Mitsubishi PKA-RP35HAL, PKA-RP50HAL Service Manual

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

SERVICE MANUAL

Indoor unit
[Model names] [Service Ref.]

PKA-RP35HAL

PKA-RP50HAL

PKA-RP35HAL
PKA-RP50HAL

March 2009

No. OCH453

NOTE:

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

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

INDOOR UNIT

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 (OCB453)

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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-HRP71/100VHA2
PUHZ-HRP100/125YHA2

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

Filter

Louver

Air outlet

Air intake

Vane

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-RP35HAL

Single phase, 50Hz, 230V

0.04

0.40
Munsell 1.0Y 9.2/0.2

Plate fin coil

Line flow fan (direct) % 1

0.030

9-10.5-12 (320-370-425)

0 (direct blow)

–

Wireless remote controller & built-in

36-40-43

16 (5/8)

898 (35-3/8)

249 (9-13/16)

295 (11-5/8)

13 (29)

PKA-RP50HAL

Cooling

Single phase, 50Hz, 230V

0.04

0.40
Munsell 1.0Y 9.2/0.2

Plate fin coil

Line flow fan (direct) % 1

0.030

9-10.5-12 (320-370-425)

0 (direct blow)

–

Wireless remote controller & built-in

36-40-43

16 (5/8)

898 (35-3/8)

249 (9-13/16)

295 (11-5/8)

13 (29)

Heating

0.03

0.30

Heating

0.03

0.30

6

5

A

)

NOISE CRITERION CURVES

5-1. SOUND LEVELS

1.0m

PKA-RP35, 50HAL

Sound level at anechoic room : Low-Middle-High

Sound level dB (A)

36 - 40 - 43

Measurement location

* Measured in anechoic room.

1.0m

5-2. NOISE CRITERION CURVES

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

70.0

65.0

60.0

55.0

50.0

45.0

40.0

35.0

30.0

25.0

20.0

15.0

pproximate minimum
audible limit on
continuous noise

High

NC-60

NC-50

NC-40

NC-30

NC-20

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

Octave band center frequencies(Hz

7

6

Min.7

250mm or greater with optional

drain pump installation.

Required space (Indoor unit)

Min.50

Min.220

Min.150

550mm or greater with optional

drain pump installation.

Min.250

Min.50

55mm or greater with left

or rear left pipng or drain

pump installation.

197

387

192

599

Top side

Front side

155

688

898

55

295

Front side (Grille open)

169

158

184

457 Gas pipe



539 Liquid pipe



610 Drain hose



Terminal block for outdoor unit

Terminal block for power supply (option)

Terminal block for

MA-remote controller (option)

Emergency operation switch

(cooling/heating)

Under side

Vane (auto)

Operation lamp

612

DEFROST/STAND BY lamp

Receiver

Knockout hole

for lower piping

Louver (manual)

Knockout hole

for lower piping

C

8

B

Size

Refrigerant pipe : :6.35

Flared connection : 1/4F

Refrigerant pipe : :12.7

Flared connection : 1/2F

:16 O.D



Liquid pipe



Gas pipe



Drain hose

Knockout hole

for right piping

Right side

Mount board

21.8020

32.7

53.5

66

128.5

153.5

231.5

273.2

449

281

193.5

180.3

278.3

167
140
115

0

174

213
238

394

449

253.5

232.5

203.5

178.5

166

103.5

91

78.5

116

41

28.5

16

0

372.3

356.3

327.5

291.5

265

225

200

125

70

15

0

15

70

125

200

225

265
238

291.5

327.5

372.3

356.3

Indoor unit outline

Mount board

4-:9 Bolt hole

77-:5.1

Tapping

screw hole

0

58

3.8

Center measurement hole :2.5

A

B

43

6

56
46

60

46

43

59

C

56

12.5

43

D

43

6

56

69

Knockout hole for piping

Knockout hole

for left piping

Left side

Sleeve

(purchased locally)

:65~:80

:65~:80

Through hole

249

A

5

PKA-RP35,50HAL

Unit : mm

OUTLINES AND DIMENSIONS

PKA-RP35HAL PKA-RP50HAL

8

7

WIRING DIAGRAM

PKA-RP35HAL PKA-RP50HAL

[Explanation of symbols]

