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SERVICE MANUAL

SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
SPLIT-TYPE, AIR CONDITIONERS

No. OCH491

INDOOR UNIT

CONTENTS

1. REFERENCE MANUAL................................... 2
2. SAFETY PRECAUTION................................... 3
  3. PART NAMES AND FUNCTIONS.................... 4
  4. SPECIFICATIONS............................................ 7
  5. NOISE CRITERION CURVES ...................... 10
6. OUTLINES AND DIMENSIONS..................... 12
7. WIRING DIAGRAM............................................. 15
  8. REFRIGERANT SYSTEM DIAGRAM............. 16
9. TROUBLESHOOTING................................... 17
10. SPECIAL FUNCTION..................................... 32
11. DISASSEMBLY PROCEDURE....................... 35

Indoor unit

[Model names]

[Service Ref.]

PCA-RP50KAQ

PCA-RP50KAQ

PCA-RP60KAQ

PCA-RP60KAQ

PCA-RP71KAQ

PCA-RP71KAQ

PCA-RP100KAQ

PCA-RP100KAQ

PCA-RP125KAQ

PCA-RP125KAQ

PCA-RP140KAQ

PCA-RP140KAQ

December 2010

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

ON/OFF

TEMP.

1
2
3
...
»

Содержание Mr.SLIM PCA-RP100KAQ

Страница 1: ...LESHOOTING 17 10 SPECIAL FUNCTION 32 11 DISASSEMBLY PROCEDURE 35 Indoor unit Model names Service Ref PCA RP50KAQ PCA RP50KAQ PCA RP60KAQ PCA RP60KAQ PCA RP71KAQ PCA RP71KAQ PCA RP100KAQ PCA RP100KAQ PCA RP125KAQ PCA RP125KAQ PCA RP140KAQ PCA RP140KAQ December 2010 NOTE This manual describes only service data of the indoor units RoHS compliant products have G mark on the spec name plate PARTS CATAL...

Страница 2: ...9 PUHZ P100 125 140VHA3R2 UK PUHZ P100 125 140YHAR1 UK OCH415 OCB415 PUHZ P200 250YHA3R2 OCH424 OCB424 SUZ KA50 60 71VA2 TH OCH472 SUZ KA50 60 71VA2 TH A OCH473 Series Outdoor unit Manual No SUZ KA VA OCS03 PUHZ RP HA4 PUHZ RP KA OCS16 PUHZ P VHA3 PUHZ P YHAR3 OCS17 Note The phrase Wired remote controller in this service manual refers only to the PAR 21MAA If you need any information for the PAR 3...

Страница 3: ...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 efficiency will be lowered Flare tool Electronic refrigeran...

Страница 4: ...or R410A Use the existing fitting specifications UNF1 2 Use high tension side pressure of 5 3MPa G or over 2 Charge hose Only for R410A Use pressure performance of 5 09MPa G or over 3 Electronic scale 4 Gas leak detector Use the detector for R134a R407C or R410A 5 Adaptor for reverse flow check Attach on vacuum pump 6 Refrigerant charge base 7 Refrigerant cylinder Only for R410A Top of cylinder Pi...

Страница 5: ...en in timer operation or when setting timer button Sets any desired room temperature CLOCK display Displays 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 displ...

Страница 6: ...erature display range is 46 102 F The display blinks if the temperature is less than 46 F or 102 F or more Louver display Indicates the action of the swing louver Does not appear if the louver is not running Power On indicator Indicates that the power is on Fan Speed indicator Shows the selected fan speed Ventilation indicator Appears when the unit is running in Ventilation mode Operation Section ...

Страница 7: ...13 16 680 26 3 4 230 9 1 16 25 55 PCA RP50KAQ 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 Wei...

Страница 8: ...g 0 11 0 76 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...

Страница 9: ...rve 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 duct system for...

Страница 10: ...D SOUND PRESSURE LEVEL dB 0 dB 0 0002 μbar BAND CENTER FREQUENCIES Hz 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 RP100GA PCA RP100GA 1 PCH P100GAH NOTCH High Medium1 Medium2 Low SPL dB 41 39 37 35 LINE 90 80...

