Mitsubishi Electric PKA Series User manual

SERVICE MANUAL
SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
SPLIT-TYPE, AIR CONDITIONERS
NOTE:
• This manual describes
only service data of the
indoor units.
• RoHS compliant products
have <G> mark on the
spec name plate.
CONTENTS
1. REFERENCE MANUAL...................................2
2. SAFETY PRECAUTION...................................3
3. PART NAMES AND FUNCTIONS................... 4
4. SPECIFICATIONS............................................6
5. NOISE CRITERION CURVES..........................7
6. OUTLINES AND DIMENSIONS.......................8
7. WIRING DIAGRAM.......................................... 9
8. REFRIGERANT SYSTEM DIAGRAM............10
9. TROUBLESHOOTING....................................11
10. SPECIAL FUNCTION.....................................26
11. DISASSEMBLY PROCEDURE.......................29
Indoor unit
[Model names] [Service Ref.]
PARTS CATALOG (OCB453)
No. OCH453
March 2009
INDOOR UNIT
PKA-RP35HAL
PKA-RP35HAL
PKA-RP50HAL
PKA-RP50HAL

2
1REFERENCE MANUAL
Service Ref. Service Manual No.
PUHZ-P200/250YHA3 OCH424/OCB424
PUHZ-RP35/50/60/71VHA4
PUHZ-RP100/125/140VKA
PUHZ-RP100/125/140/200/250YKA
OCH451
OCB451
PU(H)-P71/100VHA#2.UK
PU(H)-P71/100/125/140YHA#2.UK OC379
PUHZ-HRP71/100VHA2
PUHZ-HRP100/125YHA2 OCH425/OCB425
OCH415/OCB415
PUHZ-P100/125/140VHA3.UK
OUTDOOR UNIT’S SERVICE MANUAL

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 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 indoors during
installation, 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 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.
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.
Handle tools with care.
If dirt, dust or moisture enters 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 enters into refrigerant cycle, that can
cause deterioration of refrigerant oil or malfunction of com-
pressor.
If large amount of mineral oil enters, 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 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.)
2-1. ALWAYS OBSERVE FOR SAFETY
Before obtaining access to terminal, all supply
circuits must be disconnected.

4
Gravimeter
Unit
[3] Service tools
Use the below service tools as exclusive tools for R410A refrigerant.
No. Tool name 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
3PART NAMES AND FUNCTIONS
Indoor unit
Filter Air intake
Louver Air outlet Vane

5
ON/OFF TEMP
FAN
VANE
TEST RUN
AUTO STOP
AUTO START
h
min
LOUVER
MODE
CHECK
RESETSET CLOCK
MODEL SELECT
NOT AVAILABLE
CHECK TEST RUN
°C
AMPM
AMPM
VANE CONTROL button
Used to change the air flow direction.
CLOCK button
RESET button
SET button
ON/OFF button
The unit is turned ON and OFF alternately
each time the button is pressed.
MODE SELECT button
Used to switch the operation mode between
cooling, drying, heating, auto and fan mode.
CHECK-TEST RUN button
Only press this button to perform an
inspection check or test operation.
Do not use it for normal operation.
FAN SPEED SELECT button
Used to change the fan speed.
TIMER display
Displays when in timer operation or when
setting timer.
button
SET TEMPERATURE button sets any desired
room temperature.
CLOCK display
Displays the current time.
“ ” “ ” display
Displays the order of timer operation.
“ ” “ ” display
Displays whether timer is on or off.
Buttons used to set the “hour and minute” of
the current time and timer settings.
h and min buttons
display
display
FAN SPEED display indicates which fan
speed has been selected.
display
The vertical direction of air flow is indicated.
display
Blinks when model is selected.
display
display
CHECK and TEST RUN display indicate that
the unit is being checked or test-run.
display
OPERATION MODE display
Operation mode display indicates which
operation mode is in effect.
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.
MODEL SELECT
CHECK TEST RUN
LOUVER button
Changes left/right airflow direction.
(Not available for this model.)
SET TEMP. display indicates the desired
temperature which is set.
Lights up while the signal is transmitted to
the indoor unit when the button is pressed.
TIMER CONTROL buttons
Wireless remote controller

6
SPECIFICATIONS
4
Cooling
0.04
0.40
Heating
0.03
0.30
Single phase, 50Hz, 230V
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)
kW
A
kW
*/min(CFM)
Pa(mmAq)
kW
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
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
Operation control & Thermostat
Noise level (Low-Middle-High)
Field drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
PKA-RP50HAL
Cooling
0.04
0.40
Heating
0.03
0.30
Single phase, 50Hz, 230V
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)
kW
A
kW
*/min(CFM)
Pa(mmAq)
kW
dB
mm(in.)
mm(in.)
mm(in.)
mm(in.)
kg(lbs)
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
Operation control & Thermostat
Noise level (Low-Middle-High)
Field drain pipe I.D.
Dimensions
Weight
W
D
H
INDOOR UNIT
PKA-RP35HAL

