Page 1: Service Manual
November 2012 No.OCH527 SERVICE MANUAL R410A Outdoor unit Note: [Model name] [Service Ref.] • This manual describes only PUHZ-ZRP35VKA service data of the outdoor PUHZ-ZRP35VKA units. • RoHS compliant products have PUHZ-ZRP50VKA PUHZ-ZRP50VKA mark on the spec name plate.
Page 2: Safety Precaution
REFERENCE MANUAL INDOOR UNIT SERVICE MANUAL Service Model name Service Ref. Manual No. OCH535 PLA-ZRP35/50/60/71/125/140BA PLA-ZRP35/50/60/71/125/140BA.UK OCB535 OCH529 PLA-ZRP100BA PLA-ZRP100BA OCB529 PCA-RP35/100/125/140KAQ OCH491 PCA-RP35/50/60/71/100/125/140KAQ PCA-RP50/60/71KAQR1 OCB491 OCH492 PCA-RP71/125HAQ PCA-RP71/125HAQ OCB492 OCH453 PKA-RP35/50HAL PKA-RP35/50HAL OCB453 OCH452 PKA-RP60/71/100KAL PKA-RP60/71/100KAL OCB452 OCH528 PSA-RP71/100/125/140KA PSA-RP71/100/125/140KA OCB528 HWE10090...
Page 3 Use a vacuum pump with a reverse flow check Use new refrigerant pipes. valve. In case of using the existing pipes for R22, be careful with Vacuum pump oil may flow back into refrigerant cycle and the followings. that can cause deterioration of refrigerant oil etc. ·...
Page 4 [3] Service tools Use the below service tools as exclusive tools for R410A refrigerant. Tool name Specifications Gauge manifold · Only for R410A · Use the existing fitting specifications . (UNF1/2) · Use high-tension side pressure of 5.3MPa·G or over. Charge hose ·...
Page 5 (2) Cautions for refrigerant piping work New refrigerant R410A is adopted for replacement inverter series. Although the refrigerant piping work for R410A is same as for R22, exclusive tools are necessary so as not to mix with different kind of refrigerant. Furthermore as the working pressure of R410A is 1.6 times higher than that of R22, their sizes of flared sections and flare nuts are different.
Page 6 FEATURES PUHZ-ZRP35VKA PUHZ-ZRP60VHA PUHZ-ZRP50VKA PUHZ-ZRP71VHA PUHZ-ZRP100VKA PUHZ-ZRP125VKA PUHZ-ZRP140VKA PUHZ-ZRP100YKA PUHZ-ZRP125YKA PUHZ-ZRP140YKA CHARGELESS SYSTEM PRE-CHARGED REFRIGERANT IS SUPPLIED FOR PIPING LENGTH AT SHIPMENT Max. 30m (PUHZ-ZRP35-140) The refrigerant circuit with LEV (Linear Expansion Valve) and power receiver always control the optimal refrigerant level regardless of the length (30 m max.
Page 7: Specifications
SPECIFICATIONS PUHZ-ZRP35VKA PUHZ-ZRP50VKA Service Ref. Mode Cooling Heating Cooling Heating Single, 50Hz, 230V Power supply (phase, cycle, voltage) Max. current Munsell 3Y 7.8/1.1 External finish Linear Expansion Valve Refrigerant control Hermetic Compressor SNB092FGCM SNB130FGCM2 Model Motor output Inverter Starter type...
Page 8 PUHZ-ZRP100VKA PUHZ-ZRP125VKA PUHZ-ZRP140VKA Service Ref. Mode Cooling Heating Cooling Heating Cooling Heating Power supply (phase, cycle, voltage) Single 50Hz, 230V Max. current 26.5 External finish Munsell 3Y 7.8/1.1 Refrigerant control Linear Expansion Valve Compressor Hermetic Model ANB33FNFMT Motor output Starter type Inverter Protection devices HP switch...
Page 9 DATA 5-1. REFILLING REFRIGERANT CHARGE (R410A : kg) PUHZ-ZRP35-140 Piping length (one way) Initial Service Ref. charged PUHZ-ZRP35VKA — — PUHZ-ZRP50VKA — — PUHZ-ZRP60VHA — — PUHZ-ZRP71VHA — — PUHZ-ZRP100VKA PUHZ-ZRP100YKA PUHZ-ZRP125VKA PUHZ-ZRP125YKA PUHZ-ZRP140VKA PUHZ-ZRP140YKA Additional charge is required for pipes longer than 30 m.
Page 10 5-3. NOISE CRITERION CURVES MICROPHONE UNIT 1.5m GROUND PUHZ-ZRP35VKA PUHZ-ZRP60VHA MODE SPL(dB) LINE SPL(dB) MODE LINE COOLING PUHZ-ZRP50VKA COOLING PUHZ-ZRP71VHA HEATING HEATING NC-70 NC-70 NC-60 NC-60 NC-50 NC-50 NC-40 NC-40 NC-30 NC-30 APPROXIMATE APPROXIMATE THRESHOLD OF THRESHOLD OF HEARING FOR...
Page 11 1 , 50 Voltage Current 0.36 0.29 0.36 0.29 0.36 0.29 0.75 0.69 Outdoor unit PUHZ-ZRP71VHA PUHZ-ZRP35VKA PUHZ-ZRP50VKA PUHZ-ZRP60VHA Phase , Hz 1 , 50 1 , 50 1 , 50 1 , 50 Voltage Current 3.54 3.92 6.19 6.86 7.68...
Page 12 PLA-ZRP100BA PLA-ZRP140BA PLA-ZRP125BA Representative matching Mode Cooling Heating Cooling Heating Cooling Heating Capacity 10,000 11,200 12,500 14,000 13,400 16,000 Input 2.60 2.61 3.87 3.67 4.37 4.70 Indoor unit PLA-ZRP100BA PLA-ZRP125BA PLA-ZRP140BA Phase , Hz 1 , 50 1 , 50 1 , 50 Voltage Current...
Page 13: Outlines And Dimensions
OUTLINES AND DIMENSIONS PUHZ-ZRP35VKA Unit : mm PUHZ-ZRP50VKA OCH527...
Page 14 PUHZ-ZRP60VHA Unit : mm PUHZ-ZRP71VHA OCH527...
Page 15 PUHZ-ZRP100VKA Unit : mm PUHZ-ZRP125VKA PUHZ-ZRP140VKA PUHZ-ZRP100YKA PUHZ-ZRP125YKA PUHZ-ZRP140YKA OCH527...
Page 16: Wiring Diagram
WIRING DIAGRAM PUHZ-ZRP35VKA PUHZ-ZRP50VKA SYMBOL NAME SYMBOL NAME Terminal Block < Power Supply, Indoor/Outdoor> F1, F2 Fuse <10A > Motor for Compressor F3, F4 Fuse <3.15A > Fan Motor Relay 21S4 Solenoid Valve (Four-Way Valve) Resistor High Pressure Switch LED1, LED2 LED ...
Page 17 PUHZ-ZRP60VHA PUHZ-ZRP71VHA SYMBOL NAME SYMBOL NAME SYMBOL NAME Terminal Block Converter F1~4 Fuse Motor for Compressor CB1~CB3 Main Smoothing Capacitor Switch Fan Motor N.F. Noise Filter Circuit Board CN31 Connector 21S4 Solenoid Valve (Four-Way Valve) LI/LO Connection Terminal ...
Page 18 PUHZ-ZRP100VKA PUHZ-ZRP125VKA PUHZ-ZRP140VKA SYMBOL NAME SYMBOL NAME SYMBOL NAME Terminal Block Connection Terminal < L-Phase > Connector CN31 Motor for Compressor Connection Terminal < N-Phase > CN3S Connector MF1, MF2 Fan Motor Connection Terminal CN51 Connector ...
