Mitsubishi Electric PCA-RP50GA User manual

SERVICE MANUAL
SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
SPLIT-TYPE, AIR CONDITIONERS
No. OC328
REVISED EDITION-B
INDOOR UNIT
REMOTE CONTROLLER
CONTENTS
1. TECHNICAL CHANGES......................................2
2. REFERENCE MANUAL............................................... 2
3. SAFETY PRECAUTION...................................3
4. PART NAMES AND FUNCTIONS....................7
5. SPECIFICATIONS............................................9
6. NOISE CRITERION CURVES........................13
7. OUTLINES AND DIMENSIONS.....................15
8. WIRING DIAGRAM................................................. 19
9. REFRIGERANT SYSTEM DIAGRAM.................... 20
10. TROUBLESHOOTING................................... 21
11. SPECIAL FUNCTION.....................................33
12. DISASSEMBLY PROCEDURE.......................36
13. PARTS LIST....................................................41
14. RoHS PARTS LIST......................................... 50
ON/OFF
TEMP.
Indoor unit
[Model names] [Service Ref.]
PCA-RP50GA PCA-RP50GA PCA-RP50GA#1
PCA-RP50GA2 PCA-RP50GA2 PCA-RP50GA2#1
PCA-RP60GA PCA-RP60GA PCA-RP60GA#1
PCA-RP71GA PCA-RP71GA PCA-RP71GA#1
PCA-RP100GA PCA-RP100GA PCA-RP100GA#1
PCA-RP125GA PCA-RP125GA PCA-RP125GA#1
PCA-RP140GA PCA-RP140GA PCA-RP140GA#1
Model name
indication
PCH-P50GAH PCH-P50GAH
PCH-P60GAH PCH-P60GAH
PCH-P71GAH PCH-P71GAH
PCH-P100GAH PCH-P100GAH
PCH-P125GAH PCH-P125GAH
PCH-P140GAH PCH-P140GAH
May 2008
NOTE:
• This manual describes only
service data of the indoor
units.
• RoHS compliant products
have <G> mark on the
spec name plate.
•For servicing of RoHS com-
pliant products, refer to the
RoHS Parts List.
Revision :
• PCA-RP50~140GA(2)#1
are added in REVISED
EDITION-B.
•RoHS PARTS LIST added.
• Some descriptions have
been modified.
• Please void OC328
REVISED EDITION-A
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2
2-1. OUTDOOR UNIT’S SERVICE MANUAL
2-2. TECHNICAL DATA BOOK
TECHNICAL CHANGES
1
REFERENCE MANUAL
2
PCA-RP50GA(2) PCA-RP50GA(2)#1
PCA-RP60GA PCA-RP60GA#1
PCA-RP71GA PCA-RP71GA#1
PCA-RP100GA PCA-RP100GA#1
PCA-RP125GA PCA-RP125GA#1
PCA-RP140GA PCA-RP140GA#1
INDOOR CONTROLLER BOARD(I.B.) has been changed.
Service Ref. Service Manual No.
MXZ-8A140VA / VA1/ VA2/ VA3OC316
SUZ-KA50/60/71VA(1).TH OC322
SUZ-KA50/60/71VA(1).TH-A OC323
PUHZ-RP35/50/60/71/100/125/140VHA(1)
PUHZ-RP100/125/140YHA OC334
PUHZ-RP71/100/125/140VHA(1)-A OC337
PUHZ-RP200/250YHA(1)(2) OC338
PUHZ-RP200/250YHA(1)-A OC339
PU(H)-P • VGAA.UK
PU(H)-P • YGAA.UK OC336
PUHZ-P100/125/140VHA.UK OC359
PUHZ-RP35/50/60/71/100/125/140VHA2(1)
PUHZ-RP100/125/140YHA2(1)
PUHZ-RP35/50/60/71/100VHA3
PUHZ-RP100YHA3
OC374
PU(H)-P71/100VHA(1).UK
PU(H)-P100/125/140YHA(1).UK OC379
PUHZ-P100/125/140VHA2(1).UK OCH415 / OCB415
PUHZ-RP71/100/125/140VHA2-A
PUHZ-RP100/125/140YHA2-A OCH422 / OCB422
PUHZ-BP100/125/140VHA-A
PUHZ-BP200/250YHA-A OCH423 / OCB423
PUHZ-P200/250YHA2 OCH424 / OCB424
PUHZ-HRP71/100VHA
PUHZ-HRP100/125YHA OCH425 / OCB425
PUHZ-RP200/250YHA2 OCH428 / OCB428
Series (Outdoor unit) Manual No.
