Mitsubishi PUHZ-RP1.6VHA Operating manual

TECHNICAL & SERVICE MANUAL
SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
CONTENTS
1. TECHNICAL CHANGES·································2
2. SAFETY PRECAUTION··································3
3. COMBINATION OF INDOOR AND OUTDOOR UNITS ···7
4. PART NAMES AND FUNCTIONS··················7
5. SPECIFICATIONS···········································8
6. DATA ·····························································11
7. OUTLINES AND DIMENSIONS····················13
8. WIRING DIAGRAM·······································16
9. CONNECTING CABLE·································18
10. REFRIGERANT SYSTEM DIAGRAM ··············19
11. TROUBLESHOOTING···································25
12. DISASSEMBLY PROCEDURE ·····················71
13. PARTS LIST··················································91
14. OPTIONAL PARTS························Back Cover
No.OC294
REVISED-EDITION-C
R410A
2004
Outdoor unit
[model names]
PUHZ-RP1.6VHA
PUHZ-RP2VHA
PUHZ-RP2.5VHA
PUHZ-RP3VHA
PUHZ-RP4VHA
PUHZ-RP5VHA
PUHZ-RP6VHA
[Service Ref.]
PUHZ-RP1.6VHA
PUHZ-RP2VHA
PUHZ-RP2.5VHA
PUHZ-RP2.5VHA1
PUHZ-RP3VHA
PUHZ-RP3VHA1
PUHZ-RP4VHA
PUHZ-RP4VHA1
PUHZ-RP5VHA
PUHZ-RP5VHA1
PUHZ-RP6VHA
PUHZ-RP6VHA1
Revision:
• PUHZ-RP2.5VHA1,
PUHZ-RP3VHA1 are added in
REVISED EDITION-C.
• Please void OC294 REVISED
EDITION-B.
Model name
indication
PUHZ-RP2.5VHA
PUHZ-RP3VHA
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2
1 TECHNICAL CHANGES
PUHZ-RP4VHA ➞PUHZ-RP4VHA1
PUHZ-RP5VHA ➞PUHZ-RP5VHA1
PUHZ-RP6VHA ➞PUHZ-RP6VHA1
1. Reduced Design Pressure:
Design Pressure has been changed from 4.41MPa to 4.15MPa.
(High Pressure Switch has been changed.)
2. Partial Change on Refrigerant Circuit:
Only 1 distributor is adopted on the Heat Exchanger. (Previously 2)
3. Partial Change on Electrical Wiring:
Change of reactor (DCL).
Only 1 reactor (DCL) is adopted. (Previously 2)
4. New Service Parts as a result of the structural improvement:
• Power Receiver
• Separator
• Rubber Mount (for a Compressor)
• Thermistor (2 phase pipe, Outdoor temperature)
• Thermistor (Discharge)
• Linear Expansion Valve Coil
5. Reduced Refrigerant Amount
The Charged Refrigerant Amount has been reduced from 5.5kg to 5.0kg
6. Wider Operation Range:
A change is made on the Minimum Capacity.
(For details, please refer to the Service Manual for indoor units.)
PUHZ-RP2.5VHA ➞PUHZ-RP2.5VHA1
PUHZ-RP3VHA ➞PUHZ-RP3VHA1
1. The parts below have been changed.
• Thermistor (Outdoor pipe / TH3)
• Linear expansion valve coil
2. The refrigerant circuit has been changed.
• High pressure switch (4.41MPa ➞4.14MPa)
• Charge plug
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3
2 SAFETY PRECAUTION
Cautions for units utilizing refrigerant R410A
2-1. 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.
· For RP4, 5 and 6, be sure to perform replacement opera-
tion before test run.
· 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 enter 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 enter into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com-
pressor.
If large amount of mineral oil enter, 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.
[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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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
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5
2-2. Changed point
• Precautions when reusing existing R22 refrigerant pipes
(1) Flowchart
Connecting a new air conditioner
1Flaring work should be done so that flare meets the dimension for R410A.
