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2011
HOT WATER HEAT PUMP
Service Handbook
Service Handbook
Model
CAHV-P500YA-HPB

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Troubleshooting

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   Summary of Contents for Mitsubishi Electric CAHV-P500YA-HPB

  • Page 1

    2011 HOT WATER HEAT PUMP Service Handbook Service Handbook Model CAHV-P500YA-HPB...

  • Page 2: Safety Precautions

    Indicates a risk of injury or structural damage Indicates a risk of damage to the unit or other components in the system IMPORTANT All electric work must be performed by personnel certified by Mitsubishi Electric. General WARNING To reduce the risk of burns or frost bites, do not touch the...

  • Page 3

    To reduce the risk of injury, do not sit, stand, or place objects To prevent environmental pollution, dispose of brine in on the unit. the unit and cleaning solutions according to the local regulations. Do not connect the makeup water pipe directly to the It is punishable by law not to dispose of them according to the potable water pipe.

  • Page 4

    Any additional parts must be installed by qualified personnel. The unit should be installed only by personnel certified Only use the parts specified by Mitsubishi Electric. by Mitsubishi Electric according to the instructions detailed in the Installation/Operation Manual. Take appropriate safety measures against wind gusts and...

  • Page 5

    To reduce the risk of current leakage, overheating, smoke, or Proper grounding must be provided by a licensed fire, use properly rated cables with adequate current carrying electrician. Do not connect the grounding wire to a gas capacity. pipe, water pipe, lightning rod, or telephone wire. Improper grounding may result in electric shock, smoke, fire, Keep the unsheathed part of cables inside the terminal or malfunction due to electrical noise interference.

  • Page 6: Table Of Contents

    CONTENTS I Read Before Servicing [1] Read Before Servicing......................3 [2] Necessary Tools and Materials ....................4 [3] Brazing............................5 [4] Air Tightness Test........................6 [5] Vacuum Drying (Evacuation) ....................7 [6] Refrigerant Charging ........................ 8 [7] Remedies to be taken in case of a Refrigerant Leak..............8 [8] Characteristics of the Conventional and the New Refrigerants ..........

  • Page 7

    CONTENTS HWE10060...

  • Page 8

    I Read Before Servicing [1] Read Before Servicing ....................... 3 [2] Necessary Tools and Materials..................4 [3] Brazing..........................5 [4] Air Tightness Test ......................6 [5] Vacuum Drying (Evacuation) ..................... 7 [6] Refrigerant Charging......................8 [7] Remedies to be taken in case of a Refrigerant Leak ............8 [8] Characteristics of the Conventional and the New Refrigerants .........

  • Page 9

    - 2 - HWE10060...

  • Page 10: Read Before Servicing

    1. Check the type of refrigerant used in the system to be serviced. Refrigerant Type Hot water Heat pump CAHV-P500YA-HPB:R407C 2. Check the symptoms exhibited by the unit to be serviced. Refer to this service handbook for symptoms relating to the refrigerant cycle.

  • Page 11: Necessary Tools And Materials

    [ I Read Before Servicing ] [2] Necessary Tools and Materials Prepare the following tools and materials necessary for servicing the unit. Tools for use with R407C (Adaptability of tools that are for use with R22 or R410A) 1. To be used exclusively with R407C (not to be used if used with R22 or R410A) Tools/Materials Notes Gauge Manifold...

  • Page 12: Brazing

    [ I Read Before Servicing ] [3] Brazing No changes have been made in the brazing procedures. Perform brazing with special care to keep foreign objects (such as oxide scale, water, and dust) out of the refrigerant system. Example: Inside the brazed connection Use of oxidized solder for brazing Use of non-oxidized solder for brazing 1.

  • Page 13: Air Tightness Test

    [ I Read Before Servicing ] [4] Air Tightness Test No changes have been made in the detection method. Note that a refrigerant leak detector for R22 will not detect an R407C leak. Halide torch R22 leakage detector 1. Items to be strictly observed Pressurize the equipment with nitrogen up to the design pressure (3.85MPa), and then judge the equipment's air tightness, taking temperature variations into account.

  • Page 14: Vacuum Drying (evacuation)

    [ I Read Before Servicing ] [5] Vacuum Drying (Evacuation) (Photo1) 15010H (Photo2) 14010 Recommended vacuum gauge: ROBINAIR 14010 Thermistor Vacuum Gauge 1. Vacuum pump with a reverse-flow check valve (Photo1) To prevent the vacuum pump oil from flowing into the refrigerant circuit during power OFF or power failure, use a vacuum pump with a reverse-flow check valve.

  • Page 15: Refrigerant Charging

    [ I Read Before Servicing ] [6] Refrigerant Charging Cylinder with a siphon Cylinder without a siphon Cylin- Cylin- Cylinder color R407C is Gray. Refrigerant charging in the liquid state Valve Valve liquid liquid Charge refrigerant through the Charging refrigerant through the check joint on the high-pressure side.

  • Page 16: Characteristics Of The Conventional And The New Refrigerants

    [ I Read Before Servicing ] [8] Characteristics of the Conventional and the New Refrigerants 1. Chemical property As with R22, the new refrigerant (R407C) is low in toxicity and chemically stable nonflammable refrigerant. However, because the specific gravity of vapor refrigerant is greater than that of air, leaked refrigerant in a closed room will accumulate at the bottom of the room and may cause hypoxia.

  • Page 17: Notes On Refrigerating Machine Oil

    [ I Read Before Servicing ] [9] Notes on Refrigerating Machine Oil 1. Refrigerating machine oil in the HFC refrigerant system HFC type refrigerants use a refrigerating machine oil different from that used in the R22 system. Note that the ester oil used in the system has properties that are different from commercially available ester oil. Refrigerant Refrigerating machine oil Mineral oil...

