Mitsubishi Electric SUZ-KA60VA3 Technical & Service Manual Download Page 11

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417.5

Drain hole

175

500

330

Air in

Air out

2-Oval holes 10 21

840

109

880

452

Service panel

99.5

164.5

195

Liquid refrigerant
pipe joint
Refrigerant pipe
(flared)

6.35...(SUZ-KA50, 60VA3)

9.52...(SUZ-KA71VA3)

Gas refrigerant
pipe joint
Refrigerant pipe
(flared)

12.7...(SUZ-KA50VA3)

15.88...(SUZ-KA60, 71VA3)

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-KA50VA3.TH
SUZ-KA60VA3.TH
SUZ-KA71VA3.TH

Unit: mm

OCH530

Summary of Contents for SUZ-KA60VA3

Page 1: ...NDOOR AND OUTDOOR UNITS 2 2 TECHNICAL CHANGES 3 3 PART NAMES AND FUNCTIONS 6 4 SPECIFICATION 7 5 NOISE CRITERIA CURVES 9 6 OUTLINES AND DIMENSIONS 10 7 WIRING DIAGRAM 12 8 REFRIGERANT SYSTEM DIAGRAM 15 9 ACTUATOR CONTROL 18 10 SERVICE FUNCTIONS 19 11 TROUBLESHOOTING 19 12 DISASSEMBLY INSTRUCTIONS 49 Indication of model name NOTE This service manual describes technical data of the outdoor units HFC...

Page 2: ... SEZ KD50VA L R2 TH SEZ 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 KA25VA3 TH KA60VA3 TH KA71VA3 TH KA50VA3 TH HWE0711 BWE102050 BWE102040 HWE1008 KA35VA3 TH NOTE Please refer to the service manual of indoor unit or the technical data ...

Page 3: ...h as that of R22 some special tools and piping parts materials are required Refer to the table below 2 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 3 For refrigerant piping use clean pressure proof parts materials specifically designed for R410A Refer to 2 Ref...

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: ...A3 TH SUZ KA35VA3 TH SUZ KA50VA3 TH SUZ KA60VA3 TH SUZ KA71VA3 TH Air outlet Drain outlet Piping Drain hose Air inlet back and side Model SUZ KA VA3 TH Drain socket 1 Piping Air outlet Drain outlet Air inlet back and side Drain hose OCH530 ...

Page 7: ... 0 31 FV50S 0 27 FV50S 0 35 FV50S 0 4 FV50S Fan motor Model RC0J50 FA RC0J60 BD RC0J60 BC Current 1 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 1 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 ...

Page 8: ...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 PTC th...

Page 9: ...TER FREQUENCIES Hz NC 10 SUZ KA35VA3 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 KA50VA3 TH Test conditions Cooling Dry bulb temperature 35 C Heating Dry bulb temperature 7 C Wet bulb temper...

Page 10: ...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 KA25VA3 TH SU...

Page 11: ... refrigerant pipe joint Refrigerant pipe flared Ø 12 7 SUZ KA50VA3 Ø 15 88 SUZ KA60 71VA3 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 KA50VA3 TH SUZ KA60VA3...

Page 12: ...12 7 WIRING DIAGRAM SUZ KA25VA3 TH SUZ KA35VA3 TH OCH530 ...

Page 13: ...13 13 SUZ KA50VA3 TH OCH530 ...

Page 14: ...14 SUZ KA60VA3 TH SUZ KA71VA3 TH OCH530 ...

Page 15: ...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 Refrigerant pipe ø9 52 ...

Page 16: ...rature thermistor RT68 Ambient temperature thermistor RT65 Strainer 100 Muffler Unit mm SUZ KA60VA3 TH SUZ KA71VA3 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 p...

Page 17: ...m 10m 11m 12m 13m 14m 15m 20m SUZ KA25VA3 TH 800 0 30 60 90 120 150 180 210 240 390 SUZ KA35VA3 TH 1 150 0 30 60 90 120 150 180 210 240 390 Calculation Xg 30g mo Refrigerant piping length m 7 Models Refrigerant piping m Piping size O D mm Max Length A Max Height difference B Gas Liquid SUZ KA25VA3 TH 20 12 9 52 6 35 SUZ KA35VA3 TH SUZ KA50VA3 TH 30 30 12 7 SUZ KA60VA3 TH 15 88 SUZ KA71VA3 TH 9 52 ...

Page 18: ...pressor 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 prot...

Page 19: ...KA60VA3 TH SUZ KA71VA3 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 the power ...

