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Mitsubishi Electric PCA Series, Service Manual

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2

2-1. OUTDOOR UNIT’S SERVICE MANUAL

2-2. TECHNICAL DATA BOOK

Service Ref.

Service Manual No.

SUZ-KA50/60/71VA3.TH-A

OCH511 / OCB511

PUHZ-RP50/60/71VHA4
PUHZ-RP100/125/140VKA
PUHZ-RP100/125/140/200/250YKA
PUHZ-RP200YKAR1

OCH451 / OCB451

PUHZ-ZRP35/50VKA
PUHZ-ZRP60/71VHA
PUHZ-ZRP100/125/140VKA
PUHZ-ZRP100/125/140YKA

OCH527 / OCB527

PU(H)-P71/100VHAR3.UK
PU(H)-P71/100/125/140YHAR3.UK

OC379

PUHZ-P100/125/140VHA3R2.UK
PUHZ-P100/125/140YHAR1.UK

OCH415 / OCB415

PUHZ-P200/250YHA3R2

OCH424 / OCB424

SUZ-KA50/60/71VA2.TH

OCH472 / OCB472

SUZ-KA50/60/71VA2.TH-A

OCH473 / OCB473

SUZ-KA25/35/50/60/71VA3.TH

OCH530 / OCB530

Series (Outdoor unit)

Manual No.

SUZ-KA

•

VA

OCS03

PUHZ-RP

•

HA4

PUHZ-RP

•

KA

OCS16

PUHZ-P

•

VHA3

PUHZ-P

•

YHAR3

OCS17

PUZ-KA

•

VA3

OCS22

Note:
The phrase "Wired remote controller" in this service manual refers to the PAR-21MAA.
If you need any information for the other remote controller, please refer to either the instaollation manual or 
initilal setting manual which are in these boxes.

REFERENCE MANUAL

2

TECHNICAL CHANGES

1

PCA-RP50KAQ 

 PCA-RP50KAQR1

PCA-RP60KAQ 

 PCA-RP60KAQR1

PCA-RP71KAQ  

PCA-RP71KAQR1

INDOOR CONTROLLER BOARD (I.B.) has been changed.

OCH491B

Summary of Contents for PCA Series

Page 1: ...CA RP50KAQ PCA RP50KAQR1 PCA RP60KAQ PCA RP60KAQR1 PCA RP71KAQ PCA RP71KAQR1 PCA RP100KAQ PCA RP125KAQ PCA RP140KAQ October 2012 NOTE This manual describes only service data of the indoor units RoHS compliant products have G mark on the spec name plate PARTS CATALOG OCB491 Model name indication WIRED REMOTE CONTROLLER Option WIRELESS REMOTE CONTROLLER Option ON OFF TEMP Please void OCH491 REVISED ...

Page 2: ... OCH424 OCB424 SUZ KA50 60 71VA2 TH OCH472 OCB472 SUZ KA50 60 71VA2 TH A OCH473 OCB473 SUZ KA25 35 50 60 71VA3 TH OCH530 OCB530 Series Outdoor unit Manual No SUZ KA VA OCS03 PUHZ RP HA4 PUHZ RP KA OCS16 PUHZ P VHA3 PUHZ P YHAR3 OCS17 PUZ KA VA3 OCS22 Note The phrase Wired remote controller in this service manual refers to the PAR 21MAA If you need any information for the other remote controller pl...

Page 3: ...wing tools specifically designed for use with R410A refrigerant The following tools are necessary to use R410A refrigerant Handle tools with care If dirt dust or moisture enters into refrigerant cycle that can cause deterioration of refrigerant oil or malfunction of com pressor Do not use a charging cylinder If a charging cylinder is used the composition of refrigera nt will change and the efficie...

Page 4: ...check Attach on vacuum pump 6 Refrigerant charge base 7 Refrigerant cylinder Only for R410A Top of cylinder Pink Cylinder with syphon 8 Refrigerant recovery equipment 1 Cautions for service 1 Perform service after recovering the refrigerant left in unit completely 2 Do not release refrigerant in the air 3 After completing service charge the cycle with specified amount of refrigerant 4 When perform...

Page 5: ...the current time display Displays the order of timer operation display Displays whether timer is on or off Buttons used to set the hour and minute of the current time and timer settings h and min buttons Temperature setting display Indicates the desired temperature setting which is set display Displays selected fan speed display The vertical direction of airflow is indicated display Blinks when mo...