7
5NOISE CRITERION CURVES
* Measured in anechoic room.
PKA-RP35, 50HAL
36 - 40 - 43
Sound level dB (A)
Sound level at anechoic room : Low-Middle-High
1.0m
1.0m
Measurement location
5-1. SOUND LEVELS
5-2. NOISE CRITERION CURVES
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
65.0
70.0
63 125 250 500 1k 2k 4k 8k
NC-60
NC-50
Octave band pressure level (dB) 0dB=20μPa
A
pproximate minimum
audible limit on
continuous noise
NC-40
Octave band center fre
q
uencies
(
Hz
)
NC-20
NC-30
High
Low

8
OUTLINES AND DIMENSIONS
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
21.8 0 20
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
28.516
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
AB
43
656
46
60
46
43
59
C
56
12.5
43
D
43
656
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
PKA-RP35HAL PKA-RP50HAL

9
WIRING DIAGRAM
7
PKA-RP35HAL PKA-RP50HAL
Symbol Name Symbol Name
I.B Indoor controller board
FUSE FUSE(T3.15AL250V)
ZNR01,02 Varistor
DSA Surge absorber
CN2L Connector (LOSSNAY)
CN90 Connector (Remote operation adapter)
Connector (Emergency operation)
CNP Drain pump (option) power supply
(Drain pump (option))
CN4F Drain float switch (Drain pump (option))
DCL REACTOR
CN32 Connector ( Remote switch)
CN41 Connector (HA terminal-A)
CN51 Connector (Centrally control)
LED1 Power supply (I.B)
LED2 Power supply (R.B)
LED3 Transmission (Indoor-outdoor)
X1 Relay (Drain pump (option))
SW1 Switch (Model selection) +See table 1
SW2
SWE
Switch (Capacity code) +See table 2
[Explanation of symbols]
MS Fan motor
W.B Pcb for wireless remote controller
Switch board
SWE2 Emergency operation
M Vane motor
LED1 LED (Operation indication : Green)
REC1 Receiving unit
LED2 LED (Preparation for heating: Orange)
TB2 Terminal block(Indoor unit Power (option))
TB4 Terminal block (Indoor/outdoor connecting line)
TB5
Terminal block (Remote controller transmission line(option))
TH1 Room temp. Thermistor
Pipe temp. Thermistor/liquid
Cond./eva. temp. Thermistor
(0/15ΚΩ, 25/5.4ΚΩ Detect)
(0/15ΚΩ, 25/5.4ΚΩ Detect)
(0/15ΚΩ, 25/5.4ΚΩ Detect)
TH2
TH5
S.W
R.B Wired remote controller(option)
TB6 Terminal block (Remote controller transmission line)
DP DRAIN PUMP (OPTION)
DRAIN FLOAT SWITCH (OPTION)
FS
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.
TO OUTDOOR
UNIT
5
3
1
3
1
CN01
(BLK)
ORN
YLW
BLU
RED
GRN/YLW
I.B
+ 1(Fig. 1)
I.B
POWER SUPPLY
~(1PHASE)
230V 50Hz
L
N
ORN
ORN
YLW
BRN
TB4
TB2
S1
S2
S3
INDOOR/OUTDOOR
COMMUNICATION
CN3C(BLU)
Refer to
tables
1and 2
CN90
(WHT)
CN2L
(RED)
CN151
(WHT)
CN20
(RED)
CN44
(WHT)
CN4F
(WHT)
CN22
(BLU)
CN41
(WHT)
CN51
(WHT)
CN32
(WHT)
ZNR01
ZNR02
CNMF
(WHT)
S.W
W.B
SWE
R.B
CNP(BLU)
CN3C
(BLU)
CNRU
(WHT)
LDSWE(A)
(BLU)
LDSWE(B)
LD101(B) REC1
LED1 LED2
SWE2
CN01
(BLK)
T11 DB1
X1
U
U
FUSE
I.B
1
1
11 1 5 6 4
11
1
2
141425
TH1 TH2 TH5
2
1139
3
3
32
2
1
2
1
1
1
5
6
DSA
Mt
○
t
○
t
○
MS
3~
M
1~
TB4
TB5
S1
S2
S3
RU
BLU
BLU
ORN
ORN
DP
ORN
BRN
LED1
LED3
LED2
(OPTION PARTS)
TB6
ON
OFF
TO
OUTDOOR
UNIT
YLW YLWYLW
DCL
BLK
<Table 1>
SW1
(MODEL SELECTION)
SETTING
SETTING
ON
OFF
12345
<Table 2>
SW2 (CAPACITY CODE)
MODELS
RP35
ON
OFF
12345
ON
OFF
12345
RP50
FLOAT SW
CN4F
(WHT)
When attaching
drain pump(option),
remove the jumper
connector CN4F
and fit the drain
float switch (FS).
When attaching drain
pump (option)
FS
14

10
Thermistor TH2
Pipe temperature(Liquid)
Distributor
with strainer (#50/#50)
Thermistor TH5
(Cond./ Eva.temperature)
Thermistor TH1
(Room temperature)
Refrigerant flow in cooling
Refrigerant flow in heating
Strainer (#50)
Strainer (#50)
Heat exchanger
Refrigerant GAS pipe connection
(Flare)
Refrigerant LIQUID pipe connection
(Flare)
REFRIGERANT SYSTEM DIAGRAM
8
PKA-RP35HAL PKA-RP50HAL