Mitsubishi Electric MUFZ-KJ25VE-E1 Service Manual Download Page 52

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Distributed in Jan.  2014. No. OBH667 REVISED EDITION-B
Distributed in Oct.  2013. No. OBH667 REVISED EDITION-A
Distributed in Jun.  2013. No. OBH667
Made in Japan

HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

New publication, effective Jan. 2014
Specifications are subject to change without notice.

Summary of Contents for MUFZ-KJ25VE-E1

Page 1: ...OUBLESHOOTING 25 12 DISASSEMBLY INSTRUCTIONS 46 Models SPLIT TYPE AIR CONDITIONERS NOTE RoHS compliant products have G mark on the spec name plate HFC utilized R410A No OBH667 REVISED EDITION B OUTDOOR UNIT Indoor unit service manual MFZ KJ VE Series OBH666 PARTS CATALOG OBB667 MUFZ KJ25VE E1 ER1 MUFZ KJ35VE E1 ER1 MUFZ KJ50VE E1 ER1 MUFZ KJ25VE MUFZ KJ35VE Please void OBH667 REVISED EDITION A Rev...

Page 2: ...refrigeration cycle When the repair or the inspection of the circuit needs to be done without turning off the power exercise great caution not to touch the live parts Use the specified refrigerant only Never use any refrigerant other than that specified Doing so may cause a burst an explosion or fire when the unit is being used serviced or disposed of Correct refrigerant is specified in the manual...

Page 3: ... CHANGES 1 Air outlet Drain outlet Piping Drain hose Air inlet back and side MUFZ KJ25VE MUFZ KJ35VE PART NAMES AND FUNCTIONS 2 ACCESSORIES Model MUFZ KJ25VE MUFZ KJ35VE MUFZ KJ50VE Drain socket 1 Piping Air outlet Drain outlet Air inlet back and side Drain hose MUFZ KJ50VE OBH667B ...

Page 4: ...l Model L 0 35 FV50S 0 40 FV50S Fan motor Model RC0J50 CI RC0J60 BC Current 1 Cooling A 0 28 0 82 Heating 0 31 0 82 Dimensions W H D mm 800 550 285 840 880 330 Weight kg 37 55 Special remarks Dehumidification Cooling L h 0 6 1 4 2 0 Air flow 1 Cooling Med m3 h 1 806 2 748 Low 1 038 1 632 Heating High 2 016 2 856 Med 1 710 2 748 Low 1 326 2 274 Sound level 1 Cooling dB A 46 47 49 Heating 51 Fan spe...

Page 5: ...C64 PTC65 33 Ω Terminal block TB 5 P Relay X63 3 A 250 V X64 20 A 250 V X69 10A 250V R V coil 21S4 220 240 V AC Specifications and rated conditions of main electric parts Model Item MUZ KJ50VE Smoothing capacitor CB1 CB2 CB3 560 μF 450 V Fuse F601 F880 F901 T3 15AL250 V IGBT module IC932 5 A 600 V IC700 20 A 600 V Expansion valve coil LEV 12 V DC Reactor L 340 μH Diode module IC820 20 A 600 V Circ...

Page 6: ... BAND SOUND PRESSURE LEVEL dB re 0 0002 MICRO BAR BAND CENTER FREQUENCIES Hz COOLING FUNCTION SPL dB A LINE HEATING 47 51 NC 10 MUFZ KJ35VE NOISE CRITERIA CURVES 4 Test conditions Cooling Dry bulb temperature 35 C Heating Dry bulb temperature 7 C Wet bulb temperature 6 C OUTDOOR UNIT MICROPHONE 1 m 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 OC...