Page 19 PUHZ-ZRP100YKA PUHZ-ZRP125YKA PUHZ-ZRP140YKA SYMBOL NAME SYMBOL NAME SYMBOL NAME Terminal Block TB-N Connection Terminal Switch Terminal Block X52CA Switch 52C Relay N.F. Motor for Compressor Noise Filter Circuit Board Switch MF1, MF2 Fan Motor LI1/LI2/LI3/NI Switch ...
Page 20: Wiring Specifications
WIRING SPECIFICATIONS 8-1. FIELD ELECTRICAL WIRING (power wiring specifications) Outdoor unit model RP35, 50V RP60, 70V RP100,125V RP140V RP100, 125, 140Y ~/N (single), ~/N (single), ~/N (single), ~/N (single), 3N~ (3 ph 4-wires), Outdoor unit power supply 50 Hz, 230 V 50 Hz, 230 V 50 Hz, 230 V 50 Hz, 230 V...
Page 21 8-2. SEPARATE INDOOR UNIT/ OUTDOOR UNIT POWER SUPPLIES The following connection patterns are available. The outdoor unit power supply patterns vary on models. 1:1 System Outdoor unit power supply * The optional indoor power supply terminal kit is required. Earth leakage breaker Wiring circuit breaker or isolating switch Outdoor unit...
Page 22 8-3. INDOOR – OUTDOOR CONNECTING CABLE The cable shall not be lighter than design 60245 IEC or 60227 IEC. Wire No. Size (mm²) Outdoor power supply Max. 45m Max. 50m Max. 80m Indoor unit-Outdoor unit 1.5 (polar) 2.5 (polar) 2.5 (polar) and S3 separated Indoor unit-Outdoor unit earth Min.
Page 23 8-4. M-NET WIRING METHOD (Points to note) (1) Outside the unit, transmission wires should stay away from electric wires in order to prevent electromagnetic noise from making an influence on the signal communication. Place them at intervals of more than 5 cm. Do not put them in the same conduit tube.
Page 24 M-NET wiring M-NET (1) Use 2-core × 1.25mm² shield wire for electric wires. terminal Earth (Excluding the case connecting to system controller.) block wire (2) Connect the wire to the M-NET terminal block. Connect one core of the transmission wire (non-polar) to A terminal and the other to B. Peel the shield wire, twist the shield part to a string and connect it to S terminal.
Page 25: Refrigerant System Diagram
REFRIGERANT SYSTEM DIAGRAM PUHZ-ZRP35VKA Unit : mm (inch) PUHZ-ZRP50VKA Thermistor TH7 Heat exchanger (Outdoor) Stop valve Charge plug Thermistor TH6 (with service port) Solenoid valve (Outdoor 2-phase pipe) (Four-way valve) Refrigerant GAS pipe connection(1/2F) Strainer Thermistor TH3 (Outdoor pipe) Muffler...
Page 26 Unit : mm (inch) PUHZ-ZRP100VKA PUHZ-ZRP125VKA PUHZ-ZRP100YKA PUHZ-ZRP125YKA Thermistor TH7 (Outdoor) Heat exchanger Thermistor TH6 (Outdoor 2-phase pipe) Ball valve 4-way valve Strainer Refrigerant GAS pipe connection(5/8) Charge plug Thermistor TH3 (High pressure) Muffler (Outdoor pipe) Charge plug (Low pressure) Distributor High pressure switch 63H...
Page 27 9-1. REFRIGERANT COLLECTING (PUMP DOWN) Perform the following procedures to collect the refrigerant when moving the indoor unit or the outdoor unit. 1 Supply power (circuit breaker). * When power is supplied, make sure that “CENTRALLY CONTROLLED” is not displayed on the remote controller. If “CEN- TRALLY CONTROLLED”...
Page 28: Troubleshooting
TROUBLESHOOTING 10-1. TROUBLESHOOTING Present and past error codes are logged and displayed on the wired remote controller and 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.
Page 29 10-2-2. Test run for wired remote controller MENU RETURN SELECT ON/OFF Function buttons Select "Service" from the Main menu, and press the button. Test run Input maintenance info. Function setting Check Self check Select "Test run" with the F1 or F2 button, and press the button.
Page 30 When an error occurs, the following screen will appear. Check the error status, stop the operation, and consult your dealer. Error code, error unit, refrigerant address, unit model name, and serial Error information number will appear. Error code Error unit The model name and serial number will appear only if the information have Ref.
Page 31 While no errors are occurring, page 2/2 of the error information can be viewed by Main Main menu selecting "Error information" from the Main menu. Restriction Energy saving Errors cannot be reset from this screen. Night setback Filter information Error information Main display:...
Page 32: Operating Procedures
10-2-3. Test run for wired remote controller Operating procedures While the room temperature display on the remote "TEST RUN" and the currently selected controller is “PLEASE WAIT”, the remote controller is disabled. operation mode are displayed alternately. Wait until “PLEASE WAIT” disappears before using remote controller. 1.
Page 33 10-2-4. Test run for wireless remote controller Measure an impedance between the power supply terminal block on the outdoor unit and ground with a 500V Megger and check that it is equal to or greater than 1.0M". TEST RUN 1 Turn on the main power to the unit. TEST RUN 2 Press the button twice continuously.
Page 34 10-3. HOW TO PROCEED "SELF-DIAGNOSIS" 10-3-1. Self-diagnosis Select "Service" from the Main menu, and press the button. Test run Input maintenance info. Function setting Check Self check Select "Self check" with the F1 or F2 button, and press the button.
Page 35 10-3-2. Remote controller check * If operations cannot be completed with the remote controller, diagnose the remote controller with this function. Select "Service" from the Main menu, and press the button. Maintenance password Remote controller check Select "Remote controller check" with the F1 or F2 button, and press the button.
