Service manual

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SERVICE MANUAL

SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS

SPLIT-TYPE, AIR CONDITIONERS

No. OC328

NOTE:

• This manual describes only

service data of the indoor

units.

INDOOR UNIT

REMOTE CONTROLLER

CONTENTS

1. REFERENCE MANUAL ······································2

2. SAFETY PRECAUTION···································3

3. PART NAMES AND FUNCTIONS ···················7

4. SPECIFICATIONS············································9

5. NOISE CRITERION CURVES························13

6. OUTLINES AND DIMENSIONS ·····················15

WIRING DIAGRAM

············································19

REFRIGERANT SYSTEM DIAGRAM

··················20

9. TROUBLESHOOTING ···································21

10. DISASSEMBLY PROCEDURE ······················33

11. PARTS LIST ···················································38

ON/OFF

TEMP.

Indoor unit

[Model names] [Service Ref.]

PCA-RP50GA PCA-RP50GA

PCA-RP60GA PCA-RP60GA

PCA-RP71GA PCA-RP71GA

PCA-RP100GA PCA-RP100GA

PCA-RP125GA PCA-RP125GA

PCA-RP140GA PCA-RP140GA

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 2005

OC328--1.qxp 05.5.17 9:30 AM Page 1

Summary of content (48 pages)