Page 20: ...ilure mode recall function by the following procedures With the remote controller headed towards the indoor unit press any button that is not used in this failure mode recall function e g TIMER button OR Turn OFF the power supply and turn ON it again Press RESET button of the remote controller Judgment of indoor outdoor abnormality 1 Press OPERATE STOP ON OFF button of the remote controller the se...

Page 21: ...ll appear When the backlight is off pressing any button turns the backlight on and it will stay lit for a certain period of time depending on the screen Backlit LCD This lamp lights up in green while the unit is in operation It blinks while the remote controller is starting up or when there is an error ON OFF lamp Main display Press to change the operation mode Main menu Press to move the cursor d...

Page 22: ...n Select Self check with the F1 or F2 button and press the button 1 Select Service from the Main menu and press the button 3 Error code unit number 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...

Page 23: ...perature of heat sink 8 U8 Outdoor unit fan protection stop 9 U6 Compressor overcurrent interruption Abnormal of power module 10 U7 Abnormality of super heat due to low discharge temperature 11 U9 UH Abnormality such as overvoltage or voltage shortage and abnormal synchronous signal to main circuit Current sensor error 12 13 14 Others Other errors If the beeper does not sound again after the initi...

Page 24: ...e temperature thermistor exceeds 116 C compressor stops Compressor can restart if discharge temperature thermistor reads 100 C or less 3 minutes later Check refrigerant circuit and refrigerant amount Refer to 11 5 Check of LEV High pressure Temperature indoor coil thermistor exceeds 70 C in HEAT mode Temperature defrost thermistor exceeds 70 C in COOL mode Check refrigerant circuit and refrigerant...

Page 25: ...0 C in COOL mode Check refrigerant circuit and refrigerant amount Check stop valve U5 Fin temperature 7 time flash 2 5 seconds OFF Temperature of fin temperature thermistor on the inverter P C board exceeds 75 80 C Check around outdoor unit Check outdoor unit air passage Refer to 11 5 i Check of outdoor fan motor UB P C board temperature Temperature of P C board temperature thermistor on the inver...

Page 26: ... seconds OFF Outdoor fan motor Outdoor fan has stopped 3 times in a row within 30 seconds after outdoor fan start up Refer to 11 5 Check of outdoor fan motor Refer to 11 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 sec...

Page 27: ...ash 2 5 seconds OFF Compressor synchronous abnormality The waveform of compressor current is distorted Reconnect connector of compressor Refer to 11 5 a How to check inverter compressor 12 10 time flash 2 5 seconds OFF Outdoor fan motor Outdoor fan has stopped 3 times in a row within 30 seconds after outdoor fan start up Refer to 11 5 i Check of outdoor fan motor Refer to 11 5 l Check of inverter ...

Page 28: ... board for the chart of thermistor Color of the lead wire Color of the lead wire Discharge temperature thermistor RT62 Measure the resistance using a tester Before measurement hold the thermistor with your hands to warm it up Refer to 11 6 Test point diagram and voltage 11 6 1 Inverter P C board for the chart of thermistor Defrost thermistor RT61 Fin temperature thermistor RT64 29 42 Measure the r...

Page 29: ...er P C board for the chart of thermistor Color of the lead wire Color of the lead wire Discharge temperature thermistor RT62 Measure the resistance using a tester Before measurement hold the thermistor with your hands to warm it up Refer to 11 6 Test point diagram and voltage 11 6 4 Outdoor electronic control P C board or 11 6 2 11 6 3 Inverter P C board for the chart of thermistor Defrost thermis...

Page 30: ...ressor starts at rated frequency in COOL mode or 58Hz in HEAT mode 4 Indoor fan operates at High speed 5 After 30 minutes test run operation finishes and EMERGENCY OPERATION starts 6 To cancel test run operation EMERGENCY OPERATION press the EMERGENCY OPERATION switch or the ON OFF button on remote controller Measurement point At 3 points BLK U WHT V BLK U RED W WHT V RED W NOTE 1 Output voltage v...

Page 31: ... No Does the compressor run for 10 seconds or more after it starts After the compressor is heated with a drier does the compressor start Compressor start failure Activate pre heat control Refer to 10 2 PRE HEAT CONTROL SETTING Yes Yes F Check of compressor start failure Confirm that 1 4 is normal Electrical circuit check 1 Contact of the compressor connector 2 Output voltage of inverter P C board ...

