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Mitsubishi Electric PKA-M60KAL Service Manual
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Mitsubishi Electric PKA-M60KAL Service Manual

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SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS
SPLIT-TYPE, AIR CONDITIONERS
SERVICE MANUAL
Indoor unit
[Model Name]
PKA-M60KA
PKA-M71KA
PKA-M100KA
PKA-M60KAL
PKA-M71KAL
PKA-M100KAL
INDOOR UNIT
R32/R410A
[Service Ref.]
PKA-M60KA.TH
PKA-M71KA.TH
PKA-M100KA.TH
PKA-M60KAL.TH
PKA-M71KAL.TH
PKA-M100KAL.TH
10. FUNCTION SETTING .................................... 32
11. SPECIAL FUNCTION .................................... 33
12. DISASSEMBLY PROCEDURE ...................... 36
Notes:
• This manual describes only
service data of the indoor units.
• RoHS compliant products
have <G> mark on the spec
name plate.
CONTENTS
1. REFERENCE MANUAL .................................. 2
2. SAFETY PRECAUTION .................................. 3
3. PARTS NAMES AND FUNCTIONS ................ 8
4. SPECIFICATIONS ......................................... 10
5. NOISE CRITERION CURVES ........................ 11
6. OUTLINES AND DIMENSIONS ..................... 12
7. WIRING DIAGRAM ........................................ 13
9. TROUBLESHOOTING ................................... 16
PARTS CATALOG (OCB661)
March 2017
No. OCH661

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  • Page 1: Table Of Contents

    PKA-M60KA.TH • RoHS compliant products PKA-M60KA have <G> mark on the spec name plate. PKA-M71KA.TH PKA-M71KA PKA-M100KA.TH PKA-M100KA PKA-M60KAL.TH PKA-M60KAL PKA-M71KAL.TH PKA-M71KAL PKA-M100KAL.TH PKA-M100KAL CONTENTS 1. REFERENCE MANUAL ........2 2. SAFETY PRECAUTION ........3 3. PARTS NAMES AND FUNCTIONS ....8 4.

  • Page 2: Reference Manual

    REFERENCE MANUAL OUTDOOR UNIT’S SERVICE MANUAL Model Name Service Ref. Service Manual No. PUHZ-ZRP60/71VHA2 PUHZ-ZRP60/71VHA2 OCH635/OCB635 PUZ-ZM60/71VHA PUZ-ZM60/71VHA OCH653/OCB653 PUZ-ZM100/125/140VKA PUZ-ZM100/125/140VKA.UK OCH654/OCB654 PUZ-ZM100/125/140YKA PUZ-ZM100/125/140YKA.UK PUHZ-ZRP100/125/140VKA3 PUHZ-ZRP100/125/140VKA3.UK PUHZ-ZRP100/125/140YKA3 PUHZ-ZRP100/125/140YKA3R1.UK OCH645/OCB645 PUHZ-ZRP200/250YKA2 PUHZ-ZRP200/250YKA2.UK PUHZ-P100VHA5 PUHZ-P100VHA5.UK PUHZ-P125/140VHA4 PUHZ-P125/140VHA4.UK OCH646/OCB646 PUHZ-P100YHA3.UK PUHZ-P100YHA3 PUHZ-P125/140YHA2 PUHZ-P125/140YHA2.UK PUHZ-P200/250YKA2 PUHZ-P200/250YKA2.UK OCH647/OCB647...

  • 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; • recovery equipment and cylinders conform to the appropriate standards. d) Pump down refrigerant system, if possible. e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system. f) Make sure that cylinder is situated on the scales before recovery takes place.

  • 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. Refer to the spec name plate on outdoor unit for the type of refrigerant being used. Specifications Tool name · Use the existing fitting specifications . (UNF1/2) Gauge manifold ·...
  • Page 9 3-2. Wireless remote controller 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. display SET TEMP.

  • Page 10: Specifications

    SPECIFICATIONS Service Ref. PKA-M60KA.TH PKA-M60KAL.TH Mode Cooling Heating Power supply (phase, cycle, voltage) Single phase, 50Hz, 230V Input 0.06 0.05 Running current 0.43 0.36 External finish (Panel) Munsell 1.0Y 9.2/0.2 Heat exchanger Plate fin coil Fan (drive) o No. Line flow fan (direct) o 1 Fan motor output 0.056...

  • Page 11: Noise Criterion Curves

    41 - 45 - 49 1.0 m Measurement location Note: Measured in anechoic room. 5-2. NOISE CRITERION CURVES PKA-M60KA.TH PKA-M100KA.TH PKA-M60KAL.TH PKA-M100KAL.TH PKA-M71KA.TH PKA-M71KAL.TH External static pressure : 0Pa External static pressure : 0Pa Power source : 220, 230, 240V, 50Hz Power source : 220, 230, 240V, 50Hz 70.0...