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OC328--1.qxp 05.5.17 9:30 AM Page 1 SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS SPLIT-TYPE, AIR CONDITIONERS May 2005 No. OC328 SERVICE MANUAL Indoor unit [Model names] NOTE: • This manual describes only service data of the indoor units. [Service Ref.
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OC328--1.qxp 1 05.5.17 9:30 AM Page 2 REFERENCE MANUAL 1-1. OUTDOOR UNIT’S SERVICE MANUAL Service Manual No. Service Ref. PUHZ-RP35/50/60/71/100/125/140VHA PUHZ-RP100/125/140YHA PUHZ-RP71/100/125/140VHA-A OC334 PUHZ-RP200/250YHA OC338 PUHZ-RP200/250YHA-A OC339 PU(H)-P·VGAA.UK PU(H)-P·YGAA.UK SUZ-KA·VA.TH OC336 OC337 OC322 1-2. TECHNICAL DATA BOOK Manual No. Series (Outdoor unit) PUHZ-RP·VHA(-A) PUHZ-RP·YHA(-A) PU(H)-P·VGAA.UK PU(H)-P·YGAA.
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OC328--1.qxp 05.5.17 9:30 AM 2 Page 3 SAFETY PRECAUTION CAUTIONS RELATED TO NEW REFRIGERANT Cautions for units utilising refrigerant R407C Do not use the existing refrigerant piping. Use liquid refrigerant to charge the system. 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.
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OC328--1.qxp 05.5.17 9:30 AM Page 4 [3] Service tools Use the below service tools as exclusive tools for R407C refrigerant. No. 1 Tool name Specifications Gauge manifold ·Only for R407C. ·Use the existing fitting SPECIFICATIONS. (UNF7/16) ·Use high-tension side pressure of 3.43MPa·G or over. 2 Charge hose 3 Electronic scale 4 Gas leak detector ·Use the detector for R134a or R407C. 5 Adapter for reverse flow check. ·Attach on vacuum pump. 6 Refrigerant charge base.
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OC328--1.qxp 05.5.17 9:30 AM Page 5 CAUTIONS RELATED TO NEW REFRIGERANT Cautions for units utilising refrigerant R410A Use new refrigerant pipes. Do not use refrigerant other than R410A. In case of using the existing pipes for R22, be careful with the followings. · For RP100, 125 and 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. If other refrigerant (R22 etc.
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OC328--1.qxp 05.5.17 9:30 AM Page 6 Unit Gravimeter [3] Service tools Use the below service tools as exclusive tools for R410A refrigerant. No. 1 Specifications 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.
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OC328--1.qxp 05.5.17 9:30 AM 3 Page 7 PART NAMES AND FUNCTIONS ● Indoor Unit Left/right guide vanes Change the direction of airflow from the horizontal blower. Air outlet 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.
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OC328--1.qxp 05.5.17 9:30 AM Page 8 ● Display “Sensor” indication Displayed when the remote controller sensor is used. Day-of-Week For purposes of this explanation, all parts of the display are shown as lit. During actual operation, only the relevant items will be lit. Shows the current day of the week. Time/Timer Display “Locked” indicator Shows the current time, unless the simple or Auto Off timer is set. If the simple or Auto Off timer is set, shows the time remaining.
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OC328--1.qxp 05.5.17 9:30 AM Service Ref. Mode Power supply(phase, cycle, voltage) kW Input A Running current A Starting current External finish Heat exchanger Fan Fan(drive) x No. kW Fan motor output Airflow(Low-Medium2-Medium1-High) K/min(CFM) Pa(mmAq) External static pressure Operation control & Thermostat dB Noise level(Low-Medium2-Medium1-High) mm(in.) Unit drain pipe I.D. mm(in.) Dimensions W mm(in.) D mm(in.) H kg(lbs) Weight Service Ref.
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INDOOR UNIT Page 10 Service Ref. Mode Power supply(phase, cycle, voltage) kW Input A Running current A Starting current External finish Heat exchanger Fan Fan(drive) x No. kW Fan motor output Airflow(Low-Medium2-Medium1-High) K/min(CFM) Pa(mmAq) External static pressure Operation control & Thermostat dB Noise level(Low-Medium2-Medium1-High) mm(in.) Unit drain pipe I.D. mm(in.) Dimensions W mm(in.) D mm(in.) H kg(lbs) Weight INDOOR UNIT 05.5.17 9:30 AM Service Ref.
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INDOOR UNIT Page 11 Service Ref. Mode Power supply(phase, cycle, voltage) Input w1 kW Running current w1 A Starting current w1 A External finish Heat exchanger Fan Fan(drive) x No. Fan motor output kW Airflow(Low-Medium2-Medium1-High) K/min(CFM) External static pressure Pa(mmAq) Booster heater w1 kW Operation control & Thermostat Noise level(Low-Medium2-Medium1-High) dB Unit drain pipe I.D. mm(in.) Dimensions mm(in.) W mm(in.) D mm(in.) H Weight kg(lbs) INDOOR UNIT 05.5.17 9:30 AM Service Ref.
