Mitsubishi Electric PUHZ-SW160YKA-BS User manual

SERVICE MANUAL R410A
Outdoor unit
[Model Name]
PUHZ-SW160YKA
PUHZ-SW200YKA
[Service Ref.]
PUHZ-SW160YKA.UK
PUHZ-SW160YKAR1.UK
PUHZ-SW200YKA.UK
PUHZ-SW200YKAR1.UK
PUHZ-SW160YKA-BS.UK
PUHZ-SW160YKAR1-BS.UK
PUHZ-SW200YKA-BS.UK
PUHZ-SW200YKAR1-BS.UK
PARTS CATALOG (OCB583)
CONTENTS
TECHNICAL CHANGES ······························2
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 ··········· 15
10. TROUBLESHOOTING···························· 17
11. DISASSEMBLY PROCEDURE ················· 60

Salt proof model
PUHZ-SW160YKA-BS
PUHZ-SW200YKA-BS
No. OCH583
REVISED EDITION-A
August 2015
SPLIT-TYPE, AIR TO WATER HEAT PUMP
Note:
• This manual describes service
data of the indoor units only.
• Please void OCH583.
Revision:
• PUHZ-SW160YKAR1.UK,
PUHZ-SW160YKAR1-BS.UK,
PUHZ-SW200YKAR1.UK and
PUHZ-SW200YKAR1-BS.UK
in REVISED EDITION-A.
• Some descriptions have been
modified.

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.
ERSE-YM9EC
ERSE-MEC
EHSE-YM9EC
EHSE-MEC
ERSE-YM9EC.UK
ERSE-YM9ECR1.UK
ERSE-MEC.UK
ERSE-MECR1.UK
EHSE-YM9EC.UK
EHSE-YM9ECR1.UK
EHSE-MEC.UK
EHSE-MECR1.UK
OCH590
OCB590
PAC-IF012B-E
PAC-IF021B-E
PAC-IF032B-E
PAC-IF012B-E
PAC-IF021B-E
PAC-IF032B-E
OCB427
PAC-SIF051B-E PAC-SIF051B-E OCB536
PAC-IF061B-E
PAC-IF062B-E
PAC-IF063B-E
PAC-IF061B-E
PAC-IF062B-E
PAC-IF063B-E
OCB572
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 beaker.
• 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
TECHNICAL CHANGES
Service ref. have been changed as follows.
PUHZ-SW160YKA(-BS).UK PUHZ-SW160YKAR1(-BS).UK
PUHZ-SW200YKA(-BS).UK PUHZ-SW200YKAR1(-BS).UK
1. A compliance with ErP directive Lot1 has been authorized.
OCH583A

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
· Check that cylinder for R410A on the market is a syphon type.
· Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.)
Gravimeter
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.
OCH583A

4
2-3. PRECAUTIONS WHEN REUSING EXISTING R22 REFRIGERANT PIPES
(1) Flowchart
(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.)
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
[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
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.
The existing pipe thickness does not meet
specications or the pipes are damaged.
OCH583A

5
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
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
2-4. PRECAUTIONS FOR SALT PROOF TYPE "-BS" MODEL
Although "-BS" model has been designed to be resistant to salt damage, observe the following precautions to maintain the per-
formance of the unit.
1. Avoid installing the unit in a location where it will be exposed directly to seawater or sea breeze.
2. If the cover panel may become covered with salt, be sure to install the unit in a location where the salt will be washed away
by rainwater. (If a sunshade is installed, rainwater may not clean the panel.)
3. To ensure that water does not collect in the base of the outdoor unit, make sure that the base is level, not at angle. Water
collecting in the base of the outdoor unit could cause rust.
4. If the unit is installed in a coastal area, clean the unit with water regularly to remove any salt build-up.
5. If the unit is damaged during installation or maintenance, be sure to repair it.
6. Be sure to check the condition of the unit regularly.
7. Be sure to install the unit in a location with good drainage.
OCH583A

6
3 FEATURES
CHARGELESS SYSTEM
PRE-CHARGED REFRIGERANT IS SUPPLIED FOR PIPING LENGTH AT SHIPMENT
Maximum 30 m
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-SW160YKA
PUHZ-SW200YKA
PUHZ-SW160YKA-BS
PUHZ-SW200YKA-BS

OCH583A

7
4 SPECIFICATIONS
A
kW
W
kW
K
/min(CFM )
dB
dB
mm (in)
mm (in)
mm (in)
kg (lb)
kg (lb)
L
mm (in)
mm (in)
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
Noise level (SPL)
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-SW200YKA(-BS).UK
PUHZ-SW200YKAR1(-BS).UK
PUHZ-SW160YKA(-BS).UK
PUHZ-SW160YKAR1(-BS).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
2 to 80 m
21
4.7
HP switch
Comp. surface thermo
HP sensor
3 phase 50Hz, 400V
OUTDOOR UNIT
REFRIGERANT PIPING
4.7
19
7.1 (15.7)
9.52 (3/8)
25.4 (1)
60
62
7.7 (17.0)
12.7 (1/2)
25.4 (1)
ANB52FRNMT
2.30 (FVC68D)
136 (299.88)
58
62
OCH583A

