Mitsubishi Electric PUY-SP42VKA User 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 ser-
vice 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
3
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 refrige-
rant 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 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.
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
5
[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
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 —
[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

11
10
11
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
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
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
BA
C
1Curve 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 <m3/min>
OCH642

13
12
13
(Drainage)
When drain socket is installed
2
246
When drain socket is installed
233
Air intake
5 4 1 2 3
6 7 8
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
87
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
23
514
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
6 7 8
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 1 2 3 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
848
260
85 86 2
126
37
121
138
190 1
18
38
120°
1600 22 1493
124 76
46
190
75
387
461
71
23
514
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

15
14
15
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
12345
PCY-SP18KA
ON
OFF
12345
PCY-SP42KA
ON
OFF
12345
PCY-SP24KA
ON
OFF
12345
PCY-SP48KA
ON
OFF
12345
PCY-SP30KA
ON
OFF
12345
<Table 1>
SW1(MODEL SELECTION)
SW1
ON
OFF
12345
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
1
1
3
4
5 1
4 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
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
31
M
1~
DP
CNP
(BU)
CN01
(BK)
S1
S2
S3
7 4 1
3~
MF
MS
13
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)
2R.B
TB5
TRANSMISSION
WIRES
DC12V
21
TB6
2
1
The black square( ■) indicates a switch
position.
OCH642

16
17
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 control-
ler malfunctions, the emergency operation can be done using the emer-
gency buttons on the grille.
ADEFROST/STAND BY lamp
BOperation lamp
CEmergency operation switch (fan mode)
DEmergency operation switch (cooling)
EReceiver
Starting operation
• To operate the cooling mode, press the button Dfor 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 Dor 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