Page 7: ...d sides of the unit are clear 2 When any 2 sides of left right and rear of the unit are clear Clear 1 200 mm or more 2 Unit mm MUFZ KJ25VE MUFZ KJ35VE OUTLINES AND DIMENSIONS 5 MUFZ KJ50VE 417 5 40 42 Drain hole 175 500 330 50 Air in Air out 2 holes 10 21 360 840 109 81 880 452 Service panel 99 5 164 5 195 3 5 4 4 Liquid refrigerant pipe joint Refrigerant pipe flared Ø 6 35 Gas refrigerant pipe jo...

Page 8: ...8 WIRING DIAGRAM 6 MUFZ KJ25VE MUFZ KJ35VE OBH667B ...

Page 9: ...9 MUFZ KJ50VE OBH667B ...

Page 10: ...tube ø4 0 ø2 4 240 Outdoor heat exchanger temperature thermistor RT68 Capillary tube ø3 0 ø2 0 210 Muffler REFRIGERANT SYSTEM DIAGRAM 7 MUFZ KJ50VE Outdoor heat exchanger Flared connection Defrost thermistor RT61 Discharge temperature thermistor RT62 Flared connection Stop valve Stop valve Capillary tube ø4 0 ø2 4 100 Refrigerant flow in cooling Compressor 4 way valve Refrigerant flow in heating R...

Page 11: ...15 12 7 6 35 ADDITIONAL REFRIGERANT CHARGE R410A g Model Outdoor unit precharged Refrigerant piping length one way 7 m 8 m 9 m 10 m 11 m 12 m 13 m 14 m 15 m 20 m MUFZ KJ25 35 1 100 0 30 60 90 120 150 180 210 240 390 Calculation X g 30 g m Refrigerant piping length m 7 Model Outdoor unit precharged Refrigerant piping length one way 7 m 10 m 15 m 20 m 25 m 30 m MUFZ KJ50 1 500 0 60 160 260 360 460 C...

Page 12: ...s of wet and dry bulb thermometers to the indoor air intake as shown in the figure and at least 2 sets of wet and dry bulb thermometers to the indoor air outlet The thermometers must be attached to the position where air speed is high 2 Attach at least 2 sets of wet and dry bulb thermometers to the outdoor air intake Cover the thermometers to prevent direct rays of the sun 3 Check that the air fil...

Page 13: ... 29 0 26 8 24 5 22 3 20 1 17 8 15 6 13 4 11 1 8 9 MUFZ KJ35VE 28 0 25 9 23 7 21 6 19 4 17 2 15 1 12 9 10 8 8 6 MUFZ KJ50VE Outdoor intake air Wet bulb temperature C 15 10 5 0 5 10 15 0 4 0 5 0 6 0 7 0 8 0 9 1 0 1 1 1 2 1 3 Heating capacity at Rated frequency Capacity correction factor 15 20 26 Indoor intake air Dry bulb temperature Indoor air Dry bulb temperature difference C 22 9 21 2 19 4 17 6 1...

Page 14: ...Heating input The operational frequency of compressor Hz Input correction factors Correction of Cooling capacity Capacity correction factors Correction of Cooling input Input correction factors Correction of Heating capacity Capacity correction factors MUFZ KJ50VE Correction of Heating input Capacity correction factors The operational frequency of compressor Hz The operational frequency of compres...

Page 15: ...d to MPa on the international system of units SI unit system The conversion factor is 1 MPa Gauge 10 2 kgf cm2 Gauge 15 20 25 30 35 1 5 2 0 2 5 3 0 15 20 25 30 35 2 5 3 0 3 5 4 0 4 5 Ambient temperature C Ambient humidity 50 60 70 50 60 70 50 60 70 Outdoor current A Ambient temperature C Ambient humidity Outdoor current A MUFZ KJ35VE MUFZ KJ25VE Outdoor unit current 15 20 25 30 35 3 4 5 6 7 8 MUFZ...