PUHZ-RP • HA(-A) OCS01
PU(H)-P • GAA.UK OCS02
SUZ-KA • VA OCS03
PUHZ-RP • HA2 OCS05
PUHZ-P • HA OCS06
PU(H)-P • HA OCS07
PUHZ-P • VHA2, PUHZ-P • YHA OCS08
PUHZ-RP • HA2-A OCS09
PUHZ-BP • HA OCS10
PUHZ-HRP • HA OCS11
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3
SAFETY PRECAUTION
3
Cautions for units utilising refrigerant R407C
3-2. CAUTIONS RELATED TO NEW REFRIGERANT
Do not use the existing refrigerant piping.
The old refrigerant and lubricant in the existing piping
contains a large amount of chlorine which may cause the
lubricant deterioration of the new unit.
Use “low residual oil piping”
If there is a large amount of residual oil (hydraulic oil, etc.)
inside the piping and joints, deterioration of the lubricant
will result.
Use ESTER , ETHER or HAB as the lubricant to
coat flares and flange connection parts.
If large amount of mineral oil enter, that can cause
deterioration of refrigerant oil etc.
Use liquid refrigerant to charge the system.
If gas refrigerant is used to seal the system, the composition
of the refrigerant in the cylinder will change and performance
may drop.
Do not use a refrigerant other than R407C.
If another refrigerant (R22, etc.) is used, the chlorine in the
refrigerant may cause the lubricant deterioration.
Use a vacuum pump with a reverse flow check valve.
The vacuum pump oil may flow back into the refrigerant
cycle and cause the lubricant deterioration.
Store the piping to be used during installation
indoors with keep both ends sealed until just
before brazing.
(Store elbows and other joints in a plastic bag.)
If dust, dirt, or water enters the refrigerant cycle,
deterioration of the oil and compressor trouble may result. Ventilate the room if refrigerant leaks during
operation. If refrigerant comes into contact with
a flame, poisonous gases will be released.
3-1. ALWAYS OBSERVE FOR SAFETY
Before obtaining access to terminal, all supply
circuits must be disconnected.
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[3] Service tools
Use the below service tools as exclusive tools for R407C refrigerant.
No. Tool name Specifications
1Gauge manifold ·Only for R407C.
·Use the existing fitting SPECIFICATIONS. (UNF7/16)
·Use high-tension side pressure of 3.43MPa·G or over.
2Charge hose ·Only for R407C.
·Use pressure performance of 5.10MPa·G or over.
3Electronic scale
—
4Gas leak detector ·Use the detector for R134a or R407C.
5Adapter for reverse flow check. ·Attach on vacuum pump.
6Refrigerant charge base.
—
7Refrigerant cylinder. ·For R407C ·Top of cylinder (Brown)
·Cylinder with syphon
8Refrigerant recovery equipment.
—
[2] Refrigerant recharging
(1) Refrigerant recharging process
1Direct charging from the cylinder.
·R407C cylinder are available on the market has a syphon pipe.
·Leave the syphon pipe cylinder standing and recharge it.
(By liquid refrigerant)
(2) Recharge in refrigerant leakage case
·After recovering the all refrigerant in the unit, proceed to working.
·Do not release the refrigerant in the air.
·After completing the repair service, recharge the cycle with the specified amount of
liquid refrigerant.
[1] Cautions for service
·After recovering the all refrigerant in the unit, proceed to working.
·Do not release refrigerant in the air.
·After completing the repair service, recharge the cycle with the specified amount of
liquid refrigerant.
Gravimeter
Unit
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5
Cautions for units utilising refrigerant R410A
CAUTIONS RELATED TO NEW REFRIGERANT
Use new refrigerant pipes.
Make sure that the inside and outside of refrige-
rant 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.
Store the piping to be used during installation
indoors and keep both ends of the piping sealed
until just before brazing. (Leave elbow joints, etc.
in their packaging.)
Use ester oil, ether oil or alkylbenzene oil (small
amount) as the refrigerant oil applied to flares
and flange connections.
In case of using the existing pipes for R22, be careful with
the followings.
· For RP60/71VHA3 and RP100/125/140, be sure to
perform replacement operation before test run.
· 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 refrige-
rant 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.
Keep the tools with care.
If dirt, dust or moisture enter into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com-
pressor.
Do not use a charging cylinder.
If a charging cylinder is used, the composition of refrigera-
nt 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 deterio-
ration of refrigerant oil etc.
If dirt, dust or moisture enter into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com-
pressor.
If large amount of mineral oil enter, that can cause deterio-
ration 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.
[1] Cautions for service
(1) Perform service after collecting 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.)
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6
Gravimeter
Unit
[3] Service tools
Use the below service tools as exclusive tools for R410A refrigerant.
No. Specifications
1Gauge manifold ·Only for R410A
·Use the existing fitting specifications. (UNF1/2)
·Use high-tension side pressure of 5.3MPa·G or over.