Page 36 10-3-3. Self-diagnosis If a problem occurs in the air conditioner, the indoor and outdoor units will stop, and the problem is shown in the remote controller display. [CHECK] and the refrigerant address are displayed on the temperature display, and the error code and unit number are displayed alternately as shown below.
Page 37: Remote Controller Diagnosis
When the error history is reset, the display will look like the one shown below. Press the ON/OFF button ( in the picture in the previous page) twice However, if you fail to reset the error history, the error content will be displayed again. within 3 seconds.
Page 38 10-3-6. Self-diagnosis When a malfunction occurs to air conditioner, both indoor unit and outdoor unit will stop and operation lamp blinks to inform unusual stop. < Malfunction-diagnosis method at maintenance service> [Procedure] 1.
Page 39 • Refer to the following tables for details on the check codes. [Output pattern A] Beeper sounds Beep Beep Beep Beep Beep Beep Beep OPERATION · · · Repeated INDICATOR lamp flash pattern Approx. 2.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.
Page 40 10-4. SELF-DIAGNOSIS ACTION TABLE (Note 1) Refer to indoor unit section for code P and code E. Abnormal points and detection method Judgment and action Error Code Case 1 No voltage is supplied to termi- 1 Check following items.
Page 41 Error Code Abnormal points and detection method Case Judgment and action 1 Check disconnection or looseness or polarity 1 Contact failure or miswiring of Miswiring of indoor/outdoor unit indoor/outdoor unit connecting of indoor/outdoor unit connecting wire of connecting wire wire indoor and outdoor units.
Page 42 Abnormal points and detection method Judgment and action Error Code Case 1 Short cycle of indoor unit 1~6 Check indoor unit and repair defect. High pressure (High-pressure switch 2 Clogged filter of indoor unit 63H operated) 3 Decreased airflow caused by Abnormal if high-pressure switch 63H...
Page 43 Abnormal points and detection method Case Judgment and action Error Code 1 Disconnection or contact failure Open/short of outdoor unit thermistors 1 Check connection of connector (TH3,TH6/TH7) (TH3, TH6, TH7, and TH8) of connectors on the outdoor controller circuit board. Abnormal if open or short is detected Outdoor controller circuit Check connection of connector (CN3) on the...
Page 44 Abnormal point and detection method Case Judgment and action Error Code To find out the detail history (latest) about U9 error, turn ON SW2-1, 2-2 and 2-6. Detailed Refer to 10-10. codes 1 Abnormal increase in power source 1 Check the field facility for the power Overvoltage error •...
Page 45 From the previous page. Abnormal point and detection method Case Judgment and action Error Code 1 Abnormal increase in power 12 Check the field facility for the power PFC/Q1 error (Overvoltage/ Detailed codes Undervoltage/Overcurrent) source voltage supply. 3 Correct the wiring (U . V . W phase) to 2 Decrease in power source •...
Page 46 Abnormal points and detection method Case Judgment and action Error Code Low pressure 1 Stop valve of outdoor unit is 1 Check stop valve. Abnormal if the following conditions are closed during operation. 2 Leakage or shortage of 2 Check intake superheat. detected for continuously 3 minutes after compressor starts heating operating for 10 refrigerant...
Page 47 Error Code Abnormal points and detection method Judgment and action Case 1 Defective remote controller 1 Replace remote controller. Remote controller control board 1 Abnormal if data cannot be normally read from the nonvolatile memory of the remote controller control board. (Error code: E1) 2 Abnormal if the clock function of remote controller cannot be normally operated.
Page 48 Error Code Abnormal points and detection method Judgment and action Case 1 Indoor/ outdoor unit connecting 1 Check disconnection or looseness of indoor/ Indoor/outdoor unit communication error (Transmitting error) (Outdoor unit) wire has contact failure. outdoor unit connecting wire. 1 Abnormal if “0” receiving is detected 30 2 Defective communication circuit 2~4 Turn the power off, and on again to times continuously though outdoor con-...
Page 49 Error Code Abnormal points and detection method Judgment and action Case 1 When this error occurs, be sure to 1 Abnormal operation of 4-way Abnormal refrigerant circuit During Cooling, Dry, or Auto Cooling replace the 4-way valve. valve 2 Disconnection of or leakage in 2 Check refrigerant pipes for disconnection or operation, when the following are regarded as failures when detected for...
Page 50 Error Code Abnormal points and detection method Case Judgment and action NO ACK signal Common factor that has no Always try the followings when the error relation with abnormality source 1. Transmitting side controller detects “A7” occurs. 1 The unit of former address abnormal if a message was transmitted does not exist as address 1 Turn off the power supply of outdoor...
Page 51 From the previous page. Error Code Abnormal points and detection method Case Judgment and action 1 During group operation with Same as mentioned in “A7” of the previous 4. If displayed address or attribute is indoor unit of multi- refrigerant remote controller, indoor unit detects page.
Page 52 Error Code Abnormal points and detection method Case Judgment and action 1 Transmitting condition is 1 Check transmission waveform or noise on M-NET NO RESPONSE Abnormal if a message was transmitted repeated fault because of transmission wire. 2 Turn off the power supply of outdoor unit and there were reply (ACK) that message noise and the like.