8
5DATA
Service Ref.
Compressor model
(at 20°C)
U-V
U-W
W-V
Winding
Resistance
( ")
0.30
0.30
0.30
ANB52FRNMT
PUHZ-SW160/200YKA.UK
PUHZ-SW160/200YKA-BS.UK
PUHZ-SW160/200YKAR1.UK
PUHZ-SW160/200YKAR1-BS.UK
5-2. COMPRESSOR TECHNICAL DATA
5-1. ADJUSTING THE AMOUNT OF REFRIGERANT
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 71–80 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-SW160YKA.UK
PUHZ-SW160YKA-BS.UK
PUHZ-SW160YKAR1.UK
PUHZ-SW160YKAR1-BS.UK
80 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
[9.52overall 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
[12.7over all length[m]
o0.11 [kg/m]
=
Additional charge amount
for 70 m
SW160 3.6 kg
SW200 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."
PUHZ-SW200YKA.UK
PUHZ-SW200YKA-BS.UK
PUHZ-SW200YKAR1.UK
PUHZ-SW200YKAR1-BS.UK
OCH583A

9
5-3. NOISE CRITERION CURVES
1.5 m
1m
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-SW160YKA.UK
PUHZ-SW160YKA-BS.UK
PUHZ-SW160YKAR1.UK
PUHZ-SW160YKAR1-BS.UK
COOLING
MODE
HEATING
58
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
COOLING
MODE
HEATING
60
SPL(dB)
62
LINE
PUHZ-SW200YKA.UK
PUHZ-SW200YKA-BS.UK
PUHZ-SW200YKAR1.UK
PUHZ-SW200YKAR1-BS.UK
OCH583A

10
5-4. <REFERENCE DATA> PLATE HEAT EXCHANGER (ACH70-74 PLATES)
Nominal water ow L/min 63.1
Heating
(A7/W35) Capacity kW 22.0
COP 4.20
Power input kW 5.238
Heating
(A7/W45) Capacity kW 22.0
COP 3.20
Power input kW 6.875
Heating
(A2/W35) Capacity kW 16.0
COP 3.11
Power input kW 5.144
Heating
(A2/W45) Capacity kW 16.0
COP 2.36
Power input kW 6.779
Nominal water ow L/min 45.9
Cooling
(A35/W7) Capacity kW 16.0
EER 2.76
Power input kW 5.800
Cooling
(A35/W18) Capacity kW 18.0
EER 4.56
Power input kW 3.950
Rating conditions
Nominal operating condition
Heating (A7/W35)
Outside air temperature (Dry-bulb) + 7°C
Outside air temperature (Wet-bulb) + 6°C
Water temperature (inlet/outlet) + 30°C/+ 35°C
Heating (A7/W45)
Outside air temperature (Dry-bulb) + 7°C
Outside air temperature (Wet-bulb) + 6°C
Water temperature (inlet/outlet) + 40°C/+ 45°C
Heating (A2/W35)
Outside air temperature (Dry-bulb) + 2°C
Outside air temperature (Wet-bulb) + 1°C
Water temperature (inlet/outlet) + 30°C/+ 35°C
Heating (A2/W45)
Outside air temperature (Dry-bulb) + 2°C
Outside air temperature (Wet-bulb) + 1°C
Water temperature (inlet/outlet) + 40°C/+ 45°C
Cooling (A35/W7)
Outside air temperature (Dry-bulb) + 35°C
Outside air temperature (Wet-bulb) + 24°C
Water temperature (inlet/outlet) + 12°C/+ 7°C
Cooling (A35/W18)
Outside air temperature (Dry-bulb) + 35°C
Outside air temperature (Wet-bulb) + 24°C
Water temperature (inlet/outlet) + 23°C/+ 18°C
Note: "COP" and "Power input" in the above table do NOT contain the "pump input (based on EN 14511)".
PUHZ-SW160YKA(-BS).UK
PUHZ-SW160YKAR1(-BS).UK
Nominal water ow L/min 71.7
Heating
(A7/W35) Capacity kW 25.0
COP 4.00
Power input kW 6.250
Heating
(A7/W45) Capacity kW 25.0
COP 3.10
Power input kW 8.064
Heating
(A2/W35) Capacity kW 20.0
COP 2.80
Power input kW 7.142
Heating
(A2/W45) Capacity kW 20.0
COP 2.20
Power input kW 9.090
Nominal water ow L/min 57.3
Cooling
(A35/W7) Capacity kW 20.0
EER 2.25
Power input kW 8.888
Cooling
(A35/W18) Capacity kW 22.0
EER 4.10
Power input kW 5.365
PUHZ-SW200YKA(-BS).UK
PUHZ-SW200YKAR1(-BS).UK
OCH583A