Mitsubishi Electric SUZ-KA25VA4 Page 1 Technical & Service Manual Download

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TECHNICAL & SERVICE MANUAL

No.OCH545

SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS

R410A

Outdoor unit
[Model Name] [Service

Ref.]

SUZ-KA25VA4

SUZ-KA25VA4.TH

SUZ-KA35VA4

SUZ-KA35VA4.TH

SUZ-KA50VA4

SUZ-KA50VA4.TH

SUZ-KA60VA4

SUZ-KA60VA4.TH

SUZ-KA71VA4

SUZ-KA71VA4.TH

CONTENTS

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

2. TECHNICAL CHANGES ................................... 3

3. PARTS NAMES AND FUNCTIONS .................. 7

4. SPECIFICATION ................................................ 8

5. NOISE CRITERIA CURVES ............................ 10

6. OUTLINES AND DIMENSIONS .......................11

7. WIRING DIAGRAM .......................................... 13

8. REFRIGERANT SYSTEM DIAGRAM ............. 16

9. ACTUATOR CONTROL ................................... 19

10. SERVICE FUNCTIONS .................................... 20

11. TROUBLESHOOTING ..................................... 20

12. DISASSEMBLY INSTRUCTIONS .................... 36

Indication of
model name

Note:
• This service manual

describes technical data of
the outdoor units.

HFC

utilized

R410A

SUZ-KA25VA4.TH
SUZ-KA35VA4.TH

August 2013

PARTS CATALOG (OCB545)

Summary of Contents for SUZ-KA25VA4

Page 1: ...DOOR AND OUTDOOR UNITS 2 2 TECHNICAL CHANGES 3 3 PARTS NAMES AND FUNCTIONS 7 4 SPECIFICATION 8 5 NOISE CRITERIA CURVES 10 6 OUTLINES AND DIMENSIONS 11 7 WIRING DIAGRAM 13 8 REFRIGERANT SYSTEM DIAGRAM 16 9 ACTUATOR CONTROL 19 10 SERVICE FUNCTIONS 20 11 TROUBLESHOOTING 20 12 DISASSEMBLY INSTRUCTIONS 36 Indication of model name Note This service manual describes technical data of the outdoor units HF...

Page 2: ...KD60VA L R2 TH SEZ KD71VA L R2 TH SEZ KD25VAQR2 TH SEZ KD35VAQR2 TH SEZ KD50VAQR2 TH SEZ KD60VAQR2 TH SEZ KD71VAQR2 TH OC320 OCH493 Indoor unit Service Manual No Service Ref Heat pump without electric heater KA25VA4 TH KA60VA4 TH KA71A4 TH KA50VA4 TH HWE0711 BWE102050 BWE102040 HWE1008 KA35VA4 TH Note Please refer to the service manual of indoor unit or the technical data book for the combination ...

Page 3: ...igh as that of R22 some special tools and piping parts materi als are required Refer to the table below Take sufficient care not to allow water and other contaminations to enter the R410A refrigerant during storage and installa tion since it is more susceptible to contaminations than R22 For refrigerant piping use clean pressure proof parts materials specifically designed for R410A Refer to 2 Refr...

Page 4: ...New New Gauge manifold Charge hose Torque wrench Flare tool Flare gauge Vacuum pump adapter Electronic scale for refrigerant charging No Not substitutable for R410A Yes Substitutable for R410A No 12 7 mm and 15 88 mm 1 Tools dedicated for the air conditioner with R410A refrigerant The following tools are required for R410A refrigerant Some R22 tools can be substituted for R410A tools The diameter ...

Page 5: ...ir purge Do not discharge the refrigerant into the atmosphere Take care not to discharge refrigerant into the atmosphere during installation reinstallation or repairs to the refrigerant circuit Use the vacuum pump for air purging for the purpose of environmental protection 5 Additional charge For additional charging charge the refrigerant from liquid phase of the gas cylinder If the refrigerant is...

Page 6: ...mote controller 6 Fully close the stop valve on the gas pipe side of the outdoor unit when the pressure gauge shows 0 05 to 0 MPa Gauge approx 0 5 to 0 kgf cm and quickly stop the air conditioner Push the ON OFF button on the remote controller to stop the air conditioner Note When the extension piping is very long with a large refrigerant amount it may not be possible to perform a pump down operat...