  • Page 18: Restrictions

    II Restrictions [1] System Configuration....................... 13 [2] Types and Maximum allowable Length of Cables ............14 [3] Main Power Supply Wiring and Switch Capacity ............. 15 [4] Sample Installation......................17 [5] Switch Types and the Factory Settings................18 [6] Configuring the Settings....................19 [7] Water Pipe Installation .....................

  • Page 19

    - 12 - HWE10060...

  • Page 20: System Configuration

    [ II Restrictions ] II Restrictions [1] System Configuration <1> Schematic Diagrams of Individual and Multiple Systems (1) Individual system *Each unit is operated individually by connecting a dry contact switch/relay to each unit. Unit (MAIN circuit) Unit (SUB circuit) Unit (MAIN circuit) Unit (SUB circuit) External...

  • Page 21: Types And Maximum Allowable Length Of Cables

    [ II Restrictions ] [2] Types and Maximum allowable Length of Cables 1. Wiring work (1) Notes 1) Have all electrical work performed by an authorized electrician according to the local regulations and instructions in this man- ual. 2) Install external transmission cables at least 5cm [1-31/32"] away from the power supply cable to avoid noise interference. (Do not put the control cable and power supply cable in the same conduit tube.) 3) Provide grounding for the outdoor unit as required.

  • Page 22: Main Power Supply Wiring And Switch Capacity

    Current leakage breaker No-fuse breaker (A) System Impedance y t i CAHV-P500YA-HPB 75 A 100 mA 0.1 sec. or less 0.28 Ω 1. Use a dedicated power supply for each unit. Ensure that each unit is wired individually. 2. When installing wiring, consider ambient conditions (e.g., temperature, sunlight, rain).

  • Page 23

    [ II Restrictions ] Control cable specifications ( ² Remote controller cable ( ² M-NET cable between units External input wire size Min. 0.3 mm² External output wire size 1.25 mm² *1 Use a CVVS or CPEVS cable (Max. total length of 200 m) if there is a source of electrical interference near by (e.g., factory) or the total length of control wiring exceeds 120 m.

  • Page 24: Sample Installation

    [ II Restrictions ] [4] Sample Installation (1) Individual system *Each unit is operated individually by connecting a dry contact switch/relay to each unit. Unit (MAIN circuit) Unit (SUB circuit) Unit (MAIN circuit) Unit (SUB circuit) External External temperature temperature sensor sensor Field-supplied dry...

  • Page 25: Switch Types And The Factory Settings

    [ II Restrictions ] [5] Switch Types and the Factory Settings (1) Switch names and functions Discharge air outlet Control box (Main circuit) Service panel Intake air inlet Water outlet Service panel Water inlet Control box (Sub circuit) There are four main ways to set the settings as follows: Dip switches (SW1 - SW3) Dip switches used in combination with the push switches Rotary switches...

  • Page 26: Configuring The Settings

    [ II Restrictions ] [6] Configuring the Settings The settings must be set only by a qualified personnel. <1> Making the settings Use the LED display and the three push switches (SWP1 (↑), SWP2 (↓), and SWP3 (Enter)) to change the current settings on the circuit board and to monitor various monitored values.

  • Page 27

    [ II Restrictions ] (2) System configuration procedures: Individual system 1. Set the dip switches on the MAIN circuit board. Unit (MAIN circuit) Unit (SUB circuit) Switch settings on the MAIN circuit Set the dip switches (labeled A in the figure at right) that correspond to the items below, according to the local system.

  • Page 28

    [ II Restrictions ] (3) System configuration procedures : Multiple system 1. Set the dip switches and rotary switches. (Switches on the MAIN circuit on the main unit* AND the MAIN and SUB circuits on all sub units on the sub unit) System configuration diagram Unit (MAIN circuit)

  • Page 29

    [ II Restrictions ] 2. Switch on the power to the unit. Main unit (MAIN circuit) Main unit (SUB circuit) Check for loose or incorrect wiring, and then Sub unit (MAIN and SUB circuits) switch on the power to all units. When the power is switched on, the following codes will appear on the LED: •...

  • Page 30

    [ II Restrictions ] (4) Re-initializing the system When the settings for the items below have been changed, the system will require re-initialization. • Dip switch SW2-8 (use or non-use of an external water temperature sensor) (Re-initialization is required only for the Multiple system.) •...

  • Page 31: Water Pipe Installation

    [ II Restrictions ] [7] Water Pipe Installation 1. Schematic Piping Diagram and Piping System Components indicates the direction of Overflowed water the water flow. City water To drain outlet Heat pump unit Minimum upward Water-side gradient of 1/200 heat exchanger Minimum upward gradient of 1/200...

  • Page 32

    [ II Restrictions ] 2. Notes on pipe corrosion Water treatment and water quality control Poor-quality circulating water can cause the water-side heat exchanger to scale up or corrode, reducing heat- exchange performance. Properly control the quality of the circulating water. •...

  • Page 33

    [ II Restrictions ] (5) Suspended solids in the water Sand, pebbles, suspended solids, and corrosion products in water can damage the heating surface of the heat exchanger and cause corrosion. Install a good quality strainer (20 mesh or better) at the inlet of the unit to filter out suspended solids.

  • Page 34

    [ II Restrictions ] 3. Installing the strainer and flow switch (1) Installing the strainer Install the supplied strainer on the inlet water pipe near the unit to filter out suspended solids and prevent clogging or corrosion of the heat exchanger. Install the strainer in a way that allows for easy access for cleaning, and instruct the user to clean it regularly.

  • Page 35

    Minimum allowable flow Maximum allowable flow rate rate Heating CAHV-P500YA-HPB 7.74 15.0 The flow rate will be considered appropriate if the difference between the inlet and outlet water temperatures is between 3 ºC and 5 ºC. If the temperature difference is less than 3 ºC Decrease the flow rate.

