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SERVICE MANUAL

AIR TO WATER HEAT PUMP

No. OCH439

  CONTENTS

  1. SAFETY PRECAUTION ..........................................2

  2. SPECIFICATIONS .....................................................4

  3. DATA  .............................................................................5

  4. OUTLINES AND DIMENSIONS ............................7

  5. WIRING DIAGRAM ...................................................8

  6. WIRING SPECIFICATIONS ....................................9

  7. REFRIGERANT SYSTEM DIAGRAM ...................10

  8. TROUBLESHOOTING ...........................................11

  9. DISASSEMBLY PROCEDURE ...........................38

April  2008

Note:

•

 This manual describes only 

  service data of PUHZ-W85VHA.

•

 RoHS compliant products have 

<G> mark on the spec name plate.

R410A

[model name]

PUHZ-W85VHA

[Service Ref.]

PUHZ-W85VHA

PUHZ-W85VHA

PARTS CATALOG (OCB439)

Summary of Contents for PUHZ-W85VHA

Page 1: ...WIRING DIAGRAM 8 6 WIRING SPECIFICATIONS 9 7 REFRIGERANT SYSTEM DIAGRAM 10 8 TROUBLESHOOTING 11 9 DISASSEMBLY PROCEDURE 38 April 2008 Note This manual describes only service data of PUHZ W85VHA RoHS compliant products have G mark on the spec name plate R410A model name PUHZ W85VHA Service Ref PUHZ W85VHA PUHZ W85VHA PARTS CATALOG OCB439 ...

Page 2: ...fficiency will be lowered Do not use refrigerant other than R410A If other refrigerant R22 etc is used chlorine in refrigerant can cause deterioration of refrigerant oil etc Use a vacuum pump with a reverse flow check valve Vacuum pump oil may flow back into refrigerant cycle and that can cause deterioration of refrigerant oil etc Use the following tools specifically designed for use with R410A re...

Page 3: ...s for other refrigerants can be used if equipped with adop ter for reverse flow check Tools for other refrigerants can be used Tools for other refrigerants can be used Tools for other refrigerants can be used Tools for other refrigerants can be used Tools for other refrigerants can be used Tool exclusive for R410A Tools and materials Use R410A tools Can R22 tools be used Usable if equipped with ad...

Page 4: ... name ALFA LAVAL Running current Heating A7 W35 0 4 0 3 H C A A Cooling A35 W7 A m m 4 0 4 A A t n e r r u c x a M m m 2 8 6 2 B g n i s a c r e t u O External finish m m 3 9 W l o r t n o c t n a r e g i r f e R m m 5 2 3 H r o s s e r p m o C m m 9 6 D l e d o M s e t a l p 0 4 W k t u p t u o r o t o M Start type Protection devices e r u t a r e p m e t r e t a w t e l t u o m u m i x a M L l e...

Page 5: ...70 90 80 70 60 50 40 30 20 10 OCTAVE BAND SOUND PRESSURE LEVEL dB 0 dB 0 0002 bar 63 125 250 500 1000 2000 4000 8000 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE BAND CENTER FREQUENCIES Hz PUHZ W85VHA COOLING MODE HEATING 48 SPL dB 48 LINE 3 1 NOISE CRITERION CURVES ...

Page 6: ...rant circuit Discharge pressure MPa 2 81 2 21 Suction pressure MPa 0 73 0 64 Discharge temperature 80 65 Condensing temperature 46 38 Suction temperature 3 1 Water conditions Flow volume L min 20 4 25 8 Outlet water temperature 7 35 Outdoor conditions Intake air temperature D B 35 7 W B 24 6 The unit of pressure has been changed to MPa based on international SI system The conversion factor is 1 MP...

Page 7: ...1 G1 B 98 269 24 Service panel Handle for moving Handle for moving Terminal Connections Left Power supply wiring Right Controller wiring Earth terminal 322 943 23 473 950 673 FOUNDATION Foundation bolt height Please secure the unit firmly with 4 foundation M10 bolts Bolts and washers must be purchased locally Service space Dimensions of space needed for service access are shown in the below diagra...

Page 8: ...BOL NAME SYMBOL NAME Connection Terminal L N Phase Connection Terminal DC Voltage TABN1 N2 Connection Terminal DC Voltage TABU V W Switch Model Select Switch Model Select SW5 SW10 Relay Fuse T6 3AL250V F1 F4 X52 X54 X55 MS 3 MF1 M 1 3 1 7 3 4 1 1 1 2 1 1 7 2 CNF1 WHT TRANS CNDC PNK TH7 6 RED TH3 WHT TH4 WHT TH7 t t t t TH6 TH3 TH4 1 2 TH32 BLK t TH32 63HS 63HS WHT 3 1 CNS WHT 63H YLW 3 1 63H 1 1 C...

