Download Mitsubishi Electric PUHZ-HRP Service manual
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SPLIT-TYPE, AIR TO WATER HEAT PUMP November 2009 No. OCH466 SERVICE MANUAL R410A [Model name] [Service Ref.] PUHZ-HRP200YKA PUHZ-HRP200YKA Note: • This manual describes only service data of the outdoor unit. • Refer to Technical manual of ATW, I/F and FTC. • RoHS compliant products have <G> mark on the spec name plate. CONTENTS 1. SAFETY PRECAUTION ........................................... 2 2. SPECIFICATIONS ...................................................... 5 3. DATA .............................................................................. 7 4. OUTLINES AND DIMENSIONS ............................ 9 5. WIRING DIAGRAM ..................................................10 6. WIRING SPECIFICATIONS ..................................11 7. REFRIGERANT SYSTEM DIAGRAM....................13 8. TROUBLESHOOTING ............................................14 9. DISASSEMBLY PROCEDURE ............................47 PARTS CATALOG (OCB466) PUHZ-HRP200YKA 1 SAFETY PRECAUTION 1-1. ALWAYS OBSERVE FOR SAFETY Before obtaining access to terminal, all supply circuits must be disconnected. 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. 1-2. CAUTIONS RELATED TO NEW REFRIGERANT Cautions for units utilizing refrigerant R410A 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. Gauge manifold Charge hose Gas leak detector Torque wrench Tools for R410A Vacuum pump adaptor Electronic refrigerant charging scale Handle 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. Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released. 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. 2 [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.) Unit Gravimeter [3] Service tools Use the below service tools as exclusive tools for R410A refrigerant. No. 1 Tool name Gauge manifold Specifications · Only for R410A · Use the existing fitting specifications. (UNF1/2) · Use high-tension side pressure of 5.3 MPa·G or over. 2 Charge hose · Only for R410A · Use pressure performance of 5.09 MPa·G or over. — 3 Electronic scale 4 Gas leak detector · Use the detector for R134a, R407C or R410A. 5 Adaptor for reverse flow check · Attach on vacuum pump. 6 Refrigerant charge base 7 Refrigerant cylinder — · Only for R410A Top of cylinder (Pink) Cylinder with syphon 8 — Refrigerant recovery equipment 3 1-3. CAUTIONS FOR REFRIGERANT PIPING WORK Tools for R410A (The following table shows whether conventional tools can be used or not.) Tools and materials Gauge manifold Charge hose Gas leak detector Refrigerant recovery equipment Refrigerant cylinder Safety charger Charge valve Vacuum pump Use 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 R410A tools Tool exclusive for R410A Tool exclusive for R410A Tool for HFC refrigerant Tool exclusive for R410A Tool exclusive for R410A Tool exclusive for R410A Can R22 tools be used? Can R407C tools be used? Tool exclusive for R410A Tools for other refrigerants can be used if equipped with adapter for reverse flow check Bend the pipes Tools for other refrigerants can be used Bender Tools for other refrigerants can be used Cut the pipes Pipe cutter Tools for other refrigerants can be used Welder and nitrogen gas cylinder Weld the pipes Tools for other refrigerants can be used Refrigerant charging scale Charge refrigerant Vacuum gauge or thermis- Check the degree of vacuum. (Vacuum Tools for other refrigerants valve prevents back flow of oil and refri- can be used tor vacuum gauge and gerant to thermistor vacuum gauge) vacuum valve Charging cylinder Refrigerant charge Tool exclusive for R410A : 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. 4 (Usable if equipped with adapter for reverse flow) (Usable if equipped with adapter for reverse flow) 2 SPECIFICATIONS 2-1. SPECIFICATION 2.-1-1. PUHZ-HRP200YKA <Reference data> Plate heat exchanger (ACH50-50 plates) *2pcs [connected in parallel] Nominal water flow Heating (A7/W35) Heating (A7/W45) Heating (A7/W55) Heating (A-7/W35) Heating (A-7/W45) Heating (A-7/W55) Heating (A-15/W35) Heating (A-15/W45) Heating (A-15/W55) Heating (A2/W35) Capacity kW 23.0 kW 6.31 Capacity kW 23.0 COP 2.77 Power input kW 8.29 Capacity kW 23.0 COP 2.27 Power input kW 10.15 Capacity kW 23.0 COP 2.24 Power input kW 10.25 Capacity kW 23.0 COP 1.93 Power input kW 11.90 Capacity kW 23.0 Power input kW 13.86 Capacity kW 23.0 COP 1.66 COP 2.05 Power input kW 11.24 Capacity kW 22.2 COP 1.80 Power input kW 12.36 Capacity kW 21.2 Power input kW 15.64 Capacity kW 23.0 COP 1.36 COP Capacity 2.37 kW 9.69 L/min 57.3 kW 20.00 EER 2.22 Power input kW 9.01 Capacity kW 20.00 kW 5.64 EER Power input Rating conditions Nominal operating condition Heating (A2/W35) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A7/W35) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A7/W45) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A7/W55) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A-7/W35) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A-7/W45) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A-7/W55) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A-15/W35) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A-15/W45) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Heating (A-15/W55) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Cooling (A35/W7) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) Cooling (A35/W18) Outside air temperature (Dry-bulb) Outside air temperature (Wet-bulb) Water temperature (inlet/outlet) 3.65 Power input Nominal water flow Cooling (A35/W18) 65.9 COP Power input Cooling (A35/W7) L/min 3.55 + 2 °C + 1 °C + 30 °C/+ 35 °C + 7 °C + 6 °C + 30 °C/+ 35 °C + 7 °C + 6 °C + 40 °C/+ 45 °C + 7 °C + 6 °C + 50 °C/+ 55 °C - 7 °C — — °C/+ 35 °C - 7 °C — — °C/+ 45 °C - 7 °C — — °C/+ 55 °C - 15 °C — — °C/+ 35 °C - 15 °C — — °C/+ 45 °C - 15 °C — — °C/+ 55 °C + 35 °C + 24 °C + 12 °C/+ 7 °C + 35 °C + 24 °C + 23 °C/+ 18 °C Note: "COP" and "Power input" in the above table are values that does NOT contains the "pump input (based on EN 14511)". 5 2-1-2. Outdoor unit Model name Running current PUHZ-HRP200YKA 9.6 13.7 95 95 3 phase, 50 Hz, 400 V 25.0 32 Galvanized plate Munsell 3Y 7.8/1.1 Liner expansion valve Hermetic scroll ANB66FJHMT 4.7 Inverter HP switch LP switch Discharge thermo Oil (Model) L 1.7 (FV50S) Crankcase heater W — Heat exchanger Air Plate fin coil Water Plate heat exchanger Fan Fan (drive) × No. Propeller fan × 2 Fan motor output kW 0.150 × 2 Air flow m³/min 140 (CFM) (4,940) Defrost method Reverse cycle *¹ Noise level (SPL) Heating dB 59 *² Cooling dB 58 *² mm (in.) 1050 (41-5/16) Dimensions Width Depth mm (in.) 330 + 30 *³ (13+1-3/16) Height mm (in.) 1338 (52-11/16) Weight kg (lbs) 145 (320) Refrigerant R410A Quantity kg (lbs) 7.1 (15.7) Guaranteed operating Heating °C -25 ~ +35 Cooling °C -5 *4 ~ +46 range (Outdoor) Outlet water temp. Heating °C +60 °C +5 (Max. in heating, Min. in cooling) Cooling Nominal return water Heating °C +10 ~ +59 Cooling °C +8 ~ +28 temperature range Water flow rate range L/min 28.7 ~ 68.9 Heating(A7/W35) A Cooling(A35/W7) A Power factor Heating(A7/W35) % Cooling(A35/W7) % Power supply (phase, cycle, voltage) Max. current A Breaker size A Outer casing External finish Refrigerant control Compressor Model Motor output kW Start type Protection devices 6 Maximum outlet water temperature Maximum outlet water temptemperature [㷄] 65 60 55 50 45 40 -25 -20 -15 -10 -5 0 Ambient temperature [㷄] 5 *1 Hot gas with 4-way valve *2 at distance of 1m from outdoor unit *3 grill *4 With the optional air outlet guide, the operation at -15㷄 outdoor temperature is possible. 10 3 DATA 3-1. Addition of refrigerant At time of shipping 30 m and less 31-40 m For single combination (1 indoor unit) 7.1 kg For twin / triple / quadruple combination (2-4 indoor units) Total piping length (one way) Amount of additional refrigerant charge (kg) 41-50 m 51-60 m 61-70 m 71-80 m 5.6 kg 7.0 kg 1.4 kg 2.8 kg 4.2 kg 0.9 kg 1.8 kg Calculate the amount of additional refrigerant charge using formula provided below. No additional charge necessary When length exceeds 50 m for twin / triple / quadruple combination When the total length of the piping exceeds 50 m, calculate the amount of additional charge based on the following requirements. Note: If the calculation produces a negative number (i.e. a “minus” charge), of if calculation results in an amount that is less than the “Additional charage amount for 50 m”, perform the additional charge using the amount shown in “Additional charge amount for 50 m”. Amount of additional charge = Main piping: Liquid line size ø12.7 overall length × 0.17 + Main piping: Liquid line size ø9.52 overall length × 0.14 (Gas line: ø25.4) (m) × 0.17 (kg/m) (kg) Additional charge amount for 50 meters + (m) × 0.14 (kg/m) Branch piping: Liquid line size ø9.52 overall length × + 0.05 (Gas line: ø15.88) Branch piping: Liquid line size ø6.35 overall length × 0.02 (m) × 0.05 (kg/m) – 4.3 (kg) (m) × 0.02 (kg/m) 1.8 kg <Limits of refrigerant piping installation> Indoor unit Outdoor unit Multi distribution pipe (option) Height difference (Indoor unitOutdoor unit) Max. 30 m Height difference (Indoor unitIndoor unit) Max. 1 m A: Main piping B, C, D, E: Branch piping Max. 20m HRP200 Permissible total piping length A+B+C+D+E A+B or A+C or A+D or A+E Charge-less piping length A+B+C+D+E 80 m and less 70 m and less 30 m and less | B-C | or | B-D | or | B-E | or | C-D | or | C-E | or | D-E | No. of bends 8 m and less Within 15 : A+B+C(+D)(+E) ≤ 80 m * “D” is for triple“. * “E” is for four (quadruple). 3-2. NOISE CRITERION CURVES PUHZ-HRP200YKA MODE SPL(dB) COOLING 58 HEATING 59 LINE MICROPHONE 1m UNIT 1.5m GROUND OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 μbar) 90 80 70 NC-70 60 NC-60 50 NC-50 40 NC-40 30 NC-30 20 10 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE 63 125 NC-20 250 500 1000 2000 4000 BAND CENTER FREQUENCIES, Hz 7 8000 3-3. Standard operation data Reference data (connect to Plate HEX) (ACH50-50 plates) o 2 pcs [connected in parallel] Outdoor Water conditions conditions Refrigerant circuit Electrical circuit Total Mode Cooling (A35/W7) Heating (A7/W35) Capacity W 20,000 23,000 Input kW 9.01 6.31 Outdoor unit PUHZ-HRP200YKA Phase, Hz 3, 50 Voltage V Current A 13.7 9.6 Discharge pressure MPa 3.0 2.0 Suction pressure MPa 0.7 0.6 Discharge temperature ºC 79 73 Condensing temperature ºC 49 35 Suction temperature ºC 8 8 Evaporating temperature ºC 6 2 Evaporator inlet temperature ºC 7 —— Evaporator outlet temperature ºC 6 —— Condenser inlet temperature ºC —— 65 Condenser outlet temperature ºC —— 34 L/min 57.3 65.9 ºC 7 35 D.B. ºC 35 7 W.B. ºC 24 6 Flow volume Outlet water temperature Intake air temperature 400 Piping length : Main 2.5m, Branch 2.5m / 2.5m The unit of pressure has been changed to MPa based on international SI system. The conversion factor is: 1 (MPa) = 10.2 (kgf/cm²) 3-4. CAPACITY CORRECTION (Refrigerant piping length) Capacity ratio [%] Cooling and heating capacity is lowered according to the piping length. Capacity can be obtained by referring to the following capacity curves. Corrected pipe length (m) = actual pipe length (m) + number of bends × 0.3 (m) 100 Cooling Heating 95 HRP200 90 85 HRP200 80 75 70 5 10 15 20 25 30 35 40 45 50 55 60 65 70 Corrected pipe length [m] 8 75 80 Over 150mm Over 10mm Service space Over 10 Front piping hole (Knockout) Front trunking hole (Knockout) Power supply wiring hole (ø40Knockout) 92 ø92 75 60 55 29 55 92 75 50 Power supply wiring hole (ø27Knockout) Right piping hole (Knockout) Power supply wiring hole (ø27Knockout) Piping Knockout Hole Details Handle for moving 3 FOUNDATION BOLTS ø92 75 92 55 60 Power supply wiring hole (ø27Knockout) Rear trunking hole (Knockout) Rear piping hole (Knockout) ø9 2 Handle for moving Side Air Intake Piping and wiring connections can be made from 4 directions: FRONT,Right,Rear and Below. 4 PIPING-WIRING DIRECTIONS Power supply wiring hole (ø40Knockout) Rear Air Intake FOUNDATION <Foundation bolt height> Power supply wiring hole (ø40Knockout) Right trunking hole (Knockout) Over 500 1 ···Refrigerant GAS pipe connection (attached JOINT)ø25.4(Brazing locally) 2 ···Refrigerant LIQUID pipe connection (FLARE) ø 9.52(3/8F) *1···Indication of STOP VALVE connection location. *2···(FLARE)ø 19.05(3/4F) Example of Notes Over 1000mm Over 10mm 60 Over 500 Over 150 Dimensions of space needed Please secure the unit firmly for service access are with 4 foundation (M10) bolts. shown in the below diagram. (Bolts and washers must be purchased locally.) 