Mitsubishi PCA-RP35KAQ Service Manual
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Mitsubishi PCA-RP35KAQ Service Manual

Mitsubishi PCA-RP35KAQ Service Manual

Split-type, heat pump air conditioners split-type, air conditioners
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SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
SPLIT-TYPE, AIR CONDITIONERS

SERVICE MANUAL

Indoor unit
[Model names]
PCA-RP35KAQ
PCA-RP50KAQ
PCA-RP60KAQ
PCA-RP71KAQ
PCA-RP100KAQ
PCA-RP125KAQ
PCA-RP140KAQ
INDOOR UNIT
ON/OFF
TEMP
WIRELESS REMOTE
CONTROLLER
(Option)
[Service Ref.]
PCA-RP35KAQ
PCA-RP50KAQ
PCA-RP50KAQR1
PCA-RP60KAQ
PCA-RP60KAQR1
PCA-RP71KAQ
PCA-RP71KAQR1
PCA-RP100KAQ
PCA-RP125KAQ
PCA-RP140KAQ
Model name
indication
TEMP.
ON/OFF
WIRED REMOTE
CONTROLLER
(Option)
Revision:
• PCA-RP35KAQ and
• Some descriptions have
• Please void OCH491
NOTE:
• This manual describes only
• RoHS compliant products
CONTENTS
1. TECHNICAL CHANGES .................................. 2
2. REFERENCE MANUAL ................................... 2
3. SAFETY PRECAUTION ................................... 3
4. PART NAMES AND FUNCTIONS .................... 4
5. SPECIFICATIONS ............................................ 9
6. NOISE CRITERION CURVES ....................... 13
7. OUTLINES AND DIMENSIONS ..................... 15
8. WIRING DIAGRAM ............................................. 19
10. TROUBLESHOOTING ................................... 21
11. SPECIAL FUNCTION ..................................... 37
12. DISASSEMBLY PROCEDURE ....................... 41
PARTS CATALOG (OCB491)
October 2012
No. OCH491
REVISED EDITION-B
PCA-RP50/60/71KAQR1
have been added in
REVISED EDITION-B.
been modified.
REVISED EDITION-A.
service data of the indoor
units.
have <G> mark on the
spec name plate.

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Summary of Contents for Mitsubishi PCA-RP35KAQ

  • Page 1: Table Of Contents

    SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS SPLIT-TYPE, AIR CONDITIONERS October 2012 No. OCH491 REVISED EDITION-B SERVICE MANUAL Indoor unit Revision: [Model names] [Service Ref.] • PCA-RP35KAQ and PCA-RP50/60/71KAQR1 PCA-RP35KAQ PCA-RP35KAQ have been added in REVISED EDITION-B. PCA-RP50KAQ PCA-RP50KAQ • Some descriptions have been modified.

  • Page 2: Technical Changes

    TECHNICAL CHANGES PCA-RP50KAQ PCA-RP50KAQR1 PCA-RP60KAQ PCA-RP60KAQR1 PCA-RP71KAQ PCA-RP71KAQR1 INDOOR CONTROLLER BOARD (I.B.) has been changed. REFERENCE MANUAL 2-1. OUTDOOR UNIT’S SERVICE MANUAL Service Ref. Service Manual No. SUZ-KA50/60/71VA3.TH-A OCH511 / OCB511 PUHZ-RP50/60/71VHA4 PUHZ-RP100/125/140VKA OCH451 / OCB451 PUHZ-RP100/125/140/200/250YKA PUHZ-RP200YKAR1 PUHZ-ZRP35/50VKA PUHZ-ZRP60/71VHA OCH527 / OCB527 PUHZ-ZRP100/125/140VKA PUHZ-ZRP100/125/140YKA...

  • Page 3: Safety Precaution

    SAFETY PRECAUTION 3-1. ALWAYS OBSERVE FOR SAFETY Before obtaining access to terminal, all supply circuits must be disconnected. 3-2. CAUTIONS RELATED TO NEW REFRIGERANT Cautions for units utilising refrigerant R410A Use a vacuum pump with a reverse flow check Use new refrigerant pipes. valve.

