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Mitsubishi Electric Mr.Slim SUZ-KA25VA5, Service Manual, Page: 1 / 44

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Mitsubishi Electric Mr.Slim SUZ-KA25VA5 Service Manual Download Page 1

TECHNICAL & SERVICE MANUAL

R410A

CONTENTS

1. COMBINATION OF INDOOR AND OUTDOOR UNITS ..... 2

2. PARTS NAMES AND FUNCTIONS .................. 3

3. SPECIFICATION ................................................ 4

4. NOISE CRITERIA CURVES .............................. 6

5. OUTLINES AND DIMENSIONS ........................ 7

6. WIRING DIAGRAM ............................................ 9

7. REFRIGERANT SYSTEM DIAGRAM ............. 12

8. ACTUATOR CONTROL ................................... 16

9. SERVICE FUNCTIONS ................................... 17

10. TROUBLESHOOTING ..................................... 17

11. DISASSEMBLY PROCEDURE ........................ 34

Indication of
model name

Note: 

•  

This service manual describes 

service data of the outdoor 
units only.

HFC

utilized

R410A

SUZ-KA25VA5.TH
SUZ-KA35VA5.TH

PARTS CATALOG (OCB603)

No. OCH603

October 2015

SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS

[Model Name] 

SUZ-KA25VA5 

SUZ-KA35VA5 

SUZ-KA50VA5 

SUZ-KA60VA5 

SUZ-KA71VA5

[Service Ref.]

SUZ-KA25VA5.TH  

SUZ-KA25VA5.TH-ET

SUZ-KA35VA5.TH 

SUZ-KA35VA5.TH-ET

SUZ-KA50VA5.TH  

SUZ-KA50VA5.TH-ET

SUZ-KA60VA5.TH  

SUZ-KA60VA5.TH-ET

SUZ-KA71VA5.TH  

SUZ-KA71VA5.TH-ET

Summary of Contents for Mr.Slim SUZ-KA25VA5

Page 1: ...11 DISASSEMBLY PROCEDURE 34 Indication of model name Note This service manual describes service data of the outdoor units only HFC utilized R410A SUZ KA25VA5 TH SUZ KA35VA5 TH PARTS CATALOG OCB603 No OCH603 October 2015 SPLIT TYPE HEAT PUMP AIR CONDITIONERS Model Name SUZ KA25VA5 SUZ KA35VA5 SUZ KA50VA5 SUZ KA60VA5 SUZ KA71VA5 Service Ref SUZ KA25VA5 TH SUZ KA25VA5 TH ET SUZ KA35VA5 TH SUZ KA35VA5...

Page 2: ...0VA TH SLZ KF60VA TH SEZ KD25VAQR2 TH HWE1008 BWE102040 BWE014090 SEZ KD35VAQR2 TH SEZ KD50VAQR2 TH SEZ KD60VAQR2 TH SEZ KD71VAQR2 TH SEZ KD25VALR2 TH HWE0711 BWE012050 SEZ KD35VALR2 TH SEZ KD50VALR2 TH SEZ KD60VALR2 TH SEZ KD71VALR2 TH PLA RP35BAR4 UK OCH412 OCB412 PLA RP50BAR4 UK PLA RP60BAR4 UK PLA RP71BAR4 UK PCA RP35KAQR2 OCH491 OCB491 PCA RP50KAQR2 PCA RP60KAQR2 PCA RP71KAQR2 PEAD RP35JAQR2 ...

Page 3: ...VA5 SUZ KA60VA5 SUZ KA71VA5 Air outlet Drain outlet Piping Drain hose Air inlet back and side Model SUZ KA VA5 Drain socket 1 Piping Air outlet Drain outlet Air inlet back and side Drain hose Piping Air outlet Drain outlet Air inlet back and side Drain hose OCH603 ...

