Mitsubishi Electric SUZ-KA25VA5, SUZ-KA60VA5, SUZ-KA50VA5, SUZ-KA35VA5, SUZ-KA71VA5 Service Manual

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Page 1

TECHNICAL & SERVICE MANUAL

R410A

CONTENTS

COMBINATION OF INDOOR AND OUTDOOR UNITS

.....

2. PARTS NAMES AND FUNCTIONS

..................

3. SPECIFICATION

................................................

4. NOISE CRITERIA CURVES

..............................

5. OUTLINES AND DIMENSIONS

........................

6. WIRING DIAGRAM

............................................

7. REFRIGERANT SYSTEM DIAGRAM

.............

8. ACTUA TOR CONTROL

...................................

9. SERVICE FUNCTIONS

...................................

10. TROUBLESHOOTING

.....................................

11. DISASSEMBLY PROCEDURE

........................

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

Page 2

COMBINATION OF INDOOR AND OUTDOOR UNITS

INDOOR UNIT SERVICE MANUAL

Indoor unit

Outdoor unit

Heat pump type

SUZ-

Service Ref.

Service

manual No.

KA25VA5.TH

KA25VA5.TH-ET

KA35VA5.TH

KA35VA5.TH-ET

KA50VA5.TH

KA50VA5.TH-ET

KA60VA5.TH

KA60VA5.TH-ET

KA71VA5.TH

KA71VA5.TH-ET

Heat pump without electric heater

SLZ-KF25VA.TH

OCH600 OCB600

─ ─ ─ ─

SLZ-KF35VA.TH ─ ─ ─ ─ SLZ-KF50VA.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.UK

BWE014160

─ ─ ─ ─

PEAD-RP50JAQR2.UK ─ ─ ─ ─ PEAD-RP60JAQR2.UK ─ ─ ─ ─ PEAD-RP71JAQR2.UK ─ ─ ─ ─ PEAD-RP35JALR2.UK

BWE09350

─ ─ ─ ─

PEAD-RP50JALR2.UK ─ ─ ─ ─ PEAD-RP60JALR2.UK ─ ─ ─ ─ PEAD-RP71JALR2.UK ─ ─ ─ ─

OCH603

Page 3

PARTS NAMES AND FUNCTIONS

SUZ-KA25VA5 SUZ-KA35VA5

SUZ-KA50VA5 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

SPECIFICATION

Note: Test conditions are based on ISO 5151 Cooling : Indoor D.B. 27°C W.B. 19°C Outdoor D.B. 35°C Heating : Indoor D.B. 20°C Outdoor D.B. 7°C W.B. 6°C Refrigerant piping length (one way): 5 m *Measured under rated operating frequency.

Outdoor model

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

Power supply Single phase 230 V, 50 Hz

Compressor

Model KNB073FKFMC KNB092FFAMC SNB130FGBMT SNB172FEKMT Output W 550 650 900 1,200

Current*

Cooling

2.76 4.06 5.58 6.62 8.02

Heating 3.24 4.09 5.75 6.37 8.13

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

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

ow*

Cooling

High

m³/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

Med. 1,806 1,770 2,778 2,952 2,892

Low 1,452 1,326 2,124 2,226 2,280

Sound pressure level*

Cooling

dB(A)

47 49 52 55

Heating 48 50 52 55

Sound power level

58 62 65 65 69

Fan speed

Cooling

High

rpm

740 810 840 950

Med. 740 810 840

Low 740 490 480 450

Heating

High 860 900 810

Med. 740 770 810

Low 600 610 620 650

Fan speed regulator 3

Refrigerant lling capacity

(R410A)

kg 0.80 1.15 1.60 1.60 1.80

OCH603

Page 5

Specifications and rating conditions of main electric parts

Model

Item

SUZ-KA25VA5 SUZ-KA35VA5 SUZ-KA50VA5 SUZ-KA60VA5 SUZ-KA71VA5

Smoothing capacitor

(C61) — — 620 μF 420 V — — (C62, C63) 620 μF 420 V 620 μF 420 V 620 μF420 V — — (CB1, 2, 3) — — — 560 μF 450 V 560 μF 350 V

Diode module (DB61) 15 A 600 V 15 A 600 V 25 A 600 V — —

Fuse

(F61) T20 A L250 V T20 A L250 V T20 A L250 V — — (F62) — — — T20A L250V T20A L250V

(F701, F801, 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, PTC65) 33Ω

Terminal block

(TB1, TB2) — — — 3P 3P

(TB) 5P 5P 5P — —

Relay

(X63) 3 A 250 V 3 A 250 V 3 A 250 V — —

(X64) 20 A 250 V

(X601) — — — 3 A 250 V 3 A 250 V (X602) — — — 3 A 250 V 3 A 250 V

R.V. coil (21S4) 220–240 V AC

OCH603

Page 6

NOISE CRITERIA CURVES

OCTAVE BAND SOUND PRESSURE LEVEL, dB re 0.0002 MICRO BAR

COOLING

FUNCTION

SPL(dB(A))

LINE

High Med.

