Mitsubishi Electric PUHZ-W85VHA User manual

SERVICE MANUAL
AIR TO WATER HEAT PUMP
No. OCH439
CONTENTS
1. SAFETY PRECAUTION..........................................2
2. SPECIFICATIONS .....................................................4
3. DATA .............................................................................5
4. OUTLINES AND DIMENSIONS............................7
5. WIRING DIAGRAM...................................................8
6. WIRING SPECIFICATIONS....................................9
7. REFRIGERANT SYSTEM DIAGRAM...................10
8. TROUBLESHOOTING...........................................11
9. DISASSEMBLY PROCEDURE...........................38
April 2008
Note:
•This manual describes only
service data of PUHZ-W85VHA.
•RoHS compliant products have
<G> mark on the spec name plate.
R410A
[model name]
PUHZ-W85VHA
[Service Ref.]
PUHZ-W85VHA
PUHZ-W85VHA
PARTS CATALOG (OCB439)

2
SAFETY PRECAUTION
1
Cautions for units utilizing refrigerant R410A
1-2. CAUTIONS RELATED TO NEW REFRIGERANT
1-1. ALWAYS OBSERVE FOR SAFETY
Before obtaining access to terminal, all supply circuits must be disconnected.
[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.
[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.)
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 refrigerant 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 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 use a charging cylinder.
If a charging cylinder is used, the composition of refrigerant will change and the efficiency will be lowered.
Electronic refrigerant
charging scale
Vacuum pump adaptor
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.

33
1-3. CAUTIONS FOR REFRIGERANT PIPING WORK
Tools for R410A (The following table shows whether conventional tools can be used or not.)
Gauge manifold
Charge hose
Gas leak detector
Refrigerant recovery equipment
Refrigerant cylinder
Safety charger
Charge valve
Vacuum pump
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
Prevent compressor malfunction
when charging refrigerant by
spraying liquid refrigerant
Prevent gas from blowing out
when detaching charge hose
Vacuum drying and air
purge
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)
Refrigerant charge
Tool exclusive for R410A
Tool exclusive for R410A
Tool for HFC refrigerant
Tool exclusive for R410A
Tool exclusive for R410A
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
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)
Can R407C tools be used?
(Usable if equipped
with adopter for rever-
se flow)
: 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.
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 5.3 MPa·G or over.
2Charge hose ·Only for R410A
·Use pressure performance of 5.09 MPa·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

