SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS SPLIT-TYPE, AIR CONDITIONERS February 2012 No. OCH491 REVISED EDITION-A SERVICE MANUAL Indoor unit [Model names] PCA-RP50KAQ PCA-RP60KAQ PCA-RP71KAQ PCA-RP100KAQ PCA-RP125KAQ PCA-RP140KAQ [Service Ref.] PCA-RP50KAQ PCA-RP60KAQ PCA-RP71KAQ PCA-RP100KAQ PCA-RP125KAQ PCA-RP140KAQ Revision: • SUZ-KA50/60/71VA3.TH-A have been added as connectable outdoor units in REVISED EDITION-A. • Some descriptions have been modified. • Please void OCH491.
1 REFERENCE MANUAL 1-1. 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 PUHZ-RP100/125/140/200/250YKA PUHZ-RP200YKAR1 OCH451 OCB451 PU(H)-P71/100VHAR3.UK PU(H)-P71/100/125/140YHAR3.UK OC379 PUHZ-P100/125/140VHA3R2.UK PUHZ-P100/125/140YHAR1.UK OCH415 / OCB415 PUHZ-P200/250YHA3R2 OCH424 / OCB424 SUZ-KA50/60/71VA2.TH OCH472 SUZ-KA50/60/71VA2.TH-A OCH473 1-2.
2 SAFETY PRECAUTION 2-1. ALWAYS OBSERVE FOR SAFETY Before obtaining access to terminal, all supply circuits must be disconnected. 2-2. CAUTIONS RELATED TO NEW REFRIGERANT Cautions for units utilising refrigerant R410A Use a vacuum pump with a reverse flow check valve. Use new refrigerant pipes. 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.
[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.
3-2. 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. MODEL SELECT display display Blinks when model is selected. Lights up while the signal is transmitted to the indoor unit when the button is pressed. Temperature setting display Indicates the desired temperature setting which is set. CLOCK display OPERATION MODE display Displays the current time.
3-3. WIRED REMOTE CONTROLLER (OPTION) * 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." The factory setting is "Full." Display 13 15 12 14 16 17 18 Full mode Fri 6 7 8 9 10 1 11 20 Room Set temp. Cool 3 19 Auto 4 1 Operation mode 12 Indoor unit operation mode appears here. Appears when the buttons are locked. 2 Preset temperature 13 Preset temperature appears here.
Main menu list Setting and display items Setting details Vane · Louver · Vent. (Lossnay) Use to set the vane angle. • Select a desired vane setting from five different settings. Use to turn ON / OFF the louver. • Select a desired setting from "ON" and "OFF." Use to set the amount of ventilation. • Select a desired setting from "Off," "Low," and "High." High power Use to reach the comfortable room temperature quickly. • Units can be operated in the High-power mode for up to 30 minutes.
3-4. WIRED REMOTE CONTROLLER (OPTION) * The functions which can be used are restricted according to the model. Display Section For purposes of this explanation, all parts of the display are shown. During actual operation, only the relevant items will be lit. “Sensor” indication Day-of-Week Displays when the remote controller sensor is used. 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.
4 SPECIFICATIONS INDOOR UNIT INDOOR UNIT INDOOR UNIT 4-1. SPECIFICATIONS Service Ref. Mode Power supply(phase, cycle, voltage) kW Input A Running current External finish Heat exchanger Fan Fan(drive) × No. kW Fan motor output Airflow(Low-Medium2-Medium1-High) */min(CFM) Pa(mmAq) External static pressure Operation control & Thermostat dB Noise level(Low-Medium2-Medium1-High) mm(in.) Field drain pipe O.D. mm(in.) Dimensions W mm(in.) D mm(in.) H kg(lbs) Weight PCA-RP50KAQ Cooling 0.05 0.37 0.05 0.