Page 7: ...5VA4 TH SUZ KA35VA4 TH SUZ KA50VA4 TH SUZ KA60VA4 TH SUZ KA71VA4 TH Air outlet Drain outlet Piping Drain hose Air inlet back and side Model SUZ KA VA4 TH Drain socket 1 Piping Air outlet Drain outlet Air inlet back and side Drain hose OCH545 ...

Page 8: ...L 0 31 FV50S 0 27 FV50S 0 35 FV50S 0 4 FV50S Fan motor Model RC0J50 FA RC0J60 BD 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 High 2 106 2 778 2 952 2 892...

Page 9: ...250V T20A L250V T20A L250V F62 T20A L250V T20A L250V F701 F801 F901 T3 15A L250V T3 15A L250V T3 15A L250V IC700 15A 600V 15A 600V 20A 600V Inteligent power module IPM 20A 600V IC932 8A 600V 8A 600V 8A 600V 5A 600V 5A 600V Power factor controller PFC 20A 600V 20A 600V IC820 20A 600V 20A 600V 20A 600V Expansion valve coil LEV DC12V Reactor L61 18mH 23mH 23mH L 340μH 20A 340μH 20A Current Limiting P...

Page 10: ...ER FREQUENCIES Hz NC 10 SUZ KA35VA4 TH 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 KA50VA4 TH Test conditions Cooling Dry bulb temperature 35 C Heating Dry bulb temperature 7 C Wet bulb tempera...

Page 11: ...on 304 325 40 Liquid refrigerant 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 open 100mm or more without any obstruction in front and on both sides of the unit 350mm or more 200mm or more 100mm or more 100mm or more Open two sides of left right or rear side Drain hole 42 Unit mm SUZ KA25VA4 TH SU...

Page 12: ...refrigerant pipe joint Refrigerant pipe flared Ø 12 7 SUZ KA50VA4 Ø 15 88 SUZ KA60 71VA4 350 mm or more 100 mm or more REQUIRED SPACE Open as a rule 500mm or more if the front and both sides are open 100mm or more 200mm or more if there are obstacles to both sides Open as a rule 500mm or more if the back both sides and top are open Air in Bolt pitch for installation 360 SUZ KA50VA4 TH SUZ KA60VA4 ...

Page 13: ...13 13 7 WIRING DIAGRAM SUZ KA25VA4 TH SUZ KA35VA4 TH OCH545 ...

Page 14: ...14 SUZ KA50VA4 TH OCH545 ...

Page 15: ...15 SUZ KA60VA4 TH SUZ KA71VA4 TH OCH545 ...

Page 16: ...ffler 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 Refrigerant pipe ø9 52 wi...

Page 17: ...perature thermistor RT68 Ambient temperature thermistor RT65 Strainer 100 Muffler Unit mm SUZ KA60VA4 TH SUZ KA71VA4 TH 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 way valve Refrigerant flow in heating Refrigerant...

Page 18: ...m 10m 11m 12m 13m 14m 15m 20m SUZ KA25VA4 TH 800 0 30 60 90 120 150 180 210 240 390 SUZ KA35VA4 TH 1 150 0 30 60 90 120 150 180 210 240 390 Calculation Xg 30g m Refrigerant piping length m 7 Model Refrigerant piping m Piping size O D mm Max Length A Max Height difference B Gas Liquid SUZ KA25VA4 TH 20 12 9 52 6 35 SUZ KA35VA4 TH SUZ KA50VA4 TH 30 30 12 7 SUZ KA60VA4 TH 15 88 SUZ KA71VA4 TH 9 52 Mo...

Page 19: ...ompressor starts up OFF The fan motor turns OFF 15 seconds after the compressor has stopped running NOTE The 4 way valve reverses 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 pr...

Page 20: ...VA4 TH SUZ KA60VA4 TH SUZ KA71VA4 TH 11 1 CAUTIONS ON TROUBLESHOOTING 1 Before troubleshooting check the following 1 Check the power supply voltage 2 Check the indoor outdoor connecting wire for 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...

