Mitsubishi Electric PUHZ-ZRP100VKA3 User manual

SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
SERVICE MANUAL R410A
Outdoor unit
[Model Name]
PUHZ-ZRP100VKA3
PUHZ-ZRP125VKA3
PUHZ-ZRP140VKA3
PUHZ-ZRP100YKA3
PUHZ-ZRP125YKA3
PUHZ-ZRP140YKA3
PUHZ-ZRP200YKA2
PUHZ-ZRP250YKA2
[Service Ref.]
PUHZ-ZRP100VKA3.UK
PUHZ-ZRP125VKA3.UK
PUHZ-ZRP140VKA3.UK
PUHZ-ZRP100YKA3.UK
PUHZ-ZRP125YKA3.UK
PUHZ-ZRP140YKA3.UK
PUHZ-ZRP200YKA2.UK
PUHZ-ZRP250YKA2.UK
PARTS CATALOG (OCB645)
CONTENTS
1. REFERENCE MANUAL ································· 2
2. SAFETY PRECAUTION ································· 2
3. FEATURES····················································· 6
4. SPECIFICATIONS ·········································· 7
5. DATA······························································· 9
6. OUTLINES AND DIMENSIONS ··················· 13
7. WIRING DIAGRAM ······································ 15
8. WIRING SPECIFICATIONS·························· 18
9. REFRIGERANT SYSTEM DIAGRAM ············· 23
10. TROUBLESHOOTING·································· 26
11. FUNCTION SETTING ··································· 83
12. MONITORING THE OPERATION DATA BY THE REMOTE CONTROLLER ····92
13. EASY MAINTENANCE FUNCTION ··········· 101
14. DISASSEMBLY PROCEDURE··················· 104

Note:
•This manual describes service
data of the outdoor units only.
No. OCH645
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-ZP50/60/71/125/140EA PLA-ZP50/60/71/125/140EA.UK OCH625
OCB625
PLA-RP100/125/140EA PLA-RP100/125/140EA.UK OCH626
OCB626
PCA-RP50/60/71/100/125/140KAQ PCA-RP50/60/71/100/125/140/KAQR2(-ER) OCH491
OCB491
PKA-RP50HAL PKA-RP50HALR1(-ER) OCH453
OCB453
PKA-RP60/71/100KAL PKA-RP60/71/100KALR1.TH(-ER) OCH452
OCB452
PSA-RP71/100/125/140KA PSA-RP71/100/125/140KA OCH528
OCB528
PEAD-RP50/60/71/100/125/140JA(L)Q PEAD-RP50/60/71/100/125/140JA(L)QR2.UK HWE10090
BWE10160
PEA-RP200/250GAQ PEA-RP200/250GAQ.TH-AF HWE10070
BWE10140
SLZ-KF25/35/50/60VA SLZ-KF25/35/50/60VA.TH OCH600
OCB600
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
OCH645

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.)
Unit
Electronic weighing scale
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.
OCH645

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 —
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
ZRP100–250 models.
The existing pipe thickness does not meet
specications or the pipes are damaged.
OCH645

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.
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 0.7 mm 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 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.
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
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 (in)
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
* 36.00 mm for
indoor unit of
ZRP100, 125
and 140
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
OCH645

6
3 FEATURES
CHARGELESS SYSTEM
PRE-CHARGED REFRIGERANT IS SUPPLIED FOR PIPING LENGTH AT SHIPMENT
Maximum 30 m (PUHZ-ZRP100–250)
The refrigerant circuit with LEV (Linear Expansion Valve) and power receiver/accumulator always control the optimal refrig-
erant level regardless of the length (30 m maximum and 5 m minimum) 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-ZRP100VKA3
PUHZ-ZRP125VKA3
PUHZ-ZRP140VKA3
PUHZ-ZRP100YKA3
PUHZ-ZRP125YKA3
PUHZ-ZRP140YKA3
PUHZ-ZRP200YKA2
PUHZ-ZRP250YKA2