  • Page 36: Unit Components

    III Unit Components [1] Unit Components and Refrigerant Circuit ................ 31 [2] Control Box of the Unit..................... 33 [3] Unit Circuit Board......................34 - 29 - HWE10060...

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  • Page 38: Unit Components And Refrigerant Circuit

    [ III Unit Components ] III Unit Components [1] Unit Components and Refrigerant Circuit 1. Unit Components (1) Front view Panel TOP Pillar LF Pillar RF Frame assy L Pillar F(L) Frame assy R Fin guard LR Panel assy FU Pillar F(R) Fan guard Frame F.

  • Page 39

    [ III Unit Components ] 2. Refrigerant circuit Water side Water side Receiver HEX. HEX. Strainer Strainer Receiver Heat exchanger Heat exchanger Four way Four way valve valve Pressure switch Pressure sensor LP Pressure Thermistor Pressure Thermistor Thermistor Check joint Check joint sensor LP sensor HP...

  • Page 40: Control Box Of The Unit

    [ III Unit Components ] [2] Control Box of the Unit (1) Main circuit control box Rush current protection resister Control board Fan board INV board Capacitor DC reactor (DCL) Electromagnetic relay (72C) Noise filter Control terminal block1 Control terminal block2 Terminal block (TB1) Note.1...

  • Page 41: Unit Circuit Board

    [ III Unit Components ] [3] Unit Circuit Board 1. Control board (MAIN board) CN 2 CN332 CN801 Serial communication Pressure switch Output 18VDC signal input connection GND(Fan board) Output 17VDC CN 4 CNDC Bus voltage input Serial communication signal output driving output CN3A Remote controller...

  • Page 42

    [ III Unit Components ] 2. M-NET board CNS2 CNIT Transmission line input/output for 12VDC input CN04 centralized control system CN102 Bus voltage input 5VDC input Power supply output for centralized control system Power supply detection output Indoor/outdoor transmission line input/output Power supply ON/OFF Grounding signal input...

  • Page 43

    [ III Unit Components ] 3. INV board SC-P1 Rectifier diode output (P) Open: No-load operation setting CN5V RSH1 SC-P2 Short-circuited: Normal setting Overcurrent detection LED1 Bus voltage Input(P) Lit: Inverter in normal operation 5VDC output resistor Blink: Inverter error GND(Fan Board) Serial communication signal output...

  • Page 44

    [ III Unit Components ] 4. Fan board LED3 CN18V Lit during normal Input 18VDC CPU operation Serial communication signal output GND(Control board) Serial communication signal output CN21 Serial communication signal output GND(INV board) CNVDC Input 17VDC Bus voltage input CN22 GND(INV board) Input 5VDC...

  • Page 45

    [ III Unit Components ] 5. Noise Filter Output Output (Rectified L2-N current) (Rectified L2-N current) Surge absorber circuit Surge absorber circuit Short circuit Short circuit Grounding F1,F2,F3,F4 Fuse 250VAC 6.3A Output Grounding CN1A Input CN1B TB21 TB22 TB23 TB24 Input Input/output(L1) Input/output(L2)

  • Page 46: Remote Controller

    IV Remote Controller [1] Using the Remote Controller.................... 41 [2] Function Settings ......................46 - 39 - HWE10060...

  • Page 47

    - 40 - HWE10060...

  • Page 48: Using The Remote Controller

    [ IV Remote Controller ] IV Remote Controller [1] Using the Remote Controller <1> Starting and Stopping Operation and To Stop Operation Changing the Operation Mode 1. Press the ON/OFF (BACK) button while the unit is in operation. The power indicator and the display will light off.

  • Page 49

    [ IV Remote Controller ] <2> Setting the Water Temperature How to Set the Day of the Week and Time The current water temperature will appear in the area Day of the Week Setting labeled TIME SUN Time Setting How to Change the Temperature Setting 1.

  • Page 50

    [ IV Remote Controller ] How to Set the Weekly Timer How to View the Weekly Timer Settings 1. On the Normal Operation screen, make sure that the weekly timer icon Time Settings is displayed. 2. Press the TIMER MENU button , so that the “Set Up”...

  • Page 51

    [ IV Remote Controller ] How to Set the Simple Timer To Turn Off the Simple Timer Press the TIMER ON/OFF button so that the timer setting no longer Time Setting appears on the screen (at Action (On or Off) AFTER “–...

  • Page 52

    [ IV Remote Controller ] Using the Auto-Off Timer Checking the Current Auto-Off Timer Setting 1. This timer begins countdown when the unit starts, and shuts the unit off Timer Setting when the set time has elapsed. 2. Available settings range from 30 minutes to 4 hours in 30-minute intervals. TIMER AFTER Note:...

  • Page 53: Function Settings

    [ IV Remote Controller ] [2] Function Settings The settings for the following remote controller functions can be changed using the remote controller function selection mode. Change the settings as necessary. Item 1 Item 2 Item 3 (Setting content) 1. Display language Display language selection •...

  • Page 54

    [ IV Remote Controller ] Settings details [4]-3. Basic functions (1) Remote controller main/sub setting [4]-1. Display language setting • Press the [ ON/OFF] button to toggle between the following options. The display language can be selected from the languages listed below. Main The controller will be designated as the main controller.

  • Page 55

    [ IV Remote Controller ] - 48 - HWE10060...

  • Page 56

    V Electrical Wiring Diagram [1] Electrical Wiring Diagram....................51 - 49 - HWE10060...

  • Page 57

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  • Page 58: Electrical Wiring Diagram

    [ V Electrical Wiring Diagram ] V Electrical Wiring Diagram [1] Electrical Wiring Diagram CN142C CN142D CN142B CN142A CN801 CN3A CN102 blue blue black yellow blue - 51 - HWE10060...