FAN SPEED

HEATING

47 48

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-KA25VA5.TH SUZ-KA25VA5.TH-ET

OCTAVE BAND SOUND PRESSURE LEVEL, dB re 0.0002 MICRO BAR

COOLING

FUNCTION

SPL(dB(A))

LINE

FAN SPEED

HEATING

49 50

High Med.

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-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

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-bulb temperature 7°C Wet-bulb temperature 6°C

OUTDOOR UNIT

MICROPHONE

1 m

SUZ-KA60VA5.TH SUZ-KA71VA5.TH SUZ-KA60VA5.TH-ET SUZ-KA71VA5.TH-ET

OCTAVE BAND SOUND PRESSURE LEVEL, 0dB re 0.0002 MICRO BAR

COOLING

FUNCTION

SPL(dB(A)) LINE

High

FAN SPEED

HEATING

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

OCH603

Page 7

OUTLINES AND DIMENSIONS

800

302.5 500 Bolt pitch for installation

150

22.3

Handle

550

280

164.5

99.5

170.5

Service panel

Service port

285

344.5

400

Air in

Air out

Air in

17.5

Bolt pitch for

installation

304~325

Liquid refrigerant pipe joint Refrigerant pipe (flared) [6.35

Gas refrigerant pipe joint Refrigerant pipe (flared) [9.52

43-

35-

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

200 mm or more. Leave any two sides among right, left or rear open.

Drain hole [42

Unit: mm

SUZ-KA25V A5.TH SUZ-KA35V A5.TH SUZ-KA25VA5.TH-ET SUZ-KA35VA5.TH-ET

OCH603

Page 8

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)

Ø 6.35...(SUZ-KA50/60VA5) Ø 9.52...(SUZ-KA71VA5)

Gas refrigerant pipe 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-KA50V A5.TH SUZ-KA60V A5.TH SUZ-KA71VA5.TH SUZ-KA50VA5.TH-ET SUZ-KA60VA5.TH-ET SUZ-KA71VA5.TH-ET

OCH603

Page 9

WIRING DIAGRAM

SUZ-KA25V A5.TH SUZ-KA35V A5.TH SUZ-KA25VA5.TH-ET SUZ-KA35VA5.TH-ET

OCH603

Page 10

SUZ-KA50VA5.TH SUZ-KA50VA5.TH-ET

OCH603

Page 11

SUZ-KA60VA5.TH SUZ-KA71VA5.TH SUZ-KA60VA5.TH-ET SUZ-KA71VA5.TH-ET

OCH603

Page 12

REFRIGERANT SYSTEM DIAGRAM

Unit: mm

SUZ-KA25VA5.TH SUZ-KA25VA5.TH-ET

Unit: mm

SUZ-KA35VA5.TH SUZ-KA35VA5.TH-ET

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 (with heat insulator)

Refrigerant pipe ø6.35 (with heat insulator)

R.V. coil heating ON cooling OFF

Strainer #100

Ambient temperature 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

Refrigerant pipe ø9.52 (with heat insulator)

Refrigerant pipe ø6.35 (with heat insulator)

R.V. coil heating ON cooling OFF

Strainer #100

Capillary tube ø3.0×ø1.8×600(×2)

LEV

Ambient temperature thermistor

Muffler

Capillary tube ø3.0×ø2.0×240

Outdoor heat exchanger temperature thermistor

Muffler

RT65

RT68

OCH603

Page 13

1313

Unit: mm

SUZ-KA50VA5.TH SUZ-KA50VA5.TH-ET

SUZ-KA60VA5.TH SUZ-KA60VA5.TH-ET

Outdoor heat exchanger

Flared connection

Defrost thermistor RT61

Discharge temperature thermistor RT62

Flared connection

Stop valve

Stop valve (with service port)

Capillary tube

4.0

2.4×100 Refrigerant flow in cooling

Compressor

4-way valve

Refrigerant flow in heating

Refrigerant pipe

12.7 (SUZ-KA50VA4)

(with heat insulator)