  • Page 12: Outlines And Dimensions

    OUTLINES AND DIMENSIONS PKA-M60KA.TH PKA-M70KA.TH PKA-M100KA.TH PKA-M60KAL.TH PKA-M70KAL.TH PKA-M100KAL.TH Unit: mm Top side 423.7 431.7 Right side Left side Front side Mount board Knockout hole for left piping (855) Operation lamp 1170 Knockout hole for DEFROST/STAND BY lamp right piping...

  • Page 13: Wiring Diagram

    WIRING DIAGRAM PKA-M60KA.TH PKA-M70KA.TH PKA-M100KA.TH [LEGEND] SYMBOL NAME SYMBOL NAME INDOOR CONTROLLER BOARD VANE MOTOR FAN MOTOR DRAIN PUMP (OPTION) POWER SUPPLY SWITCH BOARD (DRAIN PUMP (OPTION)) CN105 CONNECTOR SWE2 EMERGENCY OPERATION CN2L CONNECTOR (LOSSNAY) TERMINAL BLOCK (INDOOR UNIT POWER (OPTION)) CN32 CONNECTOR (REMOTE SWITCH) TERMINAL BLOCK (INDOOR/OUTDOOR CONNECTING LINE)
  • Page 14 PKA-M60KAL.TH PKA-M70KAL.TH PKA-M100KAL.TH [LEGEND] SYMBOL NAME SYMBOL NAME INDOOR CONTROLLER BOARD VANE MOTOR FAN MOTOR DRAIN PUMP (OPTION) POWER SUPPLY SWITCH BOARD (DRAIN PUMP (OPTION)) CN105 CONNECTOR SWE2 EMERGENCY OPERATION CN2L CONNECTOR (LOSSNAY) TERMINAL BLOCK (INDOOR UNIT POWER (OPTION)) CN32...

  • Page 15: Refrigerant System Diagram

    REFRIGERANT SYSTEM DIAGRAM PKA-M60KA.TH PKA-M70KA.TH PKA-M100KA.TH PKA-M60KAL.TH PKA-M70KAL.TH PKA-M100KAL.TH Strainer (#50) Heat exchanger Refrigerant GAS pipe connection (Flare) Thermistor TH2 Refrigerant flow in cooling (Pipe temperature/liquid) Refrigerant flow in heating Thermistor TH5 (Cond./Eva. temperature) Refrigerant LIQUID pipe connection (Flare) Thermistor TH1...

