Mitsubishi Electric PCA-A24KA4, PCA-A30KA4, PCA-A36KA4, PCA-A42KA4 Service Manual

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

SERVICE MANUAL

Indoor unit
[Model names] [Service Ref.]

PCA-A24KA4

PCA-A30KA4

PCA-A36KA4

PCA-A24KA4
PCA-A30KA4
PCA-A36KA4

November 2010

No. OCH484

NOTE:

• This manual describes only
service data of the indoor
units.

• RoHS compliant products
have <G> mark on the
spec name plate.

PCA-A42KA4

PCA-A42KA4

INDOOR UNIT

COOL

DRY

AUTO

FAN

HEAT

Model name
indication

CONTENTS

1. REFERENCE MANUAL

2. SAFETY PRECAUTION

3. PART NAMES AND FUNCTIONS

4. SPECIFICATIONS

5. NOISE CRITERION CURVES

6. OUTLINES AND DIMENSIONS

7. WIRING DIAGRAM

8. REFRIGERANT SYSTEM DIAGRAM

9. TROUBLESHOOTING

10. SPECIAL FUNCTION

11. DISASSEMBLY PROCEDURE

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PARTS CATALOG (OCB484)

............

10
12

13

14

28

31

2
3

4
7
9

TEMP.

ON/OFF

WIRED REMOTE

CONTROLLER

(Option)

IR WIRELESS REMOTE
CONTROLLER (Option)

33223

1

REFERENCE MANUAL

OUTDOOR UNIT’S SERVICE MANUAL

Model name Service Ref. Service Manual No.

PUZ-A18/24/30/36/42NHA4 PUZ-A18/24/30/36/42NHA4

PUZ-A18/24/30/36/42NHA4-BS PUZ-A18/24/30/36/42NHA4-BS

PUY-A18/24/30/36/42NHA4 PUY-A18/24/30/36/42NHA4

PUY-A18/24/30/36/42NHA4-BS PUY-A18/24/30/36/42NHA4-BS

Remote controller (Optional parts)

Radio frequency interface Wired remote controller IR wireless remote controller

OCH481

OCB481

COOL

DRY

AUTO

FAN

HEAT

RF thermostat

TEMP.

ON/OFF

2

2

SAFETY PRECAUTION

2-1. ALWAYS OBSERVE FOR SAFETY

Before obtaining access to terminal, all supply
circuits must be disconnected.

2-2. CAUTIONS RELATED TO NEW REFRIGERANT

Cautions for units utilising refrigerant R410A

Use new refrigerant pipes.

Make sure that the inside and outside of refrige­rant piping is clean and it has no contaminants
such as sulfur, oxides, dirt, shaving particles, etc,
which are hazards to refrigerant cycle.
In addition, use pipes with specified thickness.

Contamination inside refrigerant piping can cause deterio­ration of refrigerant oil etc.

Store the piping to be used indoors during
installation, and keep both ends of the piping
sealed until just before brazing. (Leave elbow
joints, etc. in their packaging.)

If dirt, dust or moisture enters into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com­pressor.

The refrigerant oil applied to flare and flange
connections must be ester oil, ether oil or
alkylbenzene oil in a small amount.

If large amount of mineral oil enters, that can cause deterio­ration of refrigerant oil etc.

Do not use refrigerant other than R410A.

If other refrigerant (R22 etc.) is used, chlorine in refrige­rant can cause deterioration of refrigerant oil etc.

Use a vacuum pump with a reverse flow check
valve.

Vacuum pump oil may flow back into refrigerant cycle and
that can cause deterioration of refrigerant oil etc.

Use the following tools specifically designed for
use with R410A refrigerant.

The following tools are necessary to use R410A refrigerant.

Tools for R410A
Gauge manifold
Charge hose

Gas leak detector

Torque wrench

Flare tool
Size adjustment gauge
Vacuum pump adaptor

Electronic refrigerant
charging scale

Handle tools with care.

If dirt, dust or moisture enters into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com­pressor.

Charge refrigerant from liquid phase of gas
cylinder.

If the refrigerant is charged from gas phase, composition
change may occur in refrigerant and the efficiency will be
lowered.

[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 performing service, install a filter drier simultaneously.
Be sure to use a filter drier for new refrigerant.