Refrigerant pipe ø6.35 (with heat insulator)

LEV

R.V. coil heating ON cooling OFF

Muffler

Strainer

#100

Outdoor heat exchanger temperature thermistor RT68

Ambient temperature thermistor RT65

Strainer

#100

Strainer

#100

Muffler

15.88 (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

4.0

2.4×100 Refrigerant flow in cooling

Compressor

4-way valve

Refrigerant flow in heating

Refrigerant pipe

15.88

(with heat insulator)

Refrigerant pipe ø6.35 (with heat insulator)

LEV

R.V. coil heating ON cooling OFF

Muffler

Strainer

#100

Outdoor heat exchanger temperature thermistor RT68

Ambient temperature thermistor RT65

Strainer

#100

OCH603

Page 14

Unit: mm

SUZ-KA71VA5.TH SUZ-KA71VA5.TH-ET

Outdoor heat exchanger

Flared connection

Defrost thermistor RT61

Discharge temperature thermistor RT62

Flared connection

Stop valve

Stop valve (with service port)

Capillary tube

4.0

2.4×100 Refrigerant flow in cooling

Compressor

4-way valve

Refrigerant flow in heating

Refrigerant pipe (with heat insulator)

15.88

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

9.52

OCH603

Page 15

ADDITIONAL REFRIGERANT CHARGE (R410A: g)

MAX. REFRIGERANT PIPING LENGTH

Max. Length A

* Height difference limitations are binding regardless of the height position at which either indoor or outdoor is placed higher.

* Max. Height difference B

Indoor unit

Outdoor unit

MAX. HEIGHT DIFFERENCE

Calculation : Xg=20g/m×(Refrigerant piping length(m)−7)

Calculation : Xg=55g/m×(Refrigerant piping length(m)−7)

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

SUZ-KA25VA5 800 0 30 60 90 120 150 180 210 240 390 SUZ-KA35VA5 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-KA25VA5

20 12 9.52

6.35

SUZ-KA35VA5 SUZ-KA50VA5

30 30

12.7

SUZ-KA60VA5

15.88

SUZ-KA71VA5 9.52

Model

Outdoor unit

precharged

Refrigerant piping length (one way)

7 m 10 m 15 m 20 m 25 m 30 m

SUZ-KA50VA5 1,600 0 60 160 260 360 460 SUZ-KA60VA5 1,600 0 60 160 260 360 460

Model

Outdoor unit

precharged

Refrigerant piping length (one way)

7 m 10 m 15 m 20 m 25 m 30 m

SUZ-KA71VA5 1,800 0 165 440 715 990 1,265

Pumping Down

When relocating or disposing of the air conditioner, pump down the system by following the procedure below so that no refrigerant is released into the atmosphere.

1 Turn off the power supply (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 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. 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/cm²) 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 operation. In this case, use refrigerant recovery equipment to collect all of the refrigerant in the system. 7 Turn off the power supply (circuit breaker), remove the gauge manifold valve, and then disconnect the refrigerant pipes.

.Warning: When pumping down the refrigerant, stop the compressor before disconnecting the refrigerant pipes.

• If the refrigerant pipes are disconnected while the compressor is operating and the stop valve (ball valve) is open,

the pressure in the refrigeration cycle could become extremely high if air is drawn in, causing the pipes to burst, personal injury, etc.

OCH603

Page 16

ACTUATOR CONTROL

8-3. RELATION BETWEEN MAIN SENSOR AND ACTUATOR

8-2. R.V. COIL CONTROL

Heating

.................

Cooling .................OFF

Dry

....................

OFF

Outdoor fan

Compressor

5 seconds 15 seconds

ON OFF

Compressor

Outdoor fan motor

R.V.coil

ON OFF

<COOL>

5 seconds

<HEAT>

5 seconds

8-1. OUTDOOR FAN MOTOR CONTROL

The fan motor turns ON/OFF, interlocking with the compressor. [ON] The fan motor turns ON 5 seconds before the compressor 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 protection

○ ○

Defrost thermistor Heating: Defrosting

○ ○ ○ ○ ○

Fin temperature thermistor Protection

○ ○

Ambient temperature thermistor

Cooling: Low ambient temperature operation

○ ○ ○

Outdoor heat exchanger temperature thermistor

Cooling: Low ambient temperature operation

○ ○ ○

Cooling: High pressure protection

○ ○ ○

SUZ-KA25VA5.TH SUZ-KA35VA5.TH SUZ-KA50VA5.TH SUZ-KA25VA5.TH-ET SUZ-KA35VA5.TH-ET SUZ-KA50VA5.TH-ET SUZ-KA60VA5.TH SUZ-KA71VA5.TH SUZ-KA60VA5.TH-ET SUZ-KA71VA5.TH-ET

OCH603

Page 17

CHANGE IN DEFROST SETTING

Changing defrost finish temperature

<JS> To change the defrost finish temperature, cut/solder the JS wire of the outdoor inverter P.C. board. (Refer to "10-6-1. Inverter P.C. board".)

