Mitsubishi Electric PUHZ-P200YKA2 User manual

SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
SERVICE MANUAL R410A
Outdoor unit
[Model Name]
PUHZ-P200YKA2
PUHZ-P250YKA2
[Service Ref.]
PUHZ-P200YKA2.UK
PUHZ-P250YKA2.UK
PARTS CATALOG (OCB647)
CONTENTS
1. REFERENCE MANUAL ································· 2
2. SAFETY PRECAUTION ································· 2
3. FEATURES····················································· 6
4. SPECIFICATIONS ·········································· 7
5. DATA······························································· 8
6. OUTLINES AND DIMENSIONS ··················· 11
7. WIRING DIAGRAM ······································ 12
8. WIRING SPECIFICATIONS·························· 13
9. REFRIGERANT SYSTEM DIAGRAM ············· 18
10. TROUBLESHOOTING·································· 20
11. FUNCTION SETTING ··································· 74
12. MONITORING THE OPERATION DATA BY THE REMOTE CONTROLLER ····83
13. EASY MAINTENANCE FUNCTION ············· 92
14. DISASSEMBLY PROCEDURE····················· 95

Note:
•Thismanualdescribesservice
dataoftheoutdoorunitsonly.
No. OCH647
September 2016

2
2-1. ALWAYS OBSERVE FOR SAFETY
Before obtaining access to terminal, all supply circuits must be disconnected.
INDOOR UNIT SERVICE MANUAL
ModelName ServiceRef. Service
ManualNo.
PLA-RP35/50/60/71/100/125EA PLA-RP35/50/60/71/100/125EA.UK OCH626
OCB626
PCA-RP71/125HA PCA-RP71/125HA#1 OC329
PKA-RP35/50HAL PKA-RP35/50HALR1(-ER) OCH453
OCB453
PKA-RP60/71/100KAL PKA-RP60/71/100KALR1.TH(-ER) OCH452
OCB452
PSA-RP71/100/125KA PSA-RP71/100/125KA OCH528
OCB528
PEAD-RP50/60/71/100/125JA(L)Q PEAD-RP50/60/71/100/125JA(L)QR2.UK HWE10090
BWE10160
PEA-RP200/250GAQ PEA-RP200/250GAQ.TH-AF HWE10070
BWE10140
2SAFETY PRECAUTION
2-2. CAUTIONS RELATED TO NEW REFRIGERANT
Cautions for units utilizing refrigerant R410A
Preparation before the repair service.
• Prepare the proper tools.
• Prepare the proper 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 or cold areas in the refrigerating cycle.
• When the repair or the inspection of the circuit needs to be
done without turning off the power, exercise great caution
not to touch the live parts.
1REFERENCE MANUAL
OCH647

3
[1] Cautions for service
(1) Perform service after recovering the refrigerant left in unit completely.
(2) Do not release refrigerant in the air.
(3) After completing service, charge the cycle with specified amount of refrigerant.
(4) When performing service, install a filter drier simultaneously.
Be sure to use a filter drier for new refrigerant.
[2] Additional refrigerant charge
When charging directly from cylinder
(1)CheckthatcylinderforR410Aonthemarketisasyphontype.
(2)Chargingshouldbeperformedwiththecylinderofsyphonstoodvertically.(Refrigerantischargedfromliquidphase.)
Electronic weighing scale
Unit
Make sure that the inside and outside of refrige-
rant piping is clean and it has no contaminants
such as sulfur, oxides, dirt, shaving particles, etc,
which are hazard to refrigerant cycle.
In addition, use pipes with specified thickness.
Contamination inside refrigerant piping can cause deterio-
ration of refrigerant oil, etc.
Store the piping indoors, and both ends of the
piping sealed until just before brazing.
(Leave elbow joints, etc. in their packaging.)
If dirt, dust or moisture enters into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com-
pressor.
The refrigerant oil applied to flare and flange
connections must be ester oil, ether oil or
alkylbenzene oil in a small amount.
If large amount of mineral oil enters, that can cause deterio-
ration 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.
Charge refrigerant from liquid phase of gas
cylinder.
If the refrigerant is charged from gas phase, composition change
may occur in refrigerant and the efficiency will be lowered.
Use new refrigerant pipes.
In case of using the existing pipes for R22, be careful with
the following:
· Be sure to clean the pipes and make sure that the 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 R410A.
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 refrigerant oil or malfunction of com-
pressor.
Do not use a charging cylinder.
If a charging cylinder is used, the composition of refrigera-
nt will change and the efficiency will be lowered.
Use the following tools specifically designed for
use with R410A refrigerant.
The following tools are necessary to use R410A refrigerant.
Flare tool
Electronic refrigerant
charging scale
Vacuum pump adaptor
Size adjustment gauge
Gauge manifold
Torque wrench
Gas leak detector
Charge hose
Tools for R410A
Ventilate the room if refrigerant leaks during
operation. If refrigerant comes into contact with
a flame, poisonous gases will be released.
Never use any refrigerant other than that specified.
Doing so may cause a burst, an explosion, or fire when the
unit is being used, serviced, or disposed of.
Correct refrigerant is specified in the manuals and on the
spec labels provided with our products.
We will not be held responsible for mechanical failure,
system malfunction, unit breakdown or accidents caused
by failure to follow the instructions.
Use the specified refrigerant only.
OCH647