Do not use a charging cylinder.

If a charging cylinder is used, the composition of refrigera­nt will change and the efficiency will be lowered.

Ventilate the room if refrigerant leaks during
operation. If refrigerant comes into contact with
a flame, poisonous gases will be released.

3

[2] Additional refrigerant charge

When charging directly from cylinder

· Check that cylinder for R410A on the market is syphon type.

· Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.)

Unit

Gravimeter

[3] Service tools

Use the below service tools as exclusive tools for R407C refrigerant.

No. Tool name Specifications

Gauge manifold · Only for R410A

1

· Use the existing fitting

· Use high-tension side pressure of 5.3MPa·G or over.

Charge hose · Only for R410A

2

· Use pressure performance of 5.09MPa·G or over.

Electronic scale

3

Gas leak detector

4

Adaptor for reverse flow check

5

Refrigerant charge base

6

Refrigerant cylinder · Only for R410A · Top of cylinder (Pink)

7

Refrigerant recovery equipment

8

· Use the detector for R134a, R407C or R410A.

· Attach on vacuum pump.

· Cylinder with syphon

specifications

—

—

—

. (UNF1/2)

3

PART NAMES AND FUNCTIONS

Indoor Unit

Air outlet

Vane

4

Louver

Air intake

Filter
(Inside of Air intake)

Wired remote controller (Option)

Display Section

For purposes of this explanation,
all parts of the display are shown
as lit. During actual operation, only
the relevant items will be lit.

Identifies the current operation

Shows the operating mode, etc.
*Multilanguage display is available.

“Centrally Controlled” indicator

Indicates that operation from the
remote controller has been prohib­ited by a master controller.

“Timer is Off” indicator

Indicates that the timer is off.

Temperature Setting

Shows the target temperature.

Day-of-Week

Shows the current day of the week.

Time/Timer Display

Shows the current time, unless the simple or Auto Off
timer is set.
If the simple or Auto Off timer is set, the time to be
switched off is shown.

Up/Down Air Direction indica­tor

The indicator shows the direc­tion of the outcoming airflow.

“One Hour Only” indicator

Displays if the airflow is set to
Low or downward during COOL
or DRY mode. (Operation varies
according to model.)
The indicator goes off in one hour,
at which time the airflow direction
also changes.

TIME SUN MON TUE WED THU FRI SAT
TIMER

AFTER

ERROR CODE

°F°C

ONLY1Hr.

ON

Hr

OFF

AFTER

°F°C

FUNCTION

FILTER

WEEKLY

SIMPLE

AUTO OFF

Room Temperature display

Shows the room temperature. The room
temperature 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.

“Sensor” indication

Displayed when the remote controller
sensor is used.

“Locked” indicator

Indicates that remote controller but­tons have been locked.

“Clean The Filter” indicator

To be displays on when it is time to
clean the filter.

Timer indicators

The indicator comes on if the corre­sponding timer is set.

Fan Speed indicator

Shows the selected fan speed.

Ventilation indicator

Appears when the unit is running in
Ventilation mode.

Operation Section

Temperature setting buttons

Down

Up

Timer Menu button
(Monitor/Set button)

Mode button (Return button)

Set Time buttons

Back

Timer On/Off button
(Set Day button)

Opening the
cover

Note:

●

“PLEASE WAIT” message

Ahead

TEMP.

MENU

BACK DAY

MONITOR/SET

PAR-21MAA

CLOCK

ON/OFF

OPERATION

ON/OFF

FILTER

CHECK

TEST

CLEAR

Built-in temperature sensor

This message is displayed for approximately 3 minutes when power is supplied to the indoor unit or when the unit is recovering from a power failure.

●

“NOT AVAILABLE” message
This message is displayed if an invalid button is pressed (to operate a function that the indoor unit does not have).
If a single remote controller is used to operate multiple indoor units simultaneously that are different types, this message will not be displayed as
far as any of the indoor units is equipped with the function.

ON/OFF button

Fan Speed button

Filter button
(<Enter> button)

Test Run button

Check button (Clear button)

Airflow Up/Down button

Louver button
( Operation button)

To return operation
number

Ventilation button
( Operation button)

To go to next operation
number

5

IR wireless remote controller (Option)

CHECK

TEST RUN

Indicate that the unit is being checked or
test-run.

