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Summary of Contents for Mitsubishi Heavy Industries Hydrolution PRO Series
- Page 1 Hydrolution PRO Series Installation, Operation & Maintenance Manual MJD012A003 202403...
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Page 2: Table Of Contents
Table of Contents 1. Introduction 1.1 Introduction 1.2 Warranty 1.3 Safety 2. Residual risk 2.1 Transport and installation 2.2 Start-up and operation 2.3 Maintenance 2.4 Dismantling 2.5 Safety Data 3. Transport / Storage 3.1 Delivery of units 3.2 Storage 3.3 Transport 4. - Page 3 7. Operation Method 7.1 Basic setting 7.2 Unit operation 7.3 External signal input and output 7.4 Error resetting 7.5 Special functions 8 Commissioning 8.1 Preparation 8.2 First-Startup 9 Maintenance 9.1 Safety instructions 9.2 Maintenance guidelines 9.3 Guidance for drafting of the logbook 9.4 Error code lists 10.
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Page 4: Introduction
This manual contains basic information which is to be complied with for installation, operation and maintenance. They must therefore be read and complied with by the fitter and the responsible trained staff/operators before assembly and commissioning. All procedures detailed in the manual, including tasks for installation, commissioning and maintenance must only be performed by suitable trained and qualified personnel. -
Page 5: Safety
Drain water Lifting point Connecting hole for external Inlet of hydraulic circuit earthing Outlet of hydraulic circuit High voltage Direction of rotation of motors Moving parts Hot surface A2L refrigerant Discharge of safety valves UN3358... - Page 6 Do not open the electrical cabinet until 5min after power is off. Nameplate The heat pump is identified by the nameplate shown on the left. The identification nameplate also shows the serial number of the unit. It is important to know the label as it is essential to get assistance or any information concerning the unit described in this manual.
- Page 7 This unit contains fluorinated greenhouse gas covered by the Kyoto protocol Refrigerants are volatile or highly volatile fluorinated hydrocarbons which are liquefied under pressure. They are incombustible and not hazardous to health when used as intended. • Observe the national regulations of the country where the unit will be installed. •...
- Page 8 • Do not use direct flames or electro warming devices near the chiller to increase the pressure of the refrigerant. • A2L refrigerants are not flammable at atmospheric pressure and ambient temperature in air. In case of pressurization with air or oxygen, the mixture may get flammable. A potentially explosive atmosphere can be created at the release of refrigerants.
- Page 9 First aid measures • If health problems occur during or after handling fluorinated hydrocarbons, a doctor is to be consulted immediately. The doctor is to be informed that the work involved the use of HFCs. • In the case of acute effects, wear breath apparatus to transport the casualty is to fresh air as quickly as possible, keeping the victim warm and laying on the ground.
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Page 10: Residual Risk
heat pump. -
Page 12: Dismantling
2.5 Safety Data Refrigerant Gas Safety data of the refrigerant Preparation identification REFRIGERANT R32 1. Product identification Recommended use Refrigerant Extremely flammable gas. Contains gas under pressure; may explode if heated. My 2. Hazard identification Most important hazards displace oxygen and cause rapid suffocation. Remove from exposure, lie down. -
Page 13: Transport
The mixture may become flammable or reactive when pressurized with oxygen. Avoid heat, hot surfaces and open flames. Do not expose to Conditions to avoid temperatures exceeding 52°C. Do not store in confined space of basement, 7. Stability and reactivity store in well ventilated place. -
Page 14: Transport / Storage
To assure a persistent quality and reliability, all units are tested and inspected before leaving the factory. The heat pumps are completely assembled when shipped and contain refrigerant under pressure. The units must always be transported upright. The refrigerant circuit is filled with R32 refrigerant ready to be used. The unit is labelled as below. -
Page 15: Storage
If you put the unit into intermediate storage before the installation, the following measures have to be carried out to protect the unit from damage and corrosion: • Make sure that the water connections are provided with protective hoods. If the intermediate storage exceeds 2 months, we recommend filling the pipes with nitrogen. - Page 16 Spacer Rope (not provided) (not provided) Lifting hole (Standard) 3.3.2 Centre of gravity MODEL MCU5001VHE-W1 MCU5001VHE-W1A MCU5001VHE-W NAME MCU5001VHE-W2 MCU5001VHE-W2A x/mm y/mm 1080 1021 1063 z/mm 1031 Weight/kg...