  • Page 16: 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 17 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> [Procedure] • "...
  • Page 18 • 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 s 0.5 s 0.5 s 0.5 s Approx.
  • Page 19 • 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) •For about 2 minutes following power-on,op- For about 2 After LED 1, 2 are lighted, LED 2 is PLEASE WAIT turned off, then only LED 1 is lit.
  • Page 20 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 refer to the out- 9-3. SELF-DIAGNOSIS ACTION TABLE door unit's service manual for the details. Abnormal point and detection method Countermeasure Cause Check code...
  • Page 21 Abnormal point and detection method Countermeasure Check code Cause Freezing/overheating protection is oper- (Cooling or drying mode) (Cooling or drying mode) ating 1 Clogged filter (reduced airflow) 1 Check clogs of the filter. 1 Freezing protection (Cooling mode) 2 Short cycle of air path 2 Remove shields.
  • Page 22 Abnormal point and detection method Countermeasure Check code Cause Pipe temperature thermistor / 1–3 Check resistance value of thermistor. Condenser-Evaporator (TH5) 1 Defective thermistor For characteristics, refer to (P1) above. 1 The unit is in 3-minute resume protec- 2 Check contact failure of connector (CN44) on characteristics the indoor controller board.
  • Page 23 Abnormal point and detection method Countermeasure Check code Cause Remote controller transmission error(E3)/ 1 Set a remote controller to main, and the signal receiving error(E5) 1 2 remote controllers are set as other to sub. 1 Abnormal if remote controller could not “main.”...
  • Page 24 Abnormal point and detection method Countermeasure Check code Cause Forced compressor stop 1 Drain pump trouble 1 Check the drain pump. (due to water leakage abnormality) 1 The unit has a water leakage abnor- 2 Drain defective 2 Check whether water can be drained. mality when the following conditions, a) ·...
  • Page 25 9-4. TROUBLESHOOTING BY INFERIOR PHENOMENA Note: Refer to the outdoor unit's service manual for the detail of remote controller. Phenomena Cause Countermeasure • When LED1 on indoor controller board is also off. (1) LED2 on indoor controller board is off. 1 Power supply of rated voltage is not supplied to out- 1 Check the voltage of outdoor power door unit. supply terminal block (L, N) or (L , N).
  • Page 26 Note: Refer to the outdoor unit's service manual for the detail of remote controller. Phenomena Cause Countermeasure • W hen LED1 on indoor controller board is also blinking. (2) LED2 on indoor controller board Check indoor/outdoor unit connecting wire is blinking. Connection failure of indoor/outdoor unit connecting for connection failure. wire • When LED1 is lit. 1 Check the connection of remote controller 1 Miswiring of remote controller wires wires in the case of twin triple indoor unit Under twin triple indoor unit system, 2 or more indoor system.
  • Page 27 9-5. EMERGENCY OPERATION 9-5-1. When wireless remote controller troubles 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.
  • Page 28 9-6. HOW TO CHECK THE PARTS PKA-M60KA.TH PKA-M70KA.TH PKA-M100KA.TH PKA-M60KAL.TH PKA-M70KAL.TH PKA-M100KAL.TH Parts name Check points Room temperature Disconnect the connector then measure the resistance using a tester. thermistor (TH1) (At the ambient temperature 10 to 30:) Pipe temperature Normal...
  • Page 29 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. board and fan motor.) (It causes trouble of the indoor controller circuit Self check...
  • Page 30 9-7. TEST POINT DIAGRAM PKA-M60KA.TH PKA-M70KA.TH PKA-M100KA.TH PKA-M60KAL.TH PKA-M70KAL.TH PKA-M100KAL.TH CNMF Connect to the fan motor (MF) 1–3: 310–340 V DC 4–3: 15 V DC 5–3: 0–6.5 V DC 6–3: 0 or 15 V DC CN105 CN01 Connect to the Terminal block (TB4) 1–3 : 220–240 V AC...
  • Page 31 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. (Marks in the table below) Jumper wire ( : Short : Open) ■ The black square ( ) indicates a switch position.

  • Page 32: 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 33: Special Function

    SPECIAL FUNCTION 11-1. ROTATION FUNCTION (AND BACK-UP FUNCTION, 2ND STAGE CUT-IN FUNCTION) Optional wired remote controller with terminal bed is necessary for PKA type. 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 34 • System constraint · This function is available only in cooling mode. Ex.) Set temp. by R/C = 20: [2nd stage cut-in function]··· Request code number "322–324" Set point = 26: Room temp. < Set point −4: Room temp. ] Set point When request code number is “323”.
  • Page 35 (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 Select "Service" from the Main menu, and press the Smooth maintenance button. Request code Service menu: Cursor Select "Check" with the F1 or F2 button, and press the button.

  • Page 36: Disassembly Procedure

    DISASSEMBLY PROCEDURE PKA-M60KA.TH PKA-M70KA.TH PKA-M100KA.TH PKA-M60KAL.TH PKA-M70KAL.TH PKA-M100KAL.TH Be careful when removing heavy parts. OPERATION PROCEDURE PHOTOS & ILLUSTRATIONS 1. Removing the panel Photo 1 Front grille Screws (1) Press and unlock the knobs on both sides of the front grille and lift the front grille until it is level.
  • Page 37 OPERATION PROCEDURE PHOTOS 3. Removing the electrical box Connector for Photo 4 ground wire Fixture (1) Remove the panel and the corner box. (Refer to procedure 1) (2) Remove the front and side electrical box covers (each 1 screw). Terminal block Electrical box (3) Remove the indoor/outdoor connecting wire from termi- (TB4)
  • Page 38 OPERATION PROCEDURE PHOTOS 6. Removing the indoor fan motor and the line flow fan Photo 7 Screw of the motor band (1) Remove the panel and the corner box. (Refer to procedure 1) (2) Remove the electrical box (Refer to procedure 2) and the Lead wire of pipe ther- mistor nozzle assembly (Refer to procedure 3).
  • Page 39 OPERATION PROCEDURE PHOTOS 8. Removing the heat exchanger Photo 11 (1) Remove the panel and the corner box. (Refer to procedure 1) Heat exchanger Water cut (2) Remove the electrical box (Refer to procedure 3) and the nozzle assembly (Refer to procedure 4). (3) Remove the water cut.
  • Page 40 HEAD OFFICE : TOKYO BUILDING, 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN Copyright 2017 MITSUBISHI ELECTRIC CORPORATION Published: Mar. 2017 No.OCH661 Specifications are subject to change without notice. Made in Japan...

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