TROUBLESHOOTING

3. Troubleshooting procedure

1) Check if the OPERATION INDICATOR lamp on the outdoor P.C. board is blinking on and off to indicate an abnormality. To make sure, check how many times the abnormality indication is blinking on and off before starting service work.

2) Before servicing check that the connector and terminal are connected properly.

3) If the electronic control P.C. board is supposed to be defective, check the copper foil pattern for disconnection and the components for bursting and discoloration.

4) When troubleshooting, refer to "10-2. TROUBLESHOOTING CHECK TABLE" and "10-3. HOW TO PROCEED "SELFDIAGNOSIS"".

10-1. CAUTIONS ON TROUBLESHOOTING

1. Before troubleshooting, check the following items:

1) Check the power supply voltage.

2) Check the indoor/outdoor connecting wire for miswiring.

2. Take care the following during servicing.

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 smoothing capacitor.

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.

Housing point

Lead wire

SERVICE FUNCTIONS

Jumper wire

Defrost nish temperature (°C)

SUZ-KA25VA5 SUZ-KA35VA5 SUZ-KA50VA5

SUZ-KA60VA5 SUZ-KA71VA5

Soldered (Initial setting) 5 9 9 10

None (cut) 8 13 18 18

SUZ-KA25VA5.TH SUZ-KA35VA5.TH SUZ-KA50VA5.TH SUZ-KA25VA5.TH-ET SUZ-KA35VA5.TH-ET SUZ-KA50VA5.TH-ET SUZ-KA60VA5.TH SUZ-KA71VA5.TH SUZ-KA60VA5.TH-ET SUZ-KA71VA5.TH-ET

OCH603

Page 18

temperature thermistor, outdoor heat exchanger temperature

No. Symptoms

Abnormal point/

Condition

RemedyCondition

Outdoor unit does not operate.

1-time flash every

2.5 seconds

Outdoor power system

Overcurrent protection cut-out operates 3 consecutive times within 1 minute after the compressor gets started.

Reconnect connector of compressor. Refer to 10-5. "How to check inverter/compressor". Check stop valve.

•

Outdoor thermistors Discharge temperature thermistor shorts, or opens during compressor running.

defrost thermistor, P.C. board

thermistor or ambient temperature thermistor shorts, or opens during compressor running.

Refer to 10-5.F"Check of outdoor thermistors".

•

Outdoor control system

Nonvolatile memory data cannot be read properly.

Replace inverter P.C. board. •

6-time flash

2.5 seconds OFF

Serial signal The communication fails between the indoor and outdoor unit

for 3 minutes.

11-time flash

2.5 seconds OFF

Stop valve/ Closed valve

Closed valve is detected by compressor current. Check stop valve.

•

'Outdoor unit stops and restarts 3 minutes later' is repeated.

2-time flash

2.5 seconds OFF

Overcurrent protection

Large current flows into intelligent power module.

Reconnect connector of compressor.

Refer to 10-5. "How to check inverter/compressor". Check stop valve.

•

3-time flash

2.5 seconds OFF

Discharge temperature overheat protection

Temperature of discharge 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 10-5. "Check of LEV".

•

4-time flash

2.5 seconds OFF

Fin temperature /P.C. board temperature thermistor overheat protection

Temperature of fin temperature thermistor on the heat sink exceeds 72 to 86°C or temperature of P.C. board temperature thermistor on the inverter P.C.board exceeds 72 to 85°C.

Check around outdoor unit. Check outdoor unit air passage. Refer to 10-5. "Check of outdoor fan motor".

•

5-time flash

2.5 seconds OFF

High pressure protection

Indoor coil thermistor exceeds 70°C in HEAT mode. Defrost thermistor exceeds 70°C in COOL mode.

Check refrigerant circuit and refrigerant amount. Check stop valve.

•

8-time flash

2.5 seconds OFF

Compressor synchronous abnormality

The waveform of compressor current is distorted.

Reconnect connector of compressor. Refer to 10-5. "How to check inverter/compressor".

