Mitsubishi PKA-RP60KAL.TH, PKA-RP71KAL.TH, PKA-RP100KAL.TH Service Manual

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

SERVICE MANUAL

Indoor unit
[Model names] [Service Ref.]

PKA-RP60KAL

PKA-RP71KAL

PKA-RP100KAL

PKA-RP60KAL.TH
PKA-RP71KAL.TH

PKA-RP100KAL.TH

February 2009

No. OCH452

NOTE:

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

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

INDOOR UNIT

ON/OFF TEMP

WIRELESS REMOTE

CONTROLLER

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 (OCB452)

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2

3
4

6

7
8

9
10
11
26
29

1

REFERENCE MANUAL

OUTDOOR UNIT’S SERVICE MANUAL

Service Ref.

PUHZ-RP35/50/60/71VHA4
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

PUHZ-P200/250YHA3

PUHZ-HRP100VHA2
PUHZ-HRP100YHA2

Service Manual No.

OCH451
OCB451

OC379

OCH415/ OCB415

OCH424/ OCB424

OCH425/ OCB425

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.

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.)

3

Unit

Gravimeter

[3] Service tools

Use the below service tools as exclusive tools for R410A refrigerant.

No. Tool name 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)

3

PART NAMES AND FUNCTIONS

Indoor unit

Air inlet

Air outlet

Louver

Filter

Vane

Front grille

Emergency

switch

operation

4

Wireless remote controller

CHECK

TEST RUN

display

CHECK and TEST RUN display indicate that
the unit is being checked or test-run.

MODEL SELECT

Blinks when model is selected.

display

display

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

display

SET TEMP. display indicates the desired
temperature which is set.

display

OPERATION MODE display
Operation mode display indicates which
operation mode is in effect.

display

The vertical direction of air flow is indicated.

display

FAN SPEED display indicates which fan
speed has been selected.

ON/OFF button

The unit is turned ON and OFF alternately

each time the button is pressed.

FAN SPEED SELECT button

Used to change the fan speed.

MODE SELECT button

Used to switch the operation mode between
cooling, drying, heating, auto and fan mode.

CHECK

TEST RUN

MODEL SELECT

NOT AVAILABLE

ON/OFF TEMP

FAN

MODE

CHECK

VAN E

LOUVER

TEST RUN

RESETSET CLOCK

°C

AMPM

AMPM

AUTO STOP

AUTO START

h

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

SET TEMPERATURE button sets any desired
room temperature.

TIMER CONTROL buttons

AUTO STOP (OFF timer): when this switch
is set, the air conditioner will be

automatically 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

Only press this button to perform an
inspection check or test operation.
Do not use it for normal operation.

VANE CONTROL button

Used to change the air flow direction.

LOUVER button

Changes left/right airflow direction.

(Not available for this model.)

CLOCK button

RESET button

SET button

5

4

SPECIFICATIONS

Service Ref.

Mode
Power supply (phase, cycle, voltage)
Input
Running current
External finish (Panel)
Heat exchanger
Fan Fan (drive) % No.
Fan motor output
Airflow (Low-Middle-High)
External static pressure
Booster heater

INDOOR UNIT

Operation control & Thermostat
Noise level (Low-Middle-High)
Field drain pipe I.D.
Dimensions

Weight

Service Ref.

Mode
Power supply (phase, cycle, voltage)
Input
Running current
External finish (Panel)
Heat exchanger
Fan Fan (drive) % No.
Fan motor output
Airflow (Low-Middle-High)
External static pressure
Booster heater

INDOOR UNIT

Operation control & Thermostat
Noise level (Low-Middle-High)
Field drain pipe I.D.
Dimensions

Weight

*/min(CFM)

Pa(mmAq)

W

D
H

*/min(CFM)

Pa(mmAq)

W

D
H

kW

A

kW

kW

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

kg(lbs)

kW

A

kW

kW

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

kg(lbs)

Cooling

PKA-RP60KAL.TH

Single phase, 50Hz, 230V

0.06

0.43
Munsell 1.0Y 9.2/0.2

Plate fin coil

Line flow fan (direct) % 1

0.056

18-20-22(635-705-780)

0(direct blow)

–

Wireless remote controller & built-in

39-42-45

16 (5/8)

1,170 (46-1/16)

295 (11-5/8)

365 (14-3/8)

21 (46)

PKA-RP71KAL.TH

Cooling

Single phase, 50Hz, 230V

0.06

0.43
Munsell 1.0Y 9.2/0.2

Plate fin coil

Line flow fan (direct) % 1

0.056

18-20-22(635-705-780)

0(direct blow)

–

Wireless remote controller & built-in

39-42-45

16 (5/8)

1,170 (46-1/16)

295 (11-5/8)
365 (14-3/8)

21 (46)

Heating

0.05

0.36

Heating

0.05

0.36

Service Ref.