Page 53 Phenomena Factor Countermeasure 1 The pair number settings of the wireless remote 4. Even controlling by the wireless 1 Check the pair number settings. remote controller, no beep is controller and indoor controller board are mismatched. heard and the unit does not start operating.
Page 54 Symptoms: “PLEASE WAIT” is kept being displayed on the remote controller. Inspection method and Diagnosis flow Cause troubleshooting Check the display time of “PLEASE WAIT” after turning on the main power. 6 minutes 2 minutes or more or less How long is “PLEASE WAIT” •...
Page 55 LED display of the indoor controller board Symptoms: Nothing is displayed on the remote controller LED1 : LED2 : LED3 : Inspection method and Diagnosis flow Cause troubleshooting Check the voltage between S1 and S2 on the terminal block (TB4) of the indoor unit which is used to connect the indoor unit and the outdoor unit.
Page 56 LED display of the indoor controller board Symptoms: Nothing is displayed on the remote controller LED1 : LED2 : LED3 : Inspection method and Diagnosis flow Cause troubleshooting Check the voltage between S1 and S2 on the terminal block (TB4) of the indoor unit which is used to connect the indoor unit and the outdoor unit.
Page 57 LED display of the indoor controller board Symptoms: Nothing is displayed on the remote controller LED1 : LED2 : LED3 : — Inspection method and Diagnosis flow Cause troubleshooting Check the voltage of the terminal block (TB6) of the remote controller. DC 10V to DC 16V? •...
Page 58 • Before repair Frequent calling from customers Phone Calls From Customers How to Respond Note Unit does The operating display of remote Check if power is supplied to air conditioner. not operate controller does not come on. Nothing appears on the display unless power is at all.
Page 59 Phone Calls From Customers How to Respond Note The room cannot be cooled or heated sufficiently. Check the set temperature of remote controller. The outdoor unit cannot be operated if the set temperature is not appropriate. The outdoor unit operates in the following modes. COOL: When the set temperature is lower than the room temperature.
Page 60 Phone Calls From Customers How to Respond Note Something Air blows out for a while after However, this control is also This is not a malfunction. is wrong HEAT operation is stopped. The blower is operating just for cooling down the applied to the models which with the heated-up air conditioner.
Page 61 Phone Calls From Customers How to Respond Note A white mist is expelled from the indoor unit. This is not a malfunction. This may occur when the operation gets started in the room of high humidity. Water or moisture is expelled from the outdoor Cooling;...
Page 62 10-6. HOW TO CHECK THE PARTS PUHZ-ZRP35/50VKA PUHZ-ZRP60/71VHA PUHZ-ZRP100/125/140VKA PUHZ-ZRP100/125/140YKA Check points Parts name Thermistor (TH3) Disconnect the connector then measure the resistance with a tester. Thermistor (TH4) (At the ambient temperature 10°C~30°C) Thermistor (TH6) Normal Abnormal ...
Page 63 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...
Page 64 10-7. HOW TO CHECK THE COMPONENTS Low temperature thermistors • Thermistor (TH3) • Thermistor (TH6) • Thermistor (TH7) • Thermistor (TH33) Thermistor R0 = 15k' ± 3% B constant = 3480 ± 2% =15exp{3480( –...
Page 65 (ZRP35-ZRP71) 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. ...
Page 66 (ZRP100-ZRP140) 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. ...
Page 67 (3) How to attach and detach the coil of linear expansion valve (ZRP35-ZRP71 ) Linear expansion valve is separable into the main body and the coil as shown in the diagram below. Main body Coil Lead wire Stopper 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.
Page 68 (4) How to attach and detach the coil of linear expansion valve (ZRP100-ZRP140) Linear expansion valve is separable into the main body and the coil as shown in the diagram below. Main body Stopper Coil Lead wire 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.
Page 69: Emergency Operation
10-8. EMERGENCY OPERATION (1) When the error codes shown below are displayed on outdoor unit or microcomputer for wired remote controller or indoor unit has a failure, but no other problems are found, emergency operation will be available by setting the emergency opera- tion switch (SWE) on indoor controller board to ON and short-circuiting the connector (CN31) on outdoor controller board.
Page 70 (5) Operation data during emergency operation During emergency operation, no communication is performed with the indoor unit, so the data items needed for operation are set to the following values: Operation mode Operation data Remarks COOL HEAT Intake temperature (TH1) 20.5 —...
Page 71 Measure the resistance in the following points (connectors, etc.). If they Outdoor controller circuit board are short-circuited, it means that they are broken. PUHZ-ZRP35VKA 1. Check of Diode (DS1, DS2) PUHZ-ZRP50VKA P - R , P - S , N - R , N - S 2.
Page 72 Outdoor controller circuit board PUHZ-ZRP60/71VHA TEST POINT1 is high voltage. PUHZ-ZRP100/125/140VKA PUHZ-ZRP100/125/140YKA CN51 CNDM External signal output 1 to 2: Input of low-level sound priority mode Forced defrost, • Compressor operating signal 1 to 3: Input of external contact point detect history Demand control setting •...