Use flare nut provided with indoor and outdoor unit.
2When using gas piping of [19.05mm for RP4, 5 or 6.
Make sure that DIP SW8-1 on outdoor unit controller board is set to ON.
WThis is to keep the pressure on pipes within permissible range.
●Use different diameter joint or adjust the piping size by brazing.
3When using pipes larger than specified size for RP1.6, 2, 2.5 or 3.
Make sure that DIP SW8-1 on outdoor unit controller board is set to ON.
W This is to prevent oil flow ratio from lowering due to the decrease in flowing refrigerant.
●Use different diameter joint or adjust the piping size by brazing.
4When existing pipes are specified size.
The pipes can be reused referring to table 1 on page 18.
●Use different diameter joint or adjust the piping size by brazing.
★When using existing pipes for RP4, 5 and 6.
Make sure that DIP SW8-2 on outdoor unit controller board is set to ON and perform
replacement operation.
wChemical compounds containing chlorine left in existing pipes are collected by rep-
lace filter.
●The air conditioner automatically performs cooling operation through replace filter
for about 2 hours.
Measure the existing pipe thickness and check for damage.
Check if existing air conditioner can operate.
Existing air conditioner can
operate.
Disconnect existing air con-
ditioner from piping.
Existing pipes can be reused.
In case the unit is RP1.6, 2,
2.5 ro 3 which utilizes AB oil.
In case the unit is RP4, 5
or 6 which utilize ester oil.
Perform cooling operation
for about 30 minutes and
then do a pump down work.
Use a refrigerant recovery
equipment to collect the re-
frigerant.
Check the oil condition
when collecting the refrige-
rant.
Disconnect existing air conditioner
from pipes and clean pipes using
cleaning device.
Existing air conditioner
cannot operate.
The existing pipe thickness meets speci-
fications and the pipes are not damaged.
The existing pipe thickness does not meet
specifications or the pipes are damaged.
Oil is clean.
Connect a new air conditioner. Connect a new air conditioner.
Perform replacement operation.
Oil is dirty.
Attach a filter drier.
When the compressor bearings
are glazed, rotation scratches
are present, or the compressor
breaks down, iron particles or
oil deterioration will blacken the
oil.
·When performing replacement operation, make sure that DIP SW8-2 on outdoor unit controller board is
set to ON.
wChemical compounds containing chlorine left in existing pipes are collected by replace filter.
●The air conditioner automatically performs cooling operation through replace filter for about 2 hours.
Existing pipes cannot be
reused. Use new pipes.
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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”
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
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 RP4, 5
and 6
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 and refrigerant charge
Operation check and the two above
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
3COMBINATION OF INDOOR AND OUTDOOR UNITS
4PART NAMES AND FUNCTIONS
CHARGELESS SYSTEM
PRE-CHARGED REFRIGERANT IS SUPPLIED FOR PIPING LENGTH AT SHIPMENT.
(Max.30m(PUHZ-RP1.6~RP6))
The refrigerant circuit with LEV(Linear Expansion Valve) and power receiver always control the optimal refrigerant
level regardless of the length (30m max. and 5m min.) of piping. The additional refrigerant charging work during
installation often causes problems. Heretofore it is completely eliminated. This unique system improves the quality
and reliability of the work done.It also helps to speed up the installation time.
PUHZ-RP2.5VHA PUHZ-RP2.5VHA1
PUHZ-RP3VHA PUHZ-RP3VHA1
PUHZ-RP4VHA PUHZ-RP4VHA1
PUHZ-RP5VHA PUHZ-RP5VHA1
PUHZ-RP6VHA PUHZ-RP6VHA1
Heat pump type
Outdoor unit
PUHZ-RP
PEAD-RP·EA.UK
PEAD-RP·EA1.UK
PLA-RP·AA.UK
PLA-RP·AA1.UK
PEAD-RP·GA.UK
PLA-RP·AA
PLA-RP·AA1
—
—
OC293
REVISED EDITION-B
OC297
REVISED EDITION-B
PKA-RP·GAL
OC301
REVISED EDITION-A
PKA-RP·FAL
OC305
PCA-RP·GA OC311
Indoor unit
Service
Manual No.
