Mitsubishi Electric PUHZ-RP200YHA User manual

SERVICE MANUAL
SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
CONTENTS
1. TECHNICAL CHANGES······································2
2. REFERENCE MANUAL·······································2
3. SAFETY PRECAUTION·······································3
4. FEATURES···························································7
5. SPECIFICATIONS················································8
6. DATA ····································································9
7. OUTLINES AND DIMENSIONS·························12
8. WIRING DIAGRAM············································13
9. WIRING SPECIFICATIONS ·······························14
10. SPECIFICATIONS FOR ELECTRICAL WORK·····15
11. REFRIGERANT SYSTEM DIAGRAM ···················19
12. TROUBLESHOOTING········································21
13. FUNCTION SETTING·········································70
14. EASY MAINTENANCE FUNCTION···················77
15. MONITORING THE OPERATION DATA BY THE REMOTE CONTROLLER ···80
16. DISASSEMBLY PROCEDURE ··························90
17. PARTS LIST ·······················································98
18. RoHS PARTS LIST ··········································104
No.OC338
REVISED EDITION-C
R410A
Outdoor unit
[model names]
PUHZ-RP200YHA
PUHZ-RP250YHA
[Service Ref.]
PUHZ-RP200YHA
PUHZ-RP200YHA1
PUHZ-RP200YHA2
PUHZ-RP250YHA
PUHZ-RP250YHA1
PUHZ-RP250YHA2
Model name
indication
PUHZ-RP200YHA
PUHZ-RP200YHA1
PUHZ-RP200YHA2
PUHZ-RP250YHA
PUHZ-RP250YHA1
PUHZ-RP250YHA2
May 2007
Revision:
·
PUHZ-RP200/250YHA 2 are
added in REVISED EDITION-C.
· Some descriptions have been
modified.
· Please void OC338 REVISED
EDITION-B.
NOTE:
•This manual describes only
service data of the outdoor
units.
•RoHS compliant products
have <G> mark on the
spec name plate.
•For servicing of RoHS
compliant products, refer to
the RoHS Parts List.
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2
2REFERENCE MANUAL
Model name Service Ref.
PLA-RP35/50/60/71AA PLA-RP35/50/60/71AA.UK OC335
PLA-RP35/50/60/71/100/125/140BA PLA-RP35/50/60/71/100/125/140BA.UK OCHA12
OCB412
PLA-RP100/125/140AA2 PLA-RP100/125/140AA2.UK OC357
PCA-RP50/60/71/100/125/140GA OC328
PCA-RP50GA2 PCA-RP50/60/71/100/125/140GA PCA-RP50GA2
PCA-RP71/125HA PCA-RP71/125HA OC329
PKA-RP35/50GAL PKA-RP35/50GAL OC330
PKA-RP60/71/100FAL
PKA-RP50FAL2 PKA-RP60/71/100FAL PKA-RP50FAL2 OC331
PEAD-RP35/50/60/71EA(2) PEAD-RP35/50/60/71EA(2).UK -
PEAD-RP100/125/140EA(2) PEAD-RP100/125/140EA(2).UK
PEAD-RP60/71/100GA PEAD-RP60/71/100GA.UK
PEH-RP200/250MYA PEH-RP200/250MYA
-
-
2-2.TECHNICAL DATA BOOK
Manual No. OCS01
Service
Manual No.
2-1. INDOOR UNIT’S SERVICE MANUAL
1TECHNICAL CHANGES
PUHZ-RP200YHA1
PUHZ-RP250YHA1PUHZ-RP250YHA2
PUHZ-RP200YHA2
• CONTROLLER CIRCUIT BOARD (C.B.) has been changed.
PUHZ-RP200YHA
PUHZ-RP250YHA PUHZ-RP250YHA1
PUHZ-RP200YHA1
The parts below have been changed.
• 4-WAY VALVE AND COIL (21S4)
• BYPASS VALVE AND COIL (SV)
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3
3SAFETY PRECAUTION
Cautions for units utilizing refrigerant R410A
3-2. CAUTIONS RELATED TO NEW REFRIGERANT
Use new refrigerant pipes.
Make sure that the inside and outside of refrige-
rant piping is clean and it has no contamination
such as sulfur hazardous for use, oxides, dirt,
shaving particles, etc.
In addition, use pipes with specified thickness.
Store the piping to be used during installation
indoors and keep both ends of the piping sealed
until just before brazing. (Leave elbow joints, etc.
in their packaging.)
Use ester oil, ether oil or alkylbenzene oil (small
amount) as the refrigerant oil applied to flares
and flange connections.
In case of using the existing pipes for R22, be careful with
the followings.
· Change flare nut to the one provided with this product.
Use a newly flared pipe.
· Avoid using thin pipes.
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.
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.
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 refrigerant.
The following tools are necessary to use R410A refrigerant.