  • Page 59

    [ V Electrical Wiring Diagram ] CN801 CNIT CNS2 CN102 yellow yellow - 52 - HWE10060...

  • Page 60

    [ V Electrical Wiring Diagram ] - 53 - HWE10060...

  • Page 61

    [ V Electrical Wiring Diagram ] - 54 - HWE10060...

  • Page 62: Refrigerant Circuit

    VI Refrigerant Circuit [1] Refrigerant Circuit Diagram ..................... 57 [2] Principal Parts and Functions ..................58 - 55 - HWE10060...

  • Page 63

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  • Page 64: Refrigerant Circuit Diagram

    [ VI Refrigerant Circuit ] VI Refrigerant Circuit [1] Refrigerant Circuit Diagram Table of symbols and circuit components Symbol Component Note 1: Each unit has two circuits like the one in the diagram below. MAIN circuit SUB circuit LEV1 LEV1 Linear expansion valve (Main circuit) Refrigerant flow direction (during heating) LEV2...

  • Page 65: Principal Parts And Functions

    [ VI Refrigerant Circuit ] [2] Principal Parts and Functions 1. Outdoor unit Part Symbols Notes Usage Specifications Check method name (functions) Com- Adjusts the amount of circulat- Low-pressure shell scroll pres- (Comp) ing refrigerant by adjusting the compressor operating frequency based on Wirewound resistance the operating pressure data 20°C[68°F] : 0.092 ohm...

  • Page 66

    [ VI Refrigerant Circuit ] Part Symbols Notes Usage Specifications Check method name (functions) Thermi Controls defrosting during Degrees Celsius Resistance check stor (Pipe heating operation = 15k temperature) = 3385 0/80 R = 15 3385 1) Detects outdoor air tem- (Outdoor tem- perature perature)

  • Page 67

    [ VI Refrigerant Circuit ] - 60 - HWE10060...

  • Page 68: Control

    VII Control [1] Functions and Factory Settings of the Dipswitches ............63 [2] Operating characteristics and Control Capabilities ............79 - 61 - HWE10060...

  • Page 69

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  • Page 70: Functions And Factory Settings Of The Dipswitches

    [ VII Control ] VII Control [1] Functions and Factory Settings of the Dipswitches 1. Factory Switch Settings (Dip switch settings table) Factory setting MAIN Setting Function Usage OFF setting ON setting circuit circuit timing Depends Model setting . s i on the unit .

  • Page 71

    [ VII Control ] 2. Slide switch (SWS1) settings Individual system SWS1 Setting Unit Operation MAIN circuit SUB circuit MAIN circuit SUB circuit LOCAL Follows the input signal of the sub circuit LOCAL Follows the input signal of the MAIN circuit Ignores the signal input REMOTE Follows the input signal of the sub circuit...

  • Page 72

    [ VII Control ] Priority order of the water-temperature-setting-input-signal sources Water temperature can be controlled by using the signals from the four types of input sources listed below. The setting for the item with higher priority will override the settings for the items with lower priorities. The water temperature will be controlled according to the temperature setting in the "Target water temperature"...

  • Page 73

    [ VII Control ] Water-temperature setting Different water temperature settings can be set for different modes. Use item codes 11, 13, 22, 23, 24, or 25 to set the water temperatures. - 66 - HWE10060...

  • Page 74

    [ VII Control ] (1) Setting procedures Set the dip switches on the circuit board as follows before making the settings for the items described in this section. Step 0 Set SWS1 to OFF from the remote controller or with the local switch. Most settings (other than item codes 11 and 13 (water temperature setting)) cannot be Set the ON/OFF changed unless the ON/OFF setting is set to OFF.

  • Page 75

    [ VII Control ] (2) Scheduled operation Up to three sets of start/end times can be assigned for each day. To operate the units according to the schedule, set the item code 5 to "1", and set the time for item codes 1 and 6 through 9.

  • Page 76

    [ VII Control ] [When the operation Start/End times do not overlap] Operation Period 1 Operation Period 1 Operation Period 2 Operation Period 2 Operation Period 3 Operation Period 3 Target water temp. Item code 1219 setting Item code 1220 setting Item code 1218 setting Operation command signal...

  • Page 77

    [ VII Control ] (3) Selecting the preset temperature for different operation periods Setting procedures Step 0 Set SWS1 to OFF from the remote controller or with the local switch. Settings cannot be changed unless the ON/OFF setting is set to OFF. Set the ON/OFF switch (SWS1) to OFF.

  • Page 78

    [ VII Control ] Selecting the preset temperature for different operation periods When operating the units on schedule, preset temperatures can be selected from A, B, or C for time periods 1 through 3. Item code 1218: Operation time setting 1 Item code 1215: Preset temp.

  • Page 79

    [ VII Control ] (4) Peak-demand control operation Peak-demand control is a function used to control the power consumptions of the units during peak-demand hours. The number of units in operation and the compressor's maximum operating frequency will be controlled according to the peak-demand control signal.

  • Page 80

    [ VII Control ] (5) Setting the total number of units for a multiple system Step 0 Set SWS1 to OFF from the remote controller or with the local switch. Settings cannot be changed unless the ON/OFF switch is set to OFF. Set the ON/OFF switch (SWS1) to OFF.

  • Page 81

    [ VII Control ] (6) Selecting the item that normally appears on the LED Display content Displays the operation mode.(*1) Displays the operation mode.(*2) Displays the current water temperature. Displays the water-temperature setting. Displays the high and low refrigerant pressures. (*1) The dot lights up when the operation signal is on.