2 SERVICE SPACE 55 1 FREE SPACE (Around the unit) Handle for moving Side Air Intake 1338 330 30 26 The diagram below shows a basic example. Explanation of particular details are given in the installation manuals etc. 60 632 369 FREE 63 55 73 27 26 63 92 27 26 73 60 Less than 30 73 63 26 27 154 Rear Air Intake 160 160 1050 Earth terminal Air Discharge 600 Installation Feet 110 160 362 225 45 136 2 42 Drain hole (5-ø33) 1 Handle for moving Service panel 81 Bottom piping hole (Knockout) Front piping cover Rear piping cover Air intake Terminal connection Left···Power supply wiring Right···Indoor/Outdoor wiring 2-12×36 Oval holes (Foundation Bolt M10) 60 Brazing 70 56 40 0 53 2-U Shaped notched holes (Foundation Bolt M10) 225 19 370 417 28 342 *1 450 *1,*2 : 442 86 9 982 986 4 OUTLINES AND DIMENSIONS PUHZ-HRP200YKA Unit: mm 5 WIRING DIAGRAM PUHZ-HRP200YKA 5 1 2 CNM (WHT) 1 14 SW6 SW1 5 1 3 1 5 CNVMNT CNMNT (WHT) (WHT) 3 CN5 (WHT) SW11 SW1 LED2 LED3 LED4 SW12 M-NET SUBSTRATE 2 1 +3 CND (WHT) 3 1 3 1 3 1 X51 X54 1 SV1 (GRY) 3 A B S TB7 M-NET 5 1 SS (WHT) 21S4 FUSE2 RED P. B. 7 7 RS BLK YLW MC BLK W WHT V MS 3~ RED U SC-W SC-V SC-U 1 2 CN4 1(WHT) 2 CN5 1 (RED) TB-L3 TB-L2 TB-L1 BLK WHT RED X52A BLK ORN RED TB-P1 TB-P2 TB-C1 BRN DCL TB-N1 BLK RED CN2 (WHT) WHT FUSE1 WHT WHT 1 CN31 LEV-C 6 (BLU) 1 21S4 3 (GRN) 5 +1 CN51 CNDM (WHT) (WHT) CN4 (WHT) 1 2 F4 CY1 CY2 S3 1 3 1 6 1 6 63HS LEV-A LEV-B (WHT) (WHT) (RED) 3 4 1 2 S2 When M-NET adapter is connected 5 3 5 7 2 INDOOR UNIT 1 3 63L 1 3 (RED) 63H (YLW) F3 CNAC (WHT) 1 2 S1 M +1 CN2 1 (WHT) 7 TRANS 1 2 CNDC (PNK) TB2 M t° 3 CNS (WHT) 3 LEV-B X52 1 MS 3~ M LEV-A RED MS 3~ MF2 t° CNF1 7(WHT) 1 2 1 4 1 2 2 1 TH32 TH7/6 TH3 TH4 (BLK) (RED) (WHT) (WHT) CNF2 (WHT) 7 1 MF1 t° t° LEV-C 63HS LED1 t° 63L NAME Switch Switch<Pump Down> Connector<Emergency Operation> LED<Operation Inspection Indicators> Fuse<T6.3AL250V> Connector<Connection for Option> Connector<Connection for Option> Connector<A-Control Service Inspection Kit> Connector <Connected to Optional M-NET Adapter Board> Connector CNVMNT <Connected to Optional M-NET Adapter Board> Connector CNDM <Connected for Option (Contact Input)> CN3S Connector<Connection for Option> CN51 Connector<Connection for Option> X51,X52,X54 Relay LED5CN2M (WHT) LED1 63H SYMBOL SW9 SWP CN31 LED1,LED2 F3,F4 SV1 SS CNM CNMNT SW7 SW4 SW5 SW6 SW7 SW8 TH32 TH7 TH6 TH3 TH4 C.B. NAME Power Circuit Board Connection Terminal<U/V/W-Phase> Connection Terminal<L1/L2/L3-Power supply> Connection Terminal Connection Terminal Connection Terminal Connection Terminal 52C Relay Noise Filter Circuit Board Connection Terminal<L1/L2/L3/NI-Power supply> Connection Terminal<L1/L2/L3-Power supply> Connection Terminal<Ground> Controller Circuit Board Switch<Forced Defrost, Defect History Record Reset, Refrigerant Address> Switch<Test Operation> Switch<Function Switch> Switch<Model Select> Switch<Function Setup> Switch<Function Setup> SW9 SYMBOL P.B. SC-U/V/W TB-L1/L2/L3 TB-P1 TB-P2 TB-C1 TB-N1 X52A N.F. LI1/ LI2/LI3/NI LO1/ LO2/LO3 GD1,GD2 C.B. SW1 SW4SWP SW8 SW5 NAME Terminal Block<Power Supply> Terminal Block<Indoor/Outdoor> Motor for Compressor Fan Motor Solenoid Valve (Four-Way Valve) High Pressure Switch Low Pressure Switch High Pressure Sensor Thermistor<Outdoor Pipe> Thermistor<Discharge> Thermistor<Outdoor 2-Phase Pipe> Thermistor<Outdoor> Thermistor<Suction> Electronic Expansion Valve Reactor Reactor Main Smoothing Capacitor Rush Current Protect Resistor Fuse<T15AL250V> Capacitor LED2 SYMBOL TB1 TB2 MC MF1,MF2 21S4 63H 63L 63HS TH3 TH4 TH6 TH7 TH32 LEV-A,LEV-B,LEV-C ACL4 DCL CB1,CB2 RS FUSE1, FUSE2 CY1,CY2 CB1 CB2 +1 MODEL SELECT MODEL 2 HRP ON 200Y OFF N. F. CNAC1 (WHT) 1 TB1 N LI 2 U BLK BLU CNAC2 3 (RED) U LO 2 WHT LI 3 U LO3 BLK NI U SW5-6 +2 1 2 3 4 5 6 7 8 Ambient temp. 3°C or less (lnitial setting) SW9-3.4 +4 ON OFF ON OFF -3°C or less ON OFF -6°C or less ON OFF U GD1 GD2 CNDC1 (PNK) 3 3 2 10 1 CNL (BLU) ACL4 1 2 3 4 5 6 +3 Setting of the starting ambient temp. of the flash Injection. indicates a switch position. 0°C or less U ON OFF +2 SW5 -1 to 5 : Function Switch. GRN/YLW WHT L3 WHT 21 LO 1 RED WHT L2 3 BLK POWER SUPPLY 3N~ 400V 50Hz LI 1 BLK L1 RED CNCT (RED) 1 SW6 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 +4 SW9-1 to 2 : Function Switch 6 WIRING SPECIFICATIONS L N D For Heater S1 S2 S3 E *With Heater model only A B L N A B C D E S1 S2 S3 C D E For Power For Heater For Power D Indoor unit Outdoor unit Remote controller Main switch (Breaker) Earth For Heater D D A B E D A C E For Heater E A E Note: Only for Air to water application When multiple indoor units (Hydro boxes) are connected to the outdoor unit, wire the PCB of either one of the indoor unit and the outdoor unit (S1,S2,S3). It is impossible to connect the PCBs of multiple indoor units to the outdoor unit. FIELD ELECTRICAL WIRING (power wiring specifications) Outdoor unit model Indoor unit-Outdoor unit *2 Indoor unit-Outdoor unit earth Remote controller-Indoor unit Outdoor unit L-N (single) Outdoor unit L1-N, L2-N, L3-N (3 phase) Indoor unit-Outdoor unit S1-S2 Indoor unit-Outdoor unit S2-S3 Remote controller-Indoor unit *2 *3 HRP200Y 3N~ (3 ph 4-wires), 50 Hz, 400 V 32 A 5 × Min. 4 Cable length 50m:3×4 (Polar)/ Cable length 80m:3×6 (Polar) 1 × Min. 2.5 2 × 0.3 (Non-polar) *4 AC 230 V *4 *4 *4 AC 230 V DC 24 V DC 12 V Outdoor unit power supply Circuit rating Wiring Wire No. × size (mm2) Outdoor unit input capacity Main switch (Breaker) Outdoor unit power supply *1 *1. A breaker with at least 3.0 mm contact separation in each poles shall be provided. Use earth leakage breaker (NV). *2. Max. 80 m Total Max. including all indoor/indoor connection is 80 m. • Use one cable for S1 and S2 and another for S3 as shown in the picture. *3. The 10 m wire is attached in the remote controller accessory. *4. 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. Notes: 1. Wiring size must comply with the applicable local and national code. 2. Power supply cords and Indoor/Outdoor unit connecting cords shall not be lighter than polychloroprene sheathed flexible cord. (Design 60245 IEC 57) 3. Use an earth wire which is longer than the other cords so that it will not become disconnected when tension is applied. Caution: Be sure to install N-line. Without N-line, it could cause damage to the unit. Power supply Isolator 3 poles isolator S1 S1 A-Control S2 Outdoor Unit S2 S3 S3 A-Control Indoor Unit Warning: · In case of A-control wiring, there is high voltage potential on the S3 terminal caused by electrical circuit design that has no electrical insulation between power line and communication signal line. Therefore, please turn off the main power supply when servicing. And do not touch the S1, S2, S3 terminals when the power is energized. If isolator should be used between indoor unit and outdoor unit, please use 3-pole type. · Turn on the main power when the ambient temperature is - 20°C or higher. · In below - 20°C condition, it needs at least 4hr stand by to operate in order to warm the electrical parts. 11 INDOOR-OUTDOOR CONNECTING CABLE (HRP200) Cross section of cable Round Flat Flat Round Wire size (mm2) Number of wires 2.5 3 Polarity Clockwise : S1-S2-S3 *Pay attention to stripe of yellow and green 2.5 3 Not applicable (Because center wire has no cover finish) 1.5 4 2.5 4 L (m)*6 (30) *2 Not applicable *5 From left to right : S1-Open-S2-S3 (18) *3 Clockwise : S1-S2-S3-Open *Connect S1 nad S3 to the opposite angle (30) *4 *1 :Power supply cords of appliances shall not be lighter than design 60245 IEC or 227 IEC. *2 :In case that cable with stripe of yellow and green is available. *3 :In case of regular polarity connection (S1-S2-S3), wire size is 1.5 mm2. *4 :In case of regular polarity connection (S1-S2-S3). *5 :In the flat cables are connected as this picture, they can be used up to 30 m. (3C Flat cable × 2) S1 S2 S3 *6 :Mentioned cable length is just a reference value. It may be different depending on the condition of installation, humidity or materials, etc. Be sure to connect the indoor-outdoor connecting cables directly to the units (no intermediate connections). Intermediate connections can lead to communication error if water enters the cables and causes insufficient insulation to ground or a poor electrical contact at the intermediate connection point. 12 7 REFRIGERANT SYSTEM DIAGRAM PUHZ-HRP200YKA <Reference> System example: Plate HEX (ACH50 * 2pcs) + FTC (TH1/2) P-sensor Heat exchanger Ball valve Joint pipe (Brazing) Refrigerant GAS pipe connection (1 inch) Thermistor TH1 (Outlet water) REV/V Strainer #50 Thermistor TH7 (Outdoor) Thermistor TH6 (Outdoor 2-phase pipe) Charge plug (High pressure) Charge plug (Low pressure) Thermistor TH3 (Outdoor pipe) H/P SW Muffler Distributor Water OUT L/P SW Plate HEX Plate HEX Thermistor TH32 (Outdoor pipe) Strainer #100 Strainer #100 Thermistor TH4 (Discharge) LEV-A Strainer #100 Strainer #100 Refrigerant LIQUID pipe connection (3/8 inch) Water IN Thermistor TH2 (Liquid pipe) LEV-B Strainer #100 Stop valve (with service port) COMP Power receiver Strainer #100 HIC Refrigerant flow in cooling Refrigerant flow in heating LEV-C Symbol Strainer #100 Injection port Part name Detail COMP Compressor DC inverter scroll compressor (Mitsubishi Electric Corporation) H/P SW High pressure switch (63H) For protection (OFF: 4.15MPa) L/P SW Low pressure switch (63L) For protection (OFF: -0.03MPa) REV/V Reversing (4-way) valve (21S4) Change the refrigerant circuit (Heating / Cooling) and for Defrosting Charge plug Charge plug High pressure / Low pressure / For production test use P-Sensor Pressure sensor (63HS) For calculation of the condensing temperature from high pressure LEV-A Linear expansion valve -A Heating:Secondary LEV Cooling:Primary LEV Cooling:Secondary LEV LEV-B Linear expansion valve -B Heating:Primary LEV LEV-C Linear expansion valve -C For HIC (heating only) TH32 Suction temperature thermistor For LEV control TH3 Liquid temperature thermistor Heating:Evaporating temperature TH4 Discharge temperature thermistor For LEV control and for compressor protection Cooling:Sub cool liquid temperature TH6 2-phase pipe temperature thermistor Outdoor 2-phase pipe temperature TH7 Ambient temperature thermistor For fan control and for compressor frequency control Power Receiver Power Receiver For accumulation of refrigerant HIC Heat interchange circuit For high heating capacity Plate HEX Plate Heat Exchanger ACH50 - 50 Plates (Alfa Laval) TH1 Outlet water temperature thermistor For flow temp. controller TH2 Liquid pipe temperature thermistor For flow temp. controller 13 <Reference> System example 8 TROUBLESHOOTING 8-1. TROUBLESHOOTING <Error code display by self-diagnosis and actions to be taken for service (summary)> Present and past error codes are logged and displayed on the control board of outdoor unit. Actions to be taken for service, which depends on whether or not the trouble is reoccurring at service, are summarized in the table below. Check the contents below before investigating details. Unit conditions at service Error code Actions to be taken for service (summary) Displayed Judge what is wrong and take a corrective action according to “8-3. Self-diagnosis action table”. The trouble is reoccurring. Not displayed Logged The trouble is not reoccurring. Not logged Conduct troubleshooting and ascertain the cause of the trouble. 1 Consider the temporary defects such as the work of protection devices in the refrigerant circuit including compressor, poor connection of wiring, noise and etc. Recheck the symptom, and check the installation environment, refrigerant amount, weather when the trouble occurred, matters related to wiring and etc. 2 Reset error code logs and restart the unit after finishing service. 3 There is no abnormality in electrical component, controller board, and etc. 1 Re-check the abnormal symptom. 2 Conduct troubleshooting and ascertain the cause of the trouble. 3 Continue to operate unit for the time being if the cause is not ascertained. 4 There is no abnormality concerning of parts such as electrical component, controller board, and etc. 14 8-2. CHECK POINT UNDER TEST RUN Before test run • After installation of outdoor unit, piping work and electric wiring work, re-check that there is no water leakage, loosened connections and incorrect polarity. • Measure impedance between the ground and the power supply terminal block (L, N) on the outdoor unit by 500 V Megger and check that it is 1.0 M or over. • Turn on power supply 12 hours before test run in order to protect compressor. • Make sure to read operation manual before test run. (Especially items to secure safety.) Warning: Do not use the system if the insulation resistance is less than 1.0 MΩ. Caution: Do not carry out this test on the control wiring (low voltage circuit) terminals. ERROR CODE Self-check TEMP. ON/OFF 1 Turn on the power. 2 Press [CHECK] button twice. 3 Press [CHECK] button twice to finish self-check. OC : Outdoor unit A CHECK button B IC : Interface or FTC unit C Check code Check code Symptom P1 Flow water (TH1) sensor error P2 Refrigerant liquid Pipe (TH2) sensor error P6 Freezing/Overheating protection operation P9 Actual tank temp. (TH5) sensor error Fb FTC unit control system error (memory error, etc.) E0~E5 Signal transmission failure between remote controller and FTC. E6~EF Signal transmission failure between outdoor unit and FTC. –––– No trouble generated in the past. FFFF No corresponding unit U*, F* Outdoor unit failure. Refer to the outdoor unit wiring diagram. For description of each LED (LED1~5) provided on the FTC, refer to the following table. LED 1 (Power for microprocessor) LED 2 (Power for remote controller) Indicates whether control power is supplied. Make sure that this LED is always lit. Indicates whether power is supplied to the remote controller. This LED lights only in the case of the FTC unit which is connected to the outdoor unit refrigerant address “0“. LED 3 (Communication between FTC Indicates state of communication between the FTC and outdoor unit. Make sure that and outdoor unit) this LED is always blinking. LED 4 — LED 5 — 15 8-3. SELF-DIAGNOSIS ACTION TABLE <Abnormalities detected when the power is turned on> Error Code Abnormal point and detection method None — Judgment and action Case 1 No voltage is supplied to termi- 1 Check following items. nal block(TB1) of outdoor unit. a) Power supply breaker a) Power supply breaker is b) Connection of power supply terminal block turned off. (TB1) b) Contact failure or disconnecc) Connection of power supply terminal block tion of power supply (TB1) terminal c) Open phase (L or N phase) 2 Electric power is not charged to 2 Check following items. power supply terminal of outa) Connection of power supply terminal block door power circuit board. (TB1) a) Contact failure of power b) Connection of terminal on outdoor supply terminal power circuit board b) Open phase on the outdoor power circuit board 3 Electric power is not supplied to outdoor controller circuit board. a) Disconnection of connector (CNDC) 4 Disconnection of reactor (DCL or ACL) 3 Check connection of the connector (CNDC) on the outdoor controller circuit board. Check connection of the connector CNDC on the outdoor noise filter. Refer to 8-7. 