Page 6: ...tton This lamp lights up in green while the unit is in operation It blinks while the remote controller is starting up or when there is an error Press to save the setting Main display Press to change the operation mode Main menu Press to move the cursor down Press to return to the previous screen Main display Press to decrease temperature Main menu Press to move the cursor up Press to bring up the ...

Page 7: ...tions cannot be operated Maintenance Auto descending panel Auto descending panel Optional parts Up Down you can do Manual vane angle Use to set the vane angle for each vane to a fixed position Initial setting Main Sub When connecting two remote controllers one of them needs to be designated as a sub controller Clock Use to set the current time Main display Use to switch between Full and Basic mode...

Page 8: ...f the corre sponding timer is set Up Down Air Direction indica tor The indicator shows the direc tion of the outcoming airflow One Hour Only indicator Room Temperature display Shows the room temperature The room temperature display range is 8 39 C The display blinks if the temperature is less than 8 C or 39 C or more Louver display Indicates the action of the swing louver Does not appear if the lo...

Page 9: ...6 680 26 3 4 230 9 1 16 25 55 PCA RP50KAQ PCA RP50KAQR1 kW A kW min CFM Pa mmAq dB mm in mm in mm in mm in kg lbs Service Ref Mode Power supply phase cycle voltage Input Running current External finish Heat exchanger Fan Fan drive No Fan motor output Airflow Low Medium2 Medium1 High External static pressure Operation control Thermostat Noise level Low Medium2 Medium1 High Field drain pipe O D Dime...

Page 10: ...Heating 0 11 0 76 PCA RP125KAQ kW A kW min CFM Pa mmAq dB mm in mm in mm in mm in kg lbs Service Ref Mode Power supply phase cycle voltage Input Running current External finish Heat exchanger Fan Fan drive No Fan motor output Airflow Low Medium2 Medium1 High External static pressure Operation control Thermostat Noise level Low Medium2 Medium1 High Field drain pipe O D Dimensions Weight W D H INDOO...

Page 11: ...0 14 0 90 Heating 0 14 0 90 PCA RP140KAQ kW A kW min CFM Pa mmAq dB mm in mm in mm in mm in kg lbs Service Ref Mode Power supply phase cycle voltage Input Running current External finish Heat exchanger Fan Fan drive No Fan motor output Airflow Low Medium2 Medium1 High External static pressure Operation control Thermostat Noise level Low Medium2 Medium1 High Field drain pipe O D Dimensions Weight W...

Page 12: ... 0 B A C 1 Curve in the graphs Duct characteristics at site Q A E C 2 Q Qa A D 3 Q Designed amount of fresh air intake m3 min A Static pressure loss of fresh air intake duct system with airflow amount Q Pa B Forced static pressure at air conditioner inlet with airflow amount Q Pa C Static pressure of booster fan with airflow amount Q Pa D Static pressure loss increase amount of fresh air intake du...

Page 13: ...0 NC 20 NC 70 OCTAVE BAND SOUND PRESSURE LEVEL dB 0 dB 0 0002 μbar BAND CENTER FREQUENCIES Hz PCA RP60KAQ PCA RP60KAQR1 90 80 70 60 50 40 30 20 10 63 125 250 500 1000 2000 4000 8000 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE NC 60 NC 50 NC 40 NC 30 NC 20 NC 70 BAND CENTER FREQUENCIES Hz OCTAVE BAND SOUND PRESSURE LEVEL dB 0 dB 0 0002 μbar PCA RP71KAQ PCA RP71KAQR1 NOTCH High Medium1 Med...

Page 14: ...25 250 500 1000 2000 4000 8000 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE NC 60 NC 50 NC 40 NC 30 NC 20 NC 70 BAND CENTER FREQUENCIES Hz OCTAVE BAND SOUND PRESSURE LEVEL dB 0 dB 0 0002 μbar PCA RP140KAQ NOTCH High Medium1 Medium2 Low SPL dB 48 45 43 41 LINE 90 80 70 60 50 40 30 20 10 63 125 250 500 1000 2000 4000 8000 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE NC 60 NC 50 NC ...

Page 15: ... Knockout hole for left drain piping arrangement Refrigerant pipe connection gas pipe side flared connection Refrigerant pipe connection liquid pipe side flared connection 1 In case of the rear pipe arrangement make sure to remove the shaded portions from the independent piece Then put the independent piece back in initial position The heat exchanger might be clogged because of dust 5 10 51 246 Dr...

