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Mitsubishi Electric MR. SLIM PCA Series Service Manual
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Mitsubishi Electric MR. SLIM PCA Series Service Manual

Mitsubishi Electric MR. SLIM PCA Series 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 Name]
PCA-M35KA
PCA-M35KA-ER
PCA-M50KA
PCA-M50KA-ER
PCA-M60KA
PCA-M60KA-ER
PCA-M71KA
PCA-M71KA-ER
PCA-M100KA
PCA-M100KA-ER
PCA-M125KA
PCA-M125KA-ER
PCA-M140KA
PCA-M140KA-ER
INDOOR UNIT
[Service Ref.]
PCA-M35KA
PCA-M35KA-ER
PCA-M50KA
PCA-M50KA-ER
PCA-M60KA
PCA-M60KA-ER
PCA-M71KA
PCA-M71KA-ER
PCA-M100KA
PCA-M100KA-ER
PCA-M125KA
PCA-M125KA-ER
PCA-M140KA
PCA-M140KA-ER
Model name
indication
R32/R410A
CONTENTS
1. REFERENCE MANUAL ................................... 2
2. SAFETY PRECAUTION ................................... 3
3. PARTS NAMES AND FUNCTIONS ................. 8
4. SPECIFICATIONS .......................................... 13
5. NOISE CRITERION CURVES ....................... 17
6. OUTLINES AND DIMENSIONS ..................... 19
7. WIRING DIAGRAM ............................................. 23
9. TROUBLESHOOTING ................................... 25
10. FUNCTION SETTING ..................................... 41
11. SPECIAL FUNCTION ..................................... 42
12. DISASSEMBLY PROCEDURE ....................... 46
PARTS CATALOG (OCB659)
November 2018
No. OCH659
REVISED EDITION-A
Notes:
• Added
PCA-M35KA-ER,
PCA-M50KA-ER,
PCA-M60KA-ER,
PCA-M71KA-ER,
PCA-M100KA-ER,
PCA-M125KA-ER, and
PCA-M140KA-ER
in REVISED EDITION-A.
OCH659 is void.

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  • Page 1: Table Of Contents

    SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS SPLIT-TYPE, AIR CONDITIONERS November 2018 No. OCH659 REVISED EDITION-A SERVICE MANUAL R32/R410A Indoor unit [Service Ref.] [Model Name] PCA-M35KA Notes: PCA-M35KA • Added PCA-M35KA-ER PCA-M35KA-ER PCA-M35KA-ER, PCA-M50KA-ER, PCA-M50KA PCA-M50KA PCA-M60KA-ER, PCA-M71KA-ER, PCA-M50KA-ER PCA-M50KA-ER PCA-M100KA-ER, PCA-M60KA PCA-M60KA PCA-M125KA-ER, and PCA-M140KA-ER...

  • Page 2: Reference Manual

    REFERENCE MANUAL 1-1. OUTDOOR UNIT’S SERVICE MANUAL Model name Service Ref. Service manual No. MXZ-3E54VA-E2/ET2/ER2 MXZ-3E54VA-E2/ET2/ER2 MXZ-3E68VA-E2/ET2/ER2 MXZ-3E68VA-E2/ET2/ER2 MXZ-4E72VA-E2/ET2/ER2 MXZ-4E72VA-E2/ET2/ER2 OBH723 OBB723 MXZ-4E83VA-E4/ET4/ER3 MXZ-4E83VA-E4/ET4/ER3 MXZ-5E102VA-E4/ET4/ER3 MXZ-5E102VA-E4/ET4/ER3 MXZ-4E83VAHZ-E3/ER3 MXZ-4E83VAHZ-E3/ER3 MXZ-3F54VF-E2/ET2 MXZ-3F54VF-E2/ET2 OBH790 MXZ-3F68VF-E2/ET2 MXZ-3F68VF-E2/ET2 OBB790 MXZ-4F72VF-E2/ET2 MXZ-4F72VF-E2/ET2 MXZ-6D122VA2-E1/ET1/ER1 MXZ-6D122VA2-E1/ET1/ER1 OBH626 OBB626 PAC-MK33/53BC PAC-MK33/53BC OCH589...