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Page 17: Description
The operator alone bears the risk. Unit design In the Hydrolution PRO series of heat pumps, they're 3 kinds of capacities: 50kW, 75kW and 100kW. The dimension of 50kW and 75kW unit is the same, which 100kW is bigger. -
Page 18: Piping Diagrams
Layout of 50kW standard unit Axial fan Air heat exchanger Hydraulic circuit 7 segment display Electrical cabinet Technical box with Plate heat Refrigerant circuit inside exchanger *Box cover's removed Symbol Symbol Meaning Symbol Meaning Symbol Meaning Air heat exchanger 4-way valve Pump Solenoid valve Buffer tank... - Page 19 MCU5001VHE-W, MCU5001VHE-W1, MCU5001VHE-W2, MCU5001VHE-W1A, MCU5001VHE-W2A...
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Page 20: Hydraulic Diagrams
MCU5001VHE-W MCU5001VHE-W1, MCU5001VHE-W2 MCU5001VHE-W1A, MCU5001VHE-W2A... -
Page 21: Technical Data
Item Rated voltage 400V 3N ~ 50Hz Voltage fluctuation Within ±10% of rated voltage Power supply Voltage drop at startup Within -15% of rated voltage Interphase unbalance Within 2% 1 cycle time 5 min or more (OFF – OFF or Startup – Startup) Compressor ON/OFF Frequency 3 min or more Stop time... -
Page 22: Water Quality
5.2 Water quality Don't operate the heat pump, or stock water in the hydraulic circuit, when outlet water temperature is lower than +5℃, or the ambient temperature is lower than 15℃. It's recommended to use water under the request as below. Feature Value (25°C) - Page 23 Head pressure with optional pump HP: MCUS5001VHE2(A) LP: MCUS5001VHE1(A) Flow [㎥/h]...
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Page 24: Technical Data
5.4 Technical data Model 50kW Compressor (inverter scroll) 50kW x 1 Nom. 44.0 Cooling Capacity Max. 50.0 Nom. 47.0 Heating Capacity Max. 50.0 Cooling 15.1 Power Input Heating 13.5 Method Inverter Controlled Capacity Control 2.91 3.47 SEER 4.48 ηs ％ 180% Seasonal Space Heating Class SCOP... -
Page 25: Dimensional Drawings
5.5 Dimensional drawings Standard pumpless unit (MCUS5001VHE-W) dimensions are same for all models Standard + optional pump (MCUS5001VHE-W1, MCUS5001VHE-W2) Standard + optional pump & tank (MCUS5001VHE-W1A, MCUS5001VHE-W2A) -
Page 26: Installation
Check that the installation site is prepared for the unit weight, which is defined in the technical data in "3.3.2 Centre of gravity " . The heat pump is designed for outside installations on a horizontal level base. For an even weight distribution, a base plate made of concrete is necessary. •... - Page 27 Minimum distance from obstacle or other heat pump...
- Page 28 6.2 Special requirements for installation • Access permitted only for instructed personnel doing the maintenance. • Adequate ventilation must be ensured. • Free flames not permitted. Only welding, brazing or similar activity are permitted if an adequate ventilation is ensured. •...
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Page 29: Installation Foundation
6.3 Installation foundation When planning installation and constructing the foundation, take care of following items. • Where the unit is placed, finish the floor with mortar and provide a flat, horizontal surface. The levelness should be within 3/1,000. • Rain and condensed water are drained from the bottom of unit. Waterproof the foundation, and provide a drain ditch around the foundation. -
Page 30: External Water Circuit
6.4 External water circuit The basic water circuit of a standard heat pump contains an plate heat exchanger, temperature and pressure sensors in the inlet and outlet, vent valve and drain plug. For a detailed overview, please take a look at the circuit diagram in chapter "4.5 Hydraulic diagrams. - Page 31 One unit The installation of pipe compensators in the chilled water inlet and outlet are recommended, to protect them from vibration of connected devices. Muti-unit If you connect two or more heat pumps in parallel, we recommend installing regulating valves to keep the pressure drop of each unit equally high.
