Mitsubishi Electric PUY-SP42VKA, PUY-SP48YKA, PUY-SP48VKA, PUY-SP36YKA, PUY-SP42YKA Service Manual

SERVICE MANUAL

SPLIT-TYPE, AIR CONDITIONERS

No. OCH642

INDOOR UNIT

CONTENTS

1. REFERENCE MANUAL

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

2

2. SAFETY PRECAUTION

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

3

3. PARTS NAMES AND FUNCTIONS

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

4

4. SPECIFICATIONS

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

9

5. NOISE CRITERION CURVES ....................... 11

6. OUTLINES AND DIMENSIONS

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

12

7. WIRING DIAGRAM

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

15

8. REFRIGERANT SYSTEM DIAGRAM

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

16

9. TROUBLESHOOTING

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

17

10. DISASSEMBLY PROCEDURE

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

32

October 2016

Note:

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

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

PARTS CATALOG (OCB642)

Model name
indication

WIRED REMOTE

CONTROLLER

WIRELESS REMOTE

CONTROLLER

ON/OFF TEMP

ON/OFF

TEMP.

Series PCY

Indoor unit
[Model Name]

PCY-SP18KA

PCY-SP24KA

PCY-SP30KA

PCY-SP36KA

PCY-SP42KA

PCY-SP48KA

[Service Ref.]

PCY-SP18KA.TH

PCY-SP24KA.TH

PCY-SP30KA.TH

PCY-SP36KA.TH

PCY-SP42KA.TH

PCY-SP48KA.TH

(Option) (Option)

2

1-1. OUTDOOR UNIT’S SERVICE MANUAL

1-2. TECHNICAL DATA BOOK

REFERENCE MANUAL

1

Service Ref Service Manual No.

SUY-SA18/24/30/36VA.TH

OCH648

OCB648

PUY-SP42/48VKA.TH(-D/-N)
PUY-SP36/42/48YKA.TH(-D/-N)

OCH644

OCB644

Series (Outdoor unit) Data Book No.

SUY-SA▪VA.TH OCS40

PUY-SP▪VKA.TH

PUY-SP▪YKA.TH

OCS41

OCH642

3

SAFETY PRECAUTION

2

Cautions for units utilising refrigerant R410A

2-2. CAUTIONS RELATED TO NEW REFRIGERANT

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 hazard to refrigerant cycle.
In addition, use pipes with specified thickness.

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

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

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

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

· Avoid using thin pipes.

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.

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.

Handle tools with care.

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

Do not use a charging cylinder.

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

Flare tool

Electronic refrigerant
charging scale

Vacuum pump adaptor

Size adjustment gauge

Gauge manifold

Torque wrench

Gas leak detector

Charge hose

Tools for R410A

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

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

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

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

Never use any refrigerant other than that specified.

Doing so may cause a burst, an explosion, or fire when the
unit is being used, serviced, or disposed of.
Correct refrigerant is specified in the manuals and on the
spec labels provided with our products.
We will not be held responsible for mechanical failure,
system malfunction, unit breakdown or accidents caused
by failure to follow the instructions.

Use the specified refrigerant only.

2-1. ALWAYS OBSERVE FOR SAFETY

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

OCH642

4

[3] Service tools

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

Electronic weighing scale

Unit

3-1. INDOOR UNIT

PARTS NAMES AND FUNCTIONS

3

Air outlet

Louver

Vane

Air intake

Filter
(Inside of Air intake)

No. Tool name Specifications

1

Gauge manifold Only for 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 (Pink)

•

Cylinder with syphon

8

Refrigerant recovery equipment

—

[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) If moisture or foreign matter might have entered the refrigerant piping during the servise, ensure to remove them.

[2] Additional refrigerant charge

When charging directly from cylinder
(1) Check that cylinder for R410A on the market is syphon type.
(2) Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.)