4 Check connection of reactor. (DCL or ACL) 5 Disconnection of outdoor noise 5 a) Check connection of outdoor noise filter filter circuit board or parts failcircuit board. ure in outdoor noise filter circuit b) Replace outdoor noise filter circuit board. board Refer to 8-7. 6 Defective outdoor power circuit 6 Replace outdoor power circuit board. board 7 Defective outdoor controller circuit board 7 Replace controller board (When items above are checked but the units can not be repaired). F3 63L connector open 1 Disconnection or contact failure 1 Check connection of 63L connector on Abnormal if 63L connector circuit is open of 63L connector on outdoor outdoor controller circuit board. for 3 minutes continuously after power supRefer to 8-7. controller circuit board ply. 2 Disconnection or contact failure 2 Check the 63L side of connecting wire. 63L: Low-pressure switch of 63L 3 63L is working due to refriger- 3 Check refrigerant pressure. ant leakage or defective parts. Charge additional refrigerant. Check continuity by tester. Replace the parts if the parts are defective. 4 Defective outdoor controller 4 Replace outdoor controller circuit board. circuit board 1 Check connection of 63H connector on outdoor controller circuit board. Refer to 8-7. 2 Check the 63H side of connecting wire. F5 63H connector open 1 Disconnection or contact failure Abnormal if 63H connector circuit is open of 63H connector on outdoor for 3 minutes continuously after power supcontroller circuit board ply. 2 Disconnection or contact failure 63H: High-pressure switch of 63H 3 63H is working due to defective parts. 4 Defective outdoor controller circuit board 2 connector open 1 Disconnection or contact failure Abnormal if both 63H and 63L connector of connector (63H,63L) on circuits are open for three minutes continuoutdoor controller circuit board. ously after power supply. 2 Disconnection or contact failure of 63H, 63L 63H: High-pressure switch 3 63H and 63L are working due 63L: Low-pressure switch to defective parts. 4 Defective outdoor controller board. 1 Check connection of connector (63H,63L) on outdoor controller circuit board. Refer to 8-7. 2 Check the 63H and 63L side of connecting wire. 3 Check continuity by tester. Replace the parts if the parts are defective. 4 Replace outdoor controller circuit board. F9 16 3 Check continuity by tester. Replace the parts if the parts are defective. 4 Replace outdoor controller circuit board. Error Code EA Eb Miswiring of Interface unit/Flow temp. controller-outdoor unit connecting wire 1. Outdoor controller circuit board can automatically check the number of connected Interface unit/Flow temp. controller. Abnormal if the number cannot be checked automatically due to miswiring of Interface unit/Flow temp. controlleroutdoor unit connecting wire and etc. after power is turned on for 4 minutes. 2. Abnormal if outdoor controller circuit board recognizes excessive number of Interface unit/Flow temp. controller. Miswiring of Interface unit/Flow temp. controller-outdoor unit connecting wire (converse wiring or disconnection) Outdoor controller circuit board can automatically set the unit number of Interface unit/Flow temp. controller. Abnormal if the Interface unit/Flow temp. controller number cannot be set within 4 minutes after power on because of miswiring (converse wiring or disconnection) of Interface unit/Flow temp. controller-outdoor unit connecting wire. Start-up time over The unit cannot finish start-up process within 4 minutes after power on. EC Case Abnormal point and detection method Contact failure or miswiring of Interface unit/Flow temp. controlleroutdoor unit connecting wire Diameter or length of Interface unit/Flow temp. controller-outdoor unit connecting wire is out of specified capacity. Excessive number of Interface unit/Flow temp. controller is connected to 1 outdoor unit. (2 units or more) Defective transmitting receiving circuit of outdoor controller circuit board Defective transmitting receiving circuit of Interface/Flow temp. controller board Noise has entered into power supply or Interface/Flow temp. controller-outdoor unit connecting wire. Contact failure or miswiring of Interface unit/Flow temp. controller-outdoor unit connecting wire Diameter or length of Interface unit/Flow temp. controller-outdoor unit connecting wire is out of specified capacity. Defective transmitting receiving circuit of outdoor controller circuit board Defective transmitting receiving circuit of Interface/Flow temp. controller board Noise has entered into power supply or Interface unit/Flow temp. controller-outdoor unit connecting wire. Contact failure of Interface unit /Flow temp. controller-outdoor unit connecting wire Diameter or length of Interface unit/Flow temp. controlleroutdoor unit connecting wire is out of specified capacity. Noise has entered into power supply or Interface unit/Flow temp. controller-outdoor unit connecting wire. 17 Judgment and action Check disconnection or looseness or polarity of Interface unit/Flow temp. controller-outdoor unit connecting wire of Interface unit/Flow temp. controller and outdoor units. Check diameter and length of Interface unit/ Flow temp. controller-outdoor unit connecting wire. Total wiring length: 80 m (Including wiring connecting each Interface unit/Flow temp. controller unit and between Interface unit/Flow temp. controller and outdoor unit) Also check if the connection order of flat cable is S1, S2, S3. Check the number of Interface unit/Flow temp. controller that is connected to 1 outdoor unit. (If EA is detected.) ~ Turn the power off once, and on again to check. Replace outdoor controller circuit board or Interface/Flow temp. controller board if abnormality occurs again. Check transmission path, and remove the cause. The descriptions above, and EC. - , are for EA, Eb <Abnormalities detected while unit is operating> Error Code Abnormal point and detection method High pressure (High-pressure switch 63H operated) Abnormal if high-pressure switch 63H operated ( w ) during compressor operation. w 4.15 MPa 63H: High-pressure switch U1 U2 High discharging temperature (1) Abnormal if discharge temperature thermistor (TH4) exceeds 125: or 110: continuously for 5 minutes. Abnormal if discharge temperature thermistor (TH4) exceeds 110: or more continuously for 30 seconds after 90 seconds have passed since the defrosting operation started. (2) Abnormal if discharge superheat (Cooling: TH4 – T63HS / Heating: TH4 – T63HS) exceeds 70: continuously for 10 minutes. U3 Open/short circuit of discharge temperature thermistor (TH4) Abnormal if open (3: or less) or short (217: or more) is detected during compressor operation. (Detection is inoperative for 10 minutes of compressor starting process and for 10 minutes after and during defrosting.) Case 1 Short cycle of indoor unit 2 Clogged filter of indoor unit 3 Decreased airflow caused by dirt of indoor fan 4 Dirt of indoor heat exchanger 5 Locked indoor fan motor 6 Malfunction of indoor fan motor 7 Defective operation of stop valve (Not full open) 8 Clogged or broken pipe 9 Locked outdoor fan motor 0 Malfunction of outdoor fan motor 1 Short cycle of outdoor unit 2 Dirt of outdoor heat exchanger 3 Decreased airflow caused by defective inspection of outside temperature thermistor (It detects lower temperature than actual temperature.) 4 Disconnection or contact failure of connector (63H) on outdoor controller board 5 Disconnection or contact failure of 63H connection 6 Defective outdoor controller board 7 Defective action of linear expansion valve 8 Malfunction of fan driving circuit Judgment and action 1~6Check indoor unit and repair defectives. 7 Check if stop valve is fully open. 8 Check piping and repair defect. 9~2 Check outdoor unit and repair defect. 3 Check the detected temperature of outside temperature thermistor on LED display. (SW2 on A-Control Service Tool : Refer to 8-8.) 4~6 Turn the power off and check F5 is displayed when the power is turned again. When F5 is displayed, refer to “Judgment and action” for F5. 7 Check linear expansion valve. Refer to 8-6. 8 Replace outdoor controller board. 1 Overheated compressor operation caused by shortage of refrigerant 2 Defective operation of stop valve 3 Defective thermistor 4 Defective outdoor controller board 5 Defective action of linear expansion valve 6 Clogging with foreign objects in refrigerant circuit w Clogging occur in the parts which become below freezing point when water enters in refrigerant circuit. 1 Check intake superheat. Check leakage of refrigerant. Charge additional refrigerant. 2 Check if stop valve is fully open. 34 Turn the power off and check if U3 is displayed when the power is turned on again. When U3 is displayed, refer to “Judgement and action” for U3. 5 Check linear expansion valve. Refer to 8-6. 6 After recovering refrigerant, remove water from entire refrigerant circuit under vacuum more than 1 hour. 1 Disconnection or contact failure of connector (TH4) on the outdoor controller circuit board 2 Defective thermistor 3 Defective outdoor controller circuit board 1 Check connection of connector (TH4) on the outdoor controller circuit board. Check breaking of the lead wire for thermistor (TH4). Refer to 8-7. 2 Check resistance value of thermistor (TH4) or temperature by microcomputer. (Thermistor/TH4: Refer to 8-4.) (SW2 on A-Control Service Tool: Refer to 8-8.) 3 Replace outdoor controller board. 18 Error Code Abnormal point and detection method ( U4 ) Thermistors Symbol TH3, TH32 TH6 TH7 TH8 Name Thermistor <Outdoor pipe> Thermistor <Outdoor 2-phase pipe> Thermistor <Outdoor> Internal thermistor Temperature of heatsink Abnormal if heatsink thermistor(TH8) detects 95: U5 U6 U7 Judgment and action Case Open/short of outdoor unit thermistors 1 Disconnection or contact failure 1 Check connection of connector (TH3, TH32, (TH3, TH32, TH6, TH7, and TH8) of connectors TH7/6) on the outdoor controller circuit board. Abnormal if open or short is detected Check connection of connector (CN3) on the Outdoor controller circuit board: during compressor operation. outdoor power circuit board. TH3, TH32, TH7/6 Open detection of thermistors TH3, TH32 Check breaking of the lead wire for thermisOutdoor power circuit board: and TH6 is inoperative for 10 seconds to tor (TH3, TH32, TH6,TH7,TH8). CN3 10 minutes after compressor starting and 2 Defective thermistor Refer to 8-7. 10 minutes after and during defrosting. 3 Defective outdoor controller 2 Check resistance value of thermistor (TH3, W Check which unit has abnormality in circuit board TH32, TH6,TH7,TH8) or check temperature its thermistor by switching the mode of by microcomputer. SW2. (PAC-SK52ST) (Thermistor/TH3,TH6,TH7,TH32,TH8: (Refer to 8-7.) Refer to 8-5.) W Heatsink thermistor(TH8) is in the power (SW2 on A-Control Service Tool: Refer to module. 8-8.) 3 Replace outdoor controller circuit board. Open detection Short detection -40°C or below -40°C or below -40°C or below -35°C or below 90°C or above 90°C or above 90°C or above 170°C or above 1 The outdoor fan motor is locked. 2 Failure of outdoor fan motor 3 Air flow path is clogged. 4 Rise of ambient temperature 5 Defective thermistor 6 Defective input circuit of outdoor power circuit board 7 Failure of outdoor fan drive circuit 12 Check outdoor fan. 3 Check air flow path for cooling. 4 Check if there is something which causes temperature rise around outdoor unit. (Upper limit of ambient temperature is 46:.) Turn off power, and on again to check if U5 is displayed within 30 minutes. If U4 is displayed instead of U5, follow the action to be taken for U4. 5 Check the thermistor (TH8) temperature by microcomputer. (SW2 on A-Control Service Tool: Refer to 8-7.) 6 Replace outdoor power circuit board. 7 Replace outdoor controller circuit board. Power module 1 Outdoor stop valve is closed. Check abnormality by driving power module 2 Decrease of power supply voltage in case overcurrent is detected. 3 Looseness, disconnection or (UF or UP error condition) converse of compressor wiring connection 4 Defective compressor 5 Defective outdoor power circuit board 1 Open stop valve. 2 Check facility of power supply. 3 Correct the wiring (U•V•W phase) to compressor. Refer to 8-7 (Outdoor power circuit board). 4 Check compressor referring to 8-5. 5 Replace outdoor power circuit board. Too low superheat due to low discharge temperature Abnormal if discharge superheat is continuously detected less than or equal to -15: for 3 minutes even though linear expansion valve has minimum open pulse after compressor starts operating for 10 minutes. 12 Check the installation conditions of discharge temperature thermistor (TH4). 1 Disconnection or loose connection of discharge temperature thermistor (TH4) 2 Defective holder of discharge temperature thermistor 3 Disconnection or loose connection of linear expansion valve’s coil 4 Disconnection or loose connection of linear expansion valve’s connector 5 Defective linear expansion valve 19 3 Check the coil of linear expansion valve. Refer to 8-6. 