Mode
Power supply (phase, cycle, voltage)
Input
Running current
External finish (Panel)
Heat exchanger
Fan Fan (drive) % No.
Fan motor output
Airflow (Low-Middle-High)
External static pressure
Booster heater

INDOOR UNIT

Operation control & Thermostat
Noise level (Low-Middle-High)
Field drain pipe I.D.
Dimensions

Weight

*/min(CFM)

Pa(mmAq)

W

D
H

kW

A

kW

kW

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

kg(lbs)

Cooling

PKA-RP100KAL.TH

Single phase, 50Hz, 230V

0.08

0.57
Munsell 1.0Y 9.2/0.2

Plate fin coil

Line flow fan (direct) % 1

0.056

20-23-26(705-810-920)

0(direct blow)

–

Wireless remote controller & built-in

41-45-49

16(5/8)

1,170 (46-1/16)

295 (11-5/8)
365 (14-3/8)

21(46)

Heating

0.07

0.50

6

5

NOISE CRITERION CURVES

5-1. SOUND LEVELS

1.0m

PKA-RP60,71KAL,TH
PKA-RP100KAL,TH

Sound level at anechoic room : Low-Middle-High

Sound level dB (A)

39 - 42 - 45
41 - 45 - 49

Measurement location

* Measured in anechoic room.

1.0m

5-2. NOISE CRITERION CURVES

PKA-RP60,71KAL

External static pressure : 0Pa
Power source :

70.0

65.0

60.0

55.0

50.0

45.0

40.0

35.0

30.0

25.0

20.0

Approximate minimum
audible limit on

15.0

continuous noise

Octave band pressure level (dB) 0dB=20μPa

10.0
63 125 250 500 1k 2k 4k 8k

220, 230, 240V, 50Hz

High
Low

Octave band center frequencies (Hz)

NC-60

NC-50

NC-40

NC-30

NC-20

PKA-RP100KAL

External static pressure : 0Pa
Power source :

70.0

65.0

60.0

55.0

50.0

45.0

40.0

35.0

30.0

25.0

20.0

Approximate minimum
audible limit on

15.0

continuous noise

Octave band pressure level (dB) 0dB=20μPa

10.0
63 125 250 500 1k 2k 4k 8k

220, 230, 240V, 50Hz

High
Low

Octave band center frequencies (Hz)

NC-60

NC-50

NC-40

NC-30

NC-20

7

6

OUTLINES AND DIMENSIONS

PKA-RP60,71,100KAL.TH

65.2

140.3

11

Left side

Knockout hole
for left piping

53

32

A

30

18

35

66

365

Unit : mm

Top side

1170

431.7

444 (Gas pipe)

482 (Liquid pipe)

585 (Drain hose)

241

154

123

134

Right side

Operation lamp

Terminal block for outdoor unit

Terminal block for power supply (option)

Terminal block for

MA-remote controller (option)
Emergency operation switch
(cooling/heating)

295

DEFROST/STAND BY lamp

Receiver

Mount board

C

5

Knockout hole for
right piping

423.7

Front side

74

(855)

Front side (Grille open)

Filter hook

Sleeve
(purchased locally)

75

Through hole

75~

80

Knockout hole for piping

C

67

77

65

65

10.7

7.8

Required space (Indoor unit)

Under side

Vane (auto)

B

75-Φ5.1

BA

77

67

77

87

7.8

Air inlet

Tapping screw hole

65

Min. 48

108 mm or greater with left or
rear left piping or drain-up
mechanism installation

15.5

25

100

Louver (manual)

Knockout hole
for lower piping

0

50
75

117
125

142
192

242

279.5
292

585

4-Φ9 Bolt hole

439

454

517.4

439

530.5

430.5

Wall hole for
left rear piping

Temporarily fixing hole

314

364

384

408.5

384

339

B

110

60

189

Knockout hole for
left rear piping
(75×480)