Page 4: ... Refrigeration oil Model L 0 31 FV50S 0 27 FV50S 0 35 FV50S 0 4 FV50S Fan motor Model RC0J50 NA RC0J60 BC RC0J60 BC Current Cooling A 0 24 0 29 0 84 0 84 0 83 Heating 0 27 0 28 0 93 0 93 0 82 Dimensions W H D mm 800 550 285 840 880 330 Weight kg 30 35 54 50 53 Special remarks Air flow Cooling High m h 1 806 2 868 3 492 3 426 Med 1 806 2 868 3 066 3 006 Low 1 170 1 038 1 602 1 692 1 512 Heating Hig...

Page 5: ...1 F901 T3 15 A L250 V T3 15 A L250 V T3 15 A L250 V IC700 15 A 600 V 15 A 600 V 20 A 600 V Inteligent power module IPM 20 A 600 V IC932 8 A 600 V 8 A 600 V 8 A 600 V 5 A 600 V 5 A 600 V Power factor controller PFC 20A 600V 20A 600V IC820 20 A 600 V 20 A 600 V 20 A 600 V Expansion valve coil LEV 12 V DC Reactor L61 18 mH 23 mH 23 mH L 340 μH 20 A 340 μH 20 A Current Limiting PTC thermistor PTC64 PT...

Page 6: ...R FREQUENCIES Hz NC 10 SUZ KA35VA5 TH SUZ KA35VA5 TH ET COOLING FUNCTION SPL dB A LINE High FAN SPEED HEATING 52 52 OCTAVE BAND SOUND PRESSURE LEVEL dB re 0 0002 MICRO BAR 90 80 70 60 50 40 30 20 10 63 125 250 500 1000 2000 4000 8000 NC 60 NC 50 NC 40 NC 30 NC 20 NC 70 BAND CENTER FREQUENCIES Hz NC 10 SUZ KA50VA5 TH SUZ KA50VA5 TH ET Test conditions Cooling Dry bulb temperature 35 C Heating Dry bu...

Page 7: ...t pipe joint Refrigerant pipe flared 6 35 Gas refrigerant pipe joint Refrigerant pipe flared 9 52 4 3 3 5 2 Oval holes 10 21 REQUIRED SPACE Basically leave this space open Only if front and both sides are open leave 100 mm at minimum 350mm or more 200mm or more 100mm or more 100mm or more 200 mm or more Leave any two sides among right left or rear open Drain hole 42 Unit mm SUZ KA25VA5 TH SUZ KA35...

Page 8: ...pe joint Refrigerant pipe flared Ø 12 7 SUZ KA50VA5 Ø 15 88 SUZ KA60 71VA5 350 mm or more 100 mm or more REQUIRED SPACE Basically leave this space open Only if front and both sides are open leave 500 mm at minimum 100mm or more 500 mm or more Leave any two sides among right left or rear open Air in Bolt pitch for installation 360 Unit mm SUZ KA50VA5 TH SUZ KA60VA5 TH SUZ KA71VA5 TH SUZ KA50VA5 TH ...

Page 9: ...9 9 6 WIRING DIAGRAM MODELS SUZ KA25 35VA4 WIRING DIAGRAM SUZ KA25VA5 TH SUZ KA35VA5 TH SUZ KA25VA5 TH ET SUZ KA35VA5 TH ET OCH603 ...

Page 10: ...10 SUZ KA50VA5 TH SUZ KA50VA5 TH ET OCH603 ...

Page 11: ...11 SUZ KA60VA5 TH SUZ KA71VA5 TH SUZ KA60VA5 TH ET SUZ KA71VA5 TH ET OCH603 ...

Page 12: ...thermistor RT65 Muffler Capillary tube ø3 0 ø2 0 240 Outdoor heat exchanger temperature thermistor RT68 Muffler Outdoor heat exchanger LEV Outdoor heat exchanger Flared connection Defrost thermistor RT61 Discharge temperature thermistor RT62 Flared connection Stop valve with strainer Stop valve with service port Refrigerant flow in cooling Compressor 4 way valve Refrigerant flow in heating Refrige...

Page 13: ...g OFF Muffler Strainer 100 Outdoor heat exchanger temperature thermistor RT68 Ambient temperature thermistor RT65 Strainer 100 Strainer 100 Muffler ø15 88 SUZ KA60VA4 Outdoor heat exchanger Flared connection Defrost thermistor RT61 Discharge temperature thermistor RT62 Flared connection Stop valve Stop valve with service port Capillary tube ø4 0 ø2 4 100 Refrigerant flow in cooling Compressor 4 wa...

