Mitsubishi PCA-RP50KA, PCA-RP60KA, PCA-RP71KA, PCA-RP100KA, PCA-RP125KA Service Manual

...

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

SERVICE MANUAL

Indoor unit [Model names] [Service Ref.]

PCA-RP50KA

PCA-RP60KA

PCA-RP71KA

PCA-RP50KA PCA-RP60KA PCA-RP71KA

March 2009

No. OCH454

NOTE:

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

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

PCA-RP100KA

PCA-RP125KA

PCA-RP140KA

INDOOR UNIT

PCA-RP100KA PCA-RP125KA PCA-RP140KA

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

WIRING DIAGRAM

REFRIGERANT SYSTEM DIAGRAM

9. TROUBLESHOOTING

10. SPECIAL FUNCTION

11. DISASSEMBLY PROCEDURE

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11 14

2 3

4 6 9

TEMP.

REMOTE CONTROLLER

ON/OFF

PARTS CATALOG (OCB454)

REFERENCE MANUAL

1-1. OUTDOOR UNIT’S SERVICE MANUAL

Service Ref. Service Manual No. PUHZ-RP50/60/71VHA4

PUHZ-RP100/125/140VKA PUHZ-RP100/125/140/200/250YKA

PU(H)-P71/100VHA#2.UK PU(H)-P71/100/125/140YHA#2.UK

PUHZ-P100/125/140VHA3.UK OCH415 / OCB415 PUHZ-P200/250YHA3 OCH424 / OCB424 PUHZ-RP71/100/140VHA2#1-A

PUHZ-BP100/125/140YHA2#1-A SUZ-KA50/60VAR2.TH

SUZ-KA71VA1.TH SUZ-KA500/60VAR2.TH-A

SUZ-KA71VA1.TH MXZ-8A140VA

OCH451 OCB451

OC379

OCH422 / OCB422

OC322

OC323 OC316

1-2. TECHNICAL DATA BOOK

Series (Outdoor unit) Manual No. SUZ-KA • V A OCS03

PUHZ-RP • HA2-A OCS09

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.

In case of using the existing pipes for R22, be careful with the followings.

· For RP100, 125 and 140, be sure to perform replace ment operation before test run.

· Change flare nut to the one provided with this product. Use a newly flared pipe.

· Avoid using thin pipes.

Make sure that the inside and outside of refrigerant piping is clean and it has no contamination such as sulfur hazardous for use, oxides, dirt, shaving particles, etc. 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.

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.

Use ester oil, ether oil or alkylbenzene oil (small amount) as the refrigerant oil applied to flares and flange connections.

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

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

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.

operation. If refrigerant comes into contact with a flame, poisonous gases will be released.

[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.

[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. Specifications 1 Gauge manifold · Only for R410A

· Use the existing fitting

· 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 (Pink)

· Cylinder with syphon 8 Refrigerant recovery equipment

specifications

. (UNF1/2)

PART NAMES AND FUNCTIONS

● Indoor Unit

Vane

Air outlet

Louver

Air intake

Filter (Inside of Air intake)

Wired remote controller

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.

TIME SUN MON TUE WED THU FRI SAT TIMER AFTER

ERROR CODE

°F°C

Hr AFTER

°F°C

ONLY1Hr.

Up/Down Air Direction indicator

The indicator shows the direction of the outcoming airflow.

“One Hour Only” indicator

Displayed 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.

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 louver is not running.

(Power On indicator)

Indicates that the power is on.

ON OFF

FUNCTION

FILTER

WEEKLY

SIMPLE

AUTO OFF

“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 displayed 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

Ahead

Timer On/Off button (Set Day button)

Opening the lid

Note:



“PLEASE WAIT” message

TEMP.

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 A V AILABLE” 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)

T o return operation number

Ventilation button ( Operation button)

To go to next operation number

SPECIFICATIONS

4-1. SPECIFICATIONS

Service Ref.

Mode Power supply(phase, cycle, voltage) Input Running current External finish Heat exchanger Fan Fan(drive) × No. Fan motor output

External static pressure Operation control & Thermostat

INDOOR UNIT

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

Weight

Service Ref.

