Mitsubishi Electric PUHZ-W85VHA2 Service Manual Download Page 1

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SERVICE MANUAL

AIR TO WATER HEAT PUMP

No. OCH465

CONTENTS

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

2. SPECIFICATIONS ......................................................5

3. DATA ..............................................................................7

4. OUTLINES AND DIMENSIONS ............................9

5. WIRING DIAGRAM ..................................................10

6. WIRING SPECIFICATIONS ..................................11

7. REFRIGERANT SYSTEM DIAGRAM....................12

8. TROUBLESHOOTING ............................................13

9. DISASSEMBLY PROCEDURE ............................42

August 2009

Note:

•

This manual describes only

service data of outdoor unit.

•

RoHS compliant products have

<G> mark on the spec name plate.

R410A

PUHZ-W85VHA2.UK
PUHZ-W85VHA2-BS.UK

PARTS CATALOG (OCB465)

[Model name]

PUHZ-W85VHA2

PUHZ-W85VHA2-BS

[Service Ref.]

PUHZ-W85VHA2.UK
PUHZ-W85VHA2-BS.UK

Summary of Contents for PUHZ-W85VHA2

Page 1: ...ICATIONS 11 7 REFRIGERANT SYSTEM DIAGRAM 12 8 TROUBLESHOOTING 13 9 DISASSEMBLY PROCEDURE 42 August 2009 Note This manual describes only service data of outdoor unit RoHS compliant products have G mark on the spec name plate R410A PUHZ W85VHA2 UK PUHZ W85VHA2 BS UK PARTS CATALOG OCB465 Model name PUHZ W85VHA2 PUHZ W85VHA2 BS Service Ref PUHZ W85VHA2 UK PUHZ W85VHA2 BS UK ...

Page 2: ...ump 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 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 compressor Do not u...

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: ...cutter Welder and nitrogen gas cylinder Refrigerant charging scale Vacuum gauge or thermis tor vacuum gauge and vacuum valve Charging cylinder Air purge refrigerant charge and operation check Gas leak check Refrigerant recovery Refrigerant charge Prevent compressor malfunction when charging refrigerant by spraying liquid refrigerant Prevent gas from blowing out when detaching charge hose Vacuum dr...

Page 5: ...g A7 W35 0 5 0 3 H C A A Cooling A35 W7 A Power factor Heating A7 W35 m m 4 0 4 A Cooling A35 W7 m m 2 8 6 2 B A t n e r r u c x a M m m 3 9 W A e z i s r e k a e r B m m 5 2 3 H g n i s a c r e t u O m m 84 D h s i n i f l a n r e t x E s e t a l p 0 5 l o r t n o c t n a r e g i r f e R Compressor Model Motor output kW Start type Protection devices Maximum outlet water temperature Oil Model L W ...

Page 6: ...s of unit Heating Table 1 10 0 12 0 14 0 16 0 18 0 20 0 22 0 24 0 Water flow rate L min 5 0 7 0 9 0 11 0 13 0 15 0 17 0 19 0 Return water temp Applicable Models PUHZ W85VHA2 BS Applicable Models PUHZ W85VHA2 BS 12 0 10 0 14 0 16 0 20 0 22 0 24 0 Table 2 Water flow rate L min 5 0 6 0 7 0 8 0 9 0 10 0 11 0 12 0 13 0 14 0 15 0 Return water temp 18 0 Available range Available range Cooling ...

Page 7: ...0 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 W85VHA2 BS UK COOLING MODE HEATING 48 SPL dB 48 LINE 3 1 NOISE CRITERION CURVES ...

Page 8: ... 2 81 2 16 Suction pressure MPa 0 73 0 64 Discharge temperature ºC 80 65 Condensing temperature ºC 46 37 Suction temperature ºC 3 1 Water conditions Flow volume L min 21 5 25 8 Outlet water temperature ºC 7 35 Outdoor conditions Intake air temperature D B ºC 35 7 W B ºC 24 6 The unit of pressure has been changed to MPa based on international SI system The conversion factor is 1 MPa 10 2 kgf cm We ...

Page 9: ...8 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 diag...

Page 10: ...L 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 SW7 Switch Function Switch 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 1 2 TH33 YLW t TH33 63...