4 Check the connection or contact of LEV-A and LEV-B on outdoor controller circuit board. 5 Check linear expansion valve. Refer to 8-6. Error Code U8 Abnormal point and detection method Overvoltage or voltage shortage and synchronous signal to main circuit U9 Case Outdoor fan motor 1 Failure in the operation of the Abnormal if rotational frequency of the fan DC fan motor motor is not detected during DC fan motor 2 Failure in the outdoor circuit operation. controller board Fan motor rotational frequency is abnormal if; • 100 rpm or below detected continuously for 15 seconds at 20: or more outside air temperature. • 50 rpm or below or 1500 rpm or more detected continuously for 1 minute. 1 Decrease of power supply voltage 2 Disconnection of compressor wiring Abnormal if any of followings are detected during compressor operation; • Instantaneous decrease of DC bus voltage 3 Disconnection or loose con400V nection of CN5 on the outdoor • Increase of DC bus voltage to 760V power circuit board • Decrease of input current of outdoor unit 4 Disconnection or loose conto 0.1A only if operation frequency is more nection of CN2 on the outdoor than or equal to 40Hz or compressor curpower circuit board rent is more than or equal to 6A. Judgment and action 1 Check or replace the DC fan motor. 2 Check the voltage of the outdoor circuit controller board during operation. 3 Replace the outdoor circuit controller board. (When the failure is still indicated even after performing the action 1 above.) 1 Check the facility of power supply. 2 Correct the wiring (U•V•W phase) to compressor. Refer to 8-7 (Outdoor power circuit board). 3 Check CN5 wiring on the outdoor power circuit board. Refer to 8-7. 4 Check CN2 wiring on the outdoor power circuit board. Refer to 8-7. * Check U9 error detail (SW2 all ON). Refer to 8-8. Ud UE 1 Defective outdoor fan (fan Overheat protection motor) or short cycle of outdoor Abnormal if outdoor pipe thermistor (TH3), unit during cooling operation condensing temperature T63HS detects 70: 2 Defective outdoor pipe or more during compressor operation. thermistor (TH3), condensing temperature T63HS 3 Defective outdoor controller board 23 Turn the power off and on again to check the error code. If U4 is displayed, follow the U4 processing direction. Abnormal pressure of pressure sensor 1 Disconnection or contact fail1 Check connection of connector (63HS) on (63HS) ure of connector (63HS) on the the outdoor controller circuit board. Abnormal if pressure sensor (63HS) outdoor controller circuit board Check breaking of the lead wire for thermisdetects 0.1 MPa or less. tor (63HS). 2 Defective pressure sensor Detection is inoperative for 3 minutes after 3 Defective outdoor controller cir2 Check pressure by microcomputer. compressor starting and 3 minutes after cuit board (Prssure sensor/ 63HS) and during defrosting. (SW2: Refer to 8-8.) 3 Replace outdoor controller board. Compressor overcurrent interruption (When compressor locked) Abnormal if overcurrent of DC bus or compressor is detected within 30 seconds after compressor starts operating. UF 1 Check outdoor unit air passage. 1 Stop valve is closed. 2 Decrease of power supply voltage 3 Looseness, disconnection or converse of compressor wiring connection 4 Defective compressor 5 Defective outdoor power board 20 1 Open stop valve. 2 Check facility of power supply. 3 Correct the wiring (U•V•W phase) to compressor. Refer to 8-7 (Outdoor power circuit board). 4 Check compressor. Refer to 8-5. 5 Replace outdoor power circuit board. Error Code UH Abnormal point and detection method UP Judgment and action Current sensor error or input current error 1 Disconnection of compressor 1 Correct the wiring (U•V•W phase) to • Abnormal if current sensor detects –1.0A wiring compressor. Refer to 8-7 (Outdoor power cirto 1.0A during compressor operation. (This 2 Defective circuit of current cuit board). error is ignored in case of test run mode.) sensor on outdoor power 2 Replace outdoor power circuit board. circuit board 3 Check the facility of power supply. 3 Decrease of power supply voltage Low pressure (63L operated) Abnormal if 63L is operated (under -0.03MPa) during compressor operation. 63L: Low-pressure switch UL Case 1 Stop valve of outdoor unit is closed during operation. 2 Disconnection or loose connection of connector (63L) on outdoor controller board 3 Disconnection or loose connection of 63L 4 Defective outdoor controller board 5 Leakage or shortage of refrigerant 6 Malfunction of linear expansion valve Compressor overcurrent interruption 1 Stop valve of outdoor unit is Abnormal if overcurrent DC bus or comclosed. pressor is detected after compressor starts 2 Decrease of power supply voltoperating for 30 seconds. age 3 Looseness, disconnection or converse of compressor wiring connection 4 Defective fan of indoor/outdoor units 5 Short cycle of indoor/outdoor units 6 Defective input circuit of outdoor controller board 7 Defective compressor 8 Defective outdoor power circuit board 9 Dip switch setting difference of outdoor controller circuit board 21 1 Check stop valve. 2~4 Turn the power off and on again to check if F3 is displayed on restarting. If F3 is displayed, follow the F3 processing direction. 5 Correct to proper amount of refrigerant. 6 Check linear expansion valve. Refer to 8-6. 1 Open stop valve. 2 Check facility of power supply. 3 Correct the wiring (U·V·W phase) to compressor. Refer to 8-7 (Outdoor power circuit board). 4 Check indoor/outdoor fan. 5 Solve short cycle. 6 Replace outdoor controller circuit board. W Before the replacement of the outdoor controller circuit board, disconnect the wiring to compressor from the outdoor power circuit board and check the output voltage among phases, U, V, W, during test run. No defect on board if voltage among phases (U-V, V-W and W-U) is same. Make sure to perform the voltage check with same performing frequency. 7 Check compressor. Refer to 8-5. 8 Replace outdoor power circuit board. 9 Check the dip switch setting of outdoor controller circuit board. Error Code E0 or E4 E1 or E2 E3 or E5 Abnormal point and detection method Judgment and action 1 Check disconnection or looseness of Interface unit/Flow temp. controller or transmission wire of remote controller. 2 Set one of the remote controllers “main”, If there is no problem with the action above. 3 Check wiring of remote controller. • Total wiring length: max. 500 m (Do not use cable x 3 or more.) • The number of connecting remote controller: max. 2 units Remote controller control board 1 Defective remote controller 1 Abnormal if data cannot be read normally from the nonvolatile memory of the remote controller control board. (Error code: E1) 1 Replace remote controller. When it is not the above-mentioned problem of 1~3 4 Diagnose remote controllers. a) When “RC OK” is displayed, remote controllers have no problem. Turn the power off, and on again to check. If abnormality generates again, replace PCB of Interface unit/Flow temp. controller. b) When “RC NG” is displayed, replace remote controller. c) When “RC E3” or “ERC 00-66” is displayed, noise may be causing abnormality. 2 Abnormal if the clock function of remote controller cannot be operated normally. (Error code: E2) Remote controller transmission error (E3)/signal receiving error (E5) 1 Abnormal if remote controller could not find blank of transmission path for 6 seconds and could not transmit. (Error code: E3) 2 When remote controller receives the transmitted data same time and compares these data. Abnormal if the data is judged to be different for 30 continuous times. (Error code: E3) 1 Abnormal if Interface unit/Flow temp. controller could not find blank of transmission path. (Error code: E5) 2 When Interface unit/Flow temp. controller receives the transmitted data same time and compares these data. Abnormal if the data is judged to be different for 30 continuous times. (Error code: E5) E6 Cause Remote controller transmission error 1 Contact failure at transmission (E0)/signal receiving error (E4) wire of remote controller 1 Abnormal if main or sub remote controller 2 All remote controllers are set cannot receive any transmission normally as “sub” remote controller. In from Interface unit/Flow temp. controller this case, E0 is displayed on of refrigerant address “0” for 3 minutes. remote controller, and E4 is (Error code: E0) displayed at LED (LED1, LED2) 2 Abnormal if sub-remote controller could on the outdoor controller circuit not receive any signal for 2 minutes. (Erboard. ror code: E0) 3 Miswiring of remote controller 4 Defective transmitting receiving 1 Abnormal if Interface unit/Flow temp. circuit of remote controller controller can not receive any data 5 Noise has entered into the normally from remote controller board or transmission wire of remote from other Interface/Flow temp. controller controller. board for 3 minutes. (Error code: E4) 2 Interface unit/Flow temp. controller cannot receive any signal from remote controller for 2 minutes. (Error code: E4) 1 2 remote controllers are set as 1 Set a remote controller to main, and the other to sub. “main.” (In case of 2 remote controllers) 2 Defective transmitting receiving 2~4 Diagnose remote controller. a) When “RC OK” is displayed, remote concircuit of remote controller trollers have no problem. 3 Defective transmitting receivTurn the power off, and on again to check. ing circuit of Interface unit/Flow When becoming abnormal again, replace temp. controller indoor controller board. 4 Noise has entered into transmisb) When “RC NG” is displayed, replace sion wire of remote controller. remote controller. c) When “RC E3” or “ERC 00-66” is displayed, noise may be causing abnormality. Interface unit/Flow temp. controller or 1 Contact failure, short circuit or, * Check LED display on the outdoor controller outdoor unit communication error (Sigcircuit board. (Connect A-control service tool, miswiring (converse wiring) of nal receiving error) PAC-SK52ST.) Interface unit/Flow temp. con1 Abnormal if Interface unit/Flow temp. controller or outdoor unit connect- 1 Check disconnection or looseness of Intertroller cannot receive any signal normally face unit/Flow temp. controller or outdoor ing wire for 6 minutes after turning the power on. 2 Defective transmitting receivunit connecting wire of Interface unit/Flow temp. controller or outdoor unit. 2 Abnormal if Interface unit/Flow temp. ing circuit of outdoor controller controller cannot receive any signal norcircuit board 2~4 Turn the power off, and on again to mally for 3 minutes. check. If abnormality generates again, re3 Defective transmitting receivplace Interface unit/Flow temp. controller ing circuit of Interface unit/Flow or outdoor controller circuit board. temp. controller 4 Noise has entered into Interface unit/Flow temp. controller or outdoor unit connecting wire. 22 Error Code E8 E9 EF Ed Abnormal point and detection method Case Judgment and action Interface unit/Flow temp. controller or outdoor unit communication error (Signal receiving error) (Outdoor unit) (1) Abnormal if outdoor controller circuit board could not receive anything normally for 3 minutes. 1 Contact failure of Interface unit/ 1 Check disconnection or looseness of InterFlow temp. controller or outdoor face unit/Flow temp. controller or outdoor unit connecting wire unit connecting wire of Interface unit/Flow 2 Defective communication circuit temp. controller or outdoor unit. of outdoor controller circuit 2~4 Turn the power off, and on again to board check. Replace PCB of Interface unit/ 3 Defective communication circuit Flow temp. controller or outdoor controlof Interface unit/Flow temp. ler circuit board if abnormality is discontroller played again. 4 Noise has entered into Interface unit/Flow temp. controller or outdoor unit connecting wire. Interface unit/Flow temp. controller or outdoor unit communication error (Transmitting error) (Outdoor unit) (1) Abnormal if “0” receiving is detected 30 times continuously though outdoor controller circuit board has transmitted “1”. (2) Abnormal if outdoor controller circuit board could not find blank of transmission path for 3 minutes. 1 Interface unit/Flow temp. con- 1 Check disconnection or looseness of Intertroller or outdoor unit connectface unit/Flow temp. controller or outdoor ing wire has contact failure. unit connecting wire. 2 Defective communication circuit 2~4 Turn the power off, and on again to of outdoor controller circuit check. Replace outdoor controller circuit board board if abnormality is displayed again. 3 Noise has entered power supply. 4 Noise has entered Interface unit/Flow temp. controller or outdoor unit connecting wire. Non defined error code This code is displayed when non defined error code is received. 