INDOOR UNIT INDOOR UNIT INDOOR UNIT Service Ref. Mode Power supply(phase, cycle, voltage) kW Input A Running current External finish Heat exchanger Fan Fan(drive) × No. kW Fan motor output Airflow(Low-Medium2-Medium1-High) */min(CFM) Pa(mmAq) External static pressure Operation control & Thermostat dB Noise level(Low-Medium2-Medium1-High) mm(in.) Field drain pipe O.D. mm(in.) Dimensions W mm(in.) D mm(in.) H kg(lbs) Weight PCA-RP100KAQ Cooling 0.09 0.65 OCH491A 0.09 0.65 Munsell 6.4Y 8.9/0.
4-2.
5 NOISE CRITERION CURVES NOTCH SPL(dB) 40 High 37 Medium1 34 Medium2 32 Low PCA-RP60KAQ LINE 90 90 80 80 70 NC-70 60 NC-60 50 NC-50 40 NC-40 30 NC-30 20 10 OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 μbar) OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.
NOTCH SPL(dB) High 45 Medium1 43 Medium2 41 Low 39 LINE PCA-RP140KAQ PCA-RP140GA PCA-RP140GA#1 PCH-P140GAH 90 90 80 80 70 NC-70 60 NC-60 50 NC-50 40 NC-40 30 NC-30 20 10 OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.0002 μbar) OCTAVE BAND SOUND PRESSURE LEVEL, dB (0 dB = 0.
1 2 3 4 5 6 7 8 9 121 Ceiling 461 25 ø1 9 38 38 7 387 18 120° 85 14 2 48 233 246 When drain socket is installed (Drainage) 2 2 Drainage pipe connection(26mmI.D.
121 169 37 190 46 1 2 3 4 5 6 7 8 9 461 25 ø1 9 38 7 387 18 120° 2 8 48 246 233 (Drainage) When drain socket is installed 138 85 86 260 2 Drainage pipe connection(26mmI.D.
1 2 3 4 5 6 7 8 9 16 190 46 Electrical box 461 25 ø1 Ceiling 9 38 24 38 7 387 18 120° Electrical box 2 8 48 233 246 When drain socket is installed (Drainage) 138 260 85 86 1 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) When electrical box is pulled down 76 124 2 4 2 Drainage pipe connection(26mmI.D.
WIRED REMOTE CONTROLLER Unit : mm (Option) 19.5 130 83.5 120 PAR-21MAA 46 19 120 120 PAR-30MAA 83.
7 WIRING DIAGRAM PCA-RP50KAQ PCA-RP100KAQ PCA-RP60KAQ PCA-RP125KAQ PCA-RP71KAQ PCA-RP140KAQ [LEGEND] SYMBOL I.B CN2L CN32 CN41 CN51 FUSE LED1 LED2 LED3 SW1 SW2 SWE X1 R.B DCL MF MV TB2 NAME INDOOR CONTROLLER BOARD CONNECTOR (LOSSNAY) CONNECTOR (REMOTE SWITCH) CONNECTOR (HA TERMINAL-A) CONNECTOR (CENTRALLY CONTROL) FUSE (T6.3AL250V) POWER SUPPLY (I.B) POWER SUPPLY (R.
8 REFRIGERANT SYSTEM DIAGRAM PCA-RP50KAQ PCA-RP100KAQ PCA-RP60KAQ PCA-RP125KAQ PCA-RP71KAQ PCA-RP140KAQ Strainer #50 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) Room temperature thermistor (TH1) Pipe temperature thermistor/liquid (TH2) Distributor with strainer 1/2 #50/#50 OCH491A Strainer #50 19
9 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 trouble reoccurrence at field are summarized in the table below. Check the contents below before investigating details.
9-2. MALFUNCTION-DIAGNOSIS METHOD BY REMOTE CONTROLLER When a malfunction occurs to air conditioner, both indoor unit and outdoor unit will stop and operation lamp blinks to inform unusual stop. ■ Wireless remote controller (Option) [Procedure] Refrigerant address display CHECK CHECK display Temperature button TEMP ON/OFF 1. Press the CHECK button twice. • "CHECK" lights, and refrigerant address "00" flashes.