Page 14: ...lve with service port Capillary tube ø4 0 ø2 4 100 Refrigerant flow in cooling Compressor 4 way valve Refrigerant flow in heating Refrigerant pipe with heat insulator ø15 88 Refrigerant pipe with heat insulator LEV R V coil heating ON cooling OFF Muffler 100 Strainer 100 Outdoor heat exchanger temperature thermistor RT68 Ambient temperature thermistor RT65 Strainer 100 ø9 52 OCH603 ...

Page 15: ...y circuit breaker 2 Connect the gauge manifold valve to the service port of the stop valve on the gas pipe side of the outdoor unit 3 Fully close the stop valve on the liquid pipe side of the outdoor unit 4 Supply power circuit breaker 5 Perform the refrigerant collecting operation cooling test run For the PAR 31MAA select Service TestRun from the main menu to start the test run and then select th...

Page 16: ...everses for 5 seconds right before start up of the compressor Sensor Purpose Actuator Compressor LEV Outdoor fan motor R V coil Indoor fan motor Discharge temperature thermistor Protection Indoor coil temperature thermistor Cooling Coil frost prevention Heating High pressure protection Defrost thermistor Heating Defrosting Fin temperature thermistor Protection Ambient temperature thermistor Coolin...

Page 17: ...r miswiring 2 Take care the following during servicing 1 Before servicing the air conditioner be sure to turn OFF the main unit first with the remote controller and turn off the breaker 2 Be sure to turn OFF the power supply before removing the front panel the cabinet the top panel and the electronic control P C board 3 When removing the electrical parts be careful of the residual voltage of smoot...

Page 18: ...conds OFF DC voltage DC voltage of inverter cannot be detected normally Refer to 10 5 How to check in verter compressor 15 Outdoor unit operates 1 time flash 2 5 seconds OFF Frequency drop by current protection When the input current exceeds approximately 7A KA25 8A KA35 12A KA50 14A KA60 16A KA71 compressor The unit is normal but check the following Check if indoor filters are clogged Check if re...

Page 19: ...ber attribute will appear will appear if no error history is available 4 Resetting the error history Press the F4 button Reset on the screen that shows the error history A confirmation screen will appear asking if you want to delete the error history Press the F4 button OK to delete the error history If deletion fails Request rejected will appear Unit not exist will appear if no indoor units that ...

Page 20: ...ill appear on the remote controller display if the correct voltage 8 5 2 V DC is not supplied to the remote controller If this is the case check the remote controller wiring and indoor units OK No problems are found with the remote controller Check other parts for problems E3 6832 There is noise on the transmission line or the indoor unit or another remote controller is faulty Check the transmissi...

Page 21: ...o the indoor unit installation Check code 4 digits or check code 2 digits Error detection attribute Address 3 digits or unit address No 2 digits When there is no error history When opposite side does not exist Alternate display 4 Error history reset The error history is displayed in 3 self diagnosis results display When theD button is pressed 2 times successively within 3 seconds the self diagnosi...

Page 22: ...mote controller switching is necessary When the problem is other than the checked remote controller Error display 2 E3 6833 6832 flash Cannot send Error display 3 ERC and data error count are displayed Data error generation There is noise on the transmission line or the indoor unit or another remote controller is faulty Check the transmission line and the other remote controllers Data error count ...

Page 23: ...n a malfunction occurs to air conditioner both indoor unit and outdoor unit will stop and operation lamp blinks to inform unusual stop ON OFF TEMP FAN VANE MODE CHECK LOUVER TEST RUN AUTO STOP AUTO START h min RESET SET CLOCK CHECK CHECK display Temperature button CHECK button Refrigerant address display HOUR button ON OFF button ON OFF RESET TOO WARM TOO COOL MODE AUTO COOL DRY HEAT FAN VANE SELE...