  • Page 82

    [ VII Control ] (7) Remote water temperature setting input signal type By setting SW2-7 to ON, external analog signals can be used to set the water temperatures. Analog input type can be selected from the following four types: "0": 4-20 mA "1": 0-10 V "2": 0-5 V "3": 2-10 V...

  • Page 83

    [ VII Control ] (8) Setting the water temperature using analog signal input • When dip switch SW2-7 is set to ON (Enable external input), the target water temperature varies with the preset temperatures A and B and the type of analog input signal. •...

  • Page 84

    [ VII Control ] (9) Setting the booster heater operation conditions A temperature at which the booster heater will go into operation (TWL) can be selected. Select item code 1052 to set the threshold temperature (TWL) for booster heater operation. Booster heater operation conditions •...

  • Page 85

    [ VII Control ] Step 2 Select the item to be set with push switch SWP3. Step 3 Change the values with push switches SWP1 (↑) or SWP2 (↓). Select item code 1052 to set the operation temperature (TWL) for the booster heater. Press push switch SWP3 to select the item code.

  • Page 86: Operating Characteristics And Control Capabilities

    [ VII Control ] [2] Operating characteristics and Control Capabilities Outline of Control Method -1- Operating characteristics Function Component Symbol Control/ Unit Trigger condition Detection tion Unit Pressure High-pressure 63H1 HP 63H1 (2.95) protection switch switch OFF MPa 3.85 High-pressure 63HS HP 63HS OFF MPa...

  • Page 87

    [ VII Control ] Startup sequence rotation -2- Initial control When the power is turned on, the initial processing of the microcomputer is given top priority. During the initial processing, processing of the operation signal is suspended and is resumed after the initial processing is completed.

  • Page 88: Defrost Operation

    [ VII Control ] Control at Start-up -4- Defrost operation 1. Defrost start The defrost cycle will start when one of the following conditions 1 through 3 is met. Defrost operation will be performed individually in the circuit that meets the defrost-start condition below. Defrost operations will not be performed simultaneously in multiple circuits.

  • Page 89

    [ VII Control ] Bypass Control -5- Outdoor unit fan The fan's rotation speed will be controlled to approximate the values in the table below that are obtained based on the outside temperature and the low pressure. (Pressures and temperatures will be monitored, and the fan frequency will change accordingly in three steps.) Fan rotation Frequency (Hz) Outdoor temp.(A)

  • Page 90

    [ VII Control ] -7- LEV in the main circuit Operating range of the LEV The opening range of the LEV is between 100 and 2000 (fully open). LEV operation speed Open 133 plus/sec Close 200 plus/sec At startup For one minute and thirty seconds after startup, the valve will be fixed to the Initial Setting. During operation Ninety or more seconds after startup, the LEV opening will be controlled every 30 seconds according to the changes in com- pressor frequency, pressure, and temperature.

  • Page 91

    [ VII Control ] -9- Anti-short-cycling protection The unit has a 3-minute restart-delay function to protect the compressor from short-cycling. This function is effec- 3-minute restart delay function The 3-minite restart-delay function will tive even after a power failure. be triggered in the following situations: (1) The setting for the SWS1 (Local, Off, Remote) was changed, or (2) after Min.

  • Page 92

    [ VII Control ] Control at Initial Start-up -10- Peak-demand control General idea about demand control in the system with a combination of a heat pump and a combustion-type hot water boiler. →During peak-demand hours, the operation of the air conditioning units is given higher priority than that of the heat pump units. 1.Individual system The peak-demand control function is a function that restricts the maximum capacity of the units.

  • Page 93

    [ VII Control ] 3. Operating characteristics (w/o maximum capacity setting) Maximum operating frequency of the compressor (outlet water temperature: 65ºC) Energy-save setting (factory setting) Maximum capacity setting °CDB Outside temp. - 86 - HWE10060...

  • Page 94

    [ VII Control ] Emergency Operation Mode -11- Multiple system control 1. Electrical wiring diagram Main unit Sub unit Sub unit Unit Unit Unit Unit Unit Unit (MAIN circuit) (SUB circuit) (MAIN circuit) (SUB circuit) (MAIN circuit) (SUB circuit) External water Circuit board Circuit board Circuit board...

  • Page 95

    [ VII Control ] Control Method -12- Automatic operation of pump for freeze-up protection 1. Purpose This is a function to protect the water circuit from freezing up in winter. 2. Pump wire connection TO SUB BOX TB3 Transmission cable for multiple unit control Measurement terminal for maintenance(M-NET) LED2:CPU in operation CN52C...

  • Page 96

    [ VII Control ] Cooling/heating Circuit Control and General Function of System Equipment -13- Water-temperature control Water temperature can be controlled in the following three ways. Select one that works best. Switch Factory setting Outlet-water-temperature-based control SW3-3 Inlet-water-temperature-based control Water temperature control based on the SW2-8 external water temperature reading SW3-3...

  • Page 97

    [ VII Control ] 2. Normal Thermo-ON/OFF operations DIFF1 = 2 ºC (Initial setting): “1015” Digitally set value DIFF2 = 2 ºC (Initial setting): “1016” Digitally set value ≤ Tmax (Outside temperature -10 ºC: 65ºC, Outside temperature > -10 ºC : 70ºC) Single/Multiple Thermo-ON Thermo-ON...

  • Page 98

    [ VII Control ] Multiple system control (inlet-water-temperature-based control) When the water temperature is controlled based on the Thermo-OFF temperature representative inlet temperature, compressor frequency will Preset water temperature DIFF2/2°C be controlled as described in section -3-"Compressor frequency" (page 80). (Automatic operation according to the DIFF2/2°C preset temperature) Inlet water temperature...