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INDOOR UNIT Page 12 . Service Ref Mode Power supply(phase, cycle, voltage) Input w1 kW Running current w1 A Starting current w1 A External finish Heat exchanger Fan Fan(drive) x No. Fan motor output kW Airflow(Low-Medium2-Medium1-High) K/min(CFM) External static pressure Pa(mmAq) Booster heater w1 kW Operation control & Thermostat Noise level(Low-Medium2-Medium1-High) dB Unit drain pipe I.D. mm(in.) Dimensions mm(in.) W mm(in.) D mm(in.) H Weight kg(lbs) INDOOR UNIT 05.5.17 9:30 AM Service Ref.
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05.5.17 9:30 AM 5 Page 13 NOISE CRITERION CURVES NOTCH SPL(dB) 42 High 40 Medium1 38 Medium2 37 Low LINE PCA-RP60GA PCA-RP71GA PCH-P60GAH PCH-P71GAH 90 90 80 80 70 NC-70 60 NC-60 50 NC-50 40 NC-40 30 NC-30 20 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 µbar) OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.
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OC328--1.qxp 05.5.17 9:30 AM Page 14 PCA-RP140GA PCH-P140GAH NOTCH SPL(dB) High 48 Medium1 46 Medium2 44 Low 42 LINE OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 µbar) 90 80 70 NC-70 60 NC-60 50 NC-50 40 NC-40 30 NC-30 20 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE NC-20 10 63 125 250 500 1000 2000 4000 8000 BAND CENTER FREQUENCIES, Hz ceiling 1m 1m about 1.
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OC328--1.qxp 05.5.17 9:30 AM Page 15 OUTLINES AND DIMENSIONS 6 INDOOR UNIT PCA-RP50GA PCH-P50GAH Unit : mm NOTES: 1. Use M10 or W3/8 screws for anchor bolt. 2. When optional drain lift-up mechanism is installed, always provide upward piping for refrigerant piping.
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OC328--1.qxp 05.5.17 9:30 AM Page 16 Unit : mm PCA-RP60GA PCA-RP71GA PCH-P60GAH PCH-P71GAH NOTES: 1. Use M10 or W3/8 screws for anchor bolt. 2. When optional drain lift-up mechanism is installed, always provide upward piping for refrigerant piping.
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OC328--1.qxp 05.5.17 9:30 AM Page 17 PCA-RP100GA PCH-P100GAH Unit : mm NOTES: 1. Use M10 or W3/8 screws for anchor bolt. 2. When optional drain lift-up mechanism is installed, always provide upward piping for refrigerant piping.
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OC328--1.qxp 05.5.17 9:30 AM Page 18 PCA-RP125GA PCA-RP140GA PCH-P125GAH PCH-P140GAH Unit : mm NOTES: 1. Use M10 or W3/8 screws for anchor bolt. 2. When optional drain lift-up mechanism is installed, always provide upward piping for refrigerant piping.
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05.5.17 9:30 AM Page 19 WIRING DIAGRAM 7 PCA-RP50GA PCA-RP100GA PCH-P50GAH PCH-P100GAH NAME INDOOR POWER BOARD INDOOR CONTROLLER BOARD FUSE (T6.3AL250V) VARISTOR CONNECTOR(LOSSNAY) CONNECTOR(REMOTE SWITCH) CONNECTOR(HA TERMINAL-A) CONNECTOR(CENTRALLY CONTROL) SWITCH (MODEL SELECTION) WSee Table 1. SWITCH (CAPACITY CODE) WSee Table 2. SWITCH(EMERGENCY OPERATION) RELAY(DRAIN PUMP) RELAY(FAN MOTOR) FAN CONTROL ELEMENT POWER SUPPLY(I.B) POWER SUPPLY(R.
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OC328--1.qxp 8 05.5.
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OC328--1.qxp 05.5.17 9:30 AM 9 Page 21 TROUBLESHOOTING 9-1. TROUBLESHOOTING 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 inferior phenomenon reoccurrence at field are summarized in the table below. Check the contents below before investigating details.
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OC328--1.qxp 05.5.17 9:30 AM Page 22 9-2. SELF-DIAGNOSIS ACTION TABLE Error Code Meaning of error code and detection method Abnormality of room temperature thermistor (TH1) 1 The unit is in three-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after three minutes. (The unit returns to normal operation, if it has normally reset.) 2 Constantly detected during cooling, drying, and heating operation.
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OC328--1.qxp 05.5.17 9:30 AM Page 23 Error Code Meaning of error code and detection method Freezing/overheating protection is working 1 Freezing protection (Cooling mode) The unit is in six-minute resume prevention mode if pipe temperature stays under -15: for three minutes, three minutes after the compressor started. Abnormal if it stays under -15: for three minutes again within 16 minutes after six-minute resume prevention mode.
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OC328--1.qxp 05.5.17 9:30 AM Page 24 Error Code Meaning of error code and detection method Abnormality of pipe temperature thermistor / Condenser-Evaporator (TH5) 1 The unit is in three-minute resume protection mode if short/open of thermistor is detected. Abnormal if the unit does not get back to normal within three minutes. (The unit returns to normal operation, if it has normally reset.