Page 16: ... 535 27 24 3 35 1 84 0 55 491 3 23 1 77 0 55 518 3 15 1 73 0 55 535 3 05 1 68 0 55 562 27 26 3 45 1 48 0 43 518 3 35 1 44 0 43 545 3 30 1 42 0 43 562 3 20 1 38 0 43 578 28 18 2 94 2 79 0 95 432 2 81 2 67 0 95 454 2 70 2 57 0 95 475 2 60 2 47 0 95 497 28 20 3 06 2 54 0 83 454 2 94 2 44 0 83 481 2 85 2 37 0 83 491 2 75 2 28 0 83 513 28 22 3 19 2 26 0 71 470 3 08 2 18 0 71 500 3 00 2 13 0 71 513 2 88...

Page 17: ... 605 2 38 1 59 0 67 626 27 24 2 88 1 58 0 55 594 2 70 1 49 0 55 621 2 55 1 40 0 55 648 27 26 3 03 1 30 0 43 616 2 85 1 23 0 43 643 2 68 1 15 0 43 670 28 18 2 45 2 33 0 95 529 2 25 2 14 0 95 562 2 08 1 97 0 95 583 28 20 2 58 2 14 0 83 551 2 40 1 99 0 83 578 2 23 1 85 0 83 610 28 22 2 73 1 93 0 71 572 2 55 1 81 0 71 605 2 38 1 69 0 71 626 28 24 2 88 1 70 0 59 594 2 70 1 59 0 59 621 2 55 1 50 0 59 64...

Page 18: ...31 27 24 4 69 2 02 0 43 855 4 52 1 94 0 43 902 4 41 1 90 0 43 931 4 27 1 84 0 43 978 27 26 4 83 1 50 0 31 902 4 69 1 45 0 31 949 4 62 1 43 0 31 978 4 48 1 39 0 31 1006 28 18 4 11 3 41 0 83 752 3 94 3 27 0 83 790 3 78 3 14 0 83 827 3 64 3 02 0 83 865 28 20 4 29 3 04 0 71 790 4 11 2 92 0 71 837 3 99 2 83 0 71 855 3 85 2 73 0 71 893 28 22 4 46 2 63 0 59 818 4 31 2 54 0 59 870 4 20 2 48 0 59 893 4 03 ...

Page 19: ... 1 83 0 55 1090 27 24 4 03 1 73 0 43 1034 3 78 1 63 0 43 1081 3 57 1 54 0 43 1128 27 26 4 24 1 31 0 31 1072 3 99 1 24 0 31 1119 3 75 1 16 0 31 1166 28 18 3 43 2 85 0 83 921 3 15 2 61 0 83 978 2 91 2 41 0 83 1015 28 20 3 61 2 56 0 71 959 3 36 2 39 0 71 1006 3 12 2 21 0 71 1062 28 22 3 82 2 25 0 59 996 3 57 2 11 0 59 1053 3 33 1 96 0 59 1090 28 24 4 03 1 89 0 47 1034 3 78 1 78 0 47 1081 3 57 1 68 0 ...

Page 20: ...27 24 6 70 2 75 0 41 1283 6 45 2 64 0 41 1354 6 30 2 58 0 41 1396 6 10 2 50 0 41 1466 27 26 6 90 2 00 0 29 1354 6 70 1 94 0 29 1424 6 60 1 91 0 29 1466 6 40 1 86 0 29 1509 28 18 5 88 4 76 0 81 1128 5 63 4 56 0 81 1184 5 40 4 37 0 81 1241 5 20 4 21 0 81 1297 28 20 6 13 4 23 0 69 1184 5 88 4 05 0 69 1255 5 70 3 93 0 69 1283 5 50 3 80 0 69 1340 28 22 6 38 3 63 0 57 1227 6 15 3 51 0 57 1304 6 00 3 42 ...