  • Page 4: Part Names And Functions

    [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.

  • Page 5: Clock Button

    4-2. WIRELESS REMOTE CONTROLLER (OPTION) * The functions which can be used are restricted according to the model. CHECK TEST RUN display Indicate that the unit is being checked or test-run. display display MODEL SELECT Blinks when model is selected. Lights up while the signal is transmitted to the indoor unit when the button is pressed.

  • Page 6: Basic Mode

    4-3. WIRED REMOTE CONTROLLER (OPTION) <PAR-30MAA/PAR-31MAA> * The functions which can be used are restricted according to the model. The main display can be displayed in two different modes: "Full" and "Basic." Display The factory setting is "Full." 1 Operation mode Appears when the buttons are locked.
  • Page 7 Main menu list Setting and display items Setting details Vane · Louver · Vent. Use to set the vane angle. • Select a desired vane setting from fi ve different settings. (Lossnay) Use to turn ON / OFF the louver. •...

  • Page 8: Operation Section

    4-4. WIRED REMOTE CONTROLLER (OPTION) <PAR-21MAA> * The functions which can be used are restricted according to the model. “Sensor” indication Display Section Day-of-Week Displays when the remote controller sensor is used. Shows the current day of the week. For purposes of this explanation, all parts of the display are shown.

  • Page 9: Specifications

    SPECIFICATIONS 5-1. SPECIFICATIONS Service Ref. PCA-RP35KAQ Mode Cooling Heating Power supply(phase, cycle, voltage) Single phase, 50Hz, 230V Input 0.04 0.04 Running current 0.29 0.27 External finish Munsell 6.4Y 8.9/0.4 Heat exchanger Plate fin coil Fan(drive) × No. Sirocco fan (direct) x 2 Fan motor output 0.090...
  • Page 10 Service Ref. PCA-RP71KAQ , PCA-RP71KAQR1 Mode Cooling Heating Power supply(phase, cycle, voltage) Single phase, 50Hz, 230V Input 0.06 0.06 Running current 0.42 0.42 External finish Munsell 6.4Y 8.9/0.4 Heat exchanger Plate fin coil Fan(drive) × No. Sirocco fan (direct) x 3 Fan motor output 0.095 /min(CFM)
  • Page 11 Service Ref. PCA-RP140KAQ Mode Cooling Heating Power supply(phase, cycle, voltage) Single phase, 50Hz, 230V Input 0.14 0.14 Running current 0.90 0.90 External finish Munsell 6.4Y 8.9/0.4 Heat exchanger Plate fin coil Fan(drive) × No. Sirocco fan (direct) × 4 Fan motor output 0.160 Airflow(Low-Medium2-Medium1-High) /min(CFM)
  • Page 12 5-2. FRESH AIR INTAKE AMOUNT & STATIC PRESSURE CHARACTERISTICS ■ PCA-RP60, 71KAQ PCA-RP35, 50KAQ ■ PCA-RP60, 71KAQR1 PCA-RP50KAQR1 -100 -100 -150 -150 -200 -200 -250 -250 -300 -300 Airflow rate[m³/min] Airflow rate[m³/min] How to read curves Duct characteristics Curve in the at site ■...

  • Page 13: Noise Criterion Curves

    NOISE CRITERION CURVES PCA-RP35KAQ PCA-RP50KAQ SPL(dB) LINE NOTCH NOTCH SPL(dB) LINE High High PCA-RP50KAQR1 Medium1 Medium1 Medium2 Medium2 NC-70 NC-70 NC-60 NC-60 NC-50 NC-50 NC-40 NC-40 NC-30 NC-30 APPROXIMATE APPROXIMATE THRESHOLD OF THRESHOLD OF HEARING FOR HEARING FOR NC-20 NC-20...