• Refer to the following tables for details on the check codes. [Output pattern A] Beeper sounds OPERATION INDICATOR lamp flash pattern Beep Beep Beep Beep Off Beep 1st 2 nd 3 rd nth On On On On Beep Beep 1st Off On 2 nd · · · Repeated On 0.5 sec. Approx. 2.5 sec. 0.5 sec. 0.5 sec. Self-check Approx. 2.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.
• 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.
9-3. SELF-DIAGNOSIS ACTION TABLE Error Code P1 Abnormal point and detection method Room temperature thermistor (TH1) 1 The unit is in 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally.) 2 Constantly detected during cooling, drying, and heating operation.
Error Code P6 P8 Abnormal point and detection method Freezing/overheating protection is operating 1 Freezing protection (Cooling mode) The unit is in 6-minute resume prevention mode if pipe temperature stays under -15: for 3 minutes, 3 minutes after the compressor started. Abnormal if it stays under -15: for 3 minutes again within 16 minutes after 6-minute resume prevention mode.
Error Code P9 Abnormal point and detection method Pipe temperature thermistor/ Condenser-Evaporator (TH5) 1 The unit is in 3-minute resume protection mode if short/open of thermistor is detected. Abnormal if the unit does not get back to normal within 3 minutes. (The unit returns to normal operation, if it has been reset normally.
Error Code E6 E7 Fb (FB)* E1 or E2 PA Abnormal point and detection method Indoor/outdoor unit communication error (Signal receiving error) 1 Abnormal if indoor controller board cannot receive any signal normally for 6 minutes after turning the power on. 2 Abnormal if indoor controller board cannot receive any signal normally for 3 minutes.
9-4. TROUBLESHOOTING OF PROBLEMS 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.
Note: Refer to the manual of outdoor unit for the detail of remote controller. Phenomena (2) LED2 on indoor controller board is blinking. Cause Countermeasure • 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.
9-5. EMERGENCY OPERATION 9-5-1. 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 controller malfunctions, the emergency operation can be done using the emergency buttons on the grille.
9-6. HOW TO CHECK THE PARTS PCA-RP50KAQ PCA-RP60KAQ PCA-RP100KAQ PCA-RP125KAQ PCA-RP71KAQ PCA-RP140KAQ Parts name Check points Room temperature thermistor (TH1) Liquid pipe thermistor (TH2) Condenser/evaporator temperature thermistor (TH5) Disconnect the connector then measure the resistance with a tester. (At the ambient temperature of 10°C~30°C) Vane motor (MV) Measure the resistance between the terminals with a tester.
9-6-2. 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. (It causes trouble of the indoor controller circuit board and fan motor.) Self check Symptom : The indoor fan cannot turn around.
9-7. TEST POINT DIAGRAM Indoor controller board PCA-RP50KAQ PCA-RP100KAQ PCA-RP60KAQ PCA-RP125KAQ PCA-RP71KAQ PCA-RP140KAQ SWE Emergency operation CN2L Connector (LOSSNAY) LED3 Transmission (Indoor/outdoor) CNV Vane motor output (MV) 12V pulse output CN90 Connect to the wireless remote controller board (CNB) SW1 Model selection SW2 Capacity setting LED2 Power supply (R.B) CN4F Drain float switch (FS) (option) Jumper wire J41,J42 Pair No.
9-8. 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. (Marks in the table below) Jumper wire ( : Short : Open) The black square (■) indicates a switch position.
10 SPECIAL FUNCTION 10-1. ROTATION FUNCTION (AND BACK-UP FUNCTION, 2ND STAGE CUT-IN FUNCTION) 10-1-1. Operation (1) Rotation function (and Back-up function) • Outline of functions · Main and sub unit operate alternately according to the interval of rotation setting. w Main and sub unit should be set by refrigerant address. (Outdoor Dip switch setting) Refrigerant address "00" Main unit Refrigerant address "01" Sub unit · When error occurs to one unit, another unit will start operation.