Service Ref. 45
Heat pump without electric heater
VHA
VHA1
VHA
VHA1
VHA
VHA1
VHA
VHA1
6
3
2 2.5
VHA VHA VHA
VHA1
1.6
——
—
—
—
—
—
————
———
PUHZ-RP1.6VHA
PUHZ-RP2VHA
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8
5 SPECIFICATIONS
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
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
Function
Cooling
Heating
W
D
H
Liquid
Gas
Indoor side
Outdoor side
Height difference
Piping length
Notes1.Rating Conditions (ISO T1)
Cooling :Indoor : D.B. 27˚C(80˚F), W.B. 19˚C(66˚F) Outdoor : D.B. 35˚C(95˚F), W.B. 24˚C(75˚F)
Heating :Indoor : D.B. 20˚C(68˚F) Outdoor : D.B. 7˚C(45˚F), W.B. 6˚C(43˚F)
Refrigerant piping length (one way) : 5m (16ft)
3. Guaranteed voltage
198~264V, 50Hz
4. Above data based on indicated voltage
Indoor Unit 1 phase 230V 50Hz
Outdoor Unit 1 phase 230V 50Hz
5. Refer to the service manual of indoor unit for tha indoor unit's specifications.
2. Guaranteed operating range
Upper limit
Lower limit
Upper limit
Lower limit
Indoor
D.B. 35˚C, W.B. 22.5˚C
D.B. 19˚C, W.B. 15˚C
D.B. 28˚C
D.B. 17˚C
Outdoor
D.B. 46˚C
D.B. -5˚C
D.B. 21˚C, W.B. 15˚C
D.B. -11˚C, W.B. -12˚C
Cooling
Heating
Service Ref. PUHZ-RP1.6VHA PUHZ-RP2VHA
Cooling
4.01
0.8
Munsell 3Y 7.8/1.1
Linear Expansion Valve
Hermetic
SNB130FLBH
Line start
—
Plate fin coil
Propeller fan o1
0.043
35(1,240)
Reverse cycle
44
46
800(31-1/2)
330+23(11-13/16+7/8)
600(23-5/8)
45(99)
R410A
2.5(5.5)
0.45(NEO22)
6.35(1/4)
12.7(1/2)
Flared
Flared
Max. 30m
Max. 50m
Heating
4.23
Cooling
6.16
1.1
Heating
6.47
HP switch
Discharge thermo HP switch Discharge thermo
Single, 50Hz, 220-230-240V
OUTDOOR UNIT
REFRIGERANT PIPING
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9
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
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
Function
Cooling
Heating
W
D
H
Liquid
Gas
Indoor side
Outdoor side
Height difference
Piping length
Notes1.Rating Conditions (ISO T1)
Cooling :Indoor : D.B. 27˚C(80˚F), W.B. 19˚C(66˚F) Outdoor : D.B. 35˚C(95˚F), W.B. 24˚C(75˚F)
Heating :Indoor : D.B. 20˚C(68˚F) Outdoor : D.B. 7˚C(45˚F), W.B. 6˚C(43˚F)
Refrigerant piping length (one way) : 5m (16ft)