Page 21: ...4 75 2 52 0 53 1636 27 24 5 75 2 36 0 41 1551 5 40 2 21 0 41 1621 5 10 2 09 0 41 1692 27 26 6 05 1 75 0 29 1607 5 70 1 65 0 29 1678 5 35 1 55 0 29 1748 28 18 4 90 3 97 0 81 1382 4 50 3 65 0 81 1466 4 15 3 36 0 81 1523 28 20 5 15 3 55 0 69 1438 4 80 3 31 0 69 1509 4 45 3 07 0 69 1593 28 22 5 45 3 11 0 57 1495 5 10 2 91 0 57 1579 4 75 2 71 0 57 1636 28 24 5 75 2 59 0 45 1551 5 40 2 43 0 45 1621 5 10...

Page 22: ... 83 968 4 39 1045 4 95 1111 5 46 1144 6 02 1166 21 2 58 770 3 10 913 3 66 1012 4 17 1089 4 73 1144 5 25 1177 5 78 1221 26 2 32 825 2 88 968 3 40 1067 3 96 1144 4 52 1199 5 03 1232 5 59 1265 NOTE Q Total capacity kW INPUT Total power input W DB Dry bulb temperature WB Wet bulb temperature MUFZ KJ50VE CAPACITY 6 0 kW INPUT 1610 W INDOOR DB C OUTDOOR WB C 10 5 0 5 10 15 20 Q INPUT Q INPUT Q INPUT Q I...

Page 23: ... The fan motor turns OFF 15 seconds after the compressor has stopped running 9 3 RELATION BETWEEN MAIN SENSOR AND ACTUATOR Sensor Purpose Actuator Compressor LEV Outdoor fan motor R V coil Indoor fan motor Defrost heater Discharge temperature thermistor Protection Indoor coil temperature thermistor Cooling Coil frost prevention Heating High pressure protec tion Defrost thermistor Heating Defrostin...

Page 24: ... Prolonged low load operation in which the thermostat is OFF for a long time at low outside temperature 0 C or less may cause the following troubles To prevent those troubles activate the pre heat control 1 If moisture gets into the refrigerant cycle and freezes it may interfer the start up of the compressor 2 If liquid refrigerant collects in the compressor a failure in the compressor may occur T...

Page 25: ...r 4 When removing the electronic control P C board hold the edge of the board with care NOT to apply stress on the components 5 When connecting or disconnecting the connectors hold the housing of the connector DO NOT pull the lead wires TROUBLESHOOTING 11 3 Troubleshooting procedure 1 Check if the OPERATION INDICATOR lamp on the indoor unit is flashing on and off to indicate an abnormality To make...

Page 26: ...abnormal Check the blinking pattern and identify the abnormal point by referring to the indoor unit failure mode table Refer to indoor unit service manual Make sure to check at least two consecutive blinking cycles 2 Releasing the failure mode recall function Release the failure mode recall function by the following procedures Turn OFF the power supply and turn it ON again Press RESET button of th...

Page 27: ...ailure mode recall function Release the failure mode recall function by the following procedures Turn OFF the power supply and turn it ON again Press RESET button of the remote controller Repair the failure parts The outdoor unit is normal Release the failure mode recall function accord ing to the left mentioned procedure Deleting the memorized abnormal condition After repairing the unit recall th...

Page 28: ...ater Check the refrigerant circuit and the refrigerant amount Refer to 11 5 Check of LEV 6 time flash 2 5 seconds OFF High pressure Temperature indoor coil thermistor exceeds 70 C in HEAT mode Temperature defrost thermistor exceeds 70 C in COOL mode Check the refrigerant circuit and the refrigerant amount Check the stop valve 7 time flash 2 5 seconds OFF Fin temperature P C board temperature 7 tim...

Page 29: ...ex ceeds 75 86 C KJ25 35 75 80 C KJ50 or temperature of P C board temperature thermistor on the inverter P C board exceeds 72 85 C KJ25 35 70 75 C KJ50 Check around the outdoor unit Check the outdoor unit air passage Refer to 11 5 Check of outdoor fan motor 11 5 time flash 2 5 seconds OFF High pressure pro tection Indoor coil thermistor exceeds 70 C in HEAT mode Defrost thermistor exceeds 70 C in ...