Page 9: ...n earth longer than other cables Outdoor unit power supply N single 50 Hz 230 V Outdoor unit Circuit Breaker capacity 1 25 A Wiring Wire No size mm 2 Outdoor unit power supply earth 3 Min 4 Interface unit Flow temp controller Outdoor unit 2 3 1 5 polar Interface unit Flow temp controller Outdoor unit earth 2 1 Min 1 5 Remote controller Interface unit Flow temp controller 2 0 3 Non polar Circuit ra...

Page 10: ...ressure Inverter power board Heating Secondary LEV Cooling Primary LEV Heating Primary LEV Cooling Secondary LEV For freeze protection and for compressor frequency control Heating Evaporating temperature Cooling Sub cool liquid temperature For LEV control and for compressor protection Heating Sub cool liquid temperature Cooling Evaporating temperature For fan control and for compressor frequency c...

Page 11: ... the trouble Continue to operate unit for the time being if the cause is not ascertained There is no abnormality concerning of parts such as electrical component controller board and etc Error code display by self diagnosis and actions to be taken for service summary Present and past error codes are logged and displayed on the control board of outdoor unit Actions to be taken for service which dep...

Page 12: ...ck TB1 c Connection of power supply terminal block TB1 2 Check following items a Connection of power supply terminal block TB1 Connection of terminal LI NI LO NO on the noise filter circuit board b Connection of terminal TABT or TABS on outdoor power circuit board Refer to 8 6 3 Check connection of the CNDC connector on the outdoor power circuit board Refer to 8 6 4 Check connection of reactor DCL...

Page 13: ...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 14: ...t and action for F5 5 Check linear expansion valve Refer to 8 5 6 Replace outdoor controller board Case U2 High discharging temperature Abnormal if discharge temperature thermistor TH4 exceeds 125 or 110 continuously for 5 minutes Abnormal if during defrosting discharge temperature thermistor TH4 exceeds 110 continuously for 30 minutes 1 Overheated compressor operation caused by insufficient refri...

Page 15: ...3 TH32 TH6 TH7 on the outdoor controller circuit board Check connection of connector CN3 on the outdoor power circuit board Check the lead wire for thermistor TH3 TH32 TH6 TH7 TH8 Refer to 8 6 2 Check resistance value of thermistor TH3 TH32 TH6 TH7 TH8 or check temperature on LED display Thermistor TH3 TH32 TH6 TH7 TH8 Refer to 8 5 SW2 Refer to 8 7 3 Replace outdoor controller circuit board 1 Disc...

Page 16: ...rcuit board 6 Check CNAF wiring 7 Replace outdoor controller circuit board 8 Check CN5 wiring on the outdoor power circuit board Refer to 8 6 9 Replace outdoor power circuit board noise filter circuit board 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 Decrease of power...

Page 17: ...Error code E0 Abnormal if Interface Flow temp con troller board can not receive any data normally from remote controller board or from other Interface Flow temp control ler board for 3 minutes Error code E4 Interface Flow temp controller board cannot receive any signal from remote controller for 2 minutes Error code E4 Check disconnection or looseness of Interface unit Flow temp controller unit or...

Page 18: ...utdoor unit connecting wire 1 Check disconnection or looseness of Interface unit Flow temp controller outdoor unit connecting wire of Interface unit Flow temp controller or outdoor unit 2 4 Turn the power off and on again to check Replace Interface Flow temp con troller board or outdoor controller circuit board if abnormality is displayed again Remote controller transmission error E3 signal receiv...

Page 19: ...r starting and 3 minutes after and during defrosting 1 Disconnection or contact failure of connector 63HS on the outdoor controller circuit board 2 Defective pressure sensor 3 Defective outdoor controller circuit board 1 Check connection of connector 63HS on the outdoor controller circuit board Check breaking of the lead wire for thermistor 63HS 2 Check pressure by microcomputer Pressure sensor 63...

Page 20: ... At the ambient temperature of 10 30 TH3 Liquid pipe temperature TH4 Discharge temperature TH6 Plate Hex liquid pipe temperature TH7 Ambient temperature TH8 Heatsink temperature TH32 Inlet water temperature Normal 160k 410k 4 3k 9 6k 4 4k 9 8k 39k 105k TH4 TH3 TH6 TH7 TH32 TH8 Abnormal Open or short Measure the resistance between the terminals with a tester At the ambient temperature of 20 Solenoi...