Page 11: ...ler Outdoor unit 2 3 1 5 polar 1 Min 1 5 3 Min 4 2 0 3 Non polar AC 230V AC 230V DC 24V DC 12V Interface unit Flow temp controller Outdoor unit earth 2 Remote controller Interface unit Flow temp controller Circuit rating Outdoor unit L N single 3 Interface unit Flow temp controller Outdoor unit S1 S2 3 Interface unit Flow temp controller Outdoor unit S2 S3 3 Remote controller Interface unit Flow t...

Page 12: ... 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 control For power board protection Fo...

Page 13: ... 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 14: ... power supply terminal block TB1 b Connection of terminal on outdoor power circuit board Check connection of the connector TABT or TABS Refer to 8 6 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 Refer to 8 6 4 Check connection of reactor DCL Check connection of L1 and L2 on the active filte...

Page 15: ...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 16: ...rmistor TH4 exceeds 125 or 110 continuously for 5 minutes Abnormal if during defrosting discharge temperature thermistor TH4 exceeds 110 continuously for 30 minutes High comp surface temperature Abnormal if comp surface temperature TH33 exceeds 125 In the case of high comp surface tem perature error compressor does not restart unless the thermistor TH33 becomes less than 95 1 Overheated compressor...

Page 17: ...n of connector TH3 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 cir...

Page 18: ... Defective outdoor fan fan motor or short cycle of out door unit during cooling opera tion 2 Defective outdoor pipe thermistor TH3 3 Defective outdoor controller board 4 Defective pressure sensor 1 Check outdoor unit air passage 23 Turn the power off and on again to check the error code If U4 is displayed follow the U4 processing direction 4 Check pressure by microcomputer Pressure sensor 63HS SW2...

Page 19: ...sub remote control ler cannot receive any transmission normally from Interface unit Flow temp controller of refrigerant address 0 for 3 minutes Error code E0 Abnormal if sub remote controller could not receive any signal for 2 minutes 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 cont...

Page 20: ...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 21: ...hermistor TH3 Liquid temperature TH32 Inlet water temperature TH6 Plate HEX Liquid temperature TH7 Ambient temperature 1 Leakage or shortage of refrigerant 2 Malfunction of linear expansion valve 3 Refrigerant circuit is clogged with foreign objects w Clogging occurs in the parts which become below freezing point when water enters in refrigerant circuit 4 Disconnection of thermistor holder 1 Check...

Page 22: ... TH8 Abnormal Open or short Measure the resistance between the terminals with a tester At the ambient temperature of 20 Solenoid valve coil Four way valve 21S4 Compressor MC Normal Abnormal Open or short Measure the resistance between the terminals with a tester At the ambient temperature of 20 Normal 1450 150 Abnormal Open or short Solenoid valve coil Bypass valve SV Refer to the next page Fan mo...

Page 23: ...n motor 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 contact failure Check fuse F5 on outdoor controller circuit board Yes Yes No ...

Page 24: ...7k 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 Thermistor Comp surface TH33 0 10 20 30 40 50 20 10 0 10 20 30 40 50 Temperature Resi...

Page 25: ...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 0 5 2 5 5 2 5 4 5 Vout V PRESSURE MPa 3 2 1 WHT BLU BLK SENSOR 5V DC GND 63HS Vout MICRO COMPUTER CONTROLLER BOARD 5V DC Output Vout DC HIGH PRESSURE SENSOR ...

Page 26: ...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 27: ...se 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 wound by lead wire If the stopper is not firmly attac...

Page 28: ...harge 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 330 V VFG voltage between right pins of PC5D pin 3 and pin 4 VSP voltage between pins of C5B DC 0 V when stopped DC 1 6 5 V...

Page 29: ...ltage 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 PUHZ W85VHA2 UK PUHZ W85VHA2 BS UK E2 Connect to the earth ...

Page 30: ... circuit board CN5 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 br...

Page 31: ...unit is in trouble and Io open less than 1 1 The unit does not operate can not be switched ON and L2 short 100k 1M 1 The breaker operates open W1 1 The unit does not operate can not be switched ON 2U9 Abnormal stop W2 P and L2 short 100k 1M 1 The breaker operates open W1 1 The unit does not operate can not be switched ON 2U9 Abnormal stop W2 P and Io short 100k 1M 1 The breaker operates open W1 1 ...

Page 32: ... 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 TH33 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 ...

Page 33: ...re 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 truncated 0 500 When it is 100 pulse or more hundreds digit tens digit and ones digit are displayed by turns Example When 150...