OCH645

7
A
kW
W
kW
K
/min(CFM )
dB
dB
mm (inch)
mm (inch)
mm (inch)
kg (lb)
kg (lb)
L
mm (inch)
mm (inch)
Power supply (phase, cycle, voltage)
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
Sound pressure level
Dimensions
Weight
Refrigerant
Charge
Oil (Model)
Pipe size O.D.
Connection method
Between the indoor &
outdoor unit
Cooling
Heating
W
D
H
Liquid
Gas
Indoor side
Outdoor side
Height difference
Piping length
Service Ref. PUHZ-ZRP140VKA3.UKPUHZ-ZRP125VKA3.UK
PUHZ-ZRP100VKA3.UK
49
51
Munsell 3Y 7.8/1.1
Linear Expansion Valve
Hermetic
Inverter
—
Plate fin coil
Propeller fan o2
0.060+0.060
Reverse cycle
1,050 (41-5/16)
330+40 (13+1-9/16)
1,338 (52-11/16)
R410A
5.0 (11.0)
1.40 (FV50S)
9.52 (3/8)
15.88 (5/8)
Flared
Flared
Maximum 30 m
Maximum 75 m
28
3.3
HP switch
Comp. surface thermo
Discharge thermo
Single 50 Hz, 230 V
OUTDOOR UNIT
REFRIGERANT PIPING
3.3
2.2
26.5
ANB33FNFMT
50
52
116 (256) 118 (260)
110 (3,880) 120 (4,230)
A
kW
W
kW
K
/min(CFM )
dB
dB
mm (inch)
mm (inch)
mm (inch)
kg (lb)
kg (lb)
L
mm (inch)
mm (inch)
Power supply (phase, cycle, voltage)
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
Sound pressure level
Dimensions
Weight
Refrigerant
Charge
Oil (Model)
Pipe size O.D.
Connection method
Between the indoor &
outdoor unit
Cooling
Heating
W
D
H
Liquid
Gas
Indoor side
Outdoor side
Height difference
Piping length
Service Ref.
PUHZ-ZRP140YKA3.UKPUHZ-ZRP125YKA3.UKPUHZ-ZRP100YKA3.UK
49
51
9.5
Munsell 3Y 7.8/1.1
Linear Expansion Valve
Hermetic
Inverter
—
Plate fin coil
Propeller fan o2
0.060+0.060
Reverse cycle
1,050 (41-5/16)
330+40 (13+1-9/16)
1,338 (52-11/16)
R410A
5.0 (11.0)
1.40 (FV50S)
9.52 (3/8)
15.88 (5/8)
Flared
Flared
Maximum 30 m
Maximum 75 m
3.3
HP switch
Comp. surface thermo
Discharge thermo
3phase, 50 Hz, 400 V
OUTDOOR UNIT
REFRIGERANT PIPING
3.32.2
110 (3,880) 120 (4,230)
8 13
ANB33FNCMT
50
52
123 (271) 125 (276) 131 (289)
4 SPECIFICATIONS
OCH645

8
A
kW
W
kW
K
/min(CFM )
dB
dB
mm (inch)
mm (inch)
mm (inch)
kg (lb)
kg (lb)
L
mm (inch)
mm (inch)
Power supply (phase, cycle, voltage)
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
Sound pressure level
Dimensions
Weight
Refrigerant
Charge
Oil (Model)
Pipe size O.D.
Connection method
Between the indoor &
outdoor unit
Cooling
Heating
W
D
H
Liquid
Gas
Indoor side
Outdoor side
Height difference
Piping length
Service Ref. PUHZ-ZRP250YKA2.UK
PUHZ-ZRP200YKA2.UK
Munsell 3Y 7.8/1.1
Linear Expansion Valve
Hermetic
Inverter
—
Plate fin coil
Propeller fan o2
0.200 + 0.200
140 (4,940)
Reverse cycle
1,050 (41-5/16)
330 + 40 (13+1-9/16)
1,338 (52-11/16)
R410A
Flared
Flared & Brazing
Maximum 30 m
Maximum 100 m
21
5.5
HP switch
Comp. surface thermo
Overcurrent detection
3 phase 50 Hz, 400 V
OUTDOOR UNIT
REFRIGERANT PIPING
4.7
19
7.1 (15.7)
9.52 (3/8)
25.4 (1)
7.7 (17.0)
12.7 (1/2)
25.4 (1)
ANB52FRNMT
59
62
2.30 (FVC68D)
135 (298)
OCH645