Page 30: ...en the power supply voltage is high MUFZ KJ50 Zero cross detecting circuit Zero cross signal cannot be detected It occurs with following cases 1 Instantaneous power voltage drop Short time power failure 2 Distortion of primary voltage Refer to 11 5 Check of power supply 22 9 time flash 2 5 seconds OFF Inverter check mode The connector of compressor is disconnected inverter check mode starts Check ...

Page 31: ...m and voltage 1 Inverter P C board for the chart of thermistor Compressor Measure the resistance between terminals using a tester Temperature 10 40 C Normal Ω MUFZ KJ25 35VE MUFZ KJ50VE U V U W V W 1 66 2 26 0 87 1 18 Outdoor fan motor Measure the resistance between lead wires using a tester Temperature 10 40 C Color of lead wire Normal Ω MUFZ KJ25 35VE MUFZ KJ50VE RED BLK BLK WHT WHT RED 12 16 12...

Page 32: ...0 130 V The voltage may differ according to the tester Operation method Start cooling or heating operation by pressing EMERGENCY OPERATION switch on the indoor unit TEST RUN OPERA TION Refer to 8 3 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 of th...

Page 33: ...t TEST RUN OPERATION Refer to 8 3 Measurement Measure the time from the start of compressor to the stop of compressor due to overcurrent Compressor starts Abnormal IC700 failure Compressor winding short Abnormal Compressor lock out Starting defect Abnormal Poor contact Inverter P C board defect Disconnected connector Abnormal Refrigerant circuit defect Closed valve Normal 0 second 1 second 2 secon...

Page 34: ...easure the resistance of thermistor MUFZ KJ25 35 Thermistor Symbol Connector Pin No Board Defrost RT61 Between CN641 pin1 and pin2 Inverter P C board Discharge temperature RT62 Between CN641 pin3 and pin4 Fin temperature RT64 Between CN642 pin1 and pin2 Ambient temperature RT65 Between CN643 pin1 and pin2 Outdoor heat exchanger temperature RT68 Between CN644 pin1 and pin3 MUFZ KJ50 Thermistor Symb...

Page 35: ...e power module IC700 Turn ON the power supply and press EMERGENCY OPERATION switch once COOL mode First of all measure the resistance of R V coil to check if the coil is defective Refer to 11 4 In case CN602 is disconnected or R V coil is open voltage is generated between the terminal pins of the connector although no signal is being transmitted to R V coil Check if CN602 is connected Is there 230...

Page 36: ...easure the voltage of CN931 Between 1 and 5 Between 2 and 5 Between 3 and 5 Does the voltage between each terminal become 5 and 0 VDC repeatedly Does the outdoor fan motor rotate smoothly Replace the outdoor fan motor Replace the inverter P C board Yes Yes No Fixed to either 5 or 0 VDC No No Yes Disconnect the connectors CN931 and CN932 from the inverter P C board Check the connection between the ...

Page 37: ...r to 11 6 1 No Replace the inverter P C board Is there bus bar voltage 260 370 VDC between DB61 and DB61 MUFZ KJ25 35 325 370 VDC between JP715 and JP30 MUFZ KJ50 on the inverter P C board Refer to 11 6 1 No Check the electric parts in main circuit Yes Yes No Disconnect the connector between the compressor and the power module IC700 MUFZ KJ25 35 IGBT module IC700 MUFZ KJ50 Turn ON power supply and...

Page 38: ...e by an analog tester Properly fix the LEV coil to the expansion valve Replace the inverter P C board Replace the LEV coil Replace the expansion valve Is LEV coil properly fixed to the expansion valve Does the resistance of LEV coil have the characteristics Refer to 11 4 Do you hear the expansion valve click click Do you feel the expansion valve vibrate on touching it Turn ON the power supply Prep...