Page 21: ...otor connector CNF1 Recover wiring END END Replace fan motor Replace outdoor controller circuit board Replace outdoor controller circuit board Replace outdoor controller circuit board Replace fan motor Replace fan motor Check fan motor rotation Check fan motor rotation Is the voltage normal Is the fuse normal Is there no contact failure Check fuse F5 on outdoor controller circuit board Yes No No Y...

Page 22: ...hermistor R50 17k 2 B constant 4150 3 Rt 17exp 4150 273 t 323 1 Thermistor R120 7 465k 2 B constant 4057 2 Rt 7 465exp 4057 273 t 393 1 1 Medium temperature thermistor Thermistor Heatsink TH8 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 200 1...

Page 23: ...e thermistor Thermistor Inlet water TH32 0 15k 10 9 6k 20 6 3k 25 5 2k 30 4 3k 40 3 0k Thermistor R0 15k 2 5 B constant 3450 2 Rt 15exp 3450 273 t 273 1 0 10 20 30 40 50 20 10 0 10 20 30 40 50 Temperature Resistance k 1 ...

Page 24: ...he valve is locked sound can be heard No sound is heard when the pulse number moves from to in case coil is burnt out or motor is locked by open phase Sound can be detected by placing the ear against the screw driver handle while putting the screw driver to the linear expansion valve LEV M 1 6 1 Gray Orange Red Yellow Black 3 4 5 6 Connector LEV A DC12V Outdoor controller board Drive circuit 3 2 5...

Page 25: ...e pipes can bend due to pressure 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 wounded by lead wire If the stopper is not firmly atta...

Page 26: ...SW1 Forced defrost detect history record reset TH4 Thermistor Discharge TH3 Thermistor Liquid temperature TH7 Ambient temperature TH6 Thermistor Plate Hex liquid temperature CNDC DC 280 V 380 V Connect from out door power circuit board VCC TEST POINT 2 voltage between pins of C6B DC 15 V VDC TEST POINT 1 voltage between pins of C5E DC 280 V 380 V VFG voltage between right pins of PC5D pin 3 and pi...

Page 27: ...the earth LI NI Voltage of 220 240 V AC is input Connect to the terminal block TB1 CN5 Input current Connect to the outdoor power circuit board CN5 LO NO Voltage of 220 240 V AC is output Connect to the outdoor power circuit board TABS TABT Outdoor noise filter circuit board E2 Connect to the earth ...

Page 28: ...5 CNDC 280 380 V DC 1 3 Connect to the outdoor controller circuit board TABS TABT Connect to the outdoor noise filter circuit board Voltage among phases 220 240 V AC Brief Check of POWER MODULE w 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 are short circuited it means that they are broken 1 Check of d...

Page 29: ...or power circuit board TABP1 N2 Non connect N1 Non connect P Connect to the outdoor power circuit board TABP2 Connect to the outdoor power circuit board CNAF 1 GND 2 1 15 V DC 3 1 Control signal 4 5 Not used 6 1 Control signal Upper side Connect to the outdoor power circuit board TABN1 Lower side lo Connect to the outdoor power circuit board TABN2 ...

Page 30: ...U5 U6 U7 U8 U9 Ud UF UH UP P6 P8 UE PE Ed Abnormal high pressure 63H worked Abnormal high discharging temperature shortage of refrigerant Open short circuit of discharging thermistor TH4 Open short of outdoor unit thermistors TH3 TH32 TH6 TH7 and TH8 Abnormal temperature of heatsink Abnormality of power module Abnormality of superheat due to low discharge temperature Abnormality in outdoor fan mot...

Page 31: ...more hundreds digit tens digit and ones digit are displayed by turns Example When 2450 hours 245 10 hours 0 5 secs 0 5 secs 2 secs 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 Compressor running current 0 50 LEV A opening pulse 0 500 0 50 Value after the decimal point will be round off 0 500 When it is 100 pulse or more hundreds digit tens digit and ones digit are displayed by turns Example When 1...

Page 32: ...00 or more the hundreds digit tens digit and ones digit are displayed by turns Example When 130 0 5 secs 0 5 secs 2 secs A Code display Code display 0 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 Compressor operation duration 0 999 0 999 When it is 100 minutes or more the hundreds digit tens digit and ones digit are display...

Page 33: ...8 39 88 When the temperature is 0 or less and temperature are displayed by turns 1 ON 2 3 4 5 6 Outdoor heatsink temperature TH8 40 200 40 200 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 1 ON 2 3 4 5 6 C Discharge superheat SHd 0 255 Cooling and Heating SHd TH4 T63HS...