2Charge hose ·Only for R410A
·Use pressure performance of 5.09MPa·G or over.
3Electronic scale
4Gas leak detector ·Use the detector for R134a, R407C or R410A.
5Adaptor for reverse flow check ·Attach on vacuum pump.
6Refrigerant charge base
7Refrigerant cylinder ·Only for R410A Top of cylinder (Pink)
Cylinder with syphon
8Refrigerant recovery equipment
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77
PART NAMES AND FUNCTIONS
4
 Remote controller
Once the controls are set, the same operation mode can be repeated by simply pressing the ON/OFF button.
 Indoor Unit
Air outlet
Intake grille Air intake
Left/right guide vanes
Change the direction of airflow
from the horizontal blower.
Long-life filter
Removes dust and foreign matter from air coming in
through the grille (Recommended cleaning interval :
Approx, every 2,500 operating hours)
Up/down guide vanes
Change the direction of airflow from the
vertical blower.
 Operation buttons
PAR-21MAA
ON/OFF
FILTER
CHECK
OPERATION
CLEAR
TEST
TEMP.
MENU
BACK DAY
MONITOR/SET
CLOCK
ON/OFF
Set Temperature 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
door.
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 preceding operation
number.
Ventilation button
(Operation button)
To next operation number.
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Display
For purposes of this explanation,
all parts of the display are shown
as lit. During actual operation, only
the relevant items will be lit.
°F°C
°F°C
ERROR CODE
AFTER
TIMER
TIME SUN MON TUE WED THU FRI SAT
ON
OFF
Hr
AFTER
FILTER
FUNCTION
ONLY1Hr.
WEEKLY
SIMPLE
AUTO OFF
Identifies the current operation
Shows the operating mode, etc.
* Multilanguage display is sup-
ported.
“Centrally Controlled” indicator
Indicates that operation of the re-
mote controller has been prohib-
ited 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 orAuto Off
timer is set.
If the simple or Auto Off timer is set, shows the time
remaining.
“Sensor” indication
Displayed when the remote controller
sensor is used.
“Locked” indicator
Indicates that remote controller but-
tons have been locked.
“Clean The Filter” indicator
Comes on when it is time to clean the
filter.
Timer indicators
The indicator comes on if the corre-
sponding timer is set.
Up/Down Air Direction indica-
tor
The indicator shows the direc-
tion of the outcoming airflow.
“One Hour Only” indicator
Displayed if the airflow is set to
weak and downward during COOL
or DRY mode. (Operation varies
according to model.)
The indicator goes off after one
hour, at which time the airflow di-
rection also changes.
Room Temperature display
Shows the room temperature.
Louver display
Indicates the action of the swing
louver. Does not appear if the
louver is stationary.
(Power On indicator)
Indicates that the power is on.
Fan Speed indicator
Shows the selected fan speed.
Ventilation indicator
Appears when the unit is running in
Ventilation mode.
Caution
Only the Power on indicator lights when the unit is stopped and power supplied to the unit.
If you press a button for a feature that is not installed at the indoor unit, the remote controller will display the “Not Available”
message.
If you are using the remote controller to drive multiple indoor units, this message will appear only if he feature is not
present at the parent unit.
When power is turned ON for the first time, it is normal that “PLEASE WAIT” is displayed on the room temperature indication
(For max. 2minutes). Please wait until this “PLEASE WAIT” indication disappear then start the operation.
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99
SPECIFICATIONS
5
kW
A
A
kW
*/min(CFM)
Pa(mmAq)
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
Service Ref.
Mode
Power supply(phase, cycle, voltage)
Input
Running current
Starting current
External finish
Heat exchanger
Fan Fan(drive) x No.
Fan motor output
Airflow(Low-Medium2-Medium1-High)
External static pressure
Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Unit drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
PCA-RP60GA, PCA-RP60GA#1
Cooling
0.12
0.53
1.27
Heating
0.12
0.53
1.27
Single phase, 50Hz, 230V
Munsell 0.70Y 8.59/0.97
Plate fin coil
Sirocco fan (direct) x 3
0.070
14-15-16-18(495-530-565-635)
0(direct blow)
Remote controller & built-in
37-39-41-43
26(1)
1,310(51-9/16)
680(26-3/4)
210(8-1/4)
34(75)
Cooling
0.09
0.41
1.20
Heating
0.09
0.41
1.20
Single phase, 50Hz, 230V
Munsell 0.70Y 8.59/0.97
Plate fin coil
Sirocco fan (direct) x 2
0.054
10-11-12-13(355-390-425-460)
0(direct blow)
Remote controller & built-in
37-38-40-42
26(1)
1,000(39-3/8)
680(26-3/4)
210(8-1/4)
27(60)
PCA-RP50GA, PCA-RP50GA#1
kW
A
A
kW
*/min(CFM)
Pa(mmAq)
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
Service Ref.