Page 73 Outdoor noise filter circuit board PUHZ-ZRP60VHA PUHZ-ZRP71VHA EI, E2 Connect to the earth Connect to CNAC1, CNAC2 the earth 230V AC (Connect to the outdoor control- ler circuit board (CNAC)) Primary current (Connect to the outdoor power circuit board (CN5)) CN52C 52C relay signal (Connect to the...
Page 74 Outdoor noise filter circuit board PUHZ-ZRP100YKA PUHZ-ZRP125YKA PUHZ-ZRP140YKA LI1, LI2, LI3, NI POWER SUPPLY LI1-LI2/LI-LI3/LI3-LI1 : AC400V input LI1-NI/LI2-NI/LI3-NI : AC230V input (Connect to the terminal block (TB1)) Connect to the earth CNAC1, CNAC2 AC230V (Connect to the outdoor controller Connect to the earth circuit board (CNAC)) CNDC...
Page 75 Outdoor power circuit board Brief Check of DIP-IPM and DIP-PFC PUHZ-ZRP60VHA * 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 PUHZ-ZRP71VHA are short-circuited, it means that they are broken. 1.
Page 76 Outdoor power circuit board Brief Check of POWER MODULE * Usually, they are in a state of being short-circuited if they are broken. PUHZ-ZRP100VKA Measure the resistance in the following points (connectors, etc.). PUHZ-ZRP125VKA If they are short-circuited, it means that they are broken. 1.
Page 77 Outdoor power circuit board Brief Check of POWER MODULE * Usually, they are in a state of being short-circuited if they are broken. PUHZ-ZRP100YKA Measure the resistance in the following points (connectors, etc.). PUHZ-ZRP125YKA If they are short-circuited, it means that they are broken. 1.
Page 78 Outdoor converter circuit board PUHZ-ZRP100YKA PUHZ-ZRP125YKA PUHZ-ZRP140YKA L1-A1 L1-IN, N-IN CK-OU Connect to the ACL1 Connect to the noise filter Connect to the CK capacitor circuit board (LO1, No) Connect to the outdoor power circuit board (CN7) L1-A2, L2-A2, L3-A2 L1-OU, L2-OU, L3-OU Connect to the ACL1, ACL2, ACL3 Connect to the outdoor power circuit board...
Page 79 Outdoor M-NET board (optional) LED3 LED4 LED3 Outdoor unit CN2M Receiving Transmitting connecting display LED5 Connect to M-NET Energizing display of Serial M-NET board communication (12V power with outdoor board supply) LED1 Switch for Energizing communication display of display between M-NET board M-NET and board (5V power...
Page 80 Action by the switch operation Type of Swich No. Function Effective timing Switch No function — — — Power failure Auto recovery No auto recovery When power supply ON automatic recovery *2 3,4,5 No function — — — Model select Following SW5-6 reference Mode select *3 Demand function...
Page 81 (2) Function of connector Action by open/ short operation Types Function Effective timing Connector Short Open Connector CN31 Start When power supply ON Emergency operation Normal Special function (a) Low-level sound priority mode (Local wiring) By performing the following modiﬁ cation, operation noise of the outdoor unit can be reduced by about 3-4 dB. The low noise mode will be activated when a commercially available timer or the contact input of an ON/OFF switch is added to the CNDM connector (option) on the control board of the outdoor unit.
Page 82 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.
Page 83 Indication Error Error Outdoor controller board Detailed Contents Inspection method code reference LED1 (Green) LED2 (Red) page Check if stop valves are open. 3 blinking 1 blinking Abnormality of shell thermistor(TH32) P.42 Check if connectors (TH4, TH32, LEV-A, and LEV-B) on outdoor controller and discharging temperature (TH4) board are not disconnected.
Page 84 [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 SW2 setting...
Page 85 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit Pipe temperature / Liquid(TH3) – 40~90 – 40~90 (When the coil thermistor detects 0: or below, “–” and temperature are displayed by turns.) (Example) When -10:;...
Page 86 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit 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:;...
Page 87 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit The number of connected indoor units (The number of connected indoor units are dis- played.) Unit 2 3 4 5 6 Capacity setting display Displayed as an outdoor capacity code.
Page 88 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit Indoor setting temperature 17 – 30 17 – 30 °C 2 3 4 5 6 Outdoor pipe temperature / 2-phase -39 – 88 (TH6) (When the temperature is 0: or less, “–”...
Page 89 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit 150 – 400 (RP35 – 140V) DC bus voltage 150 – 400 (ZRP35 – 140V) 300 – 750 (RP100 – 140Y) (When it is 100V or more, hundreds digit, tens 300 –...
Page 90 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit 0 – 480 LEV-C opening pulse 0~480 (When it is 100 pulse or more, hundreds digit, tens digit and ones digit are displayed by turns.) (Example) When 130 pulse;...
Page 91 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit 0 – 255 Discharge superheat on error occurring (When the temperature is 100°C or more, hundreds digit, tens digit and ones digit are displayed by 0 –...
Page 92 The black square ( ) indicates a switch position. SW2 setting Display detail Explanation for display Unit The following code will be a help to know the Controlling status of compressor operating status of unit. operating frequency • The tens digit Display Compressor operating frequency control Primary current control Secondary current control...