Page 24: ...th 1st 2nd 3rd 1st 2nd Self check starts Start signal received Beeper sounds Refer to the following tables for details on the check codes Output pattern A The check code in the parenthesis indicates PAR 32MAA model Beeper sounds OPERATION INDICATOR lamp flashes Check code Symptom Remark Number of times Wireless remote controller Wired remote controller Beeper sounds OPERATION INDICATOR lamp flashe...

Page 25: ...m it up Refer to 10 6 Test point diagram and voltage 10 6 1 KA25 35 50 or 10 6 2 KA60 71 Inverter P C board for the chart of thermistor Defrost thermistor RT61 Fin temperature thermistor RT64 29 to 42 Ω Measure the resistance between terminals with a tester Temperature 10 to 40 C Compressor U V U W V W Normal W U V WHT RED BLK W U V WHT RED BLK Ambient temperature thermistor RT65 Outdoor heat exch...

Page 26: ... then select the cooling mode For details or for other information about starting the test run when using remote controllers refer to the installation manual for the indoor unit or the remote controller Measurement point At 3 points BLK U WHT V BLK U RED W WHT V RED W NOTE 1 Output voltage varies according to power supply voltage 2 Measure the voltage by analog type tester 3 During this check LED ...

Page 27: ...ent Measure the time from the start of compressor to the stop of compressor due to overcurrent Is the resistance of thermistor normal KA25 35 50 Refer to 10 6 1 KA60 71 10 6 2 Disconnect the connector of thermistor in the outdoor P C board see below table and measure the resistance of thermistor Replace the thermistor except RT64 When RT64 is abnormal replace the inverter P C board Reconnect the c...

Page 28: ...EAT mode even if it is set to COOL mode Disconnect connector between the compressor and the intelligent power module Turn ON the power supply and start heating test run TEST RUN OPERATION Refer to 10 5 Disconnect connector between the compressor and the intelligent power module Turn ON the power supply and start cooling test run TEST RUN OPERATION Refer to 10 5 H Check of outdoor fan motor Is the ...

Page 29: ... Yes Check the outdoor fan motor Refer to Is the fuse F901 blown on the in verter P C board Check the connection of the connectors CN931 CN932 of the outdoor fan mo tor If the connection is poor make it correct Operate the outdoor unit by starting EMERGENCY OPERATION Check the LED indication on the in verter P C board Does the LED flash 10 times Replace the inverter P C board Check the correspondi...

Page 30: ... installation condition combination of specific conditions such as antennas or wiring Check the following before asking for service 1 Devices affected by the electromagnetic noise TV sets radios FM AM broadcast shortwave 2 Channel frequency broadcast station affected by the electromagnetic noise 3 Channel frequency broadcast station unaffected by the electromagnetic noise 4 Layout of indoor outdoo...

Page 31: ...e refrigerant gas amount may be 60 or less than the normal amount Identify where the gas is leaking from and fix the leak No CAUTION Do not start the operation again to prevent hazards The operation has stopped to prevent the diesel explosion caused by air trapped in the refrigerant circuit Close the stop valve and disconnect the power plug or turn the breaker OFF Note If the abnormality can not b...

Page 32: ...ure Fin temperature thermistor RT64 Resistance k Resistance k Resistance k Fin temperature thermistor RT64 CN642 Ambient temperature thermistor RT65 CN643 Discharge temperature thermistor RT62 CN641 Defrost thermistor RT61 CN641 DB61 260 370 V DC Front side of unit 230 VAC Smoothing capacitor C62 Output to drive compressor LDU LDV LDW Fuse F701 T3 15AL 250 V Smoothing capacitor C61 Smoothing capac...

Page 33: ...20 40 60 80 100 120 140 160 180 200 Temperature Fin temperature thermistor RT64 Resistance k Resistance k Resistance k Fin temperature thermistor RT64 CN673 Ambient temperature thermistor RT65 CN672 Discharge temperature thermistor RT62 CN671 Defrost thermistor RT61 CN671 Output to drive outdoor fan motor CN932 Outdoor heat exchanger temperature thermistor RT68 CN671 Fuse F901 T3 15AL 250 V Fuse F...