  • Page 3: Safety Precaution

    SAFETY PRECAUTION MEANINGS OF SYMBOLS DISPLAYED ON THE UNIT This mark is for R32 refrigerant only. Refrigerant type is written on nameplate of outdoor unit. WARNING Read the OPERATION MANUAL carefully before operation. Service personnel are required to carefully read the OPERATION MANUAL and INSTALLATION MANUAL before operation. Further information is available in the OPERATION MANUAL, INSTALLATION MANUAL, and the like.
  • Page 4 [1] Warning for service (1) Do not alter the unit. (2) For installation and relocation work, follow the instructions in the Installation Manual and use tools and pipe components specifically made for use with refrigerant specified in the outdoor unit installation manual. (3) Ask a dealer or an authorized technician to install, relocate and repair the unit.
  • Page 5 [4] Cautions for unit using R32 refrigerant Basic work procedures are the same as those for conventional units using refrigerant R410A. However, pay careful attention to the following points. (1) Information on servicing (1-1) Checks on the Area Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimized.
  • Page 6 (3) Repair to intrinsically Safe Components Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use. Intrinsically safe components are the only types that can be worked on while live in the presence of a flammable atmos- phere.
  • Page 7 b) Isolate system electrically. c) Before attempting the procedure, ensure that: • mechanical handling equipment is available, if required, for handling refrigerant cylinders; • all personal protective equipment is available and being used correctly; • the recovery process is supervised at all times by a competent person; •...

  • Page 8: Parts Names And Functions

    Unit Electronic weighing scale [5] Service tools Use the below service tools as exclusive tools for R32/R410A refrigerant. Tool name Specifications Gauge manifold · Use the existing fitting specifications . (UNF1/2) · Use high-tension side pressure of 5.3MPa·G or over. Charge hose ·...
  • Page 9 3-2. WIRELESS REMOTE CONTROLLER (OPTION) The functions which can be used are restricted according to each model. CHECK TEST RUN display CHECK and TEST RUN display indicate that the unit is being checked or test-run. MODEL SELECT display Blinks when model is selected. display Lights up while the signal is transmitted to the indoor unit when the button is pressed.
  • Page 10 3-3. WIRED REMOTE CONTROLLER (OPTION) <PAR-33MAA> The functions which can be used are restricted according to each model. The main display can be displayed in 2 different modes: "Full" and "Basic." Display The initial setting is "Full." 1 Operation mode Indoor unit operation mode appears here.
  • Page 11 Menu structure Press the button. MENU Main menu Move the cursor to the desired item with the buttons, and press the button. SELECT Vane · Louver · Vent. (Lossnay) High power Timer ON/OFF timer Auto-OFF timer Weekly timer OU silent mode Restriction Temp.
  • Page 12 Setting and display items Setting details Vane · Louver · Vent. Use to set the vane angle. • Select a desired vane setting from 5 different settings. (Lossnay) Use to turn ON/OFF the louver. • Select a desired setting from "ON" and "OFF." Use to set the amount of ventilation.

  • Page 13: Specifications

    SPECIFICATIONS 4-1. SPECIFICATIONS Service Ref. PCA-M35KA PCA-M35KA-ER Mode Cooling Heating Power supply (phase, voltage, cycle) Single phase, 230V, 50Hz 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 Fan (drive) × No. Sirocco fan (direct) ×...
  • Page 14 Service Ref. PCA-M71KA PCA-M71KA-ER Mode Cooling Heating Power supply (phase, voltage, cycle) Single phase, 230V, 50Hz Input 0.06 Running current 0.42 External finish Munsell (6.4Y 8.9/0.4) Heat exchanger Plate fin coil Fan Fan (drive) × No. Sirocco fan (direct) × 2 Fan motor output 0.095 Airflow (Low-Medium2-Medium1-High) m...
  • Page 15 Service Ref. PCA-M140KA PCA-M140KA-ER Mode Cooling Heating Power supply (phase, voltage, cycle) Single phase, 230V, 50Hz Input 0.14 Running current 0.90 External finish Munsell (6.4Y 8.9/0.4) Heat exchanger Plate fin coil Fan Fan (drive) × No. Sirocco fan (direct) × 2 Fan motor output 0.160 Airflow (Low-Medium2-Medium1-High) m...
  • Page 16 4-2. FRESH AIR INTAKE AMOUNT & STATIC PRESSURE CHARACTERISTICS ■ PCA-M35KA PCA-M35KA-ER ■ PCA-M60KA PCA-M60KA-ER PCA-M50KA PCA-M50KA-ER PCA-M71KA PCA-M71KA-ER −50 −50 −100 −100 −150 −150 −200 −200 −250 −250 −300 −300 Airflow rate[m³/min] Airflow rate[m³/min] ■ PCA-M100KA PCA-M100KA-ER PCA-M125KA PCA-M125KA-ER How to read curves PCA-M140KA PCA-M140KA-ER...