OCH642

99

SPECIFICATIONS

4

Single phase, 50Hz, 220-240 V/Single phase, 60Hz, 220 V

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) × 3

0.095

16-17-18-20

0 (direct blow)

Remote controller & built-in

34-36-38-40

26

1,280

680
230

32

Cooling

0.07

0.61

PCY-SP18KA.TH

kW

A

kW

K/min

Pa

dB (A)

mm
mm
mm
mm

kg

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

W

D
H

INDOOR UNIT

4-1. SPECIFICATIONS

Single phase, 50Hz, 220-240 V/Single phase, 60Hz, 220 V

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) × 3

0.095

16-18-20-22

0(direct blow)

Remote controller & built-in

34-36-40-42

26

1,280

680
230

32

Cooling

0.08

0.72

PCY-SP24KA.TH

kW

A

kW

K/min

Pa

dB (A)

mm
mm
mm
mm

kg

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

W

D
H

INDOOR UNIT

Single phase, 50Hz, 220-240 V/Single phase, 60Hz, 220 V

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) × 4

0.160

24-26-28-30

0(direct blow)

Remote controller & built-in

39-41-43-45

26

1,600

680
230

37

Cooling

0.11

0.97

PCY-SP30KA.TH

kW

A

kW

K/min

Pa

dB (A)

mm
mm
mm
mm

kg

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

W

D
H

INDOOR UNIT

OCH642

10

Single phase, 50Hz, 220-240 V/Single phase, 60Hz, 220 V

Munsell 6.4Y 8.9/0.4

Plate fin coil

Sirocco fan (direct) × 4

0.160

27-29-32-34

0(direct blow)

Remote controller & built-in

42-44-46-48

26

1,600

680
230

40

Cooling

0.16

1.35

PCY-SP36/42/48KA.TH

kW

A

kW

K/min

Pa

dB (A)

mm
mm
mm
mm

kg

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

W

D
H

INDOOR UNIT

PCY-SP18KA.TH

50

0

-50

-100

-150

-200

-250

-300

Static pressure[Pa]

Airflow rate[m³/min]

0 1 2 3 4

50

0

-50

-100

-150

-200

-250

-300

Static pressure[Pa]

Airflow rate[m³/min]

0 1 2 3 4

■

PCY-SP24KA.TH PCY-SP36KA.TH

PCY-SP30KA.TH

■

PCY-SP48KA.TH

PCY-SP42KA.TH

How to read curves

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

Q

0

B

A

C

1

Curve 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
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

3

/min>

OCH642

12

(Drainage)

When drain socket

is installed

2

246

When drain socket

is installed

233

Air intake

5

4

123

678

Knockout hole for upper drain pipe arrangement

Knockout hole for fresh air intake ø100

Knockout hole for wiring arrangement 2-ø26

Drainage pipe connection(26mmI.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)

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 upper drain pipe arrangement.

Air outlet

233

Electrical box

When electrical box

is pulled down

Electrical box

8

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

A B C D

184 203 6.35 12.7

180 200 9.52 15.88

B

236

150

62140

18

1237(Suspension bolt pitch)

320

680

80

84 88

195

230

57

254

476

680

182 85

1198

8 48

260

85 86 2

126

37

121

138

190 1

18

38

120°

1280 22

1173

124 76

46 190

75

387461

2

3

5

1

4

ø125

6

[FRONT VIEW]

Ceiling

(Drainage)

PCY-SP18KA.TH

PCY-SP24KA.TH

(gas [ D)

(liquid [ C)

(71)

500 or more

250

300

1280

Less than 680

270

1

For high

attachment

Obstacle

Rear wall

Ceiling

Less than

or more

or more

(Gap to ceiling)

2500mm or more from floor

Allowing clearances

PCY-SP18KA.TH
PCY-SP24KA.TH

Unit: mm

OUTLINES AND DIMENSIONS6

OCH642

1313

(Drainage)

When drain socket

is installed

246

When drain socket

is installed

233

Knockout hole for upper drain pipe arrangement

Knockout hole for fresh air intake ø100

Knockout hole for wiring arrangement 2-ø26

678

Drainage pipe connection(26mmI.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

123

4

Ceiling

[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

upper drain pipe arrangement.