  • Page 14: Ceiling

    PCA-RP100KAQ PCA-RP125KAQ NOTCH SPL(dB) LINE NOTCH SPL(dB) LINE High High Medium1 Medium1 Medium2 Medium2 NC-70 NC-70 NC-60 NC-60 NC-50 NC-50 NC-40 NC-40 NC-30 NC-30 APPROXIMATE APPROXIMATE THRESHOLD OF THRESHOLD OF HEARING FOR HEARING FOR NC-20 NC-20 CONTINUOUS CONTINUOUS NOISE NOISE 1000 2000 4000...

  • Page 15: Outlines And Dimensions

    OUTLINES AND DIMENSIONS INDOOR UNIT Unit : mm PCA-RP35KAQ PCA-RP50KAQ PCA-RP50KAQR1 OCH491B...
  • Page 16 PCA-RP60, 71KAQ Unit : mm PCA-RP60, 71KAQR1 OCH491B...
  • Page 17 PCA-RP100, 125, 140KAQ Unit : mm OCH491B...
  • Page 18 Unit : mm WIRED REMOTE CONTROLLER (Option) 19.5 PAR-21MAA PAR-30MAA OCH491B...

  • Page 19: Wiring Diagram

    WIRING DIAGRAM PCA-RP35KAQ PCA-RP50KAQ PCA-RP60KAQ PCA-RP71KAQ PCA-RP100KAQ PCA-RP125KAQ PCA-RP140KAQ PCA-RP50KAQR1 PCA-RP60KAQR1 PCA-RP71KAQR1 [LEGEND] The black square(■)indicates a switch SYMBOL NAME SYMBOL NAME position. INDOOR CONTROLLER BOARD TERMINAL BLOCK (INDOOR/OUTDOOR CONNECTING LINE) CN2L TB5,TB6 TERMINAL BLOCK (REMOTE CONTROLLER <Table 1> CONNECTOR (LOSSNAY)

  • Page 20: Refrigerant System Diagram

    REFRIGERANT SYSTEM DIAGRAM PCA-RP35KAQ PCA-RP50KAQ PCA-RP60KAQ PCA-RP71KAQ PCA-RP100KAQ PCA-RP125KAQ PCA-RP140KAQ PCA-RP50KAQR1 PCA-RP60KAQR1 PCA-RP71KAQR1 Strainer Heat exchanger Refrigerant GAS pipe connection (Flare) Condenser/evaporator temperature thermistor (TH5) Refrigerant flow in cooling Refrigerant flow in heating Refrigerant LIQUID pipe connection (Flare) Pipe temperature...

  • Page 21: Troubleshooting

    TROUBLESHOOTING 10-1. TROUBLESHOOTING <Error code display by self-diagnosis and actions to be taken for service (summary)> Present and past error codes are logged and displayed on the wired remote controller or controller board of outdoor unit. Actions to be taken for service and the trouble reoccurrence at field are summarized in the table below. Check the contents below before investigating details.
  • Page 22 10-2. MALFUNCTION-DIAGNOSIS METHOD BY REMOTE CONTROLLER <In case of trouble during operation> When a malfunction occurs to air conditioner, both indoor unit and outdoor unit will stop and operation lamp blinks to inform unusual stop. < Malfunction-diagnosis method at maintenance service> ■...
  • Page 23 • Refer to the following tables for details on the check codes. [Output pattern A] Beeper sounds Beep Beep Beep Beep Beep Beep Beep OPERATION · · · Repeated INDICATOR lamp flash pattern Approx. 2.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.
  • Page 24 • On wireless remote controller The continuous buzzer sounds from receiving section of indoor unit. Blink of operation lamp • On wired remote controller Check code displayed in the LCD. • If the unit cannot be operated properly after test run, refer to the following table to find the cause. Symptom Cause Wired remote controller...