  • Page 17: Noise Criterion Curves

    NOISE CRITERION CURVES PCA-M35KA PCA-M50KA SPL(dB) LINE NOTCH SPL(dB) LINE NOTCH PCA-M35KA-ER High PCA-M50KA-ER 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 NC-20 HEARING FOR NC-20 CONTINUOUS CONTINUOUS...
  • Page 18 PCA-M100KA PCA-M125KA NOTCH NOTCH SPL(dB) LINE SPL(dB) LINE PCA-M125KA-ER PCA-M100KA-ER 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...

  • Page 19: Outlines And Dimensions

    OUTLINES AND DIMENSIONS PCA-M35KA PCA-M50KA Unit: mm PCA-M35KA-ER PCA-M50KA-ER OCH659A...
  • Page 20 PCA-M60KA PCA-M71KA Unit: mm PCA-M60KA-ER PCA-M71KA-ER OCH659A...
  • Page 21 PCA-M100KA PCA-M100KA-ER Unit: mm PCA-M125KA PCA-M125KA-ER PCA-M140KA PCA-M140KA-ER OCH659A...
  • Page 22 Unit: mm WIRED REMOTE CONTROLLER (Option) OCH659A...

  • Page 23: Wiring Diagram

    WIRING DIAGRAM PCA-M35KA PCA-M50KA PCA-M60KA PCA-M71KA PCA-M35KA-ER PCA-M50KA-ER PCA-M60KA-ER PCA-M71KA-ER PCA-M100KA PCA-M125KA PCA-M140KA PCA-M100KA-ER PCA-M125KA-ER PCA-M140KA-ER OCH659A...

  • Page 24: Refrigerant System Diagram

    REFRIGERANT SYSTEM DIAGRAM PCA-M35KA PCA-M50KA PCA-M60KA PCA-M71KA PCA-M35KA-ER PCA-M50KA-ER PCA-M60KA-ER PCA-M71KA-ER PCA-M100KA PCA-M125KA PCA-M140KA PCA-M100KA-ER PCA-M125KA-ER PCA-M140KA-ER 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 thermistor/liquid...

  • Page 25: Troubleshooting

    TROUBLESHOOTING 9-1. TROUBLESHOOTING <Check code displayed by self-diagnosis and actions to be taken for service (summary)> Present and past check codes are logged, and they can be displayed on the wired remote controller or controller board of out- door unit. Actions to be taken for service, which depends on whether or not the trouble is reoccurring in the field, are summa- rized in the table below.
  • Page 26 9-2. 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 27 • 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 blink pattern Approx. 2.5 s 0.5 s 0.5 s 0.5 s Approx.
  • Page 28 ● If the unit cannot be operated properly after test run, refer to the following table to find the cause. Symptom Cause Wired remote controller LED 1, 2 (PCB in outdoor unit) PLEASE WAIT For about 3 After LED 1, 2 are lit, LED 2 is turned •...
  • Page 29 Note: Errors to be detected in outdoor unit, such as codes starting with F, U or E (excluding E0 to E7), are not covered in this document. Please 9-3. SELF-DIAGNOSIS ACTION TABLE refer to the outdoor unit's service manual for the details. Abnormal point and detection method Countermeasure Check code...
  • Page 30 Abnormal point and detection method Countermeasure Check code Cause Freezing/overheating protection is (Cooling or drying mode) (Cooling or drying mode) operating Clogged filter (reduced airflow) Check clogs of the filter. Freezing protection (Cooling mode) Short cycle of air path Remove blockage. The unit is in 6-minute resume Low-load (low temperature) prevention mode if pipe <liquid or...
  • Page 31 Abnormal point and detection method Countermeasure Check code Cause Pipe temperature thermistor/ Defective thermistor – Check resistance value of thermistor. Condenser-Evaporator (TH5) characteristics For characteristics, refer to (P1). Check contact failure of connector (CN44) The unit is in 3-minute resume protection Contact failure of connector on the indoor controller board.
  • Page 32 Abnormal point and detection method Countermeasure Check code Cause Indoor/outdoor unit communication Check LED display on the outdoor control circuit board. (Connect A-control service error (Signal receiving error) tool, PAC-SK52ST.) Refer to outdoor unit ser- Abnormal if indoor controller board vice manual.
  • Page 33 Abnormal point and detection method Countermeasure Check code Cause Fan motor trouble 1 Defective fan motor 1-3 Refer to "9-6-2. DC Fan Motor (fan motor/ 2 Defective indoor controller board indoor controller board)". 3 Contact failure of fan motor connector Abnormal refrigerant circuit When this error occurs, be sure to replace Abnormal operation of 4-way...
  • Page 34 9-4. TROUBLESHOOTING OF PROBLEMS Note: Refer to the outdoor unit's service manual 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. Power supply of rated voltage is not supplied to out- Check the voltage of outdoor power door unit.
  • Page 35 Note: Refer to the outdoor unit's service manual 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 36 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.
  • Page 37 9-6. HOW TO CHECK THE PARTS PCA-M35KA PCA-M50KA PCA-M60KA PCA-M71KA PCA-M35KA-ER PCA-M50KA-ER PCA-M60KA-ER PCA-M71KA-ER PCA-M100KA PCA-M125KA PCA-M140KA PCA-M100KA-ER PCA-M125KA-ER PCA-M140KA-ER Parts name Check points Room temperature Disconnect the connector then measure the resistance with a tester. thermistor (TH1) Pipe temperature thermistor/liquid(TH2) Refer to “9-6-1.
  • Page 38 9-6-2. DC Fan motor (fan motor/indoor controller circuit board) Check method of DC fan motor (fan motor/indoor controller circuit board) 1 Notes · High voltage is applied to the connector (CNMF) for the fan motor. Pay attention to the service. ·...
  • Page 39 9-7. TEST POINT DIAGRAM Indoor controller board PCA-M35KA PCA-M50KA PCA-M60KA PCA-M71KA PCA-M35KA-ER PCA-M50KA-ER PCA-M60KA-ER PCA-M71KA-ER PCA-M100KA PCA-M125KA PCA-M140KA PCA-M100KA-ER PCA-M125KA-ER PCA-M140KA-ER CN2L Connector (LOSSNAY) Emergency operation LED3 Transmission (Indoor/outdoor) Vane motor output (MV) 12 V pulse output CN90 Connect to the wireless remote controller board (CNB) Model selection CN105...
  • Page 40 9-8. FUNCTIONS OF DIP SWITCH AND JUMPER WIRE Each function is controlled by the DIP switch and the jumper wire on the indoor controller board. SW1 and SW2 are equipped only for service parts. Model setting and capacity setting are preset in the nonvolatile memory of the controller board of the unit. ■...