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

180

200

(Drainage)

(gas ø15.88)

(liquid ø9.52)

236

150

62140

18

1557

320

680

80

84 88

195

230

233

57

254

476

680

182 85

1518

8

48

260

85 86 2

126

37

121

138

190 1

18

38

120°

1600 22

1493

124

76

46

190

75

387

461

71

2

3

5

1

4

7

ø125

6

8

Electrical box

Air outlet

Air intake

(Suspension bolt pitch)

1600

270

300

500 or more

250

Ceiling

Obstacle

1

For high

attachment

Less than 680

Rear wall

or more

or more

Less than

(Gap to ceiling)

2500mm or more from floor

Allowing clearances

Unit: mm

PCY-SP30KA.TH
PCY-SP36KA.TH
PCY-SP42KA.TH
PCY-SP48KA.TH

OCH642

14

WIRED REMOTE CONTROLLER

Unit: mm

PAR-21MAA PAR-32MAA

(Option)

130

12083.5

19.5
19

120

120

46

46

83.5

159.3

55

58

19

WIRELESS REMOTE CONTROLLER

(Option)

OCH642

1515

PCY-SP18KA.TH PCY-SP24KA.TH PCY-SP30KA.TH
PCY-SP36KA.TH PCY-SP42KA.TH PCY-SP48KA.TH

WIRING DIAGRAM7

<Table 2>SW2(CAPACITY CODE)

Manufacture/Service Manufacture/Service

MODELS

SW2

PCY-SP36KA

MODELS

ON
OFF

1 2 3 4 5

PCY-SP18KA

ON
OFF

1 2 3 4 5

PCY-SP42KA

ON
OFF

1 2 3 4 5

PCY-SP24KA

ON
OFF

1 2 3 4 5

PCY-SP48KA

ON
OFF

1 2 3 4 5

PCY-SP30KA

ON
OFF

1 2 3 4 5

<Table 1>
SW1(MODEL SELECTION)

SW1

ON
OFF

1 2 3 4 5

NOTE: Be sure to turn off the source power

and then disconnect fan motor connector.
(Failure to do so will cause trouble in Fan motor)

Manufacture/Service

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

2.Indoor and outdoor connecting wires are made with polarities, make wiring matching terminal
numbers (S1, S2, S3).

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

4.This diagram shows the wiring of indoor and outdoor connecting wires.(specification of 220 - 240 V),
adopting superimposed system of power and signal.

Notes:

CN4F
(WH)

When attaching
drain pump
(option part),
remove the jumper
connector CN4F
and fit the drain
float switch (FS).

When attaching
drain pump
(option part)

FS

1 4

SYMBOL SYMBOLNAME NAME

I.B

R.B

INDOOR CONTROLLER BOARD

FUSE (T6.3AL250V)

CONNECTOR (LOSSNAY)
CONNECTOR (REMOTE SWITCH)
CONNECTOR (HA TERMINAL-A)
CONNECTOR (CENTRALLY CONTROL)

POWER SUPPLY (I.B)
POWER SUPPLY (R.B)
TRANSMISSION (INDOOR-OUTDOOR)

RELAY (DRAIN PUMP)
WIRED REMOTE CONTROLLER BOARD

SWITCH (MODEL SELECTION)

*

See table 1

SWITCH (CAPACITY CODE)

*

See table 2

CONNECTOR (EMERGENCY OPERATION)

FAN MOTOR
VANE MOTOR

DRAIN PUMP
DRAIN FLOAT SWITCH

TERMINAL BLOCK (

INDOOR/OUTDOOR CONNECTING LINE

)
TERMINAL BLOCK (REMOTE CONTROLLER
TRANSMISSION LINE)
ROOM TEMP. THERMISTOR
(0°C/15kΩ, 25°C/5.4kΩ DETECT)
PIPE TEMP. THERMISTOR/LIQUID
(0°C/15kΩ, 25°C/5.4kΩ DETECT)
COND./EVA. TEMP. THERMISTOR
(0°C/15kΩ, 25°C/5.4kΩ DETECT)

MF

FUSE

MV

DP

CN2L

FS

CN32
CN41
CN51

TB4

LED1

TB5,TB6

LED2

TH1

LED3

X1

TH2

SW1

TH5

SW2
SWE

[LEGEND]