Page 34: ... 100 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 displ...

Page 35: ...tdoor 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 0 255 When the SHd is 100 C or more hundreds digit tens digit and ones digit are displayed by tur...

Page 36: ... 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 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 Code display Deferred error history 2 of outdoor unit Deferred error code display Blinking being deferred Lighting deferment is cancelled 00 is displayed in c...

Page 37: ...temperature TH32 when error occurred 0 100 0 100 30 1 1 ON 2 3 4 5 6 Plate HEX liquid pipe temperature TH6 when error occurred 39 88 39 88 When the temperature is 0 C or less and temperature are displayed by turns Example When 15 C 0 5 secs 0 5 secs 2 secs Condensing temperature when error occurred 39 88 39 88 When the temperature is 0 C or less and temperature are displayed by turns Example When ...

Page 38: ...t tens digit and ones digit are displayed by turns Example When 415 minutes 0 5 secs 0 5 secs 2 secs Maximum frequency when error occurred 0 150 0 150 When it is 100 Hz or more hundreds digit tens digit and ones digit are displayed by turns Example When 105 Hz 0 5 secs 0 5 secs 2 secs Requested capacity step when error occurred 0 7 0 7 Step 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...

Page 39: ...Error details To be shown while error call is deferred Code display 1 ON 2 3 4 5 6 Requested capacity step Q STEP 0 7 0 7 Step SW2 setting Display detail Explanation for display Unit Comp shell temperature TH33 3 217 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 5 secs 2 secs 1 ON 2 3 4 5 6 1 30 ...

Page 40: ...opening pulse LEV A 0 0 1 1 0 1 LEV A opening pulse LEV A 0 0 0 1 0 0 LEV B opening pulse LEV B 1 0 0 0 1 0 LEV B opening pulse LEV B 0 1 0 0 0 1 Ambient temp TH7 1 0 0 0 1 1 Water inlet temp TH32 0 0 0 0 1 1 Requested capacity step Q STEP 1 0 1 1 1 1 Heat sink temp TH8 0 1 0 0 1 1 Comp surface temp TH33 0 1 1 1 1 1 Calculated max frequency Hz 0 1 1 0 1 1 Sub Cool SC 0 0 1 0 1 1 Heatsink temp TH8 ...

Page 41: ...W85VHA2 1 0 1 1 0 1 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 SW7 1 6 No function Do NOT use PUHZ W85VHA2 OFF SW8 1 Mode selection Energy saving mode Powerful mode OFF Always 2 No function Do NOT use PUHZ W85VHA2 OFF 3 Separate Interface Flow temp control ler outdoor unit power supplies Separate power supply Outdoor unit power supply OFF Powe...

Page 42: ...lowing connectors from controller circuit board fan motor linear expansion valve 2 thermistor Liquid pipe thermistor Discharge thermistor Plate HEX Liquid thermistor Outdoor ambient high pressure sensor high pressure switch 4 way valve and bypass valve Then remove a screw 4 8 from the valve bed to remove the lead wire Pull out the disconnected wire from the electrical parts box Diagram symbol in t...

Page 43: ...TH3 and thermis tor Discharge TH4 thermistor Comp shell TH33 1 Remove the service panel See Photo 1 2 Disconnect the connectors TH3 white TH4 white and TH33 yellow 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 the sensor holder Removing the thermistor Comp shell TH33 5 Pull out the therm...

Page 44: ... unit and remove the right side panel 6 Remove the solenoid valve coil 4 way valve See Photo 9 7 Recover refrigerant 8 Remove the welded part of 4 way valve Note 1 Recover refrigerant without letting it out in the air Note 2 The welded part can be removed easily by remov ing the right side panel Note 3 When installing the 4 way valve make sure to cover it with a wet cloth to prevent it from heatin...

Page 45: ...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 remov ing 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 Rem...

Page 46: ...ee Photo 4 6 Remove 3 screws 4 10 and remove the stay See Photo 10 7 Remove 3 screw 5 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 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 service panel...

Page 47: ... Remove 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 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 48: ...ARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN Copyright 2009 MITSUBISHI ELECTRIC ENGINEERING CO LTD Distributed in Aug 2009 No OCH465 PDF 6 Made in Japan New publication effective Aug 2009 Specifications subject to change without notice ...

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