1 Noise has entered transmission 12 Turn the power off, and on again to check. wire of remote controller. Replace Interface/FTC or outdoor control2 Noise has entered Interface ler circuit board if abnormality is displayed unit/Flow temp. controlleragain. outdoor unit connecting wire. Serial communication error 1 Wire disconnection or contact 12 Check connection of each connector CN2 Abnormal if serial communication between failure of connector CN2 beand CN4 between the outdoor controller outdoor controller circuit board and outdoor tween the outdoor controller circuit board and the outdoor power circuit power circuit board is defective. circuit board and the outdoor board. power circuit board 2 Wire disconnection or contact failure of connector CN4 between the outdoor controller circuit board and the outdoor power circuit board 3 Defective communication circuit 3 Replace outdoor power circuit board. of outdoor power circuit board 4 Defective communication circuit 4 Replace outdoor controller circuit board. of outdoor controller circuit board for outdoor power circuit board 23 Error Code P1 P2 Abnormal point and detection method Cause Judgment and action Actual flow water temperature thermistor (TH1) 1 The unit is in 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally.) 2 Constantly detected during cooling, heating ECO, anti freeze, hot water and heating operation. Short: -90: or more Open: -40: or less 1 Defective thermistor characteristics 2 Contact failure of TB61 No.1-2 on PCB of Interface unit/Flow temp. controller 3 Breaking of wire or contact failure of thermistor wiring 4 Defective PCB of Interface unit/ Flow temp. controller 1–3 Check resistance value of thermistor. 0: 15.0k" 10: 9.6k" 20: 6.3k" 30: 4.3k" 40: 3.0k" If you put force on (draw or bend) the lead wire with measuring resistance value of thermistor, breaking of wire or contact failure can be detected. 2 Check contact failure of TB61 No.1-2 on PCB of Interface unit/Flow temp. controller. Refer to 8. Turn the power on again and check restart after inserting connector again. 4 Check actual flow water temperature display on remote controller. Replace PCB of Interface unit/Flow temp. controller if there is abnormal difference with actual flow water temperature. Turn the power off, and on again to operate after check. Pipe temperature thermistor/Liquid (TH2) 1 The unit is in 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally.) 2 Constantly detected during cooling, heating ECO, anti freeze, hot water and heating (except defrosting) operation Short: 90: or more Open: -40: or less 1 Defective thermistor characteristics 2 Contact failure of TB61 No.3-4 on PCB of Interface unit/Flow temp. controller 3 Breaking of wire or contact failure of thermistor wiring 4 Defective refrigerant circuit is causing thermistor temperature of 90: or more or -40: or less. 5 Defective PCB of Interface unit/ Flow temp. controller 1–3 Check resistance value of thermistor. For characteristics, refer to (P1) above. 2 Check contact failure of TB61 No.3-4 on PCB of Interface unit/Flow temp. controller. Refer to 8. Turn the power on and check restart after inserting connector again. 4 Check pipe <liquid> temperature with remote controller in test run mode. If pipe <liquid> temperature is extremely low (in cooling mode) or high (in heating mode), refrigerant circuit may have defective. 5 Check pipe <liquid> temperature with remote controller in test run mode. If there is extremely difference with actual pipe <liquid> temperature, replace PCB of Interface unit/ Flow temp. controller. Turn the power off, and on again to operate after check. P6 P9 Freezing/overheating protection is working 1 Freezing protection (Cooling mode) The unit is in 6-minute resume prevention mode if pipe temperature stays under -15: for 3 minutes, 3 minutes after the compressor started. Abnormal if it stays under -15: for 3 minutes again within 16 minutes after 6-minute resume prevention mode. (Cooling mode) 1 Short cycle of air path 2 Low-load (low temperature) operation out of the tolerance range 3 Defective outdoor fan control 4 Overcharge of refrigerant 5 Defective refrigerant circuit (clogs) (Cooling mode) 1 Remove shields. 3 Check outdoor fan motor. 45 Check operating condition of refrigerant circuit. (Heating mode) (Heating mode) 1 Remove shields. 2 Overheating protection (Heating, heating 1 Short cycle of air path ECO, Anti freeze, Hot water mode) 2 Over-load (high temperature) opThe units is in 6 minute resume preveneration out of the tolerance range tion mode if pipe temperature is detected 3 Defective outdoor fan control 3 Check outdoor fan motor. as over 70: after the compressor start- 4 Overcharge of refrigerant ed. Abnormal if the temperature of over 5 Defective refrigerant circuit (clogs) 4~6 Check operating condition of refrigerant circuit. 70: is detected again within 30 minutes 6 Bypass circuit of outdoor unit is after 6 minute resume prevention mode. defective. Actual tank temperature thermistor (TH5) 1 Defective thermistor character1 The unit is 3-minute resume prevenistics tion mode if short/open of thermistor is 2 Contact failure of TB61 No. 5-6 detected. Abnormal if the unit does not on PCB of interface unit/Flow reset normally after 3 minutes. (The unit temp. controller returns to normal operation, if it has been 3 Breaking of wire or contact reset normally) failure of thermistor wiring 4 Defective PCB of interface 2 Constantly detected during cooling, heatunit/Flow temp. controller ing, heating ECO, anti freeze and hot water operation. 24 1–3 Check resistance value of thermistor. 0: 15.0k" 10: 9.6k" 20: 6.3k" 30: 4.3k" 40: 3.0k" If you put force on (draw or bend) the lead wire with measuring resistance value of thermistor, breaking of wire or contact failure can be detected. 2 Check contact failure of TB61 No.5-6 on PCB of Interface unit/Flow temp. controller. Refer to 8. Turn the power on again and check restart after inserting connector again. 4 Check actual tank temperature display on remote controller. Replace PCB of Interface unit/Flow temp. controller if there is abnormal difference with actual tank temperature. Turn the power off, and on again to operate after check. 8-4. TROUBLESHOOTING A flowing water sound or occasional hissing sound is heard. ■ These sounds can be heard when refrigerant and/or water is (are) flowing in the indoor unit or refrigerant pipe, or when the refrigerant and/or water is (are) chugging. Water does not heat or cool well. ■ Clean the filter of water piping. (Flow is reduced when the filter is dirty or clogged.) ■ Check the temperature adjustment and adjust the set temperature. ■ Make sure that there is plenty of space around the outdoor unit. Water or vapour is emitted from the outdoor unit. ■ During cooling mode, water may form and drip from the cool pipes and joints. ■ During heating mode, water may form and drip from the heat exchanger of outdoor unit. ■ During defrosting mode, water on the heat exchanger of outdoor unit evaporates and water vapour may be emitted. The operation indicator does not appear in the remote control■ Turn on the power switch. “ ler display. “ ” will appear in the remote controller display. ■ During external signal control, “ ” appears in the remote controller display and FTC operation cannot be started or stopped using the remote controller. ” appears in the remote controller display. When restarting the outdoor unit soon after stopping it, it does ■ Wait approximately 3 minutes. (Operation has stopped to protect the outnot operate even though the ON/OFF button is pressed. door unit.) FTC operates without the ON/OFF button being pressed. ■ Is the on timer set? Press the ON/OFF button to stop operation. ■ Is the FTC connected to a external signal? Consult the concerned people who control the FTC. ■ Does “ ” appear in the remote controller display? Consult the concerned people who control the FTC. ■ Has the auto recovery feature from power failures been set? Press the ON/OFF button to stop operation. FTC stops without the ON/OFF button being pressed. ■ Is the off timer set? Press the ON/OFF button to restart operation. ■ Is the air conditioner connected to a central remote controller? Consult the concerned people who control the FTC. ■ Does “ ” appear in the remote controller display? Consult the concerned people who control the FTC. Remote controller timer operation cannot be set. ■ Are timer settings invalid? If the timer can be set, WEEKLY remote controller display. , SIMPLE , or AUTO OFF appears in the “PLEASE WAIT” appears in the remote controller display. ■ The initial settings are being performed. Wait approximately 3 minutes. ■ If the remote controller is not only for FTC, change it. An error code appears in the remote controller display. ■ The protection devices have operated to protect the FTC and outdoor unit. ■ Do not attempt to repair this equipment by yourself. Turn off the power switch immediately and consult your dealer. Be sure to provide the dealer with the model name and information that appeared in the remote controller display. • If the unit cannot be operated properly after test run, refer to the following table to find the cause. Symptom Wired remote controller For about 2 minutes after power-on PLEASE WAIT PLEASE WAIT → Error code Display messages do not appear even when operation switch is turned ON (operation lamp does not light up). LED 1, 2 (PCB in outdoor unit) After LED 1, 2 are lighted, LED 2 is turned off, then only LED 1 is lighted. (Correct operation) Only LED 1 is lighted. Subsequent to about 2 minutes after power-on → LED 1, 2 blink. Only LED 1 is lighted. → LED 1 blinks twice, LED 2 blinks once. Cause • For about 2 minutes following power-on,operation of the remote controller is not possible due to system start-up. (Correct operation) • Connector for the outdoor unit’s protection device is not connected. • Reverse or open phase wiring for the outdoor unit’s power terminal block (L1, L2, L3) • Incorrect wiring between FTC and outdoor (incorrect polarity of S1, S2, S3) • Remote controller wire short Note: Operation is not possible for about 30 seconds after cancellation of function selection. (Correct operation) For description of each LED (LED1, 2, 3) provided on the FTC, refer to the following table. LED1 (power for microprocessor) Indicates whether control power is supplied. Make sure that this LED is always lit. LED2 (power for remote controller) Indicates whether power is supplied to the remote controller. This LED lights only in the case of the FTC which is connected to the outdoor unit refrigerant addresses “0”. LED3 (communication between FTC and outdoor units) Indicates state of communication between the FTC and outdoor units. Make sure that this LED is always blinking. 25 8-5. HOW TO CHECK THE PARTS PUHZ-HRP200YKA Check points Parts name TH3: Liquid pipe temperature TH4: Discharge temperature TH6: 2-phase pipe temperature TH7: Ambient temperature TH32: Suction pipe temperature Disconnect the connector then measure the resistance with a tester. (At the ambient temperature 10~30) Normal TH4 Abnormal 160k~ 410k TH3 TH6 Open or short 4.3k~ 9.6k TH7 TH32 Fan motor(MF1,MF2) Refer to next page. Solenoid valve coil <4-way valve> (21S4) Measure the resistance between the terminals with a tester. (At the ambient temperature 20) Normal Abnormal 1435±150 Open or short Motor for compressor Measure the resistance between the terminals with a tester. (Winding temperature 20) U (MC) Abnormal Normal (U-V, U-W, W-V) V 0.37 W Open or short Linear expansion valve Disconnect the connector then measure the resistance with a tester. (LEV-A/LEV-B/LEV-C) (Winding temperature 20) M Gray Orange Red Yellow Black 1 2 3 4 5 6 Normal Gray - Black Gray - Red Gray - Yellow 46±3 26 Abnormal Gray - Orange Open or short Check method of DC fan motor (fan motor / outdoor controller circuit board) Notes · High voltage is applied to the connecter (CNF1, 2) for the fan motor. Pay attention to the service. · Do not pull out the connector (CNF1, 2) for the motor with the power supply on. (It causes trouble of the outdoor controller circuit board and fan motor.) Self check Symptom : The outdoor fan cannot turn around. Fuse check Check the fuse (F5) on outdoor controller board. Did the fuse blow? Yes Replace outdoor controller board (C.B) and fan motor (MF1, 2). No Wiring contact check Contact of fan motor connector (CNF1, 2) Is there contact failure? Yes Recover wiring. No Power supply check (Remove the connector (CNF1, 2)) Measure the voltage in the outdoor controller circuit board. TEST POINT : VDC (between 1 (+) and 4 (-) of the fan connector): VDC DC250~330V TEST POINT : VCC (between 5 (+) and 4 (-) of the fan connector): VCC DC15V Is the voltage normal? Yes Yes No Check the operation of fan. Replace outdoor controller board. NG Replace outdoor controller board. OK Check the operation. Replace the fan motor. END NG Replace the fan motor. 27 OK END 8-6. HOW TO CHECK THE COMPONENTS 50 <Thermistor feature chart> Low temperature thermistors <Liquid pipe> (TH3) <2-phase pipe> (TH6) <Ambient> (TH7) <Suction pipe> (TH32) 40 Resistance (k) • Thermistor • Thermistor • Thermistor • Thermistor Thermistor R0 = 15k' ± 3% B constant = 3480 ± 2% 1 1 Rt =15exp{3480( 273+t – 273 )} 0: 10: 20: 25: 15k' 9.6k' 6.3k' 5.2k' 30: 40: 4.3k' 3.0k' 30 20 10 0 -20 -10 0 10 20 30 40 50 Temperature () 500 High temperature thermistor • Thermistor <Discharge pipe> (TH4) 400 Resistance (k) Thermistor R120 = 7.465k' ± 2% B constant = 4057 ± 2% 1 1 Rt =7.465exp{4057( 273+t – 393)} 20: 250k' 30: 160k' 40: 104k' 50: 70k' 60: 48k' 70: 34k' 80: 24k' 90: 17.5k' 100: 13.0k' 110: 9.8k' 300 200 100 0 25 <HIGH PRESSURE SENSOR> Vout (V) CONTROLLER BOARD 4.5 5V DC 3 WHT SENSOR 2.5 Vout BLU 2 BLK 1 63HS 0.5 2.5 5 PRESSURE (MPa) - : 5V (DC) - : Output Vout (DC) 28 MICRO PROCESSOR GND 50 75 Temperature () 100 120 Linear expansion valve (1) Operation summary of the linear expansion valve • Linear expansion valve opens/closes through stepping motor after receiving the pulse signal from the outdoor controller board. • Valve position can be changed in proportion to the number of pulse signal. <Connection between the outdoor controller board and the linear expansion valve> Outdoor controller board DC12V Gray LEV 1 Drive circuit 3 Orange 3 :4 4 :3 :2 Yellow 5 :2 :1 Black 6 :1 :4 M 2 1 5 4 :3 6 Red Connector LEV-A LEV-B LEV-C <Output pulse signal and the valve operation> Output (Phase) Output 1 2 3 5 4 6 7 8 :1 ON ON OFF OFF OFF OFF OFF ON :2 OFF ON :3 OFF OFF OFF ON ON ON OFF OFF :4 OFF OFF OFF OFF OFF ON ON ON ON ON OFF OFF OFF OFF (2) Linear expansion valve operation Valve position (capacity) Opening a valve : 8 → 7 → 6 → 5 → 4 → 3 → 2 → 1 → 8 Closing a valve : 1 → 2 → 3 → 4 → 5 → 6 → 7 → 8 → 1 The output pulse shifts in above order. · When linear expansion valve operation stops, all output phase become OFF. · When the switch is turned on, 700 pulse closing valve signal will be sent till it goes to A point in order to define the valve position. (The pulse signal is being sent for about 20 seconds.) When the valve moves smoothly, there is no sound or vibration occurring from the linear expansion valve : however, when the pulse number moves from B to A or when the valve is locked, more sound can be heard. No sound is heard when the pulse number moves from B to A in case coil is burnt out or motor is locked by open-phase. Close Open · Sound can be detected by placing the ear against the screw driver handle while putting the screw driver to the linear expansion valve. 