  • Page 99

    [ VII Control ] Operation Mode -14- Controlling the operation of unit using external water temperature sensors The water temperature can be controlled using the built-in sensor on the unit or a separately sold external water temperature sensor. The factory setting for the sensor option is "built-in sensor on the unit." (SW2-8: OFF) To control the water temperature with an external water temperature sensor, set SW2-8 to ON.

  • Page 100

    [ VII Control ] External water temperature sensor TW-TH16 1. Parts that are required to install an external water Wire specifications temperature sensor Wire size 2-core cable Min. 1.25 mm (1) External water temperature sensor (2) Wiring to connect the sensor and the unit* Type CVVS or CPEVS (3) Wiring terminals to connect the wiring to the sensor and...

  • Page 101

    [ VII Control ] - 94 - HWE10060...

  • Page 102: Test Run Mode

    VIII Test Run Mode [1] Items to be checked before a Test Run ................97 [2] Test Run Method ......................99 [3] Operating the Unit......................100 [4] Refrigerant ........................101 [5] Symptoms that do not Signify Problems ................ 101 [6] Standard operating characteristics(Reference data) ............. 101 - 95 - HWE10060...

  • Page 103

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  • Page 104: Items To Be Checked Before A Test Run

    [ VIII Test Run Mode ] VIII Test Run Mode [1] Items to be checked before a Test Run (1) Check for refrigerant leak and loose cables and connectors. (2) Measure the insulation resistance between the power supply terminal block and the ground with a 500V megger and make sure it reads at least 1.0Mohm.

  • Page 105

    [ VIII Test Run Mode ] (10) Check for proper circulating water flow rate. Measure the circulating water flow rate, if possible. If it is not, check that the temperature difference between the outlet and inlet temperatures is between 3 and 5 ºC. A temperature difference of 6ºC or more indicates not enough water flow. Check for air pockets in the pipe, and make sure that the pump has the appropriate capacity for the circuit.

  • Page 106: Test Run Method

    [ VIII Test Run Mode ] [2] Test Run Method [Set Temperature] buttons ( Down/ Up buttons) [TIMER MENU] button (MONITOR/SET button) [Mode] button (BACK button) [Set Time] buttons ( Back/ Ahead buttons) [TIMER ON/OFF] button (DAY button) [CHECK] button (CLEAR button) [TEST RUN] button Not available TEMP.

  • Page 107: Operating The Unit

    [ VIII Test Run Mode ] [3] Operating the Unit 1. Initial Operation (1) Make sure the Run/Stop switch that controls the unit on the local control panel is switched off. (2) Switch on the main power. (3) Leave the main power switched on for at least 12 hours before turning on the Run/Stop switch that controls the unit on the on-site control panel to warm up the compressor.

  • Page 108: Refrigerant

    [ VIII Test Run Mode ] [4] Refrigerant CAHV-P500YA-HPB Unit type Refrigerant type R407C 5.5kg × 2 Refrigerant charge [5] Symptoms that do not Signify Problems Symptom Remote controller display Cause Fan does not stop while stopping op- Extinguished If terminals 19 and 20 on TB5 are short-circuited, the fan will be forced to operate even after the eration.

  • Page 109

    [ VIII Test Run Mode ] - 102 - HWE10060...

  • Page 110: Troubleshooting

    IX Troubleshooting [1] Maintenance items......................105 [2] Troubleshooting ......................113 [3] Troubleshooting Principal Parts ..................122 [4] Refrigerant Leak ......................138 [5] Parts Replacement Procedures ..................139 [6] Water piping configuration in the unit and how to connect the piping......147 - 103 - HWE10060...

  • Page 111

    - 104 - HWE10060...

  • Page 112: Maintenance Items

    [ IX Troubleshooting ] IX Troubleshooting [1] Maintenance items 1. Checking the error history Take the following steps to view the last six error histories (error codes). Refer to “[2] 2.Error code list” for information about error codes. (page 115) Setting procedure Step 1 Set the dip switches on the circuit board as follows to view error histories.

  • Page 113

    [ IX Troubleshooting ] Error history item list Unit and circuit type Item Item LED display Main unit Sub unit Notes code MAIN circuit SUB circuit MAIN circuit SUB circuit Error history 1 Error Code ○ ○ ○ ○ Error history 1 details (Inverter error) Error Code ○...

  • Page 114

    [ IX Troubleshooting ] 2. Checking the sensor status Setting procedure Step 1 Set the dip switches on the circuit board as follows to check temperatures and pres- Set the dip switches sures. SW2 and SW3. Step 2 Press the push switch SWP3 to toggle through the item codes listed below. Select the desired Select an item code from c01 through c36, and press either of the push switches SWP1 item with the push...

  • Page 115

    [ IX Troubleshooting ] Sensors and item code list Unit and circuit type Item Item LED display Main unit Sub unit Notes code MAIN circuit SUB circuit MAIN circuit SUB circuit MAIN circuit SUB circuit Error history 1 Error Code ○...

  • Page 116

    [ IX Troubleshooting ] 3. Operation status before error Setting procedure Step 1 Set the dip switches on the circuit board as follows to view the operation status before Set the dip switches error. SW2 and SW3. Step 2 Press the push switch SWP3 to toggle through the item codes listed below. Select the desired item with the push switch SWP3.

  • Page 117

    [ IX Troubleshooting ] Time of data storage before error Unit and circuit type Item Item LED display Main unit Sub unit code MAIN circuit SUB circuit MAIN circuit SUB circuit MAIN circuit SUB circuit Inlet water temp (Twi ) Inlet water temp 2 TH12 First decimal place ○...

  • Page 118

    [ IX Troubleshooting ] 4. Maintenance setting 1 This category includes items that are set during test run and maintenance. Setting procedure Step 1 Set the dip switches on the circuit board as follows. Set the dip switches SW2 and SW3. By setting SW3-9 to ON after setting the dip switches SW2 and SW3 as shown left, the setting values can be checked.