Page 39: ...oor fan motor 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 corresponding parts following LED indication Refer to 11 3 Yes No Yes 10 time flash No L Check of inverter P C board OBH667B ...

Page 40: ... the power supply is turned on Touch S2 and S3 with tester probes and start the emergency operation No Turn the power supply ON When the emergency operation starts does the rated voltage occur for 2 seconds between indoor terminal block S2 and S3 Yes Replace the indoor electronic control P C board Does the left lamp of the OPERA TION INDICATOR lamp on the indoor unit blink continuously 6 minutes a...

Page 41: ... No Does DC 10 V or more occur between L68A and L68B on the outdoor relay P C board Yes Does the outdoor LED blink 6 times Yes Replace the outdoor relay P C board 1 No Does DC more than 0 V occur between indoor terminal block S2 and S3 Yes Replace the outdoor inverter P C board 1 No Turn the power supply OFF Start the emergency operation No Repair has been completed Replace the outdoor inverter P ...

Page 42: ...he 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 outd...

Page 43: ...5VE 11 6 TEST POINT DIAGRAM AND VOLTAGE Fin temperature thermistor RT64 CN642 Ambient temperature thermistor RT65 CN643 Discharge temperature thermistor RT62 CN641 Defrost thermistor RT61 CN641 DB61 260 370 VDC Front side of unit 230 VAC Smoothing capacitor C62 Output to drive compressor LDU LDV LDW Fuse F701 T3 15AL250V Smoothing capacitor C61 Fuse F901 T3 15AL250V R V coil CN721 230 VAC Jumper w...

Page 44: ...or 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 15AL250V Fuse F880 T3 15AL250V LEV connector CN724 Jumper wire for changing defrost setti...

Page 45: ...45 2 Relay P C board MUFZ KJ50VE To inverter P C board CN681 CN680 CN60 L68B L68A 10 VDC OBH667B ...

Page 46: ... locking mechanism Slide the sleeve Pull the terminal while pushing the locking lever Hold the sleeve and pull out the terminal slowly Connector Sleeve Locking lever Back panel Service panel Screws of the top panel Screws of the cabinet Screws of the top panel Screw of the service panel Direction to remove Screws of the cabinet Hooks Terminal with locking mechanism Detaching points The terminal wh...

Page 47: ...t and panels Refer to 1 2 Disconnect the following connectors Inverter P C board CN721 R V coil 3 Remove the R V coil 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 1 2 Disconnect the lead wire to the reactor and the following con nectors Inverter P C board...

Page 48: ...e inverter assembly Refer to 2 3 Recover gas from the refrigerant circuit NOTE Recover gas from the pipes until the pressure gauge shows 0 kg cm2 0 MPa 4 Detach the brazed 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 brazed part of pipes connected with 4 way valve 48 Propeller nut Screws of the outdoo...

Page 49: ...panel 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 2 Photo 1 Screws of the cabinet Screws of the top panel Screws of the cabinet Screws of the top panel Screw of the back panel Screws of the cabinet Screws of the service panel S...

Page 50: ... the lead wires of the inverter P C board 7 Remove the screws of the P B support 8 Remove the inverter P C board from the relay panel 9 Disconnect the following connectors Relay P C board CN60 Terminal block CN680 Inverter P C board TAB65 Inverter P C board TB71 10 Remove the screws fixing the P B holder 11 Remove the relay P C board from the P B holder Photo 3 Photo 4 3 Removing R V coil 1 Remove...

Page 51: ...motor 1 Remove 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 1 2 Remove the back panel Refer to 1 3 Remove the inverter assem...

Page 52: ...667 REVISED EDITION B Distributed in Oct 2013 No OBH667 REVISED EDITION A Distributed in Jun 2013 No OBH667 Made in Japan HEAD OFFICE TOKYO BLDG 2 7 3 MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN New publication effective Jan 2014 Specifications are subject to change without notice ...

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