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OC328--1.qxp 05.5.17 9:30 AM Page 25 Error Code Meaning of error code and detection method Indoor/outdoor unit communication error (Signal receiving error) 1 Abnormal if indoor controller board cannot receive any signal normally for six minutes after putting the power on. 2 Abnormal if indoor controller board cannot receive any signal normally for three minutes.
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OC328--1.qxp 05.5.17 9:30 AM Page 26 9-3. TROUBLESHOOTING BY INFERIOR PHENOMENA Note: Refer to the manual of outdoor unit for the detail of remote controller. Phenomena (1)LED2 on indoor controller board is off. Cause • When LED1 on indoor controller board is also off. 1 Power supply of rated voltage is not supplied to outdoor unit. 2 Defective outdoor controller circuit board. 3 Power supply of 220~240V is not supplied to indoor unit. 4 Defective indoor power board.
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OC328--1.qxp 05.5.17 9:30 AM Page 27 Note: Refer to the manual of outdoor unit for the detail of remote controller. Phenomena Cause Countermeasure (2)LED2 on indoor controller board is blinking. • When LED1 on indoor controller board is also blinking. Check indoor/outdoor unit connecting wire Connection failure of indoor/outdoor unit connecting for connection failure. wire • When LED1 is lit.
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OC328--1.qxp 05.5.17 9:30 AM Page 28 9-4. When wired remote controller or indoor unit micro computer troubles 1. If there is not any other wrong when trouble occurs, emergency operation starts as the indoor controller board switch (SWE) is set to ON. During the emergency operation the indoor unit is as follows; (1) Indoor fan high speed operation (2) Drain-up machine operation 2.
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OC328--1.qxp 05.5.17 9:30 AM Page 29 9-5. HOW TO CHECK THE PARTS PCH-P50 / 60 / 71 / 100 / 125 / 140GAH PCA-RP50 / 60 / 71 / 100 / 125 / 140GA Parts name Check points Room temperature thermistor (TH1) Disconnect the connector then measure the resistance using a tester. (Surrounding temperature 10:~30:) Pipe temperature thermistor (TH2) Condenser/evaporator temperature thermistor (TH5) Fan motor Relay connector 1 Red 2 White 3 Black 1 2 Normal Abnormal 4.3k"~9.
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OC328--1.qxp 05.5.17 9:30 AM Page 30 < Thermistor for lower temperature > Room temperature thermistor(TH1) Pipe temperature thermistor(TH2) Condenser/evaporator temperature thermistor(TH5) Thermistor R0=15kΩ ± 3% Fixed number of B=3480 ± 2% Rt=15exp { 3480( 0: 10: 20: 25: 30: 40: 1 273+t 40 Resistance (k") Thermistor for lower temperature 50 1 )} 273 15kΩ 9.6kΩ 6.3kΩ 5.4kΩ 4.3kΩ 3.0kΩ 30 20 10 0 -20 -10 0 10 20 30 40 50 Temperature (:) 9-6.
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OC328--2.qxp 05.5.17 9:28 AM Page 31 9-6-2. Indoor controller board PCA-RP50GA PCA-RP60GA PCA-RP71GA PCA-RP100GA PCA-RP125GA PCA-RP140GA PCH-P50GAH PCH-P60GAH PCH-P71GAH PCH-P100GAH PCH-P125GAH PCH-P140GAH CN3C Transmission (Indoor/outdoor) (0~24V DC) CN2D Connect to the indoor power board (CN2S) (12.5~13.7V DC) LED1 Power supply (I.B) LED2 Power supply (R.B) LED3 Transmission (Indoor/outdoor) CN22 Connect to the terminal block(TB5) (Remote controller connecting wire) (10.4~14.
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OC328--2.qxp 05.5.17 9:28 AM Page 32 9-7. FUNCTIONS OF DIP SWITCH AND JUMPER WIRE Each function is controlled by the dip switch and the jumper wire on control p.c. board. SW1 and SW2 are equipped only for service parts. Model setting and capacity setting are memorized in the nonvolatile memory of the control p.c. board of the unit.
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OC328--2.qxp 05.5.17 9:28 AM 10 Page 33 DISASSEMBLY PROCEDURE PCH-P71GAH, PCA-RP71GA OPERATING PROCEDURE PHOTOS&ILLUSTRATIONS 1. Removing the air intake grille (1) Slide the intake grille holding 2 knobs backward to open the intake grill. (2) When the intake grille left open, push the stoppers on the rear 2 hinges to pull out the intake grille. Figure 1 Intake grill slide Intake grill Holding knobs Hinges Pull out the intake grill 2.
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OC328--2.qxp 05.5.17 9:28 AM Page 34 OPERATING PROCEDURE PHOTOS&ILLUSTRATIONS 3. Removing the fan motor (1) Remove the intake grille. (See the figure 1) (2) Disconnect the fan motor connector. (3) Remove screws for removing the motor guard. (4) Remove screws for removing the fan guard. (5) Remove the screw for removing the motor support at both left and right side. (6) Loosen the set screws at the fan motor side of the connecting joint. (7) Slide the fan motor to the left side and pull it out.