MODEL SELECT

Blinks when model is selected.

display

display

display

Lights up while the signal is transmitted to
the indoor unit when the button is pressed.

Temperature setting display

Indicates the desired temperature setting
which is set.

OPERATION MODE display

OPERATION MODE display
Indicates which operation mode is in effect.

display

The vertical direction of airflow is indicated.

display

Displays selected fan speed.

ON/OFF button

The unit is turned ON and OFF alternately

each time the button is pressed.

FAN SPEED SELECT button

Changes the fan speed.

MODE SELECT button

Switches the operation mode between
COOLING/DRY/FAN/HEATING and AUTO
mode.

+In case the outdoor unit is cooling only

type, the heating and auto mode are not
available.

COOL

DRY

AUTO

FAN

HEAT

RUN

MODEL
SELECT

FAN

SWING

NOT AVAILABLE

TEST

CHECK

ON/OFF TEMP

FAN

MODE

CHECK

VAN E

LOUVER

TEST RUN

RESETSET CLOCK

°F
°C

AMPMSTOP

AMPM

START

AUTO STOP

AUTO START

min

CLOCK display

Displays the current time.

TIMER display

Displays when in timer operation or when
setting timer.

“” “ ” display

Displays the order of timer operation.

“ ” “ ” display

Displays whether timer is on or off.

button

Sets any desired room temperature.

TIMER CONTROL buttons

h

AUTO STOP (OFF timer): when this switch
is set, the air conditioner will be
autom aticall y stopped at the preset time.
AUTO START (ON timer): when this switch is
set, the air conditioner will be automatically
started at the preset time.

"h" and "min" buttons

Buttons used to set the “hour and minute” of
the current time and timer settings.

CHECK-TEST RUN button

Performs an inspection check or test
operation. Do not use it for normal
operation.

VANE CONTROL button

Changes the air flow direction.

LOUVER button

Changes left / right airflow direction.

(Not available for this model.)

CLOCK button

RESET button

SET button

6

4

SPECIFICATIONS

Service Ref.

Power supply(phase, cycle, voltage)

External finish
Heat exchanger
Fan Fan(drive) % No.

INDOOR UNIT

Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Field drain pipe O.D.
Dimensions

Weight

Service Ref.

Power supply(phase, cycle, voltage)

External finish
Heat exchanger
Fan Fan(drive) % No.

INDOOR UNIT

Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Field drain pipe O.D.
Dimensions

Weight

Max. Fuse Size
Min.Circuit Ampacity

Fan motor output
Fan motor

Airflow(Low-Medium2-Medium1-High)

External static pressure

W

D
H

Max. Fuse Size
Min.Circuit Ampacity

Fan motor output
Fan motor

Airflow(Low-Medium2-Medium1-High)

External static pressure

W

D
H

A
A

kW

F.L.A

3

/min(CFM)

m

Pa(mmAq)

dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)

kg(lbs)

A

A

kW

F.L.A

*/min(CFM)

Pa(mmAq)

dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)

kg(lbs)

PCA-A24KA4

1 phase, 60Hz, 208/230V

15

1

White Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) % 3

0.095

0.54

Dry: 15-16-17-19(530-565-600-670)

Wet: 14-15-16-18(495-530-565-635)

0(direct blow)

Remote controller & built-in

33-35-37-40

26(1-1/32)

1,280(50-3/8)

680(26-3/4)
230(9-1/16)

32(71)

PCA-A30KA4

1 phase, 60Hz, 208/230V

15

1

White Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) % 3

0.095

0.54
Dry: 16-17-18-20(565-600-635-705)
Wet:15-16-17-19(530-565-600-670)

0(direct blow)

Remote controller & built-in

35-37-39-41

26(1-1/32)

1,280(50-3/8)

680(26-3/4)
230(9-1/16)

32(71)

Service Ref.

Power supply(phase, cycle, voltage)

External finish
Heat exchanger
Fan Fan(drive) % No.