Symbol

I.B Indoor controller board

CN2L Connector (LOSSNAY)
CN32 Connector ( Remote switch)
CN41 Connector (HA terminal-A)
CN51 Connector (Centrally control)
CN90 Connector (Remote operation adapter)
DSA Surge absorber
FUSE FUSE(T3.15AL250V)
LED1 Power supply (I.B)
LED2 Power supply (R.B)
LED3 Transmission (Indoor-outdoor)
SW1 Switch (Model selection) +See table 1
SW2

Switch (Capacity code) +See table 2
Connector (Emergency operation)

SWE
X1 Relay (Drain pump (option))
ZNR01,02

Var ist or
Drain pump (option) power supply

CNP

(Drain pump (option))

CN4F Drain float switch (Drain pump (option))

R.B

Wired remote controller(option)

TB6

Terminal block (Remote controller transmission line)

I.B

SWE

ON
OFF

Refer to
tables
1and 2

CN151
(WHT)

11

M

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 for power and signal.

+

1: When work to supply power separately for indoor and outdoor units apply, refer to Fig 1.

+

2: For power supply system of this unit, refer to the caution label located near this diagram.

Name

MS

CNMF

1

CN32

CN51

(WHT)

CN4F

(WHT)

ZNR01

ZNR02

X1

T11 DB1

LED1

LED3

LED2

CN90

(WHT)

11 1 5

2

CN2L

CN41

(RED)

(WHT)

CN20

CN44

(RED)

(WHT)

141425

○

t

t○t

TH1 TH2 TH5

1139

4

When attaching
drain pump(option),

○

remove the jumper
connector CN4F
and fit the drain
float switch (FS).

(WHT)

(WHT)

Symbol
M Vane motor
MS Fan motor
S.W

Switch board

SWE2 Emergency operation
TB2 Terminal block(Indoor unit Power (option))
TB4 Terminal block (Indoor/outdoor connecting line)

Terminal block (Remote controller transmission line(option))

TB5
TH1 Room temp. Thermistor

(0/15ΚΩ, 25/5.4ΚΩ Detect)

TH2

Pipe temp. Thermistor/liquid

(0/15ΚΩ, 25/5.4ΚΩ Detect)

TH5

Cond./eva. temp. Thermistor

(0/15ΚΩ, 25/5.4ΚΩ Detect)

W.B Pcb for wireless remote controller

LED1 LED (Operation indication : Green)

LED2 LED (Preparation for heating: Orange)

REC1 Receiving unit
DCL REACTOR

DRAIN PUMP (OPTION)

DP

DRAIN FLOAT SWITCH (OPTION)

FS

Name

3~

6

FUSE

U

CN01
(BLK)

U

DSA

3
1

CNP(BLU)

3

CN3C
(BLU)

1

LDSWE(A)

(BLU)

CNRU
(WHT)

1

CN22

(BLU)

2

When attaching drain
pump (option)

FLOAT SW

CN4F

(WHT)

DCL

1
3
5

YLW YLWYLW

ORN

BLK

DP

M
1~

ORN
BRN

W.B

6

LD101(B)

LED1

14

FS

ORN

2

RU

REC1

LED2

TB4

S1
S2
S3

S.W

LDSWE(B)

TO
OUTDOOR
UNIT

SWE2

+

1(Fig. 1)

CN01
(BLK)

1
3
5

I.B

CN3C(BLU)

<Table 1>
SW1
(MODEL SELECTION)

SETTING

12345

<Table 2>
SW2 (CAPACITY CODE)

MODELS

RP35

RP50

BLU

1

BLU

2

TB5

(OPTION PARTS)

I.B

YLW
ORN

GRN/YLW

INDOOR/OUTDOOR

3

1

COMMUNICATION

RED
BLU

YLW
ORN
ORN
BRN

R.B

TB6

TB2

TB4

S1

S2

S3

1

2

L

N

ON
OFF

SETTING

12345

12345

ON
OFF

ON
OFF

POWER SUPPLY
~(1PHASE)
230V 50Hz

TO OUTDOOR
UNIT

9

8

REFRIGERANT SYSTEM DIAGRAM

PKA-RP35HAL PKA-RP50HAL

Heat exchanger

Strainer (#50)

Refrigerant GAS pipe connection
(Flare)

Thermistor TH5
(Cond./ Eva.temperature)

Thermistor TH1
(Room temperature)

Thermistor TH2
Pipe temperature(Liquid)

Distributor
with strainer (#50/#50)

Refrigerant flow in cooling
Refrigerant flow in heating

Refrigerant LIQUID pipe connection
(Flare)

Strainer (#50)

10