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OC328--2.qxp 05.5.17 9:28 AM Page 35 OPERATING PROCEDURE PHOTOS 6. Removing the vane motor (1) Remove the air intake grille. (See the figure 1) (2) Remove the left side panel. (See the figure 3) (3) Remove the relay connector of vane motor. (4) Remove the electrical box. (5) Remove the screws of vane motor, then remove vane motor. (Note) Connect the lead wires and connectors properly and place them in the proper position so that the wires are not pinched by other parts.
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OC328--2.qxp 05.5.17 9:28 AM Page 36 OPERATING PROCEDURE PHOTOS 9. Removing the drain pan (1) Remove the air intake grille. (See the figure 1) (2) Remove the beam. (3) Remove the side panels of right and left. (See the figure 3) (4) Remove the under panel. Remove the screws of the right and left side drain pan. (5) Remove the 2 insulations in centre of the drain pan, and after removing the 2 screws, remove the drain pan.
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OC328--2.qxp 05.5.17 9:28 AM Page 37 OPERATING PROCEDURE PHOTOS 12. Removing the electric heater. (PCH only) (1) Remove the air intake grille. (See the figure 1) (2) Remove the beam. (3) Remove the electrical box cover and disconnect the connector (6P red) of the heater. (4) Loosen 2 clamps for the heater lead wires. (5) Remove the side panel (right and left). (See the figure 3) (6) Remove the under panel. (See the photo 7) (7) Remove the drain pan.
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OC328--2.qxp 05.5.17 9:28 AM 11 Page 38 PARTS LIST FAN AND HEATER PARTS PCH-P50GAH PCA-RP50GA 18 17 16 15 2 3 1 4 5 14 13 2 12 3 6 11 7 8 10 9 Q'ty / set No. Parts No.
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OC328--2.qxp 05.5.17 9:28 AM Page 39 FAN AND HEATER PARTS PCH-P60GAH, PCA-RP60GA PCH-P71GAH, PCA-RP71GA 22 21 23 20 19 1 2 3 18 17 4 16 15 14 5 6 7 5 8 13 9 10·11 12 Q'ty / set No. Parts No. Parts Name PCHPCASpecifications P60 P71 RP60 RP71 GAH GAH GA GA Remarks (Drawing No.
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OC328--2.qxp 05.5.17 9:28 AM Page 40 FAN AND HEATER PARTS PCH-P100GAH PCA-RP100GA 22 21 23 20 1 19 2 3 4 18 5 17 16 6 15 7 8 14 5 13 9 12 10·11 Q'ty / set No. Parts No.
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OC328--2.qxp 05.5.17 9:28 AM Page 41 24 FAN AND HEATER PARTS PCH-P125GAH, PCA-RP125GA PCH-P140GAH, PCA-RP140GA 3 2 1 23 25 4 22 21 5 6 7 20 8 19 9 17·18 16 10 11 9 12 15 13 14 Q'ty / set No. Parts No.
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OC328--2.qxp 05.5.17 9:28 AM Page 42 STRUCTURAL PART PCA-RP50GA PCH-P50GAH 26 25 24 23 22 21 20 1 2 19 3 4 18 17 16 15 5 6 7 8 9 10 11 12 13 14 Part number that is circled is not shown in the figure. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Parts No.
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OC328--2.qxp 05.5.17 9:28 AM Page 43 STRUCTURAL PART PCA-RP60GA PCA-RP71GA PCA-RP100GA PCH-P60GAH PCH-P71GAH PCH-P100GAH 25 24 23 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 10 11 12 13 Part number that is circled is not show in the figure. No. Parts No.
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OC328--2.qxp 05.5.17 9:28 AM Page 44 STRUCTURAL PART PCA-RP125GA PCA-RP140GA PCH-P125GAH PCH-P140GAH 27 26 25 24 23 22 21 1 2 20 3 4 5 6 19 18 17 16 15 14 7 8 10 11 9 12 13 Part number that is circled is not shown in the figure. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Parts No.
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OC328--2.qxp 05.5.17 9:28 AM Page 45 ELECTRICAL PARTS PCA-RP50GA PCA-RP60GA PCA-RP71GA PCA-RP100GA PCA-RP125GA PCA-RP140GA 7 6 1 2 3 4 5 TEMP. ON/OFF 10 9 8 No. Parts No. Parts Name Specifications R01 30L 255 CAPACITOR 3= 440V 1 T7W 39J 255 CAPACITOR 4= 440V R01 A13 255 CAPACITOR 6= 440V R01 E02 239 FUSE 250V 6.3A 50 , Q ty PCA-RP 60/71 100 125/140 GA Wiring RecomRemarks Diagram mended (Drawing No.
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OC328--2.qxp 05.5.17 9:28 AM Page 46 ELECTRICAL PARTS PCH-P50GAH, PCH-P100GAH PCH-P60GAH, PCH-P125GAH PCH-P71GAH, PCH-P140GAH 9 8 1 7 2 3 4 5 6 TEMP. ON/OFF 12 10 No. Parts No. Parts Name 11 Specifications R01 30L 255 CAPACITOR 3= 440V T7W 39J 255 CAPACITOR 4= 440V R01 A13 255 CAPACITOR 6= 440V 2 R01 E02 239 FUSE 250V 6.
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OC328--2.qxp 05.5.17 9:28 AM Page 48 TM HEAD OFFICE : MITSUBISHI DENKI BLDG., 2-2-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN CCopyright 2005 MITSUBISHI ELECTRIC ENGINEERING CO., LTD. Distributed in May 2005 No.OC328 PDF 9 Made in Japan. New publication, effective May 2005. Specifications subject to change without notice.