Page 93 FUNCTION SETTING 11-1. UNIT FUNCTION SETTING BY THE REMOTE CONTROLLER Each function can be set as necessary using the remote controller. The setting of function for each unit can only be done by the remote controller. Select function available from the table 1. ...

Page 94 (2) Functions available when setting the unit number to 01-03 or AL (07 in case of wireless remote controller) • When setting functions for an indoor unit in an independent system, set the unit number to 01 referring to 4 setting the indoor unit number of Operating Procedure.

Page 95: Service Menu

11-1-1. Selecting functions using the wired remote controller

Maintenance password is required Select "Service" from the Main menu, and press the button. Main Main menu Maintenance Initial setting *At the main display, the menu buttom and select "Service" to make the Service maintenance setting.

Page 96 Select "Service" from the Main menu, and press the button. Test run Input maintenance info. Function setting Check Self check Select "Function setting" with the F1 or F2 button, and press the button. Set the indoor unit refrigerant addresses and unit numbers with the F1 Function setting Ref.

Page 97 11-1-2. Selecting functions using the wired remote controller First, try to familiarize yourself with the flow of the function selection procedure. In this section, an example of setting the room temperature detection position is given. For actual operations, refer to steps Setting number Refrigerant address Unit number...

Page 98: Operating Procedure

[Operating Procedure] Check the setting items provided by function selection. If settings for a mode are changed by function selection, the functions of that mode will be changed accordingly. Check all the current settings according to steps , fill in the "Check" column in Table 1, and then change them as necessary. For factory settings, refer to the indoor unit's installation manual. Switch off the remote controller.

Page 99 11-1-3. Selecting functions using the wireless remote controller (Type C) Functions can be selected with the wireless remote controller. Function selection using wireless remote controller is available only for refriger- ant system with wireless function. Refrigerant address cannot be specified by the wireless remote controller. [Flow of function selection procedure] The flow of the function selection procedure is shown below.

Page 100 11-2. FUNCTION SELECTION OF REMOTE CONTROLLER 11-2-1. PAR-30MAA/PAR-31MAA The functions of the function buttons change depending on the screen. Refer to the button function guide that appears at the bottom of the LCD for the functions they serve on a given screen.

Page 101 Press the button. MENU Main menu Move the cursor to the desired item with the buttons, and press the SELECT button. Vane · Louver · Vent. (Lossnay) High power Timer On / Off timer Auto-Off timer Filter information Error information Weekly timer...

Page 102

Setting and display items Setting details Vane · Louver · Vent. Use to set the vane angle. (Lossnay) • Select a desired vane setting from ﬁ ve different settings. Use to turn ON / OFF the louver. •...

Page 103 Setting and display items Setting details Initial setting Display Make the settings for the remote controller related items as necessary. details Clock: The factory settings are "Yes" and "24h" format. Temperature: Set either Celsius (°C) or Fahrenheit (°F). Room temp. : Set Show or Hide. Auto mode: Set the Auto mode display or Only Auto display.

Page 104 11-2-2. PAR-21MAA Normal display (Display when the air conditioner is not running) Setting language (English) Hold down the button and press the button for 2 seconds. Hold down the button and press the button for 2 seconds. Press the operation mode button. Press theTIMER MENU button.

Page 105 The setting of the following remote controller functions can be changed using the remote controller function selection mode. Change the setting when needed. Item 1 Item 2 Item 3 (Setting content) 1.Change Language Language setting to display • Display in multiple languages is possible. ("CHANGE LANGUAGE") 2.Function limit (1) Operation function limit setting (operation lock) ("LOCKING FUNCTION")

Page 106 MONITORING THE OPERATION DATA BY THE REMOTE CONTROLLER 12-1. HOW TO "MONITOR THE OPERATION DATA" 12-1-1. PAR-30MAA/PAR-31MAA Details on the operation data including each thermistor temperature and error history can be conﬁ rmed with the remote controller. Select "Service" from the Main menu, and press the button.

Page 107 12-1-2. PAR-21MAA • Turn on the [Monitoring the operation data] Example) Request code "004" Discharge temperature 69 Refrigerant address "00" A: Maintenance mode B: Refrigerant address C: Data display area D: Request code display area (1) Press the button for 3 seconds so that [ Maintenance mode] appears on the screen (at TEST (2) Press the button for 3 seconds to switch to [Maintenance monitor].

Page 108 * Certain indoor/outdoor combinations do not have the request code function; therefore, no request codes are displayed. Description Request content Unit Remarks (Display range) Operation state Refer to 12-1-2. Detail Contents in Request Code. – Compressor-Operating current (rms) 0 –...

Page 109 Description Request content Unit Remarks (Display range) Indoor unit-Control state – Refer to 12-1-2.Detail Contents in Request Code. Outdoor unit-Control state – Refer to 12-1-2.Detail Contents in Request Code. Compressor-Frequency control state Refer to 12-1-2.Detail Contents in Request Code. – Outdoor unit-Fan control state Refer to 12-1-2.Detail Contents in Request Code.

Page 110 Description Request content Unit Remarks (Display range) Error history 1 (latest) Displays error history. (" - - " is displayed if no history is present.) Code Error history 2 (second to last) Displays error history. (" - - " is displayed if no history is present.) Code Error history 3 (third to last) Displays error history.

Page 111 Description Request content Unit Remarks (Display range) Indoor-Fan operating time 0 – 9999 1 hour (After filter is reset) Indoor-Total operating time 0 – 9999 10 hours (Fan motor ON time) Indoor fan output value (Sj value) 0 – 255 Fan control data –...