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Page 32: Water Connection
Anti-freezing function When the ambient temperature or water temperature is low, the anti-freezing operation will be started automatically, to prevent any damage to the unit. (1) When the ambient temperature is low and the pump is stopped, the anti-freezing operation could turn on the pump to protect the plate heat exchanger from . -
Page 33: Electrical Connection
6.6 Electrical connection The main switch can be used as an emergency stop when the operator is near the heat pump. The restore of the main switch will immediate restart the unit, without further action by the operator. • Ensure that the electric cables are de-energized and the unit is turned off. •... -
Page 34: Electrical Connection Of R/C
The power supply system on site and the pre-fuses must be designed for the total current of the unit ("5.4 Technical Data"). Make sure that the power supply corresponds to the indications on the rating plate and that the tolerances according to the "5.1 Application limits" are not exceeded. Route the electric cable into the electrical cabinet from below and connect the three phases to the main switch and the PE conductor next to the switch, in accordance with the wiring diagram (part of the... -
Page 35: Operation Method
7. Operation Method • The unit must be installed and connected in accordance to the manual, especially with the chapter "6. Installation", before the operation. • Only authorized and certified personnel is allowed to commission the unit. 7.1 Basic setting 7.1.1 When optional remote controller(R/C) or MCU controller(MCU-C) is used 1) Connect the signal cables to X,Y (R/C), A,B (MCU-C) of TB10. - Page 36 7.1.3 PWB1 7-segment setting In the following cases, change 7-segment setting of according to the table. *To change the setting, please follow the instruction in 7.2 7-segment setting method. 1) When MCU controller is connected and remote controller is not used (operation with external input), change the setting of 7-segment P10 to a higher level device.
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Page 38: Unit Operation
7.2 Unit operation 7.2.1 Local control with single unit (ON/OFF) Without using the optional remote controller, MCU controller and external , the unit could be set and turned ON/OFF by the following operation zone. The operation zone could be accessed through the small window in the door of electrical cabinet, while the unit is powered on. - Page 39 (2) Operation mode setting ・If “External operation mode input” signal is turned ON (short-circuit), it changes to the cooling operation mode. ・If “External operation mode input” signal is turned OFF (open), it changes to the heating operation mode. * Unless external input signals are used, change with the operation mode select switch. (3) Temperature setting Target water temperature can be changed with “Temperature setting input”...
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Page 40: External Signal Input And Output
7.3 External signal input and output The user could choose I/O signals by changing 7-segment setting. It's shown below that which signals could be gotten or input into PWB1. Analog I/O signals Signal name Description Applicable range C/H water pump inverter Water pump frequency value is Used when a water pump and an inverter output... - Page 41 Digital I/O signals Signal name Description Applicable range Operation status output (OFF/ON) ON when unit's turned on Unlimited Error status output ON when high level error occurs Unlimited (Normal/high level error) Error status output ON when low level error occurs Unlimited (Normal/low level error) Stop at light load output...
- Page 42 Procedure to change allocations External I/O to and from PWB1 Allocations on the microcomputer of external I/O to and from PWB1 can be changed. 7-segment display: check function allocation number, then do the setting. (1) Allocation of digital I/O functions Function 7-segment Display...
- Page 43 Allocated functions of which digital I/O can be set Function Note (If the function isn't allocated, allocation Function OFF/Open ON/Shorted refer the default setting) External operation input Default: OFF External operation mode Heating Cooling Default: OFF input Demand input Demand Default: OFF C/H water pump interlock Error...
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Page 46: Error Resetting
7.4 Error resetting If any error occurs, report or consult your dealer or service shop. Error contents (Error code) must be confirmed before resetting the error. After removing cause of error, reset as described below. Unless it is reset, the unit cannot restart. 7.4.1 Check and reset of error code with remote controller If any error occurs, the red operation LED lamp flickers. -
Page 47: Special Functions
7.4.2 Local resetting(Without remote controller or higher level device or external input ) Error code is displayed on 7-segment display of PWB1 in electrical cabinet. Confirm the error code, and report to your dealer or service shop. Procedures 1) Turn the operation switch SW14 to “STOP”. 2) Set 7-segment C00 at “1”. - Page 48 7.5.3 Snow fan control In order to prevent snowfall on the fan section while the operation is stopped in winter, the fan is operated at regular intervals to blow off snow. Valid or invalid can be selected with 7-segment setting (P30 of PWB1: Valid, 2: Invalid), and the fan operates for 30 seconds at intervals of 10 minutes, if the set outdoor temperatures are lower than the valid conditions.
