel See Photo 1 3 Remove 3 valve bed fixing screws 4 10 4 ball valve and stop valve fixing screws 5 16 then remove the valve bed 4 Remove 3 right side panel fixing screws 5 10 in the rear of th...

Page 50: ...ompressor inlet and outlet and remove the compressor Note Recover refrigerant without spreading it in the air Photo 9 Compressor MC Soundproof cover Compressor fixing nut Compressor terminal 10 Removing the high pressure switch 63H and low pres sure switch 63L 1 Remove the service panel See Photo 1 2 Remove the top panel See Photo 1 3 Remove 3 right side panel fixing screws 5 10 in the rear of the...

Page 51: ...utlet 10 Remove 2 receiver leg fixing screws 4 10 Note Recover refrigerant without spreading it in the air Photo 11 Power receiver Inlet pipe Valve bed Valve bed fixing screw Outlet pipe OPERATING PROCEDURE PHOTOS 13 Removing the pressure sensor 63HS 1 Remove the service panel See Photo 1 2 Remove the top panel See Photo 1 3 Pull out the lead wire of pressure sensor 4 Remove the band that is fixin...

Page 52: ...ARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN Copyright 2009 MITSUBISHI ELECTRIC ENGINEERING CO LTD Distributed in Nov 2009 No OCH466 PDF 7 Made in Japan New publication effective Nov 2009 Specifications subject to change without notice ...

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