3. Guaranteed voltage
198~264V, 50Hz
4. Above data based on indicated voltage
Indoor Unit 1 phase 230V 50Hz
Outdoor Unit 1 phase 230V 50Hz
5. Refer to the service manual of indoor unit for tha indoor unit's specifications.
2. Guaranteed operating range
Upper limit
Lower limit
Upper limit
Lower limit
Indoor
D.B. 35˚C, W.B. 22.5˚C
D.B. 19˚C, W.B. 15˚C
D.B. 28˚C
D.B. 17˚C
Outdoor
D.B. 46˚C
D.B. -5˚C
D.B. 21˚C, W.B. 15˚C
D.B. -11˚C, W.B. -12˚C
Cooling
Heating
Service Ref. PUHZ-RP4VHA
PUHZ-RP4VHA1
PUHZ-RP3VHA
PUHZ-RP3VHA1
PUHZ-RP2.5VHA
PUHZ-RP2.5VHA1Cooling
8.04
TNB220FMBH
Propeller fan o1
0.060
55(1,940)
47
48
943(37-1/8)
75(165)
3.5(7.7)
0.87(NEO22)
Max. 50m
Munsell 3Y 7.8/1.1
Linear Expansion Valve
Hermetic
Line start
—
Plate fin coil
Reverse cycle
950(37-3/8)
330+30(13+1-3/16)
R410A
9.52(3/8)
15.88(5/8)
Flared
Flared
Max. 30m
Heating
9.74
Cooling
6.61
Heating
7.50
Cooling
12.33
ANV33FDAMT
1.9
Propeller fan o2
0.060+0.060
100(3,530)
49
51
1,350(53-1/8)
121(267)
5.5(12.1)·····RP4VHA
5.0(11.0)·····RP4VHA1
1.40(MEL56)
Max. 75m
Heating
13.94
HP switch
Discharge thermo HP switch
LP switch
Discharge thermo
Single, 50Hz, 220-230-240V
OUTDOOR UNIT
REFRIGERANT PIPING
1.61.4
OC294-C-1.qxp 04.10.7 5:10 PM Page 9

10
Single, 50Hz, 220-230-240V
Munsell 3Y 7.8/1.1
Linear Expansion Valve
Hermetic
ANV33FDAMT
Line start
HP switch, LP switch, Discharge thermo
—
Plate fin coil
Propeller fan o2
0.060 +0.060
100(3,530)
Reverse cycle
50
52
950(37-3/8)
330+30(13+1-3/16)
1,350(53-1/8)
121(267)
R410A
5.5(12.1)·····RP5, 6VHA
5.0(11.0)·····RP5, 6VHA1
1.40(MEL56)
9.52(3/8)
15.88(5/8)
Flared
Flared
Max. 30m
Max. 75m
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
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
Function
Cooling
Heating
W
D
H
Liquid
Gas
Indoor side
Outdoor side
Height difference
Piping length
Notes1.Rating Conditions (ISO T1)
Cooling :Indoor : D.B. 27˚C(80˚F), W.B. 19˚C(66˚F) Outdoor : D.B. 35˚C(95˚F), W.B. 24˚C(75˚F)
Heating :Indoor : D.B. 20˚C(68˚F) Outdoor : D.B. 7˚C(45˚F), W.B. 6˚C(43˚F)
Refrigerant piping length (one way) : 5m (16ft)
3. Guaranteed voltage
198~264V, 50Hz
4. Above data based on indicated voltage
Indoor Unit 1 phase 230V 50Hz
Outdoor Unit 1 phase 230V 50Hz
5. Refer to the service manual of indoor unit for tha indoor unit's specifications.
2. Guaranteed operating range
Upper limit
Lower limit
Upper limit
Lower limit
Indoor
D.B. 35˚C, W.B. 22.5˚C
D.B. 19˚C, W.B. 15˚C
D.B. 28˚C
D.B. 17˚C
Outdoor
D.B. 46˚C
D.B. -5˚C
D.B. 21˚C, W.B. 15˚C
D.B. -11˚C, W.B. -12˚C
Cooling
Heating
Service Ref. Cooling
15.80
2.4
Heating
17.50
Cooling
20.73
2.9
Heating
20.37
OUTDOOR UNIT
REFRIGERANT PIPING
PUHZ-RP6VHA
PUHZ-RP6VHA1
PUHZ-RP5VHA
PUHZ-RP5VHA1
OC294-C-1.qxp 04.10.7 5:10 PM Page 10