9
5DATA
5-1. REFILLING REFRIGERANT CHARGE (R410A: kg) PUHZ-ZRP100–250
0.466
0.466
0.466
1.20
1.20
1.20
ANB33FNFMT ANB33FNCMT
PUHZ-ZRP100/125/140VKA3.UK PUHZ-ZRP100/125/140YKA3.UK
Service Ref.
Compressor model
(at 20°C)
U-V
U-W
W-V
Winding
Resistance
( ")
0.30
0.30
0.30
ANB52FRNMT
PUHZ-ZRP200/250YKA2.UK
Additional charge is required for pipes longer
than 30 m.
Service Ref. Piping length (one way) Initial
charged
10 m 20 m 30 m 40 m 50 m 60 m 75 m
PUHZ-ZRP100VKA3.UK
PUHZ-ZRP100YKA3.UK 4.6 4.8 5.0 5.6 6.2 6.8 7.4 5.0
PUHZ-ZRP125VKA3.UK
PUHZ-ZRP125YKA3.UK 4.6 4.8 5.0 5.6 6.2 6.8 7.4 5.0
PUHZ-ZRP140VKA3.UK
PUHZ-ZRP140YKA3.UK 4.6 4.8 5.0 5.6 6.2 6.8 7.4 5.0
PUHZ-ZRP200YKA2.UK 6.5 6.8 7.1 + 0.9 (8.0) + 1.8 (8.9) + 2.7 (9.8) + 3.6 (10.7) 7.1
PUHZ-ZRP250YKA2.UK 6.9 7.3 7.7 + 1.2 (8.9) + 2.4 (10.1) + 3.6 (11.3) + 4.8 (12.5) 7.7
5-3. COMPRESSOR TECHNICAL DATA
5-2. ADJUSTING THE AMOUNT OF REFRIGERANT PUHZ-ZRP200/250
Amount of additional refrigerant charge (kg)
30 m and less 31–40 m and less 41–50 m and less 51–60 m and less 61–70 m and less 71–100 m and less
0.9 kg 1.8 kg 2.7 kg 3.6 kg
1.2 kg 2.4 kg 3.6 kg 4.8 kg
Service Ref. Permitted
pipe length
PUHZ-ZRP200YKA2.UK
PUHZ-ZRP250YKA2.UK
100 m or less
Initial charge
(kg)
7.1
7.7
No additional
charge necessary
The additional charge
amount is obtained by
the following formula.
Main piping:
Liquid line size
[9.52 overall length [m]
o
0.09 [kg/m]
Branch piping: Liquid
line size
[9.52 overall length [m]
o0.06 [kg/m]
Branch piping: Liquid
line size
[6.35 overall length [m]
o0.02 [kg/m]
3.6 (kg)
Amount of additional
charge [kg]
Main piping:
Liquid line size
[12.7 over all length [m]
o0.11 [kg/m]
=
Additional charge amount
for 70 m
ZRP200 3.6 kg
ZRP250 4.8 kg
+++ –
Calculate the additional charge amount based on the following procedure.
If the calculation results in an amount that is smaller than the "Additional charge amount for 70 m," perform the additional charge using the amount shown
in "Additional charge amount for 70 m."
OCH645

10
5-4. NOISE CRITERION CURVES
1.5 m
1 m
MICROPHONE
UNIT
GROUND
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-ZRP100VKA3.UK
PUHZ-ZRP100YKA3.UK
COOLING
MODE
HEATING
49
SPL(dB)
51
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-ZRP125/140VKA3.UK
PUHZ-ZRP125/140YKA3.UK COOLING
MODE
HEATING
50
SPL(dB)
52
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-ZRP200YKA2.UK
COOLING
MODE
HEATING
59
SPL(dB)
62
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-ZRP250YKA2.UK
COOLING
MODE
HEATING
59
SPL(dB)
62
LINE
OCH645