  • Page 119

    [ IX Troubleshooting ] Maintenance item (1) list Unit type Switch Item Incre- Lower Upper Main unit Sub unit Notes Default setting code ments limit limit timing MAIN circuit SUB circuit MAIN circuit SUB circuit Forcing the units in a specific system to stop 1004 ○...

  • Page 120: Troubleshooting

    [ IX Troubleshooting ] [2] Troubleshooting Troubleshooting according to the remote controller malfunction or the external input error Both for MA remote controller and ME remote controller 1. If a problem occurs, please check the following. If a protection device has tripped and brought the unit to stop (when an error code is blinking on the LED), resolve the cause of the error before resuming operation.

  • Page 121

    [ IX Troubleshooting ] Problem Check item Cause Solution The unit has Automatic Start/Stop Water temperature is Normal stopped during thermistor has tripped. high. operation and does not restart. Water temperature is The setting for the automatic Start/Stop Change the setting for the automatic Start/ low.

  • Page 122

    [ IX Troubleshooting ] 2. Error code list Thermistor fault - 115 - HWE10060...

  • Page 123

    [ IX Troubleshooting ] Thermistor fault - 116 - HWE10060...

  • Page 124

    [ IX Troubleshooting ] Inverter fault - 117 - HWE10060...

  • Page 125

    [ IX Troubleshooting ] Inverter fault - 118 - HWE10060...

  • Page 126

    [ IX Troubleshooting ] Inverter fault - 119 - HWE10060...

  • Page 127

    [ IX Troubleshooting ] Remote controller error Multiple unit Inverter fault (incl. remote controller system error wiring fault) - 120 - HWE10060...

  • Page 128

    [ IX Troubleshooting ] - 121 - HWE10060...

  • Page 129: Troubleshooting Principal Parts

    [ IX Troubleshooting ] [3] Troubleshooting Principal Parts High-Pressure Sensor -1- High-Pressure Sensor (63HS) 1. Compare the pressure that is detected by the high pressure sensor, and the high-pressure gauge pressure to check for failure. Error history, temperature and pressure readings of the sensor, and LEV opening High pressure and low pressure will appear alternately on the 7-seg- ment LED at P-second intervals (Default: 3 seconds).

  • Page 130

    [ IX Troubleshooting ] Low-Pressure Sensor -2- Low-Pressure Sensor (63LS) 1. Compare the pressure that is detected by the low pressure sensor, and the low pressure gauge pressure to check for failure. Error history, temperature and pressure readings of the sensor, and LEV opening High pressure and low pressure will appear alternately on the 7-seg- ment LED at P-second intervals (Default: 3 seconds).

  • Page 131: Temperature Sensor

    [ IX Troubleshooting ] Solenoid Valve -3- Temperature sensor Use the flowchart below to troubleshoot the temperature sensor. Troubleshooting the thermistor (1)Thermistor <Heatsink temperature> :THHS Start Thermistor = 17 kΩ±2% { 4016 ( R = 17 Disconnect the thermistor to be checked from the circuit board. 273 +t Measure the actual temperature of the pipe at the thermistor.

  • Page 132

    [ IX Troubleshooting ] -4- LEV 1. General descriptions of the operation of the LEV in the main circuit LEV1 is driven by the pulse signal from the circuit board and is controlled by a stepping motor. The valve opening changes according to the number of pulses 1) Control board and LEV Outdoor control board Intermediate connector...

  • Page 133

    [ IX Troubleshooting ] 2. General descriptions of injection LEV operation The valve opening changes according to the number of pulses. 1) Control board and LEV Outdoor control board DC12V ø6 ø5 Brown Drive circuit ø4 ø4 Blue ø3 ø3 Orange ø2 ø2...

  • Page 134

    [ IX Troubleshooting ] (1) Judgment methods and possible failure mode Malfunction Judgment method Remedy mode Microcomputer Disconnect the control board connector and connect When the drive circuit has a driver circuit fail- the check LED as shown in the figure below. problem, replace the control board.

  • Page 135

    [ IX Troubleshooting ] 3. Injection LEV coil removal procedure The LEV consists of a coil and a valve body that can be separated from each other. Body Coils Stopper Lead wire (1) Removing the coils Fasten the body tightly at the bottom (Part A in the figure) so that the body will not move, then pull out the coils toward the top.If the coils are pulled out without the body gripped, undue force will be applied and the pipe will be bent.

  • Page 136

    [ IX Troubleshooting ] Inverter -5- Inverter Replace only the compressor if only the compressor is found to be defective. Replace only the fan motor if only the fan motor is found to be defective. Replace the defective components if the inverter is found to be defective. If both the compressor and the inverter are found to be defective, replace the defective component(s) of both devices.

  • Page 137

    [ IX Troubleshooting ] Error display/failure condition Measure/inspection item Inverter related errors Check the details of the inverter error in the error log at [1] Error history 4250, 4255, 4220, 4225, 4230, 4235, 4240, 4245, 5301, 5305, item list. 5110, 0403 Take appropriate measures to the error code and the error details in ac- Error code list cordance with [2] 2.

  • Page 138

    [ IX Troubleshooting ] (2) Inverter output related troubles Items to be checked Phenomena Remedy Disconnect the invert- Overcurrent error Replace the INV board. Check the er output wire from (4250 Detail code No. 101, 104, INV board er- the terminals of the 105, 106, and 107) ror detection INV board (SC-U,...

  • Page 139

    [ IX Troubleshooting ] Items to be checked Phenomena Remedy Put the outdoor unit into oper- Overcurrent-related problems oc- a. Check items [1] through [3] Check whether ation. cur immediately after compressor for problems. the inverter is Check the inverter output volt- startup.