500 pulse Opening a valve all the way Pulse number Extra tightning (about 32 pulse) 29 (3) How to attach and detach the coil of linear expansion valve <Composition> Linear expansion valve is separable into the main body and the coil as shown in the diagram below. Stopper Main body Coil Lead wire <How to detach the coil> Hold the lower part of the main body (shown as A) firmly so that the main body does not move and detach the coil by pulling it upward. Be sure to detach the coil holding main body firmly. Otherwise pipes can bend due to pressure. A <How to attach the coil> Hold the lower part of the main body (shown as A) firmly so that the main body does not move and attach the coil by inserting it downward into the main body. Then securely attach the coil stopper to main body. (At this time, be careful that stress is not added to lead wire and main body is not wound by lead wire.) If the stopper is not firmly attached to main body, coil may be detached from the main body and that can cause defective operation of linear expansion valve. To prevent piping stress, be sure to attach the coil holding the main body of linear expansion valve firmly. Otherwise pipe may break. Be sure to attach the stopper. A 30 8-7. TEST POINT DIAGRAM Outdoor controller circuit board PUHZ-HRP200YKA SW7 Demand control setting SW9 Function switch SW1 Forced defrost, detect history record reset, refrigerant address SW6 CN51 External signal output • Compressor operating signal • Abnormal signal CNDM Model select 1 to 2: Input of low-level sound priority mode 1 to 3: Input of external contact point SW4 Test operation SWP Pump down SW5 Function switch SW8 Pipe replace Wiring replace CNM Connect to A control service tool CN4 Transmission to outdoor power circuit board (CN4) SV1 Drain hose heater output LEV-A,B,C 21S4 Linear expansion valve 4-way valve Pressure sensor (63HS) 63H High pressure switch 63L Low pressure switch TH4 Thermistor <Discharge> CN2 Connect to the outdoor power circuit board (CN2) 1-5: Reception from power circuit board 2-5: Zero cross signal (0-5V DC) 3-4: Not used 6-5: 16V DC 7-5: 16V DC TH3 Thermistor <Liquid pipe> TH7/6 Thermistor <Outdoor/ 2-phase pipe> TH32 Thermistor <Suction pipe> VFG CNAC (Voltage between right pins of PC5C and PC5D, pin 3 and pin 4) (Same as (CNF17(+)-4(-)) 2 to 4: Power supply for outdoor controller circuit board (220V-240V AC) 1 to 3: Power supply for indoor and outdoor unit connection wire (220-240V AC) VSP (Voltage between pins of C5A, C5B): DC 0V(when stopped), DC 1– 6.5V (when operated) CNF1, CNF2 Connect to the fan motor 1-4: 250-330V DC 5-4: 15V DC 6-4: 0-6.5V DC 7-4: 15V DC(When stopped) 7.5V DC(When operated) (0V-15V pulse) CNDC 280V DC (1+, 3-) (Noise filter circuit board) CNS + - S1-S2: 220-240V AC Communication power supply D71 Voltage 24V DC 31 Outdoor noise filter circuit board PUHZ-HRP200YKA LI1, LI2, LI3, NI POWER SUPPLY LI1-LI2/LI-LI3/LI3-LI1 : AC380/400/415V input LI1-NI/LI2-NI/LI3-NI : AC220/230/240V input (Connect to the terminal block (TB1)) GD1 Connect to the earth GD3 Connect to the earth CNAC1, CNAC2 AC220/230/240V (Connect to the outdoor controller circuit board (CNAC)) CNCT Primary current CNDC (Connect to the outdoor power circuit board (CN5)) (Connect to the outdoor controller circuit board (CNDC)) CNL Connect to the ACL4 LO1, LO2, LO3 POWER SUPPLY LO1-LO2/LO2-LO3/LO3-LO1: AC380/400/415V OUTPUT (Connect to the outdoor power circuit board (TB1-L1, L2, L3)) 32 Outdoor power circuit board PUHZ-HRP200YKA CN5 Detection of primary current (Connect to the outdoor noise filter circuit board (CNCT)) CN4 Connect to the outdoor controller circuit board (CN4) Brief Check of POWER MODULE W Usually, they are in a state of being short-circuited if they are broken. Measure the resistance in the following points (connectors, etc.). If they are short-circuited, it means that they are broken. 1. Check of POWER MODULE 1 Check of DIODE circuit L1 - P1 , L2 - P1 , L3 - P1 , L1 - N1 , L2 - N1 , L3 - N1 2 Check of IGBT circuit P2 - U , P2 - V , P2 - W , N2 - U , N2 - V , N2 - W Note: The marks, L1 , L2 , L3 , N1 , N2 , P1 , P2 , U , V and W shown in the diagram are not actually printed on the board. CN2 Connect to the outdoor controller circuit board (CN2) 1-5: Power circuit board → Transmitting signal to the controller board (0-5V DC) 2-5: Zero cross signal (0-5V DC) 3-4: Not used 1, 2, 6, 7 : + ] 6-5: 16V DC [ 5 : – 7-5: 16V DC CN7 Connect to the outdoor converter circuit board (CN7) TB-U, TB-V, TB-W W W Connect to the compressor (MC) Voltage among phases: 10V-400V AC W L3 TB-L1, TB-L2, TB-L3 L2 P1 L1 P2 TAB connecter on X52A Connect to the RS resistor N1 Connect to the outdoor noise filter circuit board (LO1, LO2, LO3) 380V-415V AC N2 TB-N1 Connect to the smoothing capacitor CB2 – TB-P2 TB-C1 Connect to the smoothing capacitor CB1 + Connect to the smoothing capacitor CB1 – , CB2 + 33 POWER MODULE 8-8. FUNCTION OF SWITCHES, CONNECTORS AND JUMPERS Function of switches Type of Switch No. switch Action by the switch operation Function 1 Forced defrost +1 2 Abnormal history clear OFF Start Normal When compressor is working in heating operation. +1 Normal off or operating Clear ON 3 ON 1 2 3 4 5 6 0 ON Dip switch SW1 4 Refrigerant address setting 5 ON 1 2 3 4 5 6 4 ON ON 1 2 3 4 5 6 6 ON 1 2 3 4 5 6 9 ON 1 2 3 4 5 6 7 ON 1 2 3 4 5 6 10 ON 1 2 3 4 5 6 13 1 2 3 4 5 6 3 When power supply ON 1 2 3 4 5 6 11 ON 1 2 3 4 5 6 14 1 2 3 4 5 6 15 1 Test run Operating OFF 2 Test run mode setting Heating Cooling 1 No function — — — — — — Used Not used When power supply ON Start Normal Under suspension SW8 2 No function Separate indoor/outdoor 3 unit power supplies Push switch 1 2 3 4 5 6 2 1 2 3 4 5 6 5 1 2 3 4 5 6 12 ON ON ON ON SW4 ON 1 2 3 4 5 6 1 1 2 3 4 5 6 8 6 Effective timing ON SWP Pump down Under suspension w1 Forced defrost should be done as follows. 1 Change the DIP SW1-1 on the outdoor controller board from OFF to ON. 2 Forced defrost will start by the above operation 1 if all these conditions written below are satisfied. • Heat mode setting • 10 minutes have passed since compressor started operating or previous forced defrost finished. • Pipe temperature is less than or equal to 8:. Forced defrost will finish if certain conditions are satisfied. Forced defrost can be done if above conditions are satisfied when DIP SW1-1 is changed from OFF to ON. After DIP SW1-1 is changed from OFF to ON, there is no problem if DIP SW1-1 is left ON or changed to OFF again. This depends on the service conditions. 34 Type of Switch No. Switch 1 SW5 — Auto recovery No auto recovery When power supply ON 3,4,5 No function — — — 6 Model select 2 3 4 Dip switch No function Effective timing Power failure automatic recovery +2 2 1 SW7 +4 Action by the switch operation ON OFF — — Function Following SW5-6 reference SW7-1 SW7-2 Setting of demand Power consumption (Demand switch ON) OFF OFF 0% (Operation stop) control +3 ON OFF 50% OFF ON 75% Defrost Hz setting Defrost Hz % 0.54 Max Hz setting (heating) Max Hz(heating) % 0.8 Always Normal Always Normal Always — 5 No function — — 6 Defrost setting For high humidity Normal 1 No function — — Always — 2 Function switch Valid Normal Always SW9 3,4 SW9-3 SW9-4 Ambient temp. OFF OFF ≤ 3°C (Initial setting) OFF ON ≤ 0°C ON OFF ≤ –3°C ON ON ≤ –6°C Starting Ambient temp. of flash injection Always 1 2 3 SW6 4 5 SW5-6 SW6 Model select ON OFF 1 2 3 4 5 6 7 8 ON OFF 1 2 3 4 5 6 6 7 8 SW5 6 w2 “Power failure automatic recovery” can be set by either remote controller or this DIP SW. If one of them is set to ON, “Auto recovery” activates. Please set “Auto recovery” basically by remote controller because all units do not have DIP SW. Please refer to the indoor unit installation manual. w3 SW7-1,2 are used for demand control. SW7-1,2 are effective only at the demand control. (Refer to next page : Special function (b)) w4 Please do not use SW7-3, 4 ,6 usually. Trouble might be caused by the usage condition. 35 Special function (a) Low-level sound priority mode (Local wiring) Unit enters into Low-level sound priority mode by external signal input setting. Inputting external signals to the outdoor unit decreases the outdoor unit operation sound 3 to 4 dB lower than that of usual. Adding a commercial timer or on-off switch contactor setting to the CNDM connector which is optional contactor for demand input located on the outdoor controller board enables to control compressor operation frequency. W The performance depends on the load of conditioned outdoor temperature. Note: When the Dip SW9-1 on the control board of the outdoor unit is ON, set Dip SW9-1 to OFF. How to wire <Low-level sound priority mode circuit> Insulate this point securely as this is not used. Purchased locally Relay supply Adapter for external signal input (PAC-SC36NA) Red 3 Brown 2 Orange 1 ~ SW1 X CNDM X SW1 : Switch X : Relay (Contact spec. : DC1mA) Outdoor unit controller board Max. 10 m including local wiring 1) Make the circuit as shown above with adapter for external signal input (PAC-SC36NA). 2) Turn SW1 to on for Low-level sound priority mode. Turn SW1 to off to release Low-level sound priority mode and normal operation. (b) On demand control (Local wiring) Demand control is available by external input. In this mode, power consumption is decreased within the range of usual 0~100%. How to wire Basically, the wiring is same with (a). Connect an SW 1 which is procured locally between Orange and Red (1 and 3) of the adapter for external signal input (PACSC36NA), and insulate the tip of the brown lead wire. It is possible to set it to the following power consumption (compared with ratings) by setting the SW7-1, 2. SW7-1 SW7-2 Power consumption (SW1 on) OFF OFF 0% (Operation stop) ON OFF 50% OFF ON 75% 36 <Display function of inspection for outdoor unit> The blinking patterns of both LED1 (green) and LED2 (red) indicate the types of abnormality when it occurs. Types of abnormality can be indicated in details by connecting an optional part “A-Control Service Tool (PAC-SK52ST)” to connector CNM on outdoor controller board. [Display] (1)Normal condition Unit condition When the power is turned on When unit stops When compressor is warming up When unit operates Outdoor controller board A-Control Service Tool LED1 (Green) LED2 (Red) Lighted Lighted Lighted Lighted Lighted Not lighted Not lighted Lighted Indication of the display Error code 00, etc. 08, etc. C5, H7 etc. Alternately blinking display Operation mode (2)Abnormal condition Indication Outdoor controller board LED1 (Green) LED2 (Red) Error Contents 1 blinking 2 blinking Connector(63L) is open. Connector(63H) is open. 2 connectors are open. 2 blinking 1 blinking Miswiring of I/F or FTC or outdoor unit connecting wire, excessive number of indoor units (4 units or more) Miswiring of I/F or FTC or outdoor unit connecting wire (converse wiring or disconnection) Startup time over 2 blinking I/F or FTC or outdoor unit communication error (signal receiving error) is detected by FTC unit. I/F or FTC or outdoor unit communication error (signal receiving error) is detected by outdoor unit. I/F or FTC or outdoor unit communication error (transmitting error) is detected by outdoor unit. 3 blinking Remote controller signal receiving error is detected by remote controller. Error code +1 F3 F5 F9 — — Check if connector (63H or 63L) on the outdoor controller board is not disconnected. Check continuity of pressure switch (63H or 63L) by tester. Check if I/F or FTC or outdoor connecting wire is connected correctly. Check if 4 or more I/F or FTC units are connected to outdoor unit. Check if noise entered into I/F or FTC or outdoor connecting wire or power supply. Re-check error by turning off power, and on again. — Check if I/F or FTC or outdoor connecting wire is connected correctly. Check if noise entered into I/F or FTC or outdoor connecting wire or power supply. — (E8) Check if noise entered into I/F or FTC or outdoor controller board. — Re-check error by turning off power, and on again. E6 (E9) E0 Remote controller transmitting error is detected by remote controller. E3 Remote controller signal receiving error is detected by I/F or FTC unit. E4 Remote controller transmitting error is detected by I/F or FTC unit. E5 4 blinking Error code is not defined. Inspection method EF 1 Error code displayed on remote controller 2 Refer to Technical manual of ATW, I/F, FTC. 37 Check if connecting wire of I/F or FTC unit or remote controller is connected correctly. Check if noise entered into transmission wire of remote controller. Re-check error by turning off power, and on again. Check if noise entered into transmission wire of remote controller. Check if noise entered into I/F or FTC or outdoor connecting wire. Re-check error by turning off power, and on again. Indication Outdoor controller board LED1 (Green) LED2 (Red) Error Contents 3 blinking 1 blinking Abnormality of shell thermostat and discharging temperature (TH4) Abnormality of superheat due to low discharge temperature 2 blinking Abnormal high pressure (High pressure switch 63H operated.) Abnormal low pressure (Low pressure switch 63L operated.) 