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Page 49: Commissioning
8. Commissioning • The unit must be installed and connected in accordance to the manual, especially with the chapter "6. Installation", before the operation. • Only authorized and certified personnel is allowed to commission the unit. The main switch can be used as an emergency stop when the operator is near the heat pump. The restore of the main switch will immediate restart the unit, without further action by the operator. -
Page 50: First-Startup
8.2 First-Startup The main switch can be used as an emergency stop when the operator is near the heat pump. The restore of the main switch will immediate restart the unit, without further action by the operator. • Where the remote controller/MCU controller is connected to a system including multiple units, commissioning each unit at first. - Page 51 8.2.1 Single unit operation • Commissioning each unit according to the following list. When there are valves or pumps which are controlled with other controller other than this unit, check their operations before commissioning of single unit, and prepare them such that the unit can be commissioning. When the unit is controlled with PWB1 or the external I/O function of MCU controller, commissioning all units, after the single unit commissioning, and check operations of respective devices.
- Page 52 7-segment setting of PWB1 With built-in water pump or C/H Water pump control) Water pump commissioning...
- Page 53 When operating without remote controller, turn off the power after commissioning, then turn the dipswitch SW14 to “ON”, turn off and on again the power supply and validate the antifreeze operation of water pump. Unless the power supply is reset, it cannot validate.
- Page 54 8.2.2 System commissioning (Without MCU controller) • When commissioning the entire system, consult with the system administrator, owner and administrator of building. Regarding interlocks with other devices or controls of entire system such as the unit number control, etc., make adjustments corresponding to the system under the guidance of service personnel. (1) When the remote controller is used Check at first if 7-segment P10 (Higher level device setting on supervise PCB) is set at 4 (Default: 4), and then turn the operation switch to “Remote”...
- Page 55 (B) When using Local/Remote switch at Local 1) Set the number of units with P12. 2) Setting of higher level device (P10) is invalid. It operates according to the Local switch. Mode setting P7 is also invalid. It operates according to Local switch. Select the setting temperature from: 0: 7-segment input 1: Cooling/heating dual use external input (4 –...
- Page 56 8.2.4 Single unit commissioning check list...
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Page 57: Maintenance
9. Maintenance The main switch can be used as an emergency stop when the operator is near the heat pump. The restore of the main switch will immediate restart the unit, without further action by the operator. 9.1 Safety instructions All maintenance work is to be carried out under strict compliance with the country-specific Health &... - Page 58 c. Where the equipment receives severe vibration or impacts. d. Where operating atmosphere is heavily loaded with dust, salt, toxic gas like sulfuric acid gas or hydrogen sulfide, oil mist, etc. It should be noted also that, in order to use the product without worry, it is better concluding maintenance agreements with professional contractors for regular inspections.
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Page 59: Guidance For Drafting Of The Logbook
4) Safety valve The evaluations of the safety valves must be done in accordance with the national regulations. Where there are no criteria in national regulations, please refers to the following parts of EN 378-4: • The safety valves are checked in accordance with EN 378-2: 2016 paragraphs 6.3.4.3.1, 6.3.4.3.4 e 6.3.4.3.5 and submitted tightness test every year. - Page 60 Error codes of PWB1 PWB1 Error Code Check point level Green light Red light segment keep flashing light up high Communication error between PWB1 and PWB2 keep flashing - high Freeze risk Inlet/outlet temperature fault keep flashing - high (e.g.: heating mode: inlet temp.> outlet temp.) keep flashing light up high Duplicate address of multi PWB1 or MCU controllers(optional) keep flashing light up...
- Page 61 Error codes of PWB2 These codes could only be checked on the 7-segment display of PWB2, it won't be displayed in the remote controller (optional). PWB1 Code Check point Green light Red light segment keep flashing 1-time flash E09 Freeze risk Inlet/outlet temperature fault keep flashing 1-time flash E10 (e.g.: heating mode: inlet temp.>...
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Page 62: Malfunction
10. Malfunction Problem Possible cause Recommended action Generals No power supply Restore power supply Main switch is OFF Turn the main switch to the position of " I ON" The heat pump does not start up and the electronic Check the voltage of the power cables to the control. No power supply to the electronic control control doesn’t work. - Page 63 Error display (PWB1) Plate heat exchanger temperature sensor error Replace the plate heat exchanger temperature sensor E39 (Plate heat exchanger Communication fault between sensor and PWB2 Reconnect the connector temperature sensor fault) PWB2 fault Contact our distributor High pressure switch error Replace the high pressure switch Communication fault between HP switch and Reconnect the connector...
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Page 64: Dismantling And Disposal
11. Dismantling and disposal The decommissioning of the heat pumps must be carried out by experienced and qualified personnel for the operations required. 1. Turn the unit to OFF mode. 2. Turn the main switch to OFF. 3. Disconnect the power supply from the power cables and prevent any voltage reset. 4.
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