Page 112 12-2-1. Detail Contents in Request Code Example) Request code "004" Discharge temperature 69 Refrigerant address "00" A: Maintenance mode display B: Refrigerant address C: Data display area D: Request code display area [Operation state] (Request code :" 0") Relay output state Power currently Data display Display...

Page 113 [Fan control state] (Request code :" 53 ") Data display Fan step correction value by heatsink temperature overheat prevention control Fan step correction value by cool condensation temperature overheat prevention control Display Correction value - (minus) – 1 [Actuator output state] (Request code :"54") Data display Actuator output state Actuator output state...

Page 114 [Contact demand capacity] (Request code : " 61") Setting content Data display Display Setting value Setting content 100% [External input state] (Request code : "62") Input state : Input present Data display Contact demand Silent mode Spare 1 Spare 2 Display Input state input...

Page 115 [Outdoor unit switch setting display (SW1 to SW10, except SW3)] Request codes: 73 to 82 0: Switch OFF 1: Switch ON 0: Switch OFF 1: Switch ON SW1, SW2, SW6, SW7 Data display Data display 00 00 00 00 00 01 00 01 00 02 00 02...

Page 116 [Indoor unit – Model setting information] (Request code : "162" ) Data display Display Model setting state Display Model setting state PSA-RP•GA, PSH-PGAH PKA-RP•FAL(2), PKH-P•FALH See the table on the right. PEAD-RP•EA(2)/GA, PEHD-P•EAH PCA-RP·GA(2), PCH-P•GAH, PLA-RP·BA, PLA-RP71-100BA2 SEZ-KA•VA SLZ-KA•VA(L) PCA-RP•KA PCA-RP•HA PEA-RP400/500GA PEA-RP200/250GA...

Page 117 EASY MAINTENANCE FUNCTION 13-1. SMOOTH MAINTENANCE 13-1-1. PAR-30MAA/PAR-31MAA Maintenance data, such as the indoor/outdoor unit’s heat exchanger temperature and compressor operation current can be displayed with “Smooth maintenance”. * This cannot be executed during test operation. * Depending on the combination with the outdoor unit, this may not be supported by some models. Select "Service"...

Page 118 13-1-2. PAR-21MAA ● Reduces maintenance work drastically. ● Enables you to check operation data of the indoor and outdoor units by remote controller. Furthermore, use of maintenance stable-operation control that fixes the operating frequency, allows smooth inspection, even for inverter models. Smooth Mainte- Discharge temperature 64°C ●...

Page 119 ● Data measurement When the operation is stabilized, measure operation data as explained below. (4) Press the [TEMP] buttons ( ) to select the desired refrigerant address. [Screen (5) Select the type of data to be displayed. After selecting, go to step (6). Compressor information button MENU...

Page 120 Check Points Inspection item Result Breaker Good Retightened Enter the temperature differences between into Terminal block Outdoor Unit Good Retightened the graph given below. Indoor Unit Good Retightened Operation state is determined according to the plotted areas on (Insulation resistance) the graph.

Page 121 13-2. REFRIGERANT LEAK CHECK 13-2-1. PAR-30MAA/PAR-31MAA Refrigerant leakage is detected after a long time. To enable this function, the refrigerant volume must be saved (initial learning) after installation. Always operate this function in the following manner after installation. • Always perform test run before using this function, and conﬁ rm that the air conditioner operates normally. •...

Page 122 13-2-2. PAR-21MAA ■ Remote controller button position This air conditioner (Outdoor unit) can detect refrigerant leakage which may happen during a long period of use. In order to enable the leakage detection, the following settings are required to let the unit memorize the initial condition (initial refregerant amount).

Page 123 3. How to start "Judgment of refrigerant leakage " mode. To know the current condition of refrigerant amount, same operation must be performed. Please repeat the same procedure as when "Initial learning operation" for "Checking operation". Press CLOCK button and select the [GAS LEAK JUDGE] Refrigerant leakage Refrigerant leakage detection...

Page 124: Disassembly Procedure

DISASSEMBLY PROCEDURE PUHZ-ZRP35VKA PUHZ-ZRP50VKA OPERATING PROCEDURE PHOTOS Top panel Top panel 1. Removing the top panel, service panel, front panel, back Photo 1 fixing screws fixing screw Top panel panel and grille (1) Remove the top panel fixing screws (4 × 10), one from the right and two from the left side, and detach the top panel.

Page 125 OPERATING PROCEDURE PHOTOS 3. Removing the electrical parts box (1) Remove the service panel. (See Photo 2) Electrical parts box Photo 5 fixing screw (2) Remove the top panel. (See Photo 1) (3) Remove the front panel. (See Photo 1) Controller circuit board (C.B) (4) Remove the back panel.

Page 126 OPERATING PROCEDURE PHOTOS 5. Removing the thermistor (TH7) Photo 7 Thermistor (1) Remove the service panel. (See Photo 2) Electrical parts box (TH7) (2) Remove the top panel. (See Photo 1) (3) Disconnect the connector TH7 (red) on the controller circuit board in the electrical parts box.

Page 127 OPERATING PROCEDURE PHOTOS 8. Removing the 4-way valve Photo 10 (1) Remove the service panel. (See Photo 2) (2) Remove the top panel. (See Photo 1) (3) Remove the front panel. (See Photo 1) (4) Remove the back panel. (See Photo 1) 4-way valve (5) Remove the electrical parts box.

Page 128 OPERATING PROCEDURE PHOTOS 12. Removing the compressor (MC) Photo 12 (1) Remove the service panel. (See Photo 2) (2) Remove the top panel. (See Photo 1) (3) Remove the front panel. (See Photo 1) (4) Remove the back panel. (See Photo 1) (5) Remove the electrical parts box.