Keep the 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.
Flare tool
Electronic refrigerant
charging scale
Vacuum pump adaptor
Size adjustment gauge
Gauge manifold
Torque wrench
Gas leak detector
Charge hose
Tools for R410A
Contamination inside refrigerant piping can cause deterio-
ration of refrigerant oil etc.
If dirt, dust or moisture enters into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com-
pressor.
If large amount of mineral oil enters, that can cause deterio-
ration of refrigerant oil etc.
Ventilate the room if refrigerant leaks during
operation. If refrigerant comes into contact with
a flame, poisonous gases will be released.
3-1. ALWAYS OBSERVE FOR SAFETY
Before obtaining access to terminals,
all supply circuits must disconnected.
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4
Gravimeter
Unit
[3] Service tools
Use the below service tools as exclusive tools for R410A refrigerant.
No. 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
[1] Cautions for service
(1) Perform service after collecting 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
· Check that cylinder for R410A on the market is syphon type.
· Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.)
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5
3-3. CHANGED POINT
• Precautions when reusing existing R22 refrigerant pipes
(1) Flowchart
Connecting a new air conditioner to existing R22 refrigerant pipes
1Flare the pipe for the use with R410A refrigerant.
Use the flare nut attached to indoor and outdoor unit of the new air conditioner only.
2When reusing existing R22 refrigerant pipes of which gas pipe is [28.58mm and, in addition, when the outdoor unit is
installed to lower position than the indoor unit, be sure to change the setting of the DIP SW8-1 on the controller circuit
board of the outdoor unit to ON.
✽ This is to increase the speed of refrigerant passing in the gas pipe so that refrigerant oil can smoothly flow in the system.
• Use a different-diameter joint or brazing for the connection.
3When reusing standard-size existing R22 refrigerant pipes.
The pipes can be reused with pipe length restriction described on TECHNICAL DATA BOOK (OCS01).
Measuretheexistingpipethicknessandcheck
for damage.
The existing pipe thickness meets specifi-
cations and the pipes are not damaged. The existing pipe thickness does not meet specifications or the pipes are damaged.
Check if the existing air conditioner can operate.
The existing air conditioner can operate. The existing air conditioner cannot operate.
After operating the cooling system for about
30 minutes, do a pump down work. Use a refrigerant collecting device to collect the refrigerant.
Check the oil condition when collecting the refrigerant.
Oil is clean. (Clear to brownish color) Oil is dirty. (Black color)
When the compressor bearings are
glazed,rotationscratchesare present,
or the compressor breaks down, iron
particlesor oil deteriorationwill blacken
the oil.
Disconnect the existing air conditioner from
the pipes.
The existing piping can be reused.
After flaring the pipes again, connect the
new air conditioner. The existing pipes cannot be reused.
Use new pipes.
Perform the following inspections: air
tightness test, vacuum dryness (additional
refrigerant charge), gas leakage check
Replacement operation
Test operation
Replacement operation is the operation by which impurities remaining in
the existing piping (chlorinated compounds) are captured by the activated
carbon filter (replacement filter) in the outdoor unit.
• This model will automatically begin the replacement operation after it has been
installed when it enters the initialization phase for normal heating or cooling.How-
ever, the unit will not automatically perform the replacement operation if it is moved
to a new location where it will be used with existing R22 refrigerant piping. Under
such conditions, always use the SW8-2 operations to perform the replacement
operation before beginning the test operation.
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6
(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 time higher than that of R22, their sizes of flared sections and flare nuts are different.
1Thickness 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 0.7mm or below.)
2Dimensions 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 of its working pressure higher than that of other refriger-
ants. Therefore, to enhance airtightness and intensity, flare cutting dimension of copper pipe for R410A have been speci-
fied separately from the dimensions for other refrigerants as shown below. The dimension B of flare nut for R410A also
have partly been changed to increase intensity as shown below. Set copper pipe correctly referring to copper pipe flaring
dimensions for R410A below. For 1/2” and 5/8”, the dimension B changes.
Use torque wrench corresponding to each dimension.
3Tools for R410A (The following table shows whether conventional tools can be used or not.)
1/4”
3/8”
1/2”
5/8”
3/4”
7/8”
1”
1”-1/8”
6.35
9.52
12.70
15.88
19.05
22.20
25.40
28.58
0.8
0.8
0.8
1.0
—
—
—
—
0.8
0.8
0.8
1.0
1.0
1.0
1.0
1.0
Nominal
dimensions
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
Flare cutting dimensions
Outside
diameter Dimension A ( )
+0
-0.4
(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
Flare nut dimensions
Outside
diameter Dimension B (mm)
R410A
w
w36.0mm for
indoor unit
of RP100, 125
and 140
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
Collection of refrigerant
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
Charge refrigerant
Check the degree of vacuum. (Vacuum
valve prevents back flow of oil and refri-
gerant to thermistor vacuum gauge)
Charge refrigerant
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 adop-
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 adopter for rever-
se flow)
(Usable by adjusting
flaring dimension)
Can R407C tools be used?