4
SPECIFICATIONS
2
Power supply Phase
Voltage V noitidnocgnitarepolanimoNzHycneuqerF
Heating Capacity kW Heating (A2/W35)
(A2/W35) 2+)blub-yrD(erutarepmetriaedistuOPOC
°C
1+)blub-teW(erutarepmetriaedistuOWktupnirewoP °C
53+/-)teltuo/telni(erutarepmetretaWnim/LwolfretawlanimoN °C
Heating Capacity kW Heating (A7/W35)
(A7/W35) 7+)blub-yrD(erutarepmetriaedistuOPOC
°C
6+)blub-teW(erutarepmetriaedistuOWktupnirewoP °C
53+/03+)teltuo/telni(erutarepmetretaWnim/LwolfretawlanimoN °C
Cooling Capacity kW Cooling (A35/W7)
(A35/W7) EER (COP) Outside air temperature (Dry-bulb) +35
°C
42+)blub-teW(erutarepmetriaedistuOWktupnirewoP °C
7+/21+)teltuo/telni(erutarepmetretaWnim/LwolfretawlanimoN °C
Cooling Capacity kW Cooling (A35/W18)
(A35/W18) EER (COP) Outside air temperature (Dry-bulb) +35
°C
42+)blub-teW(erutarepmetriaedistuOWktupnirewoP °C
81+/32+)teltuo/telni(erutarepmetretaWnim/LwolfretawlanimoN °C
regnahcxetaehetalPtinuroodtuO
Model name ALFA LAVAL
Running current
Heating (A7/W35) 04-03HCAA
Cooling (A35/W7) Amm4.04:AAtnerruc.xaM mm2.862:BgnisacretuO
External finish mm39:WlortnoctnaregirfeR mm523:HrosserpmoC mm96:DledoM setalp04WktuptuorotoM
Start type
Protection devices
erutarepmetretawteltuomumixaML)ledoM(liO WretaehesacknarC
Heat exchanger (Air)
(Water)
Fan Fan (drive) × No.
Fan motor output kW
Air flow m3/min
(CFM)
Defrost method
Noise level Heating dB
Cooling dB
Dimensions Width mm(in.)
Depth mm(in.)
Height mm(in.)
)sbl(gkthgieW
Refrigerant Quantity kg(lbs) *1 grill
*2 at distance of 1m from outdoor unit
*3 Hot gas with four-way valve
*4 With the optional air outlet guide, the operation at
-15°C outdoor temperature is possible.
Guaranteed operating Heating °C
range (Outdoor) Cooling °C nim/LwolfretaW 10.0 ~ 25.8
PUHZ-W85VHA
950 (37-3/8)
330 +30*1 (13+1-3/16)
0.67 (FV50S)
Reverse cycle *3
48 *2
48 *2
Discharge thermo
-
1.3
Line start
HP switch
943 (37-1/8)
Propeller fan × 1
0.060
55
(1,940)
-20 ~ +35
Galvanized plate
10.3
13.7
23.0
Munsell 3Y 7.8/1.1
Linear expansion valve
Hermetic twin rotary
Plate fin coil
Plate heat exchanger
-5*4 ~ +46
R410A
2.4 (5.3)
1
230
50
2.06
25.8
9.0
3.90
77 (170)
7.0
3.40
2.31
25.8
7.5
2.40
7.5
21.5
TNB220FLHM1
3.91
1.92
3.12
21.5
w
H
D
Water IN
Ref.OUT
(Heating)
Ref.IN
(Heating)
Thermistor
(TH32)
Water OUT
B
A
Ambient temperature [ °C ]
-20 -15
65
60
55
50
45
40 -10 -5 0 5 10
Maximum outlet water temptemperature [°C
]

5
DATA
3
1.5m
1m
MICROPHONE
UNIT
GROUND
NC-60
NC-50
NC-40
NC-30
NC-20
NC-70
90
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-W85VHA
COOLING
MODE
HEATING
48
SPL(dB)
48
LINE
3-1. NOISE CRITERION CURVES

6
3-2. STANDARD OPERATION DATA
Mode Cooling (A35/W7) Heating (A7/W35)
Total
Capacity W 7,500 9,000
Input kW 3.12 2.31
Electrical circuit
Outdoor unit PUHZ-W85VHA
Phase, Hz 1, 50
Voltage V 230
Current A 13.7 10.3
Refrigerant circuit
Discharge pressure MPa 2.81 2.21
Suction pressure MPa 0.73 0.64
Discharge temperature 80 65
Condensing temperature 46 38
Suction temperature 3-1
Water
conditions
Flow volume L/min 20.4 25.8
Outlet water temperature 7 35
Outdoor
conditions
Intake air temperature D.B. 35 7
W.B. 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/cm2)

77
OUTLINES AND DIMENSIONS
4
PUHZ-W85VHA
Rear Air Intake
Side Air Intake
Air Discharge 2-12 x 36 oval holes
(Foundation Bolt M10)
2-U Shaped notched holes (Foundfation Bolt M10)
Installation Feet
53
417
37028
175 175600
19
33030
Drain hole (5-:33)
30
81 219
220 145145145
Handle for moving
Side Air Intake
Handle for moving
Rear Air Intake
Water IN
Air Intake
Water OUT
Handle for moving
57
Power supply wiring hole (2-:27 knockout)
See Detail
Rear cover
Front cover
34
40119
Detail Scale 1:3
ISO 228/1-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 diagram.
FREE
Over 300mm
Over 10mm
The diagram below shows a basic example. Explantion of particular details are given in the installation manuals etc.
Over 500mm
Over 10mm
1 FREE SPACE (Around the unit) 2 SERVICE SPACE 3 FOUNDATION BOLTS
Less than
Over
Over
Over300
500
500
Over10
30