Page 129 PUHZ-ZRP60VHA PUHZ-ZRP71VHA OPERATING PROCEDURE PHOTOS & ILLUSTRATION Top panel fixing screws 1. Removing the service panel and top panel Photo 1 (1) Remove 3 service panel fixing screws (5 × 12) and slide Top panel the hook on the right downward to remove the service Fan grille panel.

Page 130 OPERATING PROCEDURE PHOTOS 4. Removing the thermistor (TH6) Photo 5 Thermistor (1) Remove the service panel. (See Photo 1) (2) Remove the top panel. (See Photo 1) (TH6) Controller Electrical parts box (3) Disconnect the connector TH7/6 (red) on the controller circuit board circuit board in the electrical parts box.

Page 131 OPERATING PROCEDURE PHOTOS 7. Removing the 4-way valve coil (21S4), LEV coil (LEV(A), Photo 8 LEV(B)) 4-way valve coil 4-way valve fixing screw (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) [Removing the 4-way valve coil] (4) Remove 4-way valve coil fixing screw (M4 ×...

Page 132 OPERATING PROCEDURE PHOTOS 10. Removing the high pressure switch (63H) Photo 9 (1) Remove the service panel. (See Photo 1) (2) Remove the top panel. (See Photo 1) Lead wire of (3) Remove the electrical parts box. (See Photo 4) high pressure switch (4) Remove 3 right side panel fixing screws (5 ×...

Page 133 OPERATING PROCEDURE PHOTOS 12. Removing the compressor (MC) Photo 11 (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 × 12) and remove the front cover panel. (See Photo 1) (4) Remove 2 back cover panel fixing screws (5 ×...

Page 134 PUHZ-ZRP100VKA PUHZ-ZRP125VKA PUHZ-ZRP140VKA OPERATING PROCEDURE PHOTOS & ILLUSTRATION Photo 1 1. Removing the service panel and top panel (1) Remove 3 service panel fixing screws (5 × 12) and slide the hook on the right downward to remove the service Top panel panel.

Page 135 OPERATING PROCEDURE PHOTOS 4. Removing the thermistor (TH6) Photo 5 (1) Remove the service panel. (See Photo 1) Thermistor (TH6) circuit board (C.B.) (3) Disconnect the connector TH7/6 (red) on the controller circuit board in the electrical parts box.

Page 136 OPERATING PROCEDURE PHOTOS Figure 1 (PUHZ-ZRP100-125VKA) 7. Removing the 4-way valve coil (21S4), and LEV coil 4-way valve (LEV (A), LEV (B)), (LEV (C) :140 only) coil (21S4) 4-way valve (1) Remove the service panel. (See Photo 1) (2) Remove the top panel. (See Photo 1) [Removing the 4-way valve coil] (3) Remove 4-way valve coil fixing screw (M4 ×...

Page 137 OPERATING PROCEDURE PHOTOS 10. Removing the high pressure switch (63H) Photo 9 (PUHZ-ZRP140VKA) (1) Remove the service panel. (See Photo 1) Reactor (2) Remove the top panel. (See Photo 1) LEV coil (LEV C) (DCL) (3) Remove 3 right side panel fixing screws (5 × 12) in the rear of the unit and remove the right side panel.

Page 138 OPERATING PROCEDURE PHOTOS 13. Removing the power receiver Photo 11 (1) Remove the service panel. (See Photo 1) (2) Remove the top panel. (See Photo 1) Inlet (3) Remove 2 front cover panel fixing screws (5 × 12) and remove the front cover panel. (See Photo 4) (4) Remove 4 back cover panel fixing screws (5 ×...

Page 139 PUHZ-ZRP100YKA PUHZ-ZRP125YKA PUHZ-ZRP140YKA OPERATING PROCEDURE PHOTOS & ILLUSTRATION 1. Removing the service panel and top panel Photo 1 Top panel Top panel fixing screws (1) Remove 3 service panel fixing screws (5 × 12) and slide the hook on the right downward to remove the service Service panel panel.

Page 140 From the previous page. PHOTOS & ILLUSTRATION OPERATING PROCEDURE (7) Remove the terminal cover and disconnect the compressor Photo 5 lead wire. (8) 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 Electrical parts box hook on the right.

Page 141 PHOTOS OPERATING PROCEDURE Photo 11 5. Removing the thermistor (TH6) Thermistor (1) Remove the service panel. (See Photo 1) (TH6) Electrical parts box (2) Remove the top panel. (See Photo 1) (3) Disconnect the connector TH7/6 (red), on the controller circuit board in the electrical parts box.

Page 142 OPERATING PROCEDURE PHOTOS Photo 15 8. Removing the 4-way valve coil (21S4), and LEV coil (LEV(A), LEV(B)), (LEV(C): 140 only) (1) Remove the service panel. (See Photo 1) 4-way valve (2) Remove the top panel. (See Photo 1) [Removing the 4-way valve coil] (3) Remove 4-way valve coil fixing screw (M4 ×...

Page 143 OPERATING PROCEDURE PHOTOS 12. Removing the reactors (ACL1, ACL2, ACL3) Photo 16 (1) Remove the service panel. (See Photo 1) (2) Remove the 4 fixing screws the reactor box. (2/front, 2/back of reactor). (3) Disconnect the lead wires from the reactor. (See Photo 17) (4) Remove each 4 fixing screws (2/front, 2/back of reactor) of 3 reactors.

Page 144 Compressor (MC) fixing screws HEAD OFFICE : TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN New publication, effective Nov. 2012 CCopyright 2012 MITSUBISHI ELECTRIC CORPORATION Specifications are subject to change without notice. Distributed in Nov. 2012 No.OCH527 Made in Japan...

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Mitsubishi Electric Mr.Slim PUHZ-ZRP35VKA Service Manual

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