Page 16: ...s refrigerant pipe will be only upward Air outlet 233 Electrical box When electrical box is pulled down Electrical box 9 7 In case of the rear pipe arrangement make sure to remove the shaded portions from the independent piece Then put the independent piece back in initial position The heat exchanger might be clogged because of dust 5 10 51 246 A B 236 150 62 140 18 1237 Suspension bolt pitch 320 ...

Page 17: ...VIEW Electrical box When electrical box is pulled down 2 NOTES 1 Use M10 or W3 8 screw for anchor bolt 2 Please be sure when installing the drain pump option parts refrigerant pipe will be only upward In case of the rear pipe arrangement make sure to remove the shaded portions from the independent piece Then put the independent piece back in initial position The heat exchanger might be clogged bec...

Page 18: ...18 WIRED REMOTE CONTROLLER Unit mm PAR 21MAA PAR 30MAA 130 120 83 5 19 5 19 120 120 46 46 83 5 Option OCH491B ...

Page 19: ...1 RU SW2 SW1 CNB 9 5 t t t TH2 TH5 TH1 MV BZ M W B I B 1 4 2 1 2 1 2 1 Refer to tables 1 and 2 TB4 YLW ORN ORN BRN YLW YLW ORN DCL TO OUTDOOR UNIT 1 3 5 3 1 M 1 DP OPTION PARTS D U M CNP BLU OUTDOOR CN01 BLK S1 S2 S3 7 4 1 3 MF MS OPTION PARTS 1 3 REMOCON CN22 BLU WIRELESS CN90 WHT VANE CNV WHT Pair No FAN CNMF WHT INTAKE CN20 RED FLOAT SW CN4F WHT LIQUID PIPE CN44 WHT CN32 WHT CN51 WHT CN41 WHT X...

Page 20: ...istor TH1 Refrigerant flow in cooling Refrigerant flow in heating Strainer 50 Strainer 50 Heat exchanger Refrigerant GAS pipe connection Flare Refrigerant LIQUID pipe connection Flare REFRIGERANT SYSTEM DIAGRAM 9 PCA RP35KAQ PCA RP50KAQ PCA RP60KAQ PCA RP71KAQ PCA RP100KAQ PCA RP125KAQ PCA RP140KAQ PCA RP50KAQR1 PCA RP60KAQR1 PCA RP71KAQR1 OCH491B ...

Page 21: ...bleshooting of problems The trouble is not reoccurring Logged Not logged Consider the temporary defects such as the work of protection devices in the refrigerant circuit including compressor poor connection of wiring noise and etc Re check the symptom and check the installation environment refrigerant amount weather when the trouble occurred matters related to wiring and etc Reset error code logs ...

Page 22: ...dure 1 Press the CHECK button twice 2 Press the temperature buttons 3 Point the remote controller at the sensor on the indoor unit and press the HOUR button 4 Point the remote controller at the sensor on the indoor unit and press the ON OFF button Malfunction diagnosis method at maintenance service 10 2 MALFUNCTION DIAGNOSIS METHOD BY REMOTE CONTROLLER In case of trouble during operation When a ma...

Page 23: ...ller Wired remote controller 1 P1 Intake sensor error P9 Pipe TH5 sensor error 2 P2 Pipe TH2 sensor error 3 E6 E7 Indoor outdoor unit communication error 4 P4 Drain sensor error Float switch connector CN4F open 5 P5 PA Drain pump error Forced compressor stop due to water leakage abnormality 6 P6 Freezing Overheating protection operation 7 EE Communication error between indoor and outdoor units 8 P...

Page 24: ...n device is not connected Reverse or open phase wiring for the outdoor unit s power terminal block L1 L2 L3 Incorrect wiring between indoor and outdoor units incorrect polarity of S1 S2 S3 Remote controller wire short Note Operation is not possible for about 30 seconds after cancellation of function selection Correct operation For description of each LED LED1 2 3 provided on the indoor controller ...

Page 25: ...cs refer to P1 above 2 Check contact failure of connector CN44 on the indoor controller board Refer to 10 7 Turn the power on and check restart after inserting connector again 4 Check pipe liquid temperature with remote controller in test run mode If pipe liquid temperature is extremely low in cooling mode or high in heating mode refrigerant circuit may have defective 5 Check pipe liquid temperatu...