• System constraint · This function is available only in cooling mode. Ex.) Set temp. by R/C = 20: Set point = 26: When request code number is “323”. 26: 2nd unit Cut-in [2nd stage cut-in function]··· Request code number "322~324" Start operation Main unit IC-1 Room temp. Set point Sub unit start operation Room temp. < Set point -4 Sub unit stop Run 4 degree C 22: 2nd unit Cut-out Sub unit IC-2 Stop Run 20: 10-1-2.
(2) Setting method of each function by wired remote controller ■ PAR-30MAA Stop operation ( Check menu Error history Refrigerant volume check Refrigerant leak check Smooth maintenance Request code Service menu: ) Select "Service" from the Main menu, and press the button. Cursor Select "Check" with the F1 or F2 button, and press the button. F1 Select "Request code" with the F1 or F2 button, and press the F2 F3 F4 button. Set the Refrigerant address and Request code. Request code Ref.
■ PAR-21MAA B: Refrigerant address C: Data display area D: Request code display area 1. Stop operation( ). 2. Press the TEST button ( ) for 3 seconds so that [Maintenance mode] appears on the screen ( ). After a while, [00] appears in the refrigerant address number display area.(at ) 3. Press the CHECK button ( ) for 3 seconds to switch to [Maintenance monitor]. Note) It is not possible to switch to [Maintenance monitor] during data request in maintenance mode (i.e.
11 DISASSEMBLY PROCEDURE PCA-RP50KAQ PCA-RP100KAQ PCA-RP60KAQ PCA-RP125KAQ PCA-RP71KAQ PCA-RP140KAQ OPERATING PROCEDURE Be careful when removing heavy parts. (Photo: PCA-RP125KAQ) PHOTOS & ILLUSTRATIONS 1. Removing the air intake grille (1) Slide the air intake grille holding knobs (at 2 or 3 locations) to the rear to open the air intake grille. (See Figure 1) (2) While the air intake grille left open, push the stoppers on the rear hinges (at 2 or 3 locations) to pull out the air intake grille.
OPERATING PROCEDURE 3. Removing the room temperature thermistor (TH1) (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. (4) Remove 2 screws from the electrical box and pull the electrical box downward. Temporarily secure the electrical box using 2 hooks in the back of electrical box. (5) Disconnect the connector CN20 (red) from the indoor controller board.
OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS 5. Removing the fan (3 connection) (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. (4) Remove 2 screws from the electrical box and pull the electrical box downward. Temporarily secure the electrical box using 2 hooks in the back of electrical box. (5) Remove 4 screws from the fan guard of the fan motor.
OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS Photo 13 7. Removing the vane motor (1) Remove the air intake. (See Figure 1, 2) (2) Remove the right side panel. (See Figure 3, 4) (3) Remove the connector of vane motor. (4) Remove 2 screws of vane motor cover , then remove vane motor. Vane motor and cover Connector Screws 8. Removing the under panel (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 beam.
OPERATING PROCEDURE PHOTOS & ILLUSTRATIONS 10. Removing the thermistors/Liquid pipe (TH2) and condenser/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. (See Photo 15, 16, 17) (5) Disconnect the connector CN44 (white) from the indoor controller board. (6) Remove 6 screws from the pipe cover and remove the pipe cover.
OPERATING PROCEDURE 13. Removing the heat exchanger (1) Remove the air intake grille. (See Figure 1, 2) (2) Remove the beam. (See Photo 1) (3) Remove the electrical cover. (See Photo 1) (4) Pull the electrical box downward. (See Photo 2) (5) Remove the left and right side panels. (See Figure 3) (6) Remove the under panel. (See Photo 14) (7) Remove the drain pan. (See Photo 15,16,17) (8) Remove the pipe cover. (See Photo 18) (9) Remove the pipe thermistors (TH2 and TH5) from each holder.