3 blinking Abnormality of outdoor fan motor rotational speed Protection from overheat operation (TH3), (T63HS) 4 blinking Compressor overcurrent breaking(Start-up locked) Compressor overcurrent breaking Abnormality of current sensor (P.B.) Abnormality of power module 5 blinking Open/short of discharge thermistor (TH4) Open/short of outdoor thermistors (TH3, TH32, TH6, TH7 and TH8) 6 blinking Abnormality of heatsink temperature 7 blinking Abnormality of voltage Error code +1 U2 U7 U1 UL U8 Check if stop valves are open. Check if connectors (TH4, LEV-A, and LEV-B) on outdoor controller board are not disconnected. Check if unit is filled with specified amount of refrigerant. Measure resistance values among terminals on indoor valve and outdoor linear expansion valve using a tester. Check if outdoor unit have a short cycle on their air ducts. Check if connector(63H)(63L) on outdoor controller board is not disconnected. Check if heat exchanger and filter is not dirty. Measure resistance values among terminals on linear expansion valve using a tester. Check the outdoor fan motor. Check if connector (TH3) (63HS) on outdoor controller board is disconnected. Ud UF UP UH U6 U3 Check if stop valves are open. Check looseness, disconnection, and converse connection of compressor wiring. Measure resistance values among terminals on compressor using a tester. Check if outdoor unit has a short cycle on its air duct. U4 Check if connectors(TH3,TH32,TH4, and TH7/6)on outdoor controller board and connector (CN3) on outdoor power board are not disconnected. Measure resistance value of outdoor thermistors. U5 Check if outdoor unit have a short cycle on their air ducts. Measure resistance value of outdoor thermistor (TH8). U9 Check looseness, disconnection, and converse connection of compressor wiring. Measure resistance value among terminals on compressor using a tester. Check if power supply voltage decreases. 4 blinking 1 blinking Abnormality of water temperature thermistor (TH1) P1 Abnormality of pipe temperature thermistor / Liquid (TH2) P2 Abnormality of actual tank temperature thermistor P9 (TH5) 3 blinking Freezing (cooling)/overheating (heating, heating ECO, anti freeze, hot water) protection Inspection method P6 Check if terminal on I/F or FTC are not disconnected. Measure resistance value of I/F or FTC thermistors. Check if short cycle of air path. Check if heat exchanger and filter is not dirty. Measure resistance value on outdoor fan motor. Check if the inside of refrigerant piping is not clogged. 1 Error code displayed on remote controller 2 Refer to Technical manual of ATW, I/F and FTC. 38 <Outdoor unit operation monitor function> [When optional part “A-Control Service Tool(PAC-SK52ST)” is connected to outdoor controller board(CNM)] Digital indicator LED1 displays 2 digit number or code to inform operation condition and the meaning of error code by controlling DIP SW2 on “A-Control Service Tool”. Operation indicator SW2 : Indicator change of self diagnosis Explanation for display Display detail SW2 setting Unit ON 1 2 3 4 5 6 <Digital indicator LED1 working details> (Be sure that 1 to 6 in the SW2 are set to OFF.) 1 second interval (1) Display when the power supply ON When the power supply ON, blinking displays by turns. Wait for 4 minutes at the longest. (2) When the display lights (Normal operation) 1 Operation mode display. SW2 (Lighting) ON LED1 (Initial setting) 1 2 3 4 5 6 The ones digit : Relay output Warming-up Display Compressor The tens digit : Operation mode Display Operation Model O OFF / FAN C COOLING / DRY + H HEATING d DEFROSTING w C5 is displayed during replacement operation. Compressor 4-way valve 0 — — — — 1 — — — ON 2 — — ON — 3 — — ON ON 4 — ON — — — ON 5 — ON 2 Display during error postponement Postponement code is displayed when 6 — ON compressor stops due to the work of 7 ON — protection device. 8 — ON Postponement code is displayed while A ON — error is being postponed. (3) When the display blinks Inspection code is displayed when compressor stops due to the work of protection devices. Display Inspection unit 0 Outdoor unit 1 Interface or FTC Display F3 F5 F9 E8 E9 EA Eb EC E0~E6 Display U1 U2 U3 U4 U5 U6 U7 U8 Ud UF UH UL UP P1~P9 Solenoid valve ON — ON ON — — ON — Contents to be inspected (During operation) Abnormal high pressure (63H operated) Abnormal high discharging temperature, shortage of refrigerant Open/short circuit of discharging thermistor (TH4) Open/short of outdoor unit thermistors (TH3, TH32, TH6, TH7 and TH8) Abnormal temperature of heatsink Abnormality of power module Abnormality of superheat due to low discharge temperature Abnormality in outdoor fan motor Overheat protection Compressor overcurrent interruption (When Comp. locked) Current sensor error Abnormal low pressure (63L operated) Compressor overcurrent interruption Abnormality of Interface or FTC units Contents to be inspected (When power is turned on) 63L connector (red) is open. 63H connector(yellow) is open. 2 connectors(63H/63L) are open. Interface or FTC/outdoor communication error (Signal receiving error) (Outdoor unit) Interface or FTC/outdoor communication error (Transmitting error) (Outdoor unit) Miswiring of Interface or FTC/outdoor unit connecting wire Miswiring of Interface or FTC/outdoor unit connecting wire (converse wiring or disconnection) Startup time over Communication error except for outdoor unit 39 SW2 setting ON Explanation for display Display detail Pipe temperature / Liquid(TH3) −40~90 1 2 3 4 5 6 −40~90 (When the coil thermistor detects 0: or below, “–” and temperature are displayed by turns.) (Example) When −10:; 0.5 secs. 0.5secs. 2 secs. Unit : 10 Discharge temperature (TH4) 3~217 ON 1 2 3 4 5 6 ON 3~217 (When the discharge thermistor detects 100: or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 105:; 0.5 secs. 0.5secs. 2 secs. 1 05 : Output step of outdoor FAN 0~10 0~10 The number of ON / OFF times of compressor 0~9999 0~9999 (When the number of times is 100 or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 42500 times (425 × 100 times); 0.5 secs. 0.5secs. 2 secs. 4 25 100 times 0~9999 (When it is 100 hours or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 2450 hours (245 × 10 hours); 0.5 secs. 0.5secs. 2 secs. 2 45 10 hours Step 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON Compressor integrating operation times 0~9999 1 2 3 4 5 6 ON Compressor operating current 0~50 0~50 w Omit the figures after the decimal fractions. Compressor operating frequency 0~225 0~255 (When it is 100Hz or more, hundreds digit, tens digit and ones digit are displayed by turns. (Example) When 125Hz; 0.5 secs. 0.5secs. 2 secs. 1 25 Hz 0~480 (When it is 100 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns. (Example) When 150 pulse; 0.5 secs. 0.5secs. 2 secs. 1 50 Pulse A 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON LEV-A opening pulse 0~480 1 2 3 4 5 6 ON Error postponement code history (1) of outdoor unit Postponement code display Blinking: During postponement Lighting: Cancellation of postponement “00” is displayed in case of no postponement. Operation mode on error occurring Operation mode of when operation stops due to error is displayed by setting SW2 like below. 1 2 3 4 5 6 ON (SW2) ON 1 2 3 4 5 6 1 2 3 4 5 6 40 Code display Code display SW2 setting ON 1 2 3 4 5 6 ON Explanation for display Display detail Pipe temperature / Liquid (TH3) on error −40~90 occurring (When the coil thermistor detects 0: or below, “–” −40~90 and temperature are displayed by turns.) (Example) When −15:; 0.5 secs. 0.5secs. 2 secs. 15 : Compressor temperature (TH4) or discharge temperature (TH4) on error occurring 3~217 3~217 (When the temperature is 100: or more, the hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 130:; 0.5 secs. 0.5secs. 2 secs. 1 30 : Compressor operating current on error occurring 0~20 0~20 Error code history (1) (latest) Alternate display of abnormal unit number and code When no error history, “ 0 ” and “– –” are displayed by turns. Error code history (2) Alternate display of error unit number and code When no error history, “ 0 ” and “– –” are displayed by turns. Thermo ON time 0~999 0~999 (When it is 100 minutes or more, the hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 245 minutes; 0.5 secs. 0.5secs. 2 secs. 2 45 1 2 3 4 5 6 ON Unit A 1 2 3 4 5 6 ON Code display 1 2 3 4 5 6 ON Code display 1 2 3 4 5 6 ON 1 2 3 4 5 6 Test run elapsed time 0~120 0~120 (When it is 100 minutes or more, the hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 105 minutes; 0.5 secs. 0.5secs. 2 secs. 1 05 41 Minute Minute SW2 setting Explanation for display Display detail The number of connected indoor units ON 0~3 (The number of connected indoor units are displayed.) Unit Unit 1 2 3 4 5 6 Capacity setting display Displayed as an outdoor capacity code. Model HRP200 ON Code 40 Code display 1 2 3 4 5 6 Outdoor unit setting information • The tens digit (Total display for applied setting) Setting details Display details H·P / Cooling only 0 : H·P 1 : Cooling only Single phase / 3 phase 0 : Single phase 2 : 3 phase ON • The ones digit Setting details 1 2 3 4 5 6 Display details Defrosting switch 0 : Normal Code display 1 : For high humidity (Example) When heat pump, 3 phase and defrosting (normal) are set up, “20” is displayed. ON Pipe temperature / Liquid (TH2) −39~88 −39~88 (When the temperature is 0: or less, “–” and temperature are displayed by turns.) : 1 2 3 4 5 6 ON Actual flow water temperature (TH1) 8~39 8~39 : 1 2 3 4 5 6 42 SW2 setting ON Explanation for display Display detail Pressure saturation temperature (T63HS) −39~88 −39~88 (When the temperature is 0: or less, “–” and temperature are displayed by turns.) Unit : 1 2 3 4 5 6 ON Ambient temperature (TH7) −39~88 −39~88 (When the temperature is 0: or less, “–” and temperature are displayed by turns.) : 1 2 3 4 5 6 Outdoor heatsink temperature (TH8) −40~200 −40~200 (When the temperature is 0: or less, “–” and temperature are displayed by turns.) (When the thermistor detects 100: or more, hundreds digit, tens digit and ones digit are displayed by turns.) ON 1 2 3 4 5 6 ON Discharge superheat SHd 0~255 Cooling = TH4-T63HS Heating = TH4-T63HS 0~255 (When the temperature is 100°C or more, hundreds digit, tens digit and ones digit are displayed by turns.) Sub cool. SC 0~130 Cooling = T63HS-TH3 Heating = T63HS-TH2 0~130 (When the temperature is 100°C or more, hundreds digit, tens digit and ones digit are displayed by turns.) Input current of outdoor unit 0~500 (When it is 100 or more, hundreds digit, tens digit and ones digit are displayed by turns.) : °C 1 2 3 4 5 6 ON °C 1 2 3 4 5 6 ON 0.1 A 1 2 3 4 5 6 ON 0~480 (When it is 100 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns.) LEV-B opening pulse 0~480 Pulse 1 2 3 4 5 6 ON 0~255 (When it is 100Hz or more, hundreds digit, tens digit and ones digit are displayed by turns.) Targeted operation frequency 0~255 Hz 1 2 3 4 5 6 ON 180~370 (When it is 100V or more, hundreds digit, tens digit and ones digit are displayed by turns.) DC bus voltage 180~370 1 2 3 4 5 6 43 V SW2 setting Capacity save 0~255 ON 1 2 3 4 5 6 ON When there is no setting of capacity save “100” is displayed. Error postponement code history (2) of outdoor unit 1 2 3 4 5 6 ON Error postponement code history (3) of outdoor unit 1 2 3 4 5 6 ON Explanation for display Display detail 0~255 (When the capacity is 100% hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 100%; 0.5 secs. 0.5secs. 2 secs. 1 00 Code display Postponement code display Blinking: During postponement Lighting: Cancellation of postponement “00” is displayed in case of no postponement. Code display Error code history (3) (Oldest) Alternate display of abnormal unit number and code When no error history, “0” and “– –“ are displayed by turns. Error thermistor display 3: Liquid pipe thermistor (TH3) 6: 2-phase pipe thermistor (TH6) 7: Ambient temp. thermistor (TH7) 8: Heatsink thermistor (TH8) 32: Suction pipe thermistor (TH32) When there is no error thermistor, “–“ is displayed. 