Page 26: ...range 4 Defective indoor fan motor Fan motor is defective Indoor controller board is defec tive 5 Defective outdoor fan control 6 Overcharge of refrigerant 7 Defective refrigerant circuit clogs 8 Bypass circuit of outdoor unit is defective Cooling or drying mode 1 Check clogs of the filter 2 Remove blockage 4 Refer to 10 6 5 Check outdoor fan motor 67 Check operating condition of refrigerant circu...

Page 27: ...ecting remote control ler max 2 units When it is not the above mentioned problem of 1 3 4 Diagnose remote controllers a When RC OK is displayed Remote controllers have no problem Turn the power off and on again to check If abnormality generates again replace indoor controller board b When RC NG is displayed Replace remote controller c When RC E3 or ERC 00 66 is dis played noise may be causing abno...

Page 28: ...Indoor controller board Abnormal if data cannot be read normally from the nonvolatile memory of the indoor controller board 1 Defective indoor controller board 1 Replace indoor controller board The check code in the parenthesis indicates PAR 30MAA model Remote controller control board 1 Abnormal if data cannot be read nor mally from the nonvolatile memory of the remote controller control board Err...

Page 29: ...n of 4 way valve 2 Disconnection of or leakage in refrigerant pipes 3 Air into refrigerant piping 4 Abnormal operation no rotation of indoor fan Defective fan motor Defective indoor control board 5 Defective refrigerant circuit clogging 1 When this error occurs be sure to replace the 4 way valve 2 Check refrigerant pipes for disconnection or leakage 3 After the recovery of refrigerant vacuum dry t...

Page 30: ...k S1 and S2 When AC 220 240V is not detected check indoor outdoor unit connecting wire for miswiring When AC 220 240V is detected check 4 below 4 Check the fuse on indoor controller board Check the wiring connection If no problem are found indoor controller board is defective 1 Check the voltage of indoor power supply terminal block L N When AC220 240V is not detected check the power supply wiring...

Page 31: ...ntroller Check indoor outdoor unit connecting wire for connection failure 1 Check the connection of remote controller wires in case of twin triple indoor unit system When 2 or more indoor units are wired in one refrigerant system connect remote controller wires to one of those units 2 Check the setting of refrigerant address in case of grouping control system If there are some units whose refriger...

Page 32: ... function it is possible to activate emergency operation by using the indoor unit emergency operation switch SW1 SW2 of the wireless signal receiver board However if the indoor unit microprocessor has failed it is necessary to proceed with points 2 and 3 below as in the case of the wired remote controller 2 When you activate emergency operation of the cooling or heating you have to set the switch ...

Page 33: ...ort Other than short Measure the resistance between the terminals with a tester At the ambient temperature of 20 C 30 C Vane motor MV Abnormal Open or short Red Yellow Red Blue Red Orange Red White Connector Normal 300Ω 2 1 Moving part 4 3 Switch Magnet Moving part Yellow Blue Red Orange White MV PCA RP35KAQ PCA RP50KAQ PCA RP60KAQ PCA RP71KAQ PCA RP100KAQ PCA RP125KAQ PCA RP140KAQ PCA RP50KAQR1 P...

Page 34: ...connector VDC DC310 340V TEST POINT VCC between 5 and 4 of the fan connector VCC DC15V Wiring recovery Replace the indoor controller board Replace the fan motor Replace the indoor controller board Replace the fan motor Is the voltage normal Is there contact failure No Yes No Check the operation of fan END Yes OK Check the operation END OK Check method of DC fan motor fan motor indoor controller ci...

Page 35: ...oor CNP Drain pump output DP 220 240V AC option CN01 Connect to the Terminal Block TB4 Indoor outdoor connecting line Between and 220 240V AC CNV Vane motor output MV 12V pulse output SWE Emergency operation Jumper wire J41 J42 Pair No setting for wireless remote controller FUSE 6 3A 250V CNMF Fan motor DC 310 340V DC15V DC0 6 5V Stop Dc0 or 15V Operation DC7 5V 0 15V pulse VSP Voltage between pin...

Page 36: ...nnected There is no jumper JP1 because these models have the cond eva temperature thermistor TH5 Marks in the table below Jumper wire Short Open Without TH5 With TH5 Model JP1 For product Service parts Indoor controller board type JP3 1 2 3 4 5 ON OFF Service board MODELS PCA RP50KAQ PCA RP35KAQ 1 2 3 4 5 ON OFF 1 2 3 4 5 ON OFF PCA RP60KAQ 1 2 3 4 5 ON OFF PCA RP71KAQ 1 2 3 4 5 ON OFF PCA RP100KA...