Mode Power supply(phase, cycle, voltage) Input Running current External finish Heat exchanger Fan Fan(drive) × No. Fan motor output

External static pressure Operation control & Thermostat

INDOOR UNIT

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

Weight

Airflow(Low-Medium2-Medium1-High)

D H

Airflow(Low-Medium2-Medium1-High)

D H

*/min(CFM)

Pa(mmAq)

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

kg(lbs)

*/min(CFM)

Pa(mmAq)

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

kg(lbs)

Cooling

0.05

0.37

Cooling

0.06

0.39

PCA-RP50KA

Heating

Single phase, 50Hz, 230V

0.05

0.37

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) x 2

0.090

10-11-13-15(355-390-460-530)

0(direct blow)

Remote controller & built-in

32-34-37-40

26(1)

960(37-13/16)

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

25(55)

PCA-RP60KA

Heating

Single phase, 50Hz, 230V

0.06

0.39

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) x 3

0.095

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

0(direct blow)

Remote controller & built-in

33-35-37-40

26(1)

1,280(50-3/8)

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

32(71)

Service Ref.

Mode Power supply(phase, cycle, voltage) Input Running current External finish Heat exchanger Fan Fan(drive) × No. Fan motor output

External static pressure Operation control & Thermostat

INDOOR UNIT

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

Weight

Airflow(Low-Medium2-Medium1-High)

D H

*/min(CFM)

Pa(mmAq)

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

kg(lbs)

Cooling

0.06

0.42

PCA-RP71KA

Heating

Single phase, 50Hz, 230V

0.06

0.42

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) x 3

0.095

16-17-18-20(565-600-635-705)

0(direct blow)

Remote controller & built-in

35-37-39-41

26(1)

1,280(50-3/8)

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

32(71)

Service Ref.

Mode Power supply(phase, cycle, voltage) Input Running current External finish Heat exchanger Fan Fan(drive) × No. Fan motor output

External static pressure Operation control & Thermostat

INDOOR UNIT

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

Weight

Airflow(Low-Medium2-Medium1-High)

D H

*/min(CFM)

Pa(mmAq)

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

kg(lbs)

Cooling

0.09

0.65

PCA-RP100KA

Heating

Single phase, 50Hz, 230V

0.09

0.65

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) × 4

0.160

22-24-26-28(775-850-920-990)

0(direct blow)

Remote controller & built-in

37-39-41-43

26(1)

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

36(79)

Service Ref.

Mode Power supply(phase, cycle, voltage) Input Running current External finish Heat exchanger Fan Fan(drive) × No. Fan motor output

External static pressure Operation control & Thermostat

INDOOR UNIT

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

Weight

Service Ref.

Mode Power supply(phase, cycle, voltage) Input Running current External finish Heat exchanger Fan Fan(drive) × No. Fan motor output

External static pressure Operation control & Thermostat

INDOOR UNIT

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

Weight

Airflow(Low-Medium2-Medium1-High)

D H

Airflow(Low-Medium2-Medium1-High)

D H

*/min(CFM)

Pa(mmAq)

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

kg(lbs)

*/min(CFM)

Pa(mmAq)

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

kg(lbs)

Cooling

0.11

0.76

Cooling

0.14

0.90

PCA-RP125KA

Heating

Single phase, 50Hz, 230V

0.11

0.76

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) × 4

0.160

23-25-27-29(810-885-955-1025)

0(direct blow)

Remote controller & built-in

39-41-43-45

26(1)

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

38(84)

PCA-RP140KA

Heating

Single phase, 50Hz, 230V

0.14

0.90

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) × 4

0.160

24-26-29-32(850-920-1025-1130)

0(direct blow)

Remote controller & built-in

41-43-45-48

26(1)

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

39(86)

4-2. FRESH AIR INTAKE AMOUNT & STATIC PRESSURE CHARACTERISTICS



PCA-RP50KA

PCA-RP60, 71KA

50 0

-50

-100

-150

-200

-250

Static pressure[Pa]

-300 0 1 2 3 4

Airflow rate[m³/min]



PCA-RP100, 125, 140KA

50 0

-50

-100

-150

-200

-250

Static pressure[Pa]

-300 0 1 2 3 4

Airflow rate[m³/min]

50 0

-50

-100

-150

-200

-250

Static pressure[Pa]

-300 0 1 2 3 4

How to read curves

Duct characteristics at site

Curve in the graphs

Airflow rate[m³/min]

Q…Designed amount of fresh air intake

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 airflow amount Q <Pa>

E…Static pressure of indoor unit with

airflow amount Q <Pa>

Qa…Estimated amount of fresh air

intake without D <m

/min>

NOISE CRITERION CURVES5

PCA-RP50GA

PCA-RP50KA PCA-RP60KA

PCA-RP50GA#1 PCH-P50GAH

NOTCH

Medium1 Medium2

SPL(dB)