Ester oil:
Alkylbenzene oil: minimum amount
(Usable if equipped
with adopter 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
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7
4 FEATURES
CHARGELESS SYSTEM
PRE-CHARGED REFRIGERANT IS SUPPLIED FOR PIPING LENGTH AT SHIPMENT. (Max.30m)
The refrigerant circuit with LEV(Linear Expansion Valve) and accumulator always control the optimal refrigerant level regard-
less of the length (30m max. and 5m min.) of piping. The additional refrigerant charging work during installation often causes
problems. It is completely eliminated by chargeless system. This unique system improves the quality
and reliability of the work done.It also helps to speed up the installation time.
PUHZ-RP200YHA
PUHZ-RP200YHA1
PUHZ-RP200YHA2
PUHZ-RP250YHA
PUHZ-RP250YHA1
PUHZ-RP250YHA2
Indoor unit Outdoor unit PUHZ-RP·YHA
200 250
PEH-RP·MYA
Indoor unit Outdoor unit PUHZ-RP·YHA
200 250
PLA-RP100AA2 ✕ 2
PLA-RP125AA2✕ 2
PEAD-RP100EA2✕ 2
PEAD-RP125EA ✕ 2
PEAD-RP100GA ✕ 2
PKA-RP100FAL ✕ 2
PCA-RP100GA ✕ 2
PCA-RP125GA ✕ 2
Indoor unit Outdoor unit PUHZ-RP·YHA
200 250
PLA-RP60AA ✕ 3
PLA-RP71AA ✕ 3
PEAD-RP60EA ✕ 3
PEAD-RP71EA ✕ 3
PEAD-RP60GA ✕ 3
PEAD-RP71GA ✕ 3
PKA-RP60FAL ✕ 3
PKA-RP71FAL ✕ 3
PCA-RP60GA ✕ 3
PCA-RP71GA ✕ 3
Indoor unit Outdoor unit
PUHZ-RP·YHA
200 250
PLA-RP50AA ✕ 4
PLA-RP60AA ✕ 4
PEAD-RP50EA ✕ 4
PEAD-RP60EA ✕ 4
PEAD-RP60GA ✕ 4
PKA-RP50GAL ✕ 4
PKA-RP50FAL2 ✕ 4
PKA-RP60FAL ✕ 4
PCA-RP50GA(2) ✕ 4
PCA-RP60GA ✕ 4
Ratio of distributing Part No.
Synchronized twin 50:50 MSDD-50WR-E
Synchronized triple 33:33:33 MSDT-111R-E
Synchronized quadruple 25:25:25:25 MSDF-1111R-E
PLA-RP50BA ✕ 4
PLA-RP60BA ✕ 4
PLA-RP100BA ✕ 2
PLA-RP125BA✕ 2PLA-RP60BA ✕ 3
PLA-RP71BA ✕ 3
PCA-RP125HA ✕ 2
PCA-RP71HA ✕ 3
4-1. COMBINATION OF INDOOR AND OUT DOOR UNITS
4-1-1. 1:1 SYSTEM
4-1-2. SYNCHRONIZEDTWIN,TRIPLE AND QUADRUPLE SYSTEM
(1) Synchronized twin (50:50) (2) Synchronized triple (33:33:33) (3)
Synchronized quadruple (25:25:25:25)
4-1-3. MULTI DISTRIBUTION PIPE (OPTION)
4-2. FEATURES
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8
5SPECIFICATIONS
3-ph, 50Hz, 400V (4wires)
Munsell 3Y 7.8/1.1
Linear Expansion Valve
Hermetic
ANV47FFBMT
Line start
HP switch, LP switch, Discharge thermo
—
Plate fin coil
Propeller fan o1
0.635
150(5,300)
Reverse cycle
900(35-7/16)
750(29-17/32)
1,798(70-25/32)
198(436)
R410A
10.5(23.1)
2.30(MEL56)
Flared
Flared & Brazing
Max. 40m
Max. 120m
Btu/h
kW
A
A
kW
W
kW
K
/min(CFM )
dB
dB
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
kg(lbs)
L
mm(in.)
mm(in.)
Power supply (phase, cycle, voltage)
Running current
Max. current
External finish
Refrigerant control
Compressor
Model
Motor output
Starter type
Protection devices
Crankcase heater
Heat exchanger
Fan Fan(drive) oNo.
Fan motor output
Airflow
Defrost method
Noise level
Dimensions
Weight
Refrigerant
Charge
Oil (Model)
Pipe size O.D.