Страница 11: ...B 0 dB 0 0002 μbar PCA RP140GA PCA RP140GA 1 PCH P140GAH NOTCH High Medium1 Medium2 Low SPL dB 45 43 41 39 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 40 NC 30 NC 20 NC 70 BAND CENTER FREQUENCIES Hz OCTAVE BAND SOUND PRESSURE LEVEL dB 0 dB 0 0002 μbar PCA RP140GA PCA RP140GA 1 PCH P140GAH NOTCH High Medium1...

Страница 12: ... connection 26mmI D Drainage pipe connection for the left arrangement Knock out 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 posit...

Страница 13: ...rts 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 32...

Страница 14: ... FRONT 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 clog...

Страница 15: ... 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 X1 FUSE 2 R B TB5 TRANSMISSION WIRES DC...

Страница 16: ...stor TH5 Room temperature thermistor 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 8 PCA RP50KAQ PCA RP60KAQ PCA RP71KAQ PCA RP100KAQ PCA RP125KAQ PCA RP140KAQ ...

Страница 17: ...oting by inferior phenomena 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 l...

Страница 18: ...MOTE CONTROLLER In case of trouble during operation When a malfunction occurs to air conditioner both indoor unit and outdoor unit will stop and operation lamp blinks to inform unusual stop ON OFF TEMP FAN VANE MODE CHECK LOUVER TEST RUN AUTO STOP AUTO START h min RESET SET CLOCK CHECK CHECK display Temperature button CHECK button Refrigerant address display HOUR button ON OFF button To be continu...

Страница 19: ...lashes Check code Number of times Wireless remote controller 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 ...

Страница 20: ...ction 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 control...

Страница 21: ...eristics refer to P1 above 2 Check contact failure of connector CN44 on the indoor controller board Refer to 9 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 temp...

Страница 22: ...rance 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 9 6 5 Check outdoor fan motor 67 Check operating condition of refrigerant ...

Страница 23: ...onnecting 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 a...

Страница 24: ...uit board to transmit signals 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 Remote controller control board 1 Abnormal if data cannot be read nor mally from the nonvolatile memory of the remote controller control board Error code E1 2 Abnormal if the c...

Страница 25: ...nal block 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 suppl...

Страница 26: ...e controller Check indoor outdoor unit connecting wire for connection failure 1 Check the connection of remote con troller 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 ref...

Страница 27: ...ot 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 switc...

Страница 28: ...Other than open UP Normal Open Short 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 PCA RP50KAQ PCA RP60KAQ PCA RP71KAQ PCA RP100KAQ PCA RP125KAQ PCA RP140K...

Страница 29: ...fan 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 controlle...

Страница 30: ...P 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 pins of C626 DC0V FAN stop DC1...

Страница 31: ...mper line is disco 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 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 ON OFF PCA RP60KAQ ON OFF PCA RP71KAQ 1 2 3 4 5 ON OFF P...

Страница 32: ...lternately according to the interval of rotation setting w 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 ...

Страница 33: ...ion OFF 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 funct...

Страница 34: ...ars on the screen when Maintenance monitor is activated The display now allows you to set a request code No 4 Press the TEMP and buttons to select the desired refrigerant address 5 Press the CLOCK and buttons to set the desired request code No 311 318 321 324 6 Press the button to perform function setting If above setting operations are done correctly Request code number will appear in data displa...

Страница 35: ... 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 and remove the indoor controller board See Photo 3 Figure 1 Photo 1 Photo 2 slide Air intake grille...

Страница 36: ...l cover 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 R...

Страница 37: ...Remove 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 P...

Страница 38: ...the 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 ...

Страница 39: ...uide 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 ...

Страница 40: ...hoto 1 3 Remove the electrical cover See Photo 1 4 Pull the electrical box downward See Photo 2 5 Remove the left and right side panels See Figure 3 6 Remove the under panel See Photo 14 7 Remove the drain pan See Photo 15 16 17 8 Remove the pipe cover See Photo 18 9 Remove the pipe thermistors TH2 and TH5 from each holder See Photo 19 10 Remove the pipe band fixing screw and remove the pipe band ...

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