High

Low

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

APPROXIMATE

THRESHOLD OF HEARING FOR CONTINUOUS NOISE

63 125 250 500 1000 2000 4000 8000

BAND CENTER FREQUENCIES, Hz

LINE 40 37 34 32

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

APPROXIMATE

THRESHOLD OF HEARING FOR CONTINUOUS NOISE

63 125 250 500 1000 2000 4000 8000

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

NOTCH

High Medium1 Medium2

Low

BAND CENTER FREQUENCIES, Hz

SPL(dB)

40 37 35 33

LINE

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

PCA-RP100GA

PCA-RP71KA

PCA-RP100GA#1 PCH-P100GAH

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

APPROXIMATE

THRESHOLD OF HEARING FOR CONTINUOUS NOISE

63 125 250 500 1000 2000 4000 8000

NOTCH

High Medium1 Medium2

Low

BAND CENTER FREQUENCIES, Hz

SPL(dB)

41 39 37 35

LINE

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

PCA-RP125GA

PCA-RP100KA

PCA-RP125GA#1 PCH-P125GAH

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

APPROXIMATE

THRESHOLD OF HEARING FOR CONTINUOUS NOISE

63 125 250 500 1000 2000 4000 8000

NOTCH

High Medium1 Medium2

Low

BAND CENTER FREQUENCIES, Hz

SPL(dB)

43 41 39 37

LINE

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

PCA-RP125KA PCA-RP140KA

PCA-RP140GA PCA-RP140GA#1 PCH-P140GAH

NOTCH

High Medium1 Medium2

Low

SPL(dB)

45 43 41 39

LINE

PCA-RP140GA PCA-RP140GA#1 PCH-P140GAH

NOTCH

High Medium1 Medium2

Low

SPL(dB)

48 45 43 41

LINE

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

APPROXIMATE

THRESHOLD OF HEARING FOR CONTINUOUS NOISE

63 125 250 500 1000 2000 4000 8000

BAND CENTER FREQUENCIES, Hz

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

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

APPROXIMATE

THRESHOLD OF HEARING FOR CONTINUOUS NOISE

63 125 250 500 1000 2000 4000 8000

BAND CENTER FREQUENCIES, Hz

NC-70

NC-60

NC-50

NC-40

NC-30

NC-20

about 1.4m

MICROPHONE

ceiling

unit

OUTLINES AND DIMENTIONS6

PCA-RP50KA

62140

150

Unit : mm

When drain socket

is installed

(Drainage)

(gas ø12.7)

(liquid ø6.35)

184

203

233

246

drain lift up mechanism(option parts),

NOTES.

680

320

230

195

84 88

1.Use M10 or W3/8 screw for anchor bolt.

680

476

refrigerant pipe will be only upward.

2.Please be sure when installing the

254

182 85

917(Suspension bolt pitch)

85 86 2

26024

120°

[FRONT VIEW]

Electrical box

Ceiling

3 2

126

190

169

124 76

853

960 22

878

Air outlet

Air intake

138

387

121

(71)

ø125

461

When drain socket

is installed

(Drainage)

233

246

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)

Electrical box

is pulled down

When electrical box

1111

Drainage pipe 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)

Knock out hole for upper drain pipe arrangement

Knock out hole for fresh air intake ø100

Knock out hole for wiring arrangement 2-ø22

Knock out hole for wiring arrangement 2-ø26

234

678

Accessory···Drain socket (I.D. 26)

PCA-RP60, 71KA

180

179

200

203 B

236

When drain socket

(gas ø15.88)

(liquid )

233

is installed

(Drainage)

246

RP71

ø6.35

RP60

ø9.52

ø15.88

ø9.52

ø15.88

Unit : mm

320

62140

150

1237(Suspension bolt pitch)

680

5 LIQUID SIDE

230

195

84 88

1173

1280 22

NOTES.

drain lift up mechanism(option parts),

1.Use M10 or W3/8 screw for anchor bolt.

2.Please be sure when installing the

680

Available pipe size

refrigerant pipe will be only upward.

Use the current nuts meeting the pipe size of the outdoor unit.

476

254

182 85

:Initial flare nut size

4 GAS SIDE

1198

Air outlet

85 86 2

260

[FRONT VIEW]

Electrical box

120°

Ceiling

190 1

126

124 76

16937

190

138

387

(71)

121

ø125

461

When electrical box

is pulled down

When drain socket

is installed

(Drainage)

246

233

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)

Drainage pipe 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)

123

Electrical box

Air intake

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

Knock out hole for upper drain pipe arrangement

Knock out hole for fresh air intake ø100

Knock out hole for wiring arrangement 2-ø22

Knock out hole for wiring arrangement 2-ø26

Accessory···Drain socket (I.D. 26)

789

Flare nut ø6.35 (RP60 only)

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