W.B

RU

BZ
LED1

SW1
SW2

OPTION PARTS

PCB FOR WIRELESS REMOTE CONTROLLER

RECEIVING UNIT

BUZZER
LED (OPERATION INDICATION : GREEN)

EMERGENCY OPERATION (FAN)
EMERGENCY OPERATION (COOL)

CN3C

(BU)

1 9

113

4

5 1

4 1

1234567891011121314151617

18

19

20

CN2L

ON OFF

SWE

J42J41

SW2SW1

LED3 LED2 LED1

LED2

LED1

RU

SW2

SW1

CNB

9

5

tº tº tº

TH2 TH5 TH1

MV

BZ

M

W.B

I.B

1 4

2 1

1 5

21

21

Refer to tables 1 and 2

TB4
YE
OG

OG
BN

YE

OG

TO OUTDOOR
UNIT

1 3 5

3

1

M

1~

DP

CNP
(BU)

CN01

(BK)

S1
S2
S3

7 4 1

3~

MF

MS

1

3

CN22

(BU)

CN90
(WH)

CNV

(WH)

Pair No.

CNMF

(

WH)

CN20

(RD)

CN4F
(WH)

CN105

CN44
(WH)

CN32
(WH)

CN51(WH)

CN41(WH)

X1

FUSE

+–

(OPTION PART)

2

R.B

TB5

TRANSMISSION
WIRES
DC12V

21

TB6

2
1

The black square(■)indicates a switch
position.

OCH642

16

Pipe temperature
thermistor/liquid
(TH2)

Distributor
with strainer 1/2
#50/#50

Condenser/evaporator
temperature thermistor
(TH5)

Room temperature
thermistor (TH1)

Refrigerant flow in cooling

Strainer
#50

Strainer
#50

Heat exchanger

Refrigerant GAS pipe connection
(Flare)

Refrigerant LIQUID pipe connection
(Flare)

REFRIGERANT SYSTEM DIAGRAM8

PCY-SP18KA.TH PCY-SP24KA.TH PCY-SP30KA.TH
PCY-SP36KA.TH PCY-SP42KA.TH PCY-SP48KA.TH

OCH642

27

9-5. EMERGENCY OPERATION

9-5-1. When wireless remote controller fails or its battery is exhausted

9-5-2. When wired remote controller or indoor unit microprocessor fails

When the remote controller cannot be used

When the batteries of the remote controller run out or the remote control­ler malfunctions, the emergency operation can be done using the emer­gency buttons on the grille.
A DEFROST/STAND BY lamp
B Operation lamp
C Emergency operation switch (fan mode)
D Emergency operation switch (cooling)

E Receiver

Starting operation

• To operate the cooling mode, press the

button D

for more than 2

seconds

.

• To operate the fan mode, press the

button C

for more than 2

seconds

.

* Lighting of the Operation lamp

B

means the start of operation.

Note:

• Details of emergency mode are as shown below.

Operation mode COOL
Set temperature 24 °C
Fan speed High
Air flow direction Horizontal

Stopping operation

• To stop operation, press the

button D or the button C .

CD

ABE

1. When the wired remote control or the indoor unit microprocessor has failed, but all other components work properly,
if you set the switch (SWE) on the indoor controller board ON, the indoor unit will begin emergency operation.
When emergency operation is activated, the indoor unit operates as follows:
(1) Indoor fan is running at high speed. (2)Drain pump is operating.

Note on the wireless remote control: when the remote control does not 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. Before you activate emergency operation, check the following points:
(1) Emergency operation cannot be activated when:

• the indoor fan malfunctions.

• when it has detected the malfunction of drain pump during self-diagnosing.

(2) Emergency operation becomes continuous only by switching the power source on/off.
ON/OFF on the remote control or temperature control, etc. does not function.
(3) After emergency operation has been deactivated, set the switches, etc. to their original positions.
(4) Movement of the vanes does not work in emergency operation, therefore you have to slowly set them
manually to the appropriate position.

OCH642