Connection method
Between the indoor &
outdoor unit
Mode
Cooling
Heating
W
D
H
Liquid
Gas
Indoor side
Outdoor side
Height difference
Piping length
Service Ref.
Cooling
64,800
19.0(10.0~22.4)
10.0 24
4.5
55
56
9.52(3/8)
25.4(1)
Heating
76,400
22.4(10.0~25.0)
10.4
Cooling
75,000
22.0(12.5~28.0)
11.5 24
5.5
58
58
12.7(1/2)
28.58(1-1/8)
Heating
92,100
27.0(15.7~31.5)
12.4
OUTDOOR UNIT
REFRIGERANT PIPING
PUHZ-RP250YHA
PUHZ-RP250YHA1
PUHZ-RP250YHA2
PUHZ-RP200YHA
PUHZ-RP200YHA1
PUHZ-RP200YHA2
Capacity
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9
6DATA
Parts name
Outdoor unit
250V 6.3A
ANV47FFBMT
HAM-BD32
(0~480 Pulse)
2.7mH 25A
DC12V
0:/15t, 10:/9.6t, 20:/6.3t, 25:/5.4t, 30:/4.3t, 40:/3.0t
0:/15t, 10:/9.6t, 20:/6.3t, 25:/5.4t, 30:/4.3t, 40:/3.0t
0:/15t, 10:/9.6t, 20:/6.3t, 25:/5.4t, 30:/4.3t, 40:/3.0t
20:/250t, 30:/160t, 40:/104t, 50:/70t, 60:/48t, 70:/34t, 80:/24t, 90:/15t, 100:/13t

6P 635W o1
PA6Y635-T
5P
(L1, L2, L3, N, )
OFF 3.60+0.2MPa
ON 2.80i0.15MPa
OFF -0.03i0.03MPa
ON 0.05i0.04MPa
VT60100
LB64 AC220~240V
(DM50G461)
PUHZ-RP200YHA
PUHZ-RP250YHA
FUSE
(F 3,4)
250V 15A
FUSE
(FUSE1,2)
Solenoid Valve Coil
(Four-way Valve)
21S4
Linear Expansion
Valve
(LEV-A)
Reactor
(DCL)
Motor Compressor
(MC)
High Pressure
Switch
(63H)
Low Pressure
Switch
(63L)
Fan Motor
(MF)
Thermistor
(Discharge)
(TH4)
Thermistor
(Outdoor)
(TH7)
Terminal Block
(Power Supply)
(TB1)
3P
(S1, S2, S3)
Terminal Block
(Indoor / Outdoor)
(TB2)
2200=400V
16"30W
Main Smoothing Capacitor
(CB1, CB2)
Rush Current
Protect Resister
(RS)
Thermistor
(Outdoor Pipe)
(TH3, TH32 )
Thermistor
(Outdoor2-PhasePipe)
(TH6)
Linear Expansion
Valve Coil
(LEV-A)
Solenoid Valve
(Four-way Valve)
VF20100
Solenoid Valve
<Bypass Valve>
LD2 AC220~240V
Solenoid Valve Coil
<Bypass Valve>
(SV)
PUHZ-RP200YHA1/YHA2
PUHZ-RP250YHA1/YHA2
STF0731Z
FDF6A-008-RK
STF AC220~240V
(BG50T388)
AC220~240V
6-1. ELECTRICAL PARTS SPECIFICATIONS
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10
6-2. COMPRESSOR TECHNICAL DATA
U-V
U-W
W-V
Unit
Compressor model
Winding
Resistance
( ")
ANV47FFBMT
(at 20°C)
0.72
0.72
0.72
PUHZ-RP200, 250YHA
PUHZ-RP200, 250YHA1
PUHZ-RP200, 250YHA2
1m
1m
MICROPHONE UNIT
GROUND
6-3. NOISE CRITERION CURVES
90
80
70
60
50
40
30
20
10 63 125 250 500 1000 2000 4000 8000
APPROXIMATE
THRESHOLD OF
HEARING FOR
CONTINUOUS
NOISE
OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 µbar)
BAND CENTER FREQUENCIES, Hz
NC-60
NC-50
NC-40
NC-30
NC-20
NC-70
PUHZ-RP200YHA
PUHZ-RP200YHA1
PUHZ-RP200YHA2
COOLING
MODE
HEATING
55.0
SPL(dB)
56.0
LINE
90
80
70
60
50
40
30
20
10 63 125 250 500 1000 2000 4000 8000
APPROXIMATE
THRESHOLD OF
HEARING FOR
CONTINUOUS
NOISE
OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 µbar)
BAND CENTER FREQUENCIES, Hz
NC-60
NC-50
NC-40
NC-30
NC-20
NC-70
PUHZ-RP250YHA
PUHZ-RP250YHA1
PUHZ-RP250YHA2
COOLING
MODE
HEATING
58.0
SPL(dB)
58.0
LINE
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