  • Page 25: Self-Diagnosis Action Table

    Note: Refer to the manual of outdoor unit for the details of display 10-3. SELF-DIAGNOSIS ACTION TABLE such as F, U, and other E. Abnormal point and detection method Countermeasure Error Code Cause 1 Defective thermistor 1–3 Check resistance value of thermistor. Room temperature thermistor (TH1) 1 The unit is in 3-minute resume characteristics...
  • Page 26 Abnormal point and detection method Countermeasure Error Code Cause Freezing/overheating protection is (Cooling or drying mode) (Cooling or drying mode) operating 1 Clogged filter (reduced airflow) 1 Check clogs of the filter. 1 Freezing protection (Cooling mode) 2 Short cycle of air path 2 Remove blockage.
  • Page 27 Abnormal point and detection method Countermeasure Error Code Cause 1 Defective thermistor 1–3 Check resistance value of thermistor. Pipe temperature thermistor/ Condenser-Evaporator (TH5) characteristics For characteristics, refer to (P1) above. 2 Check contact failure of connector (CN44) 1 The unit is in 3-minute resume protection 2 Contact failure of connector on the indoor controller board.
  • Page 28 Abnormal point and detection method Countermeasure Error Code Cause 1 Contact failure, short circuit or, Indoor/outdoor unit communication * Check LED display on the outdoor control circuit board. (Connect A-control service error (Signal receiving error) miswiring (converse wiring) of tool, PAC-SK52ST.) 1 Abnormal if indoor controller board indoor/outdoor unit connecting Refer to outdoor unit service manual.
  • Page 29 Abnormal point and detection method Countermeasure Error Code Cause Abnormal refrigerant circuit 1 When this error occurs, be sure to replace 1 Abnormal operation of 4-way During Cooling, Dry, or Auto Cooling the 4-way valve. valve operation, when the following are 2 Check refrigerant pipes for disconnection or 2 Disconnection of or leakage in regarded as failures when detected for...

  • Page 30: Troubleshooting Of Problems

    10-4. TROUBLESHOOTING OF PROBLEMS Note: Refer to the manual of outdoor unit for the detail of remote controller. Phenomena Cause Countermeasure (1) LED2 on indoor controller board • When LED1 on indoor controller board is also off. is off. 1 Power supply of rated voltage is not supplied to out- 1 Check the voltage of outdoor power door unit.
  • Page 31 Note: Refer to the manual of outdoor unit for the detail of remote controller. Phenomena Cause Countermeasure (2) LED2 on indoor controller board • When LED1 on indoor controller board is also blinking. Check indoor/outdoor unit connecting wire is blinking. Connection failure of indoor/outdoor unit connecting for connection failure.

  • Page 32: Emergency Operation

    10-5. EMERGENCY OPERATION 10-5-1. When wireless remote controller fails or its battery is exhausted 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.
  • Page 33 10-6. HOW TO CHECK THE PARTS PCA-RP35KAQ PCA-RP50KAQ PCA-RP60KAQ PCA-RP71KAQ PCA-RP100KAQ PCA-RP125KAQ PCA-RP140KAQ PCA-RP50KAQR1 PCA-RP60KAQR1 PCA-RP71KAQR1 Parts name Check points Room temperature Disconnect the connector then measure the resistance with a tester. thermistor (TH1) (At the ambient temperature of 10°C~30°C)
  • Page 34 10-6-2. DC Fan motor (fan motor/indoor controller circuit board) Check method of DC fan motor (fan motor/indoor controller circuit board) Notes · High voltage is applied to the connecter (CNMF) for the fan motor. Pay attention to the service. · Do not pull out the connector (CNMF) for the motor with the power supply on. board and fan motor.) (It causes trouble of the indoor controller circuit Self check...
  • Page 35 10-7. TEST POINT DIAGRAM Indoor controller board PCA-RP35KAQ PCA-RP50KAQ PCA-RP60KAQ PCA-RP71KAQ PCA-RP100KAQ PCA-RP125KAQ PCA-RP140KAQ PCA-RP50KAQR1 PCA-RP60KAQR1 PCA-RP71KAQR1 CN2L Emergency operation Connector (LOSSNAY) LED3 Transmission (Indoor/outdoor) Vane motor output (MV) 12V pulse output CN90 Connect to the wireless remote controller board (CNB)
  • Page 36 Setting by the dip switch and jumper wire Remarks Functions For service board Model settings Service board MODELS 1 2 3 4 5 PCA-RP35KAQ 1 2 3 4 5 PCA-RP50KAQ 1 2 3 4 5 PCA-RP60KAQ Capacity settings 1 2 3 4 5 PCA-RP71KAQ...