  • Page 140

    [ IX Troubleshooting ] (3) Trouble treatment when the main power breaker is tripped Items to be checked Phenomena Remedy Check the breaker capacity. Use of a non-specified break- Replace it with a specified breaker. Perform Meg check between the Zero to several ohm, or Meg Check each part and wiring.

  • Page 141

    [ IX Troubleshooting ] (5) Simple checking procedure for individual components of main inverter circuit Before inspecting the inside of the control box, turn off the power, keep the unit off for at least 10 minutes, and confirm that the voltage between FT-P and FT-N on INV Board has dropped to DC20V or less. Part name Judgment method IGBT module...

  • Page 142

    [ IX Troubleshooting ] Judgment value (reference) Black ( + ) SC-P1 FT-N SC-L1 SC-L2 SC-L3 SC-P1 5 - 200 ohm 5 - 200 ohm 5 - 200 ohm FT-N Red (-) SC-L1 5 - 200 ohm SC-L2 5 - 200 ohm SC-L3 5 - 200 ohm Black ( + )

  • Page 143

    [ IX Troubleshooting ] Control Circuit -6- Control Circuit Troubleshooting transmission power circuit of outdoor unit Check the voltage at the indoor/outdoor transmission terminal block (TB3) of outdoor unit. DC 24 ~ 30 V Check whether the transmission line is disconnected, check for contact failure, and repair the problem.

  • Page 144

    [ IX Troubleshooting ] Outdoor Unit Fan -7- Fan The rotation speed of the fan is controlled by the inverter. Check the inverter output status on the LED to check the rotation speed. The maximum rotation speed of the fan is approximately 670 rpm. Make appropriate settings on the display function to get the output to be displayed [%].

  • Page 145: Refrigerant Leak

    • It may also be in violation of applicable laws. • MITSUBISHI ELECTRIC CORPORATION cannot be held responsible for malfunctions or accidents resulting from the use of the wrong type of refrigerant.

  • Page 146: Parts Replacement Procedures

    • It may also be in violation of applicable laws. • MITSUBISHI ELECTRIC CORPORATION cannot be held responsible for malfunctions or accidents resulting from the use of the wrong type of refrigerant.

  • Page 147

    [ IX Troubleshooting ] 1. Compressor Replacement instructions Follow the procedures below (Step 1 through 6) to remove the compressor components and replace the compressor. Reassemble them in the reverse order after replacing the compressor. control boxes service panels compressor covers 1.

  • Page 148

    [ IX Troubleshooting ] Attachment instructions for INJ pipe fixing plate 903@@@@ INJ pipe fixing plate Butyl rubber attachment Temporary tightening INJ pipe fixing plate 1. Hold the attachment and INJ pipe fixing plate against 2. Press the butyl rubber on the fixing plate against the terminal box, aligning the holes with the hole on the the compressor shell.

  • Page 149

    [ IX Troubleshooting ] 2. Check valve Replacement instructions 1) Remove the lower service panels. (Panel FB) ø 12.7 1/2"] ø 12.7 1/2"] Check valve Check valve ø 12.7 1/2"] ø 12.7 1/2"] 1. Debraze A-B parts (total 2 places), and remove the Check valve . 2.

  • Page 150

    [ IX Troubleshooting ] 3. LEV replacement instructions 2) Remove the cables from the Frame Assy MU (top) and MB (bottom), 1) Remove the upper and and remove the Frame assy MU and MB. lower service panels. (Panel FU and FB) Work procedure (1) Remove the service panel.

  • Page 151

    [ IX Troubleshooting ] 4. Thermistor replacement instructions (liquid pipe/gas pipe/water temperature detection) 1) Remove the service panel. 2) Remove the lead wire of the piping sensor from the control board. 3) Pull out the temperature sensor from the tenperature sensor housing, and replace the temperature sensor with the new one.

  • Page 152

    [ IX Troubleshooting ] 5. Solenoid valve replacement instructions 2) Remove the cables from the Frame Assy MU (top) and MB (bottom), 1) Remove the upper and and remove the Frame assy MU and MB. lower service panels. (Panel FU and FB) (1) Remove the service panel.

  • Page 153

    [ IX Troubleshooting ] 6. 4-way valve replacement instructions 2) Remove the cables from the Frame Assy MU (top) and MB (bottom), 1) Remove the upper and and remove the Frame assy MU and MB. lower service panels. (Panel FU and FB) (1) Remove the service panel.

  • Page 154: Water Piping Configuration In The Unit And How To Connect The Piping

    [ IX Troubleshooting ] [6] Water piping configuration in the unit and how to connect the piping (1) Water piping configuration in the unit The pipe that connects the two plate heat exchangers are connected to each heat exchanger with a joint with ferrules. Note that the tightening torque for these joints are different than the ones for screw-in joints.

  • Page 155

    [ IX Troubleshooting ] - 148 - HWE10060...

  • Page 156: Attachments

    X Attachments [1] R407C saturation temperature table................151 - 149 - HWE10060...

  • Page 157

    - 150 - HWE10060...

  • Page 158: R407c Saturation Temperature Table

    [ X Attachments ] X Attachments [1] R407C saturation temperature table Saturation pressure Saturating temperature °C Saturation pressure Saturating temperature °C Saturation pressure Saturating temperature °C Saturation pressure Saturating temperature °C Saturation pressure Saturating temperature °C MPa(gauge) Saturated liquid Saturated gas MPa(gauge) Saturated liquid Saturated gas MPa(gauge)

  • Page 159

    [ X Attachments ] - 152 - HWE10060...

  • Page 160

    Service Handbook Service Handbook Model CAHV-P500YA-HPB http://Global.MitsubishiElectric.com Issued in Feb. 2011 HWE10060 New publication effective Feb. 2011. Printed in Japan Specifications subject to change without notice.

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