  • Page 41: Function Setting

    FUNCTION SETTING 10-1. UNIT FUNCTION SETTING BY THE REMOTE CONTROLLER Each function can be set as necessary using the remote controller. The setting of function for each unit can only be done by the remote controller. (1) Functions available when setting the unit number to 00 Refer to the service manual that comes with each outdoor unit.

  • Page 42: Special Function

    SPECIAL FUNCTION 11-1. ROTATION FUNCTION (AND BACK-UP FUNCTION, 2ND STAGE CUT-IN FUNCTION) Note that this function is not available for SUZ, MXZ, and PUMY models. 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.
  • Page 43 • System constraint · This function is available only in cooling mode. Ex.) Set temp. by R/C = 20˚C [2nd stage cut-in function]··· Request code number "322–324" Set point = 26˚C Room temp. ] Set point Room temp. < Set point −4: When request code number is “323”.
  • Page 44 (2) Setting method of each function by wired remote controller ■ PAR-3xMAA ("x" represents 0 or later) Stop operation ( Check menu Error history Refrigerant volume check Refrigerant leak check Smooth maintenance Select "Service" from the Main menu, and press the button.
  • Page 45 (3) Rotation and back up operation ■ PAR-3xMAA ("x" represents 0 or later) Press the button. Main Main menu Maintenance Initial setting Select "Service" with the [Cursor] buttons ( ) or the [Page] buttons ( Service ), and press the button.

  • Page 46: Disassembly Procedure

    DISASSEMBLY PROCEDURE PCA-M35KA PCA-M50KA PCA-M60KA PCA-M71KA PCA-M35KA-ER PCA-M50KA-ER PCA-M60KA-ER PCA-M71KA-ER PCA-M100KA PCA-M125KA PCA-M140KA PCA-M100KA-ER PCA-M125KA-ER PCA-M140KA-ER (Photo: PCA-M125KA) : Indicates the visible parts in the photos/figures. Be careful when removing heavy parts. PHOTOS & FIGURES OPERATING PROCEDURE 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 47 OPERATING PROCEDURE PHOTOS & FIGURES 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 48 OPERATING PROCEDURE PHOTOS & FIGURES 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 49 OPERATING PROCEDURE PHOTOS & FIGURES 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 50 OPERATING PROCEDURE PHOTOS & FIGURES 10. Removing the pipe temperature thermistors/liquid (TH2) Photo 18 and condenser/evaporator temperature thermistor (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.
  • Page 51 OPERATING PROCEDURE PHOTOS & FIGURES Photo 22 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.
  • Page 52 HEAD OFFICE : TOKYO BUILDING, 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN Copyright 2017 MITSUBISHI ELECTRIC CORPORATION Issued: Nov. 2018 No. OCH659 REVISED EDITION-A Published: Mar. 2017 No. OCH659 Made in Japan Specifications are subject to change without notice.

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