Page 34: ...onnector Sleeve Locking lever NOTE Turn OFF power supply before disassembling S O T O P E R U D E C O R P G N I T A R E P O 1 Removing the cabinet 1 Remove the screw fixing the service panel 2 Pull down the service panel and remove it 3 Disconnect the power supply and indoor outdoor con necting wire 4 Remove the screws fixing the top panel 5 Remove the top panel 6 Remove the screws fixing the cabi...

Page 35: ...s Refer to procedure 1 2 Disconnect the following connectors Inverter P C board CN721 R V coil 3 Remove the R V coil Photo 5 4 Removing the discharge temperature thermistor defrost thermistor outdoor heat exchanger tempera ture thermistor and ambient temperature thermistor 1 Remove the cabinet and panels Refer to procedure 1 2 Disconnect the lead wire to the reactor and the following con nectors I...

Page 36: ...ove the cabinet and panels Refer to procedure 1 2 Remove the inverter assembly Refer to procedure 2 3 Recover gas from the refrigerant circuit NOTE Recover gas from the pipes until the pressure gauge shows 0 kg cm 0 MPa 4 Detach the welded part of the suction and the discharge pipe connected with compressor 5 Remove the nuts of compressor legs 6 Remove the compressor 7 Detach the welded part of pi...

Page 37: ...el 6 Remove the valve cover 7 Disconnect the power supply and indoor outdoor connect ing wire 8 Remove the screws of the cabinet 9 Remove the cabinet 10 Remove the screws of the back panel 11 Remove the back panel Photo 1 Photo 2 Screws of the cabinet Screws of the top panel Screws of the top panel Screw of the back panel Screws of the cabinet Screws of the cabinet Screws of the service panel Scre...

Page 38: ...move the inverter assembly 7 Remove the screw of the earth wire screw of the P C board cover and screws of the terminal block support 8 Remove the heat sink support from the P C board support 9 Remove the screw of the inverter P C board and the inverter P C board from the P C board support Photo 3 Photo 4 Photo 5 3 Removing R V coil 1 Remove the cabinet and panels Refer to procedure 1 2 Disconnect...

Page 39: ...and service panel Refer to procedure 1 2 Disconnect the following connectors Inverter P C board CN931 and CN932 Fan motor 3 Remove the propeller nut 4 Remove the propeller 5 Remove the screws fixing the fan motor 6 Remove the fan motor 6 Removing the compressor and 4 way valve 1 Remove the top panel cabinet and service panel Refer to procedure 1 2 Remove the back panel Refer to procedure 1 3 Remov...

Page 40: ...ect the power supply and indoor outdoor connect ing wire 8 Remove the screws of the cabinet 9 Remove the cabinet 10 Remove the screws of the back panel 11 Remove the back panel Photo 1 Photo 2 Screws of the cabinet Screws of the top panel Screws of the top panel Screw of the back panel Screws of the cabinet Screws of the cabinet Screws of the service panel Screw of the valve cover Screws of the ca...

Page 41: ...e the compressor connector 4 Remove the screws fixing the relay panel 5 Remove the relay panel 6 Remove the earth wires and the lead wires of the inverter P C board 7 Remove the screws of the PB support 8 Remove the inverter P C board from the relay panel Photo 3 Photo 4 3 Removing R V coil 1 Remove the cabinet and panels Refer to procedure 1 2 Disconnect the following connector Inverter P C board...

Page 42: ...emove the top panel cabinet and service panel Refer to 1 2 Disconnect the following connectors Inverter P C board CN931 and CN932 Fan motor 3 Remove the propeller 4 Remove the screws fixing the fan motor 5 Remove the fan motor 6 Removing the compressor and 4 way valve 1 Remove the top panel cabinet and service panel Refer to procedure 1 2 Remove the back panel Refer to procedure 1 3 Remove the inv...

Page 43: ...43 OCH603 ...

Page 44: ...7 3 MARUNOUCHI CHIYODA KU TOKYO100 8310 JAPAN Copyright 2015 MITSUBISHI ELECTRIC CORPORATION Distributed in Oct 2015 No OCH603 Made in Japan New publication effective Oct 2015 Specifications are subject to change without notice ...

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