Page 37: ...ernately according to the interval of rotation setting Main and sub unit should be set by refrigerant address Outdoor Dip switch setting Refrigerant address 00 Main unit Refrigerant address 01 Sub unit When error occurs to one unit another unit will start operation Back up function System constraint This function is available only by the grouping control system INDOOR UNIT OUTDOOR UNIT 1 1 of 2 re...

Page 38: ...FF Monitoring the request code of current setting Setting contents Rotation ON Alternating interval 28days and back up function Rotation ON Alternating interval 14days and back up function Rotation ON Alternating interval 1day and back up function Back up function only No 5 324 Rotation ON Alternating interval 7days and back up function Rotation ON Alternating interval 5days and back up function R...

Page 39: ... button and press the button Set the Refrigerant address and Request code Select the item to be changed with the F1 or F2 button Select the required setting with the F3 or F4 button Select the required code No 311 318 321 324 with the F3 or F4 button Ref address setting 0 15 Request code setting Press the button Data will be collected and displayed Request code 311 Rotation and Back up OFF 0311 Se...

Page 40: ...4 button 8 Press the F3 or F4 button to set the Refrigerant address 0 9 Press the F3 or F4 button to set the desired request code No Rotation Back up operation Please match request code with 311 318 either 2nd stage cut in operation Please match request code with 321 324 either 0 Press the button Data will be collected and displayed 1 Press the F3 or F4 button to set the Refrigerant address 1 Plea...

Page 41: ...al box and pull the electrical box downward Temporarily secure the electrical box using 2 hooks in the back of electrical box 5 Disconnect the connectors on the indoor controller board Removing the electrical box 6 Disconnect the wires from the terminal blocks and pull out the electrical box See Photo 2 Removing the indoor controller board 6 Remove the 6 supports from the indoor controller board a...

Page 42: ...ver and remove the electrical cover 4 Remove 2 screws from the electrical box and pull the electrical box downward 5 Temporarily secure the electrical box using 2 hooks in the back of electrical box 6 Remove 4 screws fixing fan guard of the fan motor 2 screws See Photo 5 2 screws Upper the electrical box 7 Remove 2 screws fixing fan guard of piping side and remove the fan guard See Photo 6 8 Remov...

Page 43: ...ve 4 screws from the fan guard of the fan motor See Photo 5 6 Remove 2 screws from the left side beam and remove the beam See Photo 1 7 Remove the 3 screws from center fan guard and remove the fan guard 2 screws See Photo 9 1 screw Drain pan side 8 Remove 2 screws from the left fan guard and remove the fan guard See Photo 10 9 Loosen 2 set screws 2 hexagon set screws of connect ing joint See Photo...

Page 44: ...right side panel See Figure 3 4 3 Remove the connector of vane motor 4 Remove 2 screws of vane motor cover then remove vane motor Photo 13 Screws Connector Vane motor and cover Photo 14 Under panel fixing screws 9 Removing the drain pan 1 Remove the air intake grille See Figure 1 2 2 Remove the side panel right and left See Figure 3 4 3 Remove the under panel See Photo 14 Remove the screws of the ...

Page 45: ... vane 10 Removing the thermistors Liquid pipe TH2 and con denser evaporator TH5 1 Remove the air intake grille See Figure 1 2 2 Remove the left and right side panels See Figure 3 4 3 Remove the under panel See Photo 14 4 Remove the drain pan See Photo 15 16 17 5 Disconnect the connector CN44 white from the indoor controller board 6 Remove 6 screws from the pipe cover and remove the pipe cover See ...

Page 46: ...from each holder See Photo 19 10 Remove the pipe band fixing screw and remove the pipe band See Photo 22 11 Remove 2 screws from the heat exchanger and remove the heat exchanger Photo 22 Pipe band fixing screw Pipe band Heat exchanger fixing screws Heat exchanger Vane Photo 23 Heat exchanger CCopyright 2010 MITSUBISHI ELECTRIC CORPORATION Distributed in Oct 2012 No OCH491 REVISED EDITION B Distrib...

Page 47: ...l Number PCA RP140BA PCA RP35 140KAQ Installation Manual PCA RP35 140KAQ Parts Catalogue OCB491A PCA RP35 140KAQ Service Manual OCH491 PCA RP50 140KAQ Instruction Book BG79U612H03 PCA RP125 140 Declaration of Conformity ...

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