  • Page 37: Special Function

    SPECIAL FUNCTION 11-1. ROTATION FUNCTION (AND BACK-UP FUNCTION, 2ND STAGE CUT-IN FUNCTION) 11-1-1. Operation (1) Rotation function (and Back-up function) • Outline of functions · Main and sub unit operate alternately according to the interval of rotation setting. * Main and sub unit should be set by refrigerant address. (Outdoor Dip switch setting) Refrigerant address "00"...
  • Page 38 • System constraint · This function is available only in cooling mode. [2nd stage cut-in function]··· Request code number "322~324" Ex.) Set temp. by R/C = 20: Set point = 26: Room temp. Set point Room temp. < Set point -4 When request code number is “323”.
  • Page 39 (2) Setting method of each function by wired remote controller ■ PAR-30MAA/PAR-31MAA Check menu Stop operation ( Error history Refrigerant volume check Refrigerant leak check Smooth maintenance Select "Service" from the Main menu, and press the button. Request code Service menu: Cursor Select "Check"...
  • Page 40 (3) Rotation and back up operation PAR-30MAA/PAR-31MAA Press the button. Main Main menu Maintenance Initial setting Select "Service" with the [Cursor] buttons ( ) or the [Page] buttons ( Service ), and press the button. Main display: Cursor Page Enter the current maintenance password (4 numerical digits). Service menu •...

  • Page 41: Disassembly Procedure

    DISASSEMBLY PROCEDURE PCA-RP35KAQ PCA-RP50KAQ PCA-RP60KAQ PCA-RP71KAQ PCA-RP100KAQ PCA-RP125KAQ PCA-RP140KAQ PCA-RP50KAQR1 PCA-RP60KAQR1 PCA-RP71KAQR1 Be careful when removing heavy parts. (Photo: PCA-RP125KAQ) OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS Figure 1 1. Removing the air intake grille (1) Slide the air intake grille holding knobs (at 2 or 3 loca- tions) to the rear to open the air intake grille.
  • Page 42 OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS 3. Removing the room temperature thermistor (TH1) Photo 4 (1) Remove the air intake grille. (See Figure 1, 2) Casing (2) Remove the beam by removing screws. (See Photo 1) (3) Remove 2 screws from the electrical cover, and remove the electrical cover.
  • Page 43 OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS 5. Removing the fan (3 connection) Photo 9 Fan guard Beam (1) Remove the air intake grille. (See Figure 1, 2) (2) Remove the beam by removing screws. (See Photo 1) (3) Remove 2 screws from the electrical cover, and remove the electrical cover.
  • Page 44 OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS Photo 13 7. Removing the vane motor (1) Remove the air intake. (See Figure 1, 2) Connector (2) Remove the right side panel. (See Figure 3, 4) Vane motor and cover (3) Remove the connector of vane motor. (4) Remove 2 screws of vane motor cover , then remove vane motor.
  • Page 45 OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS 10. Removing the thermistors/Liquid pipe (TH2) and con- Photo 18 denser/evaporator (TH5) (1) Remove the air intake grille. (See Figure 1, 2) (2) Remove the left and right side panels. (See Figure 3,4) (3) Remove the under panel. (See Photo 14) (4) Remove the drain pan.
  • Page 46 Heat exchanger Vane HEAD OFFICE : TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN CCopyright 2010 MITSUBISHI ELECTRIC CORPORATION Distributed in Oct. 2012 No.OCH491 REVISED EDITION-B New publication, effective Oct. 2012 Distributed in Feb. 2012 No.OCH491 REVISED EDITION-A Specifications are subject to change without notice.

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