Page 34: ...led 00 is displayed in case of no deferment Code display Deferred error history 3 of outdoor unit 1 ON 2 3 4 5 6 1 ON 2 3 4 5 6 Deferred error code display Blinking being deferred Lighting deferment is cancelled 00 is displayed in case of no deferment Code display Error code history 3 Oldest Faulty unit number and error code are displayed alternately When no error history 0 and are displayed by tu...

Page 35: ... ON 2 3 4 5 6 15 1 ON 2 3 4 5 6 Pulse LEV A opening pulse when error occured 0 500 0 500 When it is 100 pulse or more hundreds digit tens digit and ones digit are displayed by turns Example When 130 pulse 0 5 secs 0 5 secs 2 secs Water inlet temperature TH32 when error occured 0 100 0 100 30 1 1 ON 2 3 4 5 6 Plate HEX liquid pipe temperature TH6 when error occured 39 88 39 88 When the temperature ...

Page 36: ...5 1 15 4 1 05 1 ON 2 3 4 5 6 Error details No error Over voltage Insufficient voltage Input current sensor error ACTM error Cause Power PCB Power PCB Control PCB Control PCB Code 00 01 02 04 20 U9 Error details To be shown while error call is deferred Code display 1 ON 2 3 4 5 6 Compressor frequency control status The following code will be a help to know the operat ing status of unit Ten place le...

Page 37: ... 1 2 1 0 1 0 0 0 1 ON 0 OFF As shown in the left table Make sure to set SW6 3 to 6 and SW10 1 2 correctly SW10 1 2 SW8 1 Mode selection Energy saving mode Powerful mode OFF Always 2 No function Do NOT use PUHZ W85VHA OFF 3 Separate Interface Flow temp controller outdoor unit power supplies Separate power supply Outdoor unit power supply OFF Power supply connection method selection When power suppl...

Page 38: ...ve all the following connectors from controller circuit board fan motor linear expansion valve x2 thermistor Liquid pipe thermistor Discharge thermistor Plate HEX Liquid thermistor Outdoor ambient high pressure sensor high pressure switch four way valve and bypass valve Then remove a screw 4 x 8 from the valve bed to remove the lead wire Pull out the disconnected wire from the electrical parts box...

Page 39: ...are combined together Refer to No 4 above to remove thermistor Plate HEX Liquid 6 Removing the thermistor Liquid pipe TH3 and thermistor Discharge TH4 1 Remove the service panel See photo 1 2 Disconnect the connectors TH3 white and TH4 white on the controller circuit board 3 Loosen the clamps for the lead wire 4 Pull out the thermistor Liquid pipe TH3 See photo 5 and thermistor Discharge TH4 from ...

Page 40: ...unit and remove the right side panel 6 Remove the solenoid valve coil Four way valve See photo 9 7 Recover refrigerant 8 Remove the welded part of four way valve Note 1 Recover refrigerant without letting it out in the air Note 2 The welded part can be removed easily by removing the right side panel Note 3 When installing the four way valve make sure to cover it with a wet cloth to prevent it from...

Page 41: ...efrigerant 7 Remove the welded part of high pressure switch Note 1 Recover refrigerant without letting it out in the air Note 2 The welded part can be removed easily by removing the right side panel Note 3 When installing the high pressure switch make sure to cover it with a wet cloth to prevent it from heating 100 C or more then braze the pipes so that the inside of pipes are not oxidized 13 Remo...

Page 42: ...See photo 4 6 Remove 3 screws 4 x 10 and remove the stay See photo 10 7 Remove 3 screw 5 x 10 in the rear of the unit and remove the right side panel 8 Recover the refrigerant 9 Remove 2 welded pipes of receiver 10 Remove 2 receiver leg fixing screws 4 x 10 then remove the receiver Note 1 Recover refrigerant without letting it out in the air 16 Removing the plate heat exchanger 1 Remove the servic...

Page 43: ...move CN2 CN4 CNDC lead wire connectors from con troller circuit board C B 2 Remove LO NO CN5 lead wire connectors from noise fil ter circuit board N F 3 Remove 4 screws 4 x 10 for fixing the C B base and detach the C B base from the electrical parts box 4 Remove all lead wires on active filter module ACTM L1 L2 P Io CNAF 4 wires 5 Remove the active filter module ACTM from the electrical parts box ...

Page 44: ...ARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN Copyright 2008 MITSUBISHI ELECTRIC ENGINEERING CO LTD Distributed in Apr 2008 No OCH439 PDF 8 Made in Japan New publication effective Apr 2008 Specifications subject to change without notice ...

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