Mode
Power supply(phase, cycle, voltage)
Input
Running current
Starting current
External finish
Heat exchanger
Fan Fan(drive) x No.
Fan motor output
Airflow(Low-Medium2-Medium1-High)
External static pressure
Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Unit drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
Cooling
0.12
0.53
1.27
Heating
0.12
0.53
1.27
Single phase, 50Hz, 230V
Munsell 0.70Y 8.59/0.97
Plate fin coil
Sirocco fan (direct) x 3
0.070
14-15-16-18(495-530-565-635)
0(direct blow)
Remote controller & built-in
37-39-41-43
26(1)
1,310(51-9/16)
680(26-3/4)
210(8-1/4)
34(75)
PCA-RP71GA, PCA-RP71GA#1
kW
A
A
kW
*/min(CFM)
Pa(mmAq)
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
Service Ref.
Mode
Power supply(phase, cycle, voltage)
Input
Running current
Starting current
External finish
Heat exchanger
Fan Fan(drive) x No.
Fan motor output
Airflow(Low-Medium2-Medium1-High)
External static pressure
Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Unit drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
kW
A
A
kW
*/min(CFM)
Pa(mmAq)
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
Service Ref.
Mode
Power supply(phase, cycle, voltage)
Input
Running current
Starting current
External finish
Heat exchanger
Fan Fan(drive) x No.
Fan motor output
Airflow(Low-Medium2-Medium1-High)
External static pressure
Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Unit drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
PCA-RP50GA2, PCA-RP50GA2#1
Cooling
0.12
0.53
1.27
Heating
0.12
0.53
1.27
Single phase, 50Hz, 230V
Munsell 0.70Y 8.59/0.97
Plate fin coil
Sirocco fan (direct) x 3
0.070
14-15-16-18(495-530-565-635)
0(direct blow)
Remote controller & built-in
37-39-41-43
26(1)
1,310(51-9/16)
680(26-3/4)
210(8-1/4)
34(75)
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10
kW
A
A
kW
*/min(CFM)
Pa(mmAq)
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
Service Ref.
Mode
Power supply(phase, cycle, voltage)
Input
Running current
Starting current
External finish
Heat exchanger
Fan Fan(drive) x No.
Fan motor output
Airflow(Low-Medium2-Medium1-High)
External static pressure
Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Unit drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
PCA-RP100GA, PCA-RP100GA#1
Cooling
0.15
0.69
1.48
Heating
0.15
0.69
1.48
Single phase, 50Hz, 230V
Munsell 0.70Y 8.59/0.97
Plate fin coil
Sirocco fan (direct) x 3
0.090
20-21-23-25(705-740-810-885)
0(direct blow)
Remote controller & built-in
40-41-43-45
26(1)
1,310(51-9/16)
680(26-3/4)
270(10-5/8)
37(82)
Cooling
0.22
1.01
2.20
Heating
0.22
1.01
2.20
Single phase, 50Hz, 230V
Munsell 0.70Y 8.59/0.97
Plate fin coil
Sirocco fan (direct) x 4
0.150
27-30-32-34(955-1,060-1,130-1,200)
0(direct blow)
Remote controller & built-in
41-43-45-46
26(1)
1,620(63-3/4)
680(26-3/4)
270(10-5/8)
43(95)
PCA-RP125GA, PCA-RP125GA#1
kW
A
A
kW
*/min(CFM)
Pa(mmAq)
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
Service Ref.
Mode
Power supply(phase, cycle, voltage)
Input
Running current
Starting current
External finish
Heat exchanger
Fan Fan(drive) x No.
Fan motor output
Airflow(Low-Medium2-Medium1-High)
External static pressure
Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Unit drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
kW
A
A
kW
*/min(CFM)
Pa(mmAq)
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
Service Ref.
Mode
Power supply(phase, cycle, voltage)
Input
Running current
Starting current
External finish
Heat exchanger
Fan Fan(drive) x No.
Fan motor output
Airflow(Low-Medium2-Medium1-High)
External static pressure
Operation control & Thermostat
Noise level(Low-Medium2-Medium1-High)
Unit drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
PCA-RP140GA, PCA-RP140GA#1
Cooling
0.22
1.01
2.20
Heating
0.22
1.01
2.20
Single phase, 50Hz, 230V
Munsell 0.70Y 8.59/0.97
Plate fin coil
Sirocco fan (direct) x 4
0.150
27-30-32-34(955-1,060-1,130-1,200)
0(direct blow)
Remote controller & built-in
42-44-46-48
26(1)
1,620(63-3/4)
680(26-3/4)
270(10-5/8)
45(99)
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