INDOOR UNIT

Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Field drain pipe O.D.
Dimensions

Weight

Max. Fuse Size
Min.Circuit Ampacity

Fan motor output
Fan motor

Airflow(Low-Medium2-Medium1-High)

External static pressure

W

D
H

A
A

kW

F.L.A

*/min(CFM)

Pa(mmAq)

dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)

kg(lbs)

PCA-A36KA4

1 phase, 60Hz, 208/230V

15

2

White Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) % 4

0.160

0.97
Dry: 22-24-26-28(775-850-920-990)
Wet:20-22-24-26(705-775-850-920)

0(direct blow)

Remote controller & built-in

37-39-41-43

26(1-1/32)

1,600(63)
680(26-3/4)
230(9-1/16)

36(79)

7

Service Ref.

Power supply(phase, cycle, voltage)

External finish
Heat exchanger
Fan Fan(drive) % No.

INDOOR UNIT

Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Field drain pipe O.D.
Dimensions

Weight

Max. Fuse Size
Min.Circuit Ampacity

Fan motor output
Fan motor

Airflow(Low-Medium2-Medium1-High)

External static pressure

W
D
H

A
A

kW

F.L.A

*/min(CFM)

Pa(mmAq)

dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)

kg(lbs)

PCA-A42KA4

1 phase, 60Hz, 208/230V

15

2

White Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) % 4

0.160

0.97
Dry: 23-25-27-29(810-885-955-1025)
Wet: 21-23-25-27(740-810-885-955)

0(direct blow)

Remote controller & built-in

39-41-43-45

26(1-1/32)
1,600(63)

680(26-3/4)

230(9-1/16)

38(84)

8

NOISE CRITERION CURVES5

NOTCH

PCA-A24KA4 PCA-A30KA4

SPL(dB)

High
Medium1
Medium2

Low

90

80

70

60

50

40

30

OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 bar)

PCA-A36KA4

APPROXIMATE

20

THRESHOLD OF
HEARING FOR
CONTINUOUS
NOISE

10

63 125 250 500 1000 2000 4000 8000

BAND CENTER FREQUENCIES, Hz

NOTCH

High

SPL(dB)

Medium1
Medium2

Low

90

LINE
40
37
35
33

90

80

OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 bar)

70

60

50

40

30

APPROXIMATE

20

THRESHOLD OF
HEARING FOR
CONTINUOUS
NOISE

10

63 125 250 500 1000 2000 4000 8000

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

LINE

43

PCA-A42KA4

41
39
37

90

NOTCH

High
Medium1
Medium2

Low

BAND CENTER FREQUENCIES, Hz

NOTCH

High
Medium1
Medium2

Low

SPL(dB)

41
39
37
35

SPL(dB)

45
43
41
39

LINE

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

LINE

OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 bar)

80

70

60

50

40

30

APPROXIMATE

20

THRESHOLD OF
HEARING FOR
CONTINUOUS
NOISE

10

63 125 250 500 1000 2000 4000 8000

BAND CENTER FREQUENCIES, Hz

3.3ft

3.3ft
about 4.62ft

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 bar)

80

70

60

50

40

30

APPROXIMATE

20

THRESHOLD OF
HEARING FOR
CONTINUOUS
NOISE

10

63 125 250 500 1000 2000 4000 8000

BAND CENTER FREQUENCIES, Hz

ceiling

unit

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

MICROPHONE

9

OUTLINES AND DIMENTIONS6

PCA-A24KA4 PCA-A30KA4 Unit: inch (mm)

Drainage

liquid Φ3/8(Φ9.52)

gas Φ5/8(Φ15.88)

When drain socket

is installed

9-5/16(236)

7-7/8(200)

9-3/16(233)

9-11/16(246)

7-1/16(180)

Emergency operation

switch <Heating>

DEFROST/STAND BY lamp

Operation lamp

Receiver

In case of wireless remote controller

and i-see sensor(Optional Parts)

Emergency operation

switch <Cooling>

2-1/4(57)

i-see sensor

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.