1 2 3 4 5 6 Operation frequency on error occurring 0~255 ON % Postponement code display Blinking: During postponement Lighting: Cancellation of postponement “00” is displayed in case of no postponement. Code display 1 2 3 4 5 6 ON Unit Code display 0~255 (When it is 100Hz or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 125Hz; 0.5 secs. 0.5secs. 2 secs. Hz 1 2 3 4 5 6 1 ON Fan step on error occurring 0~10 25 0~10 Step 1 2 3 4 5 6 ON Outdoor pipe temperature (TH33) −39~88 −39~88 (When the temperature is 0: or less, “–” and temperature are displayed by turns.) : 1 2 3 4 5 6 ON 1 2 3 4 5 6 LEV-A opening pulse on error occurring 0~480 0~480 (When it is 100 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 130 pulse; 0.5 secs. 0.5secs. 2 secs. 1 30 44 Pulse SW2 setting ON Explanation for display Display detail Unit Actual water temperature (TH1) on error 8~39 occurring 8~39 : 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON Pipe temperature / Liquid (TH2) on error −39~88 occurring (When the temperature is 0°C or less, “–” and −39~88 temperature are displayed by turns.) (Example) When −15°C; 0.5 secs. 0.5secs. 2 secs. 15 Pressure saturation temperature (T63HS) on error occurring −39~88 1 2 3 4 5 6 ON −39~88 (When the temperature is 0°C or less, “–” and temperature are displayed by turns.) (Example) When −15°C; 0.5 secs. 0.5secs. 2 secs. 15 Outdoor pipe temperature / 2-phase. (TH6) on error occurring −39~88 1 2 3 4 5 6 ON Outdoor outside temperature (TH7) on error occurring −39~88 1 2 3 4 5 6 ON Outdoor heatsink temperature (TH8) on error occurring −40~200 1 2 3 4 5 6 Discharge superheat on error occurring SHd 0~255 ON 1 2 3 4 5 6 ON 1 2 3 4 5 6 −39~88 (When the temperature is 0°C or less, “–” and temperature are displayed by turns.) (Example) When −15°C; 0.5 secs. 0.5secs. 2 secs. 15 Cooling = TH4-T63HS Heating = TH4-T63HS Sub cool on error occurring SC 0~130 Cooling = T63HS-TH3 Heating = T63HS-TH2 45 −39~88 (When the temperature is 0°C or less, “–” and temperature are displayed by turns.) (Example) When −15°C; 0.5 secs. 0.5secs. 2 secs. 15 −40~200 (When the temperature is 0°C or less, “–” and temperature are displayed by turns.) (When the temperature is 100°C or more, hundreds digit, tens digit and ones digit are displayed by turns.) : : : : : 0~255 (When the temperature is 100°C or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 150°C; 0.5 secs. 0.5secs. 2 secs. 1 50 : 0~130 (When the temperature is 100°C or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 115°C; 0.5 secs. 0.5secs. 2 secs. 1 15 : SW2 setting Explanation for display Display detail Thermo-on time until error stops 0~999 ON 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON 1 2 3 4 5 6 ON Unit 0~999 (When it is 100 minutes or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 415 minutes; 0.5 secs. 0.5secs. 2 secs. 4 15 Pipe temperature / Liquid (TH2 (3)) Indoor 3 −39~88 −39~88 (When the temperature is 0°C or less, “–” and temperature are displayed by turns.) Replacement operation W If replacement operation is conducted even once, “1” is displayed. If replacement operation time is less than 2 hrs. “0” is displayed. 1: Conducted. 0: Not yet. U9 Error status during the Error postponement period 1 2 3 4 5 6 Minute : – Description Normal Overvoltage error Undervoltage error Input current sensor error L1-phase open error Abnormal power synchronous signal Detection point Display — 00 Power circuit board 01 Controller circuit board 02 Controller circuit board 04 Power circuit board 08 Code display Display examples for multiple errors: Overvoltage (01) + Undervoltage (02) = 03 Undervoltage (02) + Power-sync signal error (08) = 0A Controlling status of compressor operating frequency The following code will be a help to know the operating status of unit. •The tens digit Display Compressor operating frequency control 1 Primary current control Secondary current control 2 ON •The ones digit (In this digit, the total number of 1 2 3 4 5 6 activated control is displayed.) Display Compressor operating frequency control Preventive control for excessive temp1 erature rise of discharge temperature Preventive control for excessive temp2 erature rise of condensing temperature 4 Frosting preventing control Preventive control for excessive temp8 erature rise of radiator panel (Example) The following controls are activated. LED • Primary current control • Preventive control for excessive temperature rise of condensing temperature • Preventive control for excessive temperature rise of heatsink Code display ON LEV-C opening pulse 0~480 0~480 (When it is 100 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns.) 1 2 3 4 5 6 46 Pulse 9 DISASSEMBLY PROCEDURE PUHZ-HRP200YKA PHOTOS & ILLUSTRATION OPERATING PROCEDURE 1. Removing the service panel and top panel (1) Remove 3 service panel fixing screws (5 × 10) and slide the hook on the right downward to remove the service panel. (2) Remove screws (3 for front, 3 for rear/5 × 10) of the top panel and remove it. Photo 1 Top panel Top panel fixing screws Service panel Grille fixing screws Slide Grille fixing screws Service panel fixing screws Cover panel fixing screws Photo 2 2. Removing the fan motor (MF1, MF2) (1) Remove the service panel. (See Photo 1.) Front panel (2) Remove the top panel. (See Photo 1.) (3) Remove 4 fan grille fixing screws (5 × 10) to detach the fan Propeller grille. (See Photo 1.) (4) Remove a nut (for right handed screw of M6) to detach the propeller. (See Photo 2.) (5) Disconnect the connectors, CNF1, CNF2 on controller circuit board in electrical parts box. Nut (6) Remove 4 fan motor fixing screws (5 × 20) to detach the fan motor. (See Photo 3.) Photo 3 Fan motor fixing screws Fan motor Fan motor fixing screws 3. Removing the electrical parts box (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Disconnect the connecting wires from terminal block. (4) Disconnect the connectors on the controller circuit board. (5) Remove the terminal cover and disconnect the compressor lead wire. (6) Remove 2 electrical parts box fixing screws (4 × 10) and detach the electrical parts box by pulling it upward. The electrical parts box is fixed with 2 hooks on the left and 1 hook on the right. Photo 4 Controller circuit board (C.B.) Electrical parts box Electrical parts box fixing screws Noise filter circuit board (N.F.) Terminal block (TB1) 47 Terminal block (TB2) PHOTOS OPERATING PROCEDURE 4. Removing the thermistor <Outdoor 2-phase pipe> (TH6) Photo 5 (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Disconnect the connectors, TH6 and TH7 (red), on the Electrical controller circuit board in the electrical parts box. parts box (4) Loosen the 2 wire clamps on top of the electrical parts box. (5) Pull out the thermistor <Outdoor 2-phase pipe> (TH6) from the sensor holder. Thermistor <Outdoor 2-phase pipe>(TH6) Note: In case of replacing thermistor <Outdoor 2-phase pipe> (TH6), replace it together with thermistor <Outdoor> (TH7) since they are combined together. Refer to No.6 below to remove thermistor <Outdoor>. Clamp Photo 6 5. Removing the thermistor <Outdoor> (TH7) (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Disconnect the connector TH7 (red) on the controller circuit board in the electrical parts box. (4) Loosen the 2 wire clamps on top of the electrical parts box. (See Photo 5.) (5) Pull out the thermistor <Outdoor> (TH7) from the sensor holder. Note: In case of replacing thermistor <Outdoor> (TH7), replace it together with thermistor <Outdoor 2-phase pipe> (TH6), since they are combined together. Refer to No.5 above to remove thermistor <Outdoor 2-phase pipe>. 6. Removing the thermistor <Liquid pipe> (TH3), thermistor <Discharge> (TH4) and thermistor <Suction pipe> (TH32) (1) Remove the service panel. (See Photo 1.) (2) Disconnect the connectors, TH3 (white) and TH4 (white) on the controller circuit board in the electrical parts box. (3) Loosen the clamp for the lead wire in the rear of the electrical parts box. [Removing the thermistor<Liquid pipe>(TH3)] (4) Pull out the thermistor <Liquid pipe> (TH3) from the sensor holder. [Removing the thermistor<Suction pipe>(TH32)] (4) Pull out the thermistor <Suction pipe> (TH32) from the thermo-holder. (TH32 : See. Figure 2) [Removing the thermistor<Discharge>(TH4)] (4) Pull out the thermistor <Discharge> (TH4) from the sensor holder. Lead wire of thermistor <Outdoor> (TH7) Photo 7 Thermistor <Discharge> (TH4) Soundproof cover (upper) for compressor Compressor (MC) 48 Sensor holder Thermistor <Outdoor pipe> (TH3) PHOTOS OPERATING PROCEDURE 7. Removing the 4-way valve coil (21S4) and linear expansion valve coil (LEV-A, LEV-B, LEV-C) (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Remove the electrical parts box. (See Photo 4.) Figure 1 Linear expansion valve coil (LEV-C) Linear expansion valve [Removing the 4-way valve coil] (4) Remove 4-way valve coil fixing screw (M4 × 6). (5) Remove the 4-way valve coil by sliding the coil toward you. [Removing the linear expansion valve coil] (4) Remove 3 right side panel fixing screws (5 × 10) in the rear of the unit then remove the right side panel. (5) Remove the linear expansion valve coil by sliding the coil upward. Linear expansion valve coil (LEV-A) Linear expansion valve coil (LEV-B) 8. Removing the 4-way valve (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Remove the electrical parts box. (See Photo 4.) (4) Remove 3 valve bed fixing screws (4 × 10), 4 ball valve and stop valve fixing screws (5 × 16) then remove the valve bed. (5) Remove 3 right side panel fixing screws (5 × 10) in the rear of the unit then remove the right side panel. (6) Remove the 4-way valve coil. (7) Recover refrigerant. (8) Remove the welded part of 4-way valve. 9. Removing the linear expansion valve (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Remove 3 valve bed fixing screws (4 × 10), 4 ball valve and stop valve fixing screws (5 × 16) then remove the valve bed. (4) Remove 3 right side panel fixing screws (5 × 10) in the rear of the unit then remove the right side panel. (5) Remove the linear expansion valve coil. (6) Recover refrigerant. (7) Remove the welded part of linear expansion valve. 49 4-way valve coil (21S4) 4-way 4-way valve valve coil fixing screw Note 1: Recover refrigerant without spreading it in the air. Note 2: The welded part can be removed easily by removing the right side panel. Note 3: When installing the parts of refrigerant circuit, cover it with a wet cloth to prevent it from heating (120°C or more), then braze the pipes so that the inside of pipes are not oxidized. OPERATING PROCEDURE PHOTOS 10. Removing the high pressure switch (63H) and low pressure switch (63L) (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Remove 3 right side panel fixing screws (5 × 10) in the rear of the unit and remove the right side panel. (4) Pull out the lead wire of high pressure switch and low pressure switch. (5) Recover refrigerant. (6) Remove the welded part of high pressure switch and low pressure switch. Note 1: Recover refrigerant without spreading it in the air. Note 2: The welded part can be removed easily by removing the right side panel. Note 3: When installing the parts of refrigerant circuit, cover it with a wet cloth to prevent it from heating (100°C or more), then braze the pipes so that the inside of pipes are not oxidized. Photo 8 High pressure switch Figure 2 Suction pipe thermistor (TH32) Low pressur switch (63L) 11. Removing the compressor (MC) (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Remove 2 front cover panel fixing screws (5 × 10) and remove the front cover panel. (4) Remove 4 back cover panel fixing screws (5 × 10) and remove the back cover panel. (5) Remove the electrical parts box. (See Photo 4.) (6) Remove 3 valve bed fixing screws (4 × 10), 4 ball valve and stop valve fixing screws (5 × 16), then remove the valve bed. (7) Remove 3 right side panel fixing screws (5 × 10) in the rear of the unit and remove the right side panel. (8) Remove 3 separator fixing screws (4 × 10) and remove the separator. (9) Remove the soundproof cover for compressor. (10) Remove the terminal cover and remove the compressor lead wire. (11) Recover refrigerant. (12) Remove the 3 points of the compressor fixing nut using a spanner or a adjustable wrench. (13) Remove the welded pipe of compressor inlet and outlet and remove the compressor. Photo 9 Note: Recover refrigerant without spreading it in the air. 50 Compressor terminal Compressor (MC) Soundproof cover Compressor fixing nut PHOTOS OPERATING PROCEDURE 12. Removing the power receiver (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Remove 2 front cover panel fixing screws (5 × 10) and remove the front cover panel. (4) Remove 4 back cover panel fixing screws (5 × 10) and remove the back cover panel. (5) Remove the electrical parts box. (See Photo 4.) (6) Remove 3 valve bed fixing screws (4 × 10) and 4 ball valve and stop valve fixing screws (5 × 16) and then remove the valve bed. (7) Remove 3 right side panel fixing screws (5 × 10) in the rear of the unit and then remove the right side panel. (8) Recover refrigerant. (9) Remove 4 welded pipes of power receiver inlet and outlet. (10) Remove 2 receiver leg fixing screws (4 × 10). Photo 10 Note: Recover refrigerant without spreading it in the air. Separator Power receiver Valve bed fixing screw Valve bed Valve bed fixing screws Compressor Separator fixing screw Compressor fixing nuts Power receiver leg fixing screws Photo 11 Inlet pipe Outlet pipe Power receiver 13. Removing the pressure sensor (63HS) (1) Remove the service panel. (See Photo 1.) (2) Remove the top panel. (See Photo 1.) (3) Pull out the lead wire of pressure sensor. (4) Remove the band that is fixing the rubber mount and the sensor. (5) Recover refrigerant. (6) Remove the welded part of pressure sensor. Note 1: Recover refrigerant without spreading it in the air. Note 2: The welded part can be removed easily by removing the right side panel. Note 3: When installing the pressure sensor, make sure to cover it with a wet cloth to prevent it from heating (100°C or more), then braze the pipes so that the inside of pipes are not oxidized. Figure 3 4-way valve Low pressure switch (63L) Muffler Fixing band High pressure sensor (63HS) Rubber mount 51 High pressure switch (63H) Compressor (MC) HEAD OFFICE : TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN Copyright 2009 MITSUBISHI ELECTRIC ENGINEERING CO., LTD. Distributed in Nov. 2009 No. OCH466 PDF 7 Made in Japan New publication, effective Nov. 2009 Specifications subject to change without notice