8
WIRING DIAGRAM5
PUHZ-W85VHA
TB1
MC
MF1
21S4
63H
TH3
TH4
TH6
TH7
TH8
LEV-A, LEV-B
DCL
Terminal Block <Power Supply,Interface unit /
Flow temp. controller>
Motor for Compressor
Fan Motor
Solenoid Valve <Four-Way Valve>
High Pressure Switch
63HS High Pressure Sensor
SV Solenoid Valve <Bypass Valve>
Thermistor <Liquid>
Thermistor <Discharge>
Thermistor <Plate HEX Liquid>
Thermistor <Ambient>
Thermistor <Heat sink>
TH32 Thermistor <Inlet water>
Electronic Expansion Valve
Reactor
ACTM Active Filter Module
CY1,CY2 Capacitor
Power Circuit Board
Connection Terminal <U/V/W-Phase>
P.B.
TABS/T
Noise Filter Circuit Board
Connection Terminal <L-Phase>
Connection Terminal <Ground>
N.F.
LI,LO Connection Terminal <N-Phase>
NI,NO
EI,E2
Controller Circuit Board
Connector <Connection for Option>
Connector
<Connection
for Option(Contact Input)>
Switch <Function Switch>
Switch <Function Switch>
Switch <Function Switch>
Switch <Function Switch>
SW1
SV1
CNDM
SW2
SW6
SW8
LED3 LED <Operation/ Inspection Indicators>
C.B.
TABP1/P2
Power ModuleIPM Diode bridgeDS2, DS3
52C Relay
52C
SYMBOL 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
MS
3~
MF1
M
1
3
1
7
34 11121
17
2
CNF1
(WHT)
TRANS
CNDC
(PNK)
TH7/6
(RED) TH3 (WHT) TH4 (WHT)
TH7
t° t° t° t°
TH6 TH3 TH4
12
TH32
(BLK)
t°
TH32 63HS
63HS
(WHT )
31
CNS
(WHT )
63H
(YLW)
3
1
63H
*
1
?1
C. B.
P. B.
N. F.
SW6
SW1
SW8
SW2
SW5
SW10
LED3
2
22
7
CN2
(WHT)
F3
12 12
1313
13
2
71
1
2
1
2
1
2
7
6
CNAC
(WHT)
CN4
(WHT)
12
34
F4
F2
F1 21S4
(GRN)
SV2
(BLU)
X52 X55
13 SV1
(GRY)
X54
21S4 SV
2
2
LN
CNDC
(PNK)
DS2
DS3
TABN
TABP
IPM
U
TABP2
TABV
TABW
TABN2
TABN1
TABS
TABP1
TABT
TABU
MS
3
~
UVW
MC
CN2
(WHT)
41
CNAF
(WHT)
CN4
(WHT)
CN5
(RED)
CN3
(WHT)
RED
RED
WHT WHT
WHT
WHT BLK
BLU
RED
BLU
BRN
ORN
YLW
GRN/YLW
BLK
TH8
t°
1613
15
CNVMNT
(WHT)
CNMNT
(WHT)
LEV-A
(WHT)
LEV-A
1
5
CN51
(WHT)
1
3
CNDM
(WHT)
1
3
CN3S
(WHT)
DCL
ACTM
L1
LO
52C
NO
LI NI
CN5
(RED)
L2
N2
Io
N1
P
4
16
RED
BLK
RED
WHT
RED
BLU
CNAC2
(RED)
CNAC1
(WHT)
CN52C
(BLK)
WHT
2
2
1
3
E2
EI
U
U
1
2
1
2
3
1
TB1
CY1
CY2
S1 S2 S3
RED
POWER SUPPLY
~ / N 230V 50Hz
Interface unit /
Flow temp. controller
M
61
LEV-B
(RED)
CN52C
(RED)
LEV-B
BLU
WHT
001010
123456
SW6
*1 MODEL SELECT
1=ON, 0=OFF 00
12
SW10