Page 21: ... 5 Check of inverter P C board 13 12 time flash 2 5 seconds OFF Each phase current of compressor Each phase current of compressor cannot be detected nor mally Refer to 11 5 How to check in verter compressor 14 13 time flash 2 5 seconds OFF DC voltage DC voltage of inverter cannot be detected normally Refer to 11 5 How to check in verter compressor 15 Outdoor unit operates 1 time flash 2 5 seconds ...

Page 22: ...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 are correspond to the entered a...

Page 23: ...n the remote controller display if the correct voltage 8 5 12 VDC is not supplied to the remote con troller 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 transmission line and...

Page 24: ...r code history for each unit using the remote controller 1 Switch to self diagnosis mode Press the CHECK button H in the picture above twice within 3 seconds The display content will change as shown below 2 Set the unit number or refrigerant address you want to diagnose Press the TEMP buttons and F in the picture above to select the desired number or address The number address changes between 01 a...

Page 25: ... will change as shown below Press the FILTER button in the picture in the previous page Remote controller self diagnosis result When the remote controller is functioning correctly Check for other possible causes as there is no problem with the remote controller When the remote controller malfunctions Error display 1 NG blinks The remote controller s transmitting receiv ing circuit is defective The...

Page 26: ...e is cancelled Procedure 1 Press the CHECK button twice 2 Press the temperature buttons 3 Point the remote controller at the sensor on the indoor unit and press the HOUR button 4 Point the remote controller at the sensor on the indoor unit and press the ON OFF button Malfunction diagnosis method at maintenance service 11 3 6 Self diagnosis Wireless remote controller In case of trouble during opera...

Page 27: ...ck code in the following table nth 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 Notes The check code in the parenthesis indicates PAR 30MAA model Beeper sounds OPERATION INDICATOR lamp flashes Check code Symptom Remark Number of times Wireless remote controller Wired remote controller Beeper ...

Page 28: ...rement hold the thermistor with your hands to warm it up Refer to 11 6 Test point diagram and voltage 11 6 1 KA25 35 50 or 11 6 2 KA60 71 Inverter P C board for the chart of thermistor Defrost thermistor RT61 Fin temperature thermistor RT64 29 42 Measure the resistance between terminals with a tester Temperature 10 C 40 C Compressor U V U W V W Normal W U V WHT RED BLK W U V WHT RED BLK Ambient te...

Page 29: ... 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 30: ...me from the start of compressor to the stop of compressor due to overcurrent Is the resistance of thermistor normal KA25 35 50 Refer to 11 6 1 KA60 71 11 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 connector of thermi...

Page 31: ...HEAT 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 11 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 11 5 H Check of outdoor fan motor Is the...

Page 32: ...coil with a hand 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...

Page 33: ... 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 34: ...e 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 VDC Front side of unit 230 VAC Smoothing capacitor C62 Output to drive compressor LDU LDV LDW Fuse F701 T3 15AL250V Smoothing capacitor C61 Smoothing capacitor C63 Fuse F901 T3 15AL250V R V coil CN721 23...

Page 35: ...0 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 15AL250V Fuse F880 T3 15AL250V LEV connector CN724 ...

Page 36: ...ing points Connector 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 fix...

Page 37: ...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 38: ...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 39: ...ve 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 Screw of the ...

Page 40: ...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 41: ...ervice 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 Remove the...

Page 42: ...ve 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 Screw of the valve cove...

Page 43: ...ve 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 screw 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 44: ...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 45: ...45 OCH545 ...

Page 46: ...3 MARUNOUCHI CHIYODA KU TOKYO100 8310 JAPAN Copyright 2013 MITSUBISHI ELECTRIC CORPORATION Distributed in Aug 2013 No OCH545 Made in Japan New publication effective Aug 2013 Specifications are subject to change without notice TM ...

Page 47: ...elated Links Model Number SUZ KA60VA4 SUZ KA35 71VA4 Declaration of Conformity SUZ KA25 71VA4 Service Handbook OCH545 SUZ KA25 71VA4 Parts Catalogue OCB545 SUZ KA25 71VA4 Installation Manual RG79Y534H01 ...

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