Page 32: ... OPERATION switch twice HEAT mode Disconnect connector between the compressor and the intelligent power module Turn ON the power supply and press EMERGENCY OPERATION switch once COOL mode SUZ KA25 35 50VA3 TH Is the resistance of thermistor normal Refer to 11 6 1 Disconnect the connector of thermistor in the outdoor P C board see below table and measure the resistance of thermistor Replace the the...

Page 33: ...ntrol P C board or the inverter P C board Yes Yes No Fixed to either 5 or 0 VDC No No Yes SUZ KA25 35 50VA3 TH J Check of power supply Is there voltage 230 VAC between the indoor terminal block S1 and S2 No Yes Replace the indoor electronic control P C board Rectify indoor outdoor connecting wire Yes If lights up OK If flashes refer to 11 3 Does the left lamp of OPERATION INDICATOR lamp on the ind...

Page 34: ...perly fix the LEV coil to the expansion valve 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 Preparation of the remote controller While pressing both OPE...

Page 35: ...he LEV coil with a hand Yes Check the outdoor fan motor Refer to H 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 bo...

Page 36: ...tronic control P C board repeat 3 6 second OFF and 0 8 second ON quick blinking 3 Yes No Lighted or not lighted Replace the inverter P C board or the outdoor electronic control P C board 2 2 Be careful of the residual voltage of smoothing capacitor Turn OFF the power supply Remove the short circuit between outdoor terminal block S2 and S3 Turn ON the power supply Is there amplitude of 10 to 20 VDC...

Page 37: ...ntrol P C board repeat 3 6 second OFF and 0 8 second ON quick blinking 3 Yes No Lighted or not lighted Replace the inverter P C board or the outdoor electronic control P C board 2 2 Be careful of the residual voltage of smoothing capacitor Turn OFF the power supply Remove the short circuit between outdoor terminal block S2 and S3 Turn ON the power supply Is there amplitude of 10 to 20 VDC between ...

Page 38: ...ion 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 outdoor unit of ...

Page 39: ... between the terminals Output voltage is 50 130 V The voltage may differ according to the tester Operation method Test run operation 1 Press EMERGENCY OPERATION switch to start COOL or HEAT mode COOL Press once HEAT Press twice 2 Test run operation starts and continues to operate for 30 minutes 3 Compressor operates at rated frequency in COOL mode or 74 Hz in HEAT mode 4 Indoor fan operates at Hig...

Page 40: ...o not recover refrigerant gas while heating Heating part Connect the compressor and activate the inverter Then measure the time until the inverter stops due to over current Operation method Start heating or cooling operation by pressing EMERGENCY OPERATION switch on the indoor unit TEST RUN OPERATION Refer to 11 5 b Measurement Measure the time from the start of compressor to the stop of compresso...

Page 41: ...pin5 and pin6 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 VAC between CN602 and on the inverter P C board 3 minutes after the power supply is...

Page 42: ...Check the connection between the connector CN931 and CN932 J Check of power supply Is there voltage 230 VAC between the indoor terminal block S1 and S2 No Yes Replace the indoor electronic control P C board Rectify indoor outdoor connecting wire Yes If lights up OK If flashes refer to 11 3 Does the upper lamp of OPERATION INDICATOR on the indoor unit light up Does LED on the inverter P C board lig...

Page 43: ... vibrate on touching it Turn ON the power supply Preparation of the remote controller While pressing both OPERATION SELECT button and TOO COOL button on the remote controller at the same time press RESET button First release RESET button And release the other two buttons after all LCD except the set temperature in operation display section of the remote controller is displayed after 3 seconds Yes ...

Page 44: ... 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 SUZ KA60 71VA3 TH OCH530 ...

Page 45: ...oor outdoor connect ing wire Yes Correct them No A Turn OFF the power supply Check once more if the indoor outdoor connecting wire is not miswiring Short circuit outdoor terminal block S2 and S3 1 B 1 Miswiring may damage indoor electronic control P C board during the operation Be sure to confirm the wiring is correct before the opera tion starts Turn ON the power supply Does the LED on the invert...

Page 46: ...lation 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 outdoor unit ...

Page 47: ...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 48: ...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 49: ...hing 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 fi...

Page 50: ... 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 In...

Page 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ... 3 MARUNOUCHI CHIYODA KU TOKYO100 8310 JAPAN cCopyright 2012 MITSUBISHI ELECTRIC CORPORATION Distributed in Oct 2012 No OCH530 Made in Japan New publication effective Oct 2012 Specifications are subject to change without notice ...

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