9
WIRING SPECIFICATIONS6
FIELD ELECTRICAL WIRING (power wiring specifications)
Notes: 1. Wiring size must comply with the applicable local and national codes.
2. Power supply cables and the cables between Controller and Outdoor unit shall not be lighter than polychloro-
prene sheathed flexible cables.
(Design 60245 IEC 57 )
3. Be sure to connect the cables between Controller and Outdoor unit directly to the units (no intermediate
connections are allowed).
Intermediate connections may result in communication errors. If water enters at the intermediate connection
point, it may cause insufficient insulation to ground or a poor electrical contact .
(If an intermediate connection is necessary, be sure to take measures to prevent water from entering the
cables.)
4. Install an earth longer than other cables.
Outdoor unit power supply ~/N (single), 50 Hz, 230 V
Outdoor unit Circuit Breaker capacity *1 25 A
Wiring
Wire No. ×
size (mm2)
Outdoor unit power supply, earth 3 × Min. 4
Interface unit/Flow temp. controller-Outdoor unit *2 3 × 1.5 (polar)
Interface unit/Flow temp. controller-Outdoor unit earth *2 1 × Min. 1.5
Remote controller-Interface unit/Flow temp. controller 2 × 0.3 (Non-polar)
Circuit rating
Outdoor unit L-N (single) *3 AC 230 V
Interface unit/Flow temp. controller-Outdoor unit S1-S2 *3 AC 230 V
Interface unit/Flow temp. controller-Outdoor unit S2-S3 *3 DC 24 V
Remote controller-Interface unit/Flow temp. controller *3 DC 12 V
*1.A breaker with at least 3.0 mm contact separation in each pole shall be provided. Use earth leakage breaker (NV).
*2.Max. 80 m
*3.The figures are NOT always against the ground.
S3 terminal has DC 24 V against S2 terminal. However between S3 and S1, these terminals are NOT electrically insulated by the transformer or other device.

10
REFRIGERANT SYSTEM DIAGRAM7
Distributor
TH7
Strainer(#100) Strainer(#100)
Receiver
LEV-B
TH6
TH32
Plate HEX
Water IN
Water OUT
Strainer
(#100)
TH3
CHECK/V
CHECK/V CHECK/V
H/P SW
TH4
TH8 P/B
LEV-A
COMP
REV/V
P-Sensor
S/V
Strainer
(#100)
Refrigerant flow in heating
Refrigerant flow in cooling
COMP
H/P SW
Plate HEX
REV/V
S/V
CHECK/V
P-Sensor
P/B
LEV-A
LEV-B
TH32
TH3
TH4
TH6
TH7
TH8
Receiver
DC inverter twin rotary compressor (Mitsubishi Electric Corporation)
For protection (OFF:4.15MPa)
ACH30 - 40 Plates (Alfa Laval)
Change the refrigerant circuit (Heating / Cooling) and for Defrosting
For production test use
High pressure / Low pressure / For production test use
For calculation of the condensing temperature from high pressure
Inverter power board
Heating: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
For accumulation of refrigerant
Compressor
High pressure switch (63H)
Plate Heat Exchanger
Reversing (4-way) valve (21S4)
Solenoid valve
Check valve
Pressure sensor (63HS)
Power board
Linear expansion valve -A
Linear expansion valve -B
Inlet water temperature thermistor
Liquid temperature thermistor
Discharge temperature thermistor
Plate HEX liquid temperature thermistor
Ambient temperature thermistor
Heatsink temperature thermistor
Receiver
Symbol Part name Detail
PUHZ-W85VHA