Performtheairtighttest,vacuumairpurging,
additionalrefrigerant charging(if necessary),
andgasleakcheck.
•Refertotheowchartbelowtodetermineiftheexistingpipescanbeusedandifitisnecessarytousealterdrier.
•Ifthediameteroftheexistingpipesisdifferentfromthespecieddiameter,refertotechnologicaldatamaterialstoconrmif
thepipescanbeused.
▼
▼
▼
▼
▼
▼▼
Measuretheexistingpipethicknessand
checkfordamage.
The existing pipe thickness meets specica-
tions and the pipes are not damaged.
Checkiftheexistingairconditionercanoperate.
Afteroperatingthecoolingsystemforabout30
minutes,doapumpdownwork.
Disconnecttheexistingairconditionerfromthe
pipes.
Attachthenewairconditioner
Testrun Theexistingpipescannotbereused.
Usenewpipes.
•Iftheexistingairconditionercannotoperate,usea
refrigerantrecoverydevicetocollecttherefrigerant.
•Incaseexistingpipeswereusedforgasoroil
heatpumpsystems,besuretocleanthepipesfor
P200/250models.
The existing pipe thickness does not meet
specications or the pipes are damaged.
4
2-3. PRECAUTIONS WHEN REUSING EXISTING R22 REFRIGERANT PIPES
(1) Flowchart
[3] Service tools
Use the below service tools as exclusive tools for R410A refrigerant.
No. Toolname Specifications
1Gaugemanifold · OnlyforR410A
· Usetheexistingfittingspecifications.(UNF1/2)
· Usehigh-tensionsidepressureof5.3MPa·Gorover.
2Chargehose · OnlyforR410A
· Usepressureperformanceof5.09MPa·Gorover.
3Electronicscale —
4Gasleakdetector · UsethedetectorforR134a,R407CorR410A.
5Adaptorforreverseflowcheck · Attachonvacuumpump.
6Refrigerantchargebase —
7Refrigerantcylinder · OnlyforR410A · Topofcylinder(Pink)
· Cylinderwithsyphon
8Refrigerantrecoveryequipment —
OCH647

5
(2) Cautions for refrigerant piping work
NewrefrigerantR410Aisadoptedforreplacementinverterseries.AlthoughtherefrigerantpipingworkforR410Aissame
asforR22,exclusivetoolsarenecessarysoasnottomixwithdifferentkindofrefrigerant.Furthermoreastheworking
pressureofR410Ais1.6timeshigherthanthatofR22,theirsizesofflaredsectionsandflarenutsaredifferent.
1Thicknessofpipes
BecausetheworkingpressureofR410AishighercomparedtoR22,besuretouserefrigerantpipingwiththickness
shownbelow.(Neverusepipesof0.7mmorbelow.)
2Dimensionsofflarecuttingandflarenut
ThecomponentmoleculesinHFCrefrigerantaresmallercomparedtoconventionalrefrigerants.Inadditiontothat,
R410Aisarefrigerant,whichhashigherriskofleakagebecauseitsworkingpressureishigherthanthatofotherrefriger-
ants.Therefore,toenhanceairtightnessandstrength,flarecuttingdimensionofcopperpipeforR410Ahasbeenspeci-
fiedseparatelyfromthedimensionsforotherrefrigerantsasshownbelow.ThedimensionBofflarenutforR410Aalso
haspartlybeenchangedtoincreasestrengthasshownbelow.Setcopperpipecorrectlyreferringtocopperpipeflaring
dimensionsforR410Abelow.For1/2and5/8inchpipes,thedimensionBchanges.
Usetorquewrenchcorrespondingtoeachdimension.
3ToolsforR410A(Thefollowingtableshowswhetherconventionaltoolscanbeusedornot.)
1/4
3/8
1/2
5/8
3/4
6.35
9.52
12.70
15.88
19.05
0.8
0.8
0.8
1.0
—
0.8
0.8
0.8
1.0
1.0
Nominal
dimensions (inch)
Diagram below: Piping diameter and thickness
Outside
diameter (mm)
Thickness (mm)
R410A R22
1/4
3/8
1/2
5/8
3/4
6.35
9.52
12.70
15.88
19.05
9.1
13.2
16.6
19.7
—
9.0
13.0
16.2
19.4
23.3
Nominal
dimensions (in)
Flare cutting dimensions
Outside
diameter
Dimension A ( )
+0
-0.4 (mm)
(mm)
R410A R22
1/4
3/8
1/2
5/8
3/4
6.35
9.52
12.70
15.88
19.05
17.0
22.0
26.0
29.0
—
17.0
22.0
24.0
27.0
36.0
Nominal
dimensions (in)
Flare nut dimensions
Outside
diameter
Dimension B (mm)
(mm)
R410A R22
Gauge manifold
Charge hose
Gas leak detector
Refrigerant recovery equipment
Refrigerant cylinder
Applied oil
Safety charger
Charge valve
Vacuum pump
Flare tool
Bender
Pipe 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
Apply to flared section
Prevent compressor malfunction
when charging refrigerant by
spraying liquid refrigerant
Prevent gas from blowing out
when detaching charge hose
Vacuum drying and air
purge
Flaring work of piping
Bend the pipes
Cut the pipes
Weld the pipes
Refrigerant charge
Check the 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
Ester oil and alkylbenzene
oil (minimum amount)
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 other refrigerants
can be used by adjusting
flaring dimension
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 adapter for rever-
se flow)
(Usable by adjusting
flaring dimension)
Can R407C tools be used?
Ester oil:
Alkylbenzene oil: minimum amount
(Usable if equipped
with adapter for rever-
se flow)
(Usable by adjusting
flaring dimension)
: Prepare a new tool. (Use the new tool as the tool exclusive for R410A.)
: Tools for other refrigerants can be used under certain conditions.
: Tools for other refrigerants can be used.
DimensionA
DimensionB
OCH647