Piping connection department

Liquid pipe

Gas pipe

Drain hose

0

01010

0

Refrigerant pipe : 9.52
Flared connection : 3/8F

Refrigerant pipe : 15.88
Flared connection : 5/8F

54

Center measurement hole Φ2.5

3

Mount board

110

60

314

R37.5

339

216.5

Wall hole for
right rear piping

16 O.D

364

349.2

384.5

384

408.5

Indoor unit outline

439

454

465.5

439

449.2

54
32
25

12.5

0

12.5

37.5

62.5

87.5

104.5

129.5
167

217

229.5

264
292

308.5
311

585

Min. 7

550 mm or greater with optional

265 mm or greater with optional

drain-up mechanism installation

drain-up mechanism installation

Air outlet

Min. 220Min. 72.4

Min. 50.5

Min. 250

8

7

WIRING DIAGRAM

PKA-RP60KAL.TH PKA-RP71KAL.TH PKA-RP100KAL.TH

[LEGEND]

SYMBOL SYMBOLNAME NAME

I.B

CN2L
CN32
CN41
CN51
CN90
DSA
FUSE
LED1
LED2
LED3
SW1
SW2
SWE
X1
ZNR01,02
CNP

CN4F

R.B

TB6

Indoor controller board
Connector (LOSSNAY)
Connector (Remote switch)
Connector (HA terminal-A)
Connector (Centrally control)
Connector (Remote operation adapter)
Surge absorber
FUSE (T3.15AL250V)
Power supply (I.B)
Power supply (R.B)
Transmission (Indoor-outdoor)
Switch (Model selection) +See table 1
Switch (Capacity code) +See table 2
Connector (Emergency operation)
Relay (Drain pump(option))
Var ist or
Drain pump (option) power supply
(Sold separately:Drain pump(option))
Drain float switch (Sold separately:Drain pump (option))
Wired remote controller
Terminal block (Remote controller transmission line)

MF

M
MS
S.W

SWE2
TB2
TB4
TB5
TH1

TH2

TH5

W.B

LED1

LED2

REC1
DCL

DP

FS

Vane motor
Fan motor
Switch board
Emergency operation
Terminal block (Indoor unit Power (option))
Terminal block (Indoor/outdoor connecting line)
Terminal block (Remote controller transmission line)
Room temp. Thermistor
(0 / 15k, 25 / 5. 4k Detect)
Pipe temp. Thermistor/liquid
(0 / 15k, 25 / 5. 4k Detect)
Cond. / eva. temp. Thermistor
(0 / 15k, 25 / 5. 4k Detect)

Pcb for wireless remote controller
LED (Operation indication : Green)
LED (Preparation for heating : Orange)
Receiving unit
REACTOR

DRAIN PUMP (OPTION)
DRAIN FLOAT SWITCH (OPTION)

+1(Fig. 1)

CN01

I.B

(BLK)

1
3
5

I.B

31

CN3C (BLU)

YLW
ORN

INDOOR/OUTDOOR

COMMUNICATION

RED

BLU

GRN/YLW

YLW
ORN
ORN
BRN

TB2

TB4

S1
S2
S3

L

N

Notes:

1. SymboIs used in wiring diagram above are, :Connector, : Terminal (block).

2. Indoor and outdoor connecting wires have poIarities, make sure to match terminal numbers
(S1, S2, S3) for correct wirings.

3. Since the outdoor side electric wiring may change, be sure to check the outdoor unit electric
wiring diagram for servicing.

4. This diagram shows the wiring of indoor and outdoor connecting wires.(specification of 230V),
adopting superimposed system of power and signal.
+1 When work to Supply power separately to indoor and outdoor units was applied,refer to Fig 1.
+2 For power supply system of this unit, refer to the caution label located near this diagram.

POWER SUPPLY
~(1PHASE)
230V 50Hz

TO OUTDOOR
UNIT

9

8

REFRIGERANT SYSTEM DIAGRAM

PKA-RP60KAL.TH PKA-RP71KAL.TH PKA-RP100KAL.TH

Strainer (#50)

Heat exchanger

Refrigerant GAS pipe connection
(Flare)

Thermistor TH5
(Cond./ Eva.temperature)

Thermistor TH1
(Room temperature)

Thermistor TH2
Pipe temperature(Liquid)

Distributor
with strainer (#50/#100)

Refrigerant flow in cooling
Refrigerant flow in heating

Refrigerant LIQUID pipe connection
(Flare)

Strainer (#50)

10