•

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 10-5. "Check of outdoor fan motor. Refer to 10-5. "Check of inverter P.C. board.

•

12-time flash

2.5 seconds OFF

Each phase current of compressor

Each phase current of compressor cannot be detected normally.

Refer to 10-5. "How to check inverter/compressor".

•

13-time flash

2.5 seconds OFF

DC voltage DC voltage of inverter cannot be detected normally. Refer to 10-5. "How to check in-

verter/compressor".

•

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 refrigerant is short. Check if indoor/outdoor unit air circulation is short cycled.

•

3-time flash

2.5 seconds OFF

Frequency drop by high pressure protection

Temperature of indoor coil thermistor exceeds 55°C in HEAT mode, compressor frequency lowers.

Frequency drop by defrosting in COOL mode

Indoor coil thermistor reads 8°C or less in COOL mode, compressor frequency lowers.

4-time flash

2.5 seconds OFF

Frequency drop by discharge temperature protection

Temperature of discharge temperature thermistor exceeds 111°C, compressor frequency lowers.

Check refrigerant circuit and refrigerant amount. Refer to 10-5. "Check of LEV". Refer to 10-5. "Check of outdoor thermistors".

•

7-time flash

2.5 seconds OFF

Low discharge temperature protection

Temperature of discharge temperature thermistor has been 50°C or less for 20 minutes.

Refer to 10-5. "Check of LEV". Check refrigerant circuit and refrig-

erant amount.

•

8-time flash

2.5 seconds OFF

PAM protection PAM: Pulse Amplitude Modulation

The overcurrent flows into PFC (Power factor correction : IC820) or the bus-bar voltage reaches 394 V or more, PAM stops and restarts.

This is not malfunction. PAM protection will be activated in the following cases:

1. Instantaneous power voltage drop. (Short time power failure)

2. When the power supply voltage is high.

9-time flash

2.5 seconds OFF

Inverter check mode The connector of compressor is disconnected, inverter check

mode starts.

Check if the connector of the compressor is correctly connected. Refer to 10-5. "How to check inverter/compressor".

•

Notes: 1. The location of LED is illustrated at the right figure. Refer to “11-6-1. Inverter P.C. board”.

2. LED is lighted during normal operation. The flashing frequency shows the number of times the LED blinks after every 2.5-second OFF.

(Example) When the flashing frequency is “2”.

ON OFF

2.5-second OFF

0.5-second ON

0.5-second ON LED

Flashing →

Inverter P.C. board

•

I F

•

Check of indoor/outdoor connecting wire.

Replace indoor or outdoor P.C. board if abnormality is displayed again.

(KA25/35/50)

(KA60/71) Zero cross detecting circuit

Zero cross signal for PAM control cannot be detected.

LED

indication

check

code

E8 E9 UE

Fin temperature thermistor,

frequency lowers.

16-time flash

2.5 seconds OFF

Outdoor refrigerant system abnormality

A closed valve and air trapped in the refrigerant circuit are detected based on the temperature sensed by the indoor and outdoor thermistors and the current of the compressor.

•

Check for a gas leak in a connecting

piping, etc.

Check stop valve.

•

Refer to 10-5

refrigerant circuit”.

•

"Check of outdoor

10-2. TROUBLESHOOTING CHECK TABLE

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Page 19

F1 F2 F3 F4

unem ecivreS

rosruC

:unem niaM

Test run Input maintenance info. Function setting Check Self check

kcehc fleS

:tceleS

Ref. address

sserddA

kcehc fleS

Ref. address

Return:

teseR

Error Unt # CI.prG

Self check

Return:

Reset

Ref. address

Error

Unt #

Grp.

-- --

When there is no error history

Self check

Delete error history?

Ref. address

Cancel OK

Self check

Return:

Ref. address

Error history deleted

With theF1orF2button, enter the refrigerant address, and press the button.

Select "Self check" with the F1 or F2 button, and press the button.

Select "Service" from the Main menu, and press the button.

Check code, unit number, attribute will appear.

"-" will appear if no error history is available.

Resetting the error history.

Press the

button (Reset) on the screen that shows the error history.

A conrmation screen will appear asking if you want to delete the error history.

Press the

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 address are found.

Navigating through the screens

• To go back to the Service menu ..........

button

• To return to the previous screen .......

button

10-3. HOW TO PROCEED "SELF-DIAGNOSIS"

10-3-1. Self-diagnosis <PAR-32MAA>

As this air conditioner has a function to memorize all the failures that had occured, the latest failure detail can be recalled by following the procedure below. Use this function when the check code is not displayed