26-3/4(680)

18-3/4(476)

10(254)

6

2-7/16(62)

3-1/8(80)

12-5/8(320)

26-3/4(680)

2(51)

3/8(10)

3/16(5)

14

9/16

In case of wireless

remote controller

and i-see sensor

9-1/16(230)

7-11/16(195)

3-7/16(88)

3-5/16(84)

(Optional Parts)

3-3/8(85)

5-1/2(140)

11/16(18)

5-7/8(150)

48-11/16(1237) (Suspension bolt pitch)

46-3/16(1173)

7-3/16(182)

47-3/16(1198)

Air outlet

4-15/16(126)

1/16(1)

7-1/12(190)

1-7/16(37)

1/16(2) 1/16(2)50-3/8(1280)

Air intake

4

3-3/8(85)

10-1/4(260)

1/16(2)

3-3/8(86)

120°

Ceiling

3(76)

5-7/16(138)

11/16(18)

1-1/2(38)

15/16(Φ125)

Φ4-

4-3/4(121)

4-7/8(124)

15-1/4(387)

7

7

8

8

18-1/8(461)

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

1-7/8(48)5/16(8)

position.(The heat exchanger might be clogged because of dust)

When drain socket

2

Drainage

is installed

9-11/16(246)

9-3/16(233)

1

5

[FRONT VIEW]

3

Electrical box

7-1/2(190)

2-15/16(75)

2

When electrical box

1-13/16(46)

is pulled down

Electrical box

1010

Drainage pipe connection(1(26mm)I.D.)

Drainage pipe connection(for the left arrangement)

Knockout hole for left drain-piping arrangement

Refrigerant-pipe connection(gas pipe side/flared connection)

Refrigerant-pipe connection(liquid pipe side/flared connection)

Knockout hole for upper drain pipe arrangement

Knockout hole for fresh air intake Φ3-15/16(Φ100)

Knockout hole for wiring arrangement Φ7/8(Φ22)

3

214

5

6

Accessory...Drain socket (1(26mm) I.D.)

8

7

PCA-A36KA4 PCA-A42KA4 Unit: inch (mm)

Drainage

When drain socket

is installed

gas Φ5/8(Φ15.88)

liquid Φ3/8(Φ9.52)

9-5/16(236)

9-3/16(233)

7-7/8(200)

7-1/16(180)

2(51)

3/8(10)

80

3-1/8

62

2-7/165-1/2

6

26-3/4(680)

12-5/8(320)

3/16(5)

1/16(2)

9-1/16(230)

9-11/16(246)

14

9/16

In case of wireless

remote controller

and i-see sensor

(Optional Parts)

7-11/16(195)

3-7/16(88)

3-5/16(84)

85

Emergency operation

switch <Heating>

DEFROST/STAND BY lamp

Operation lamp

Receiver

In case of wireless remote controller

and i-see sensor(Optional Parts)

Emergency operation

switch <Cooling>

57

2-1/4

26-3/4(680)

18-3/4(476)

10(254)

Air intake

140

11/16(18)

5-7/8(150)

61-5/16(1557) (Suspension bolt pitch)

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.

4-15/16(126)

1/16(1)

4

3-3/8(85)

10-1/4(260)

1/16(2)

3-3/8(86)

1

1

5

120°

7-1/2(190)

5-7/16(138)

11/16(18)

Φ125)

1-7/16(37)

1-1/2(38)

Φ4-15/16(

4-3/4(121)

15-1/4(387)

7

8

18-1/8(461)

Ceiling

3(76)

[FRONT VIEW]

4-7/8(124)

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)

58-3/4(1493)

1/16(2) 63(1600)

Electrical box

1-7/8(48)5/16(8)

Air outlet

Drainage

When drain socket

is installed

9-11/16(246)

9-3/16(233)

2

182

7-3/16 3-3/8

59-3/4(1518)

Knockout hole for upper drain pipe arrangement

Knockout hole for fresh air intake Φ3-15/16(Φ100)

Knockout hole for wiring arrangement Φ7/8(Φ22)

Drainage pipe connection(1(26mm)I.D.)

Drainage pipe connection(for the left arrangement)

Knockout hole for left drain-piping arrangement

Refrigerant-pipe connection

(gas pipe side/flared connection)

Refrigerant-pipe connection

(liquid pipe side/flared connection)

5

4

3

2

11

Accessory...Drain socket (1(26mm)I.D.)

8

7

6

Electrical box

3

7-1/2(190)

When electrical box

2-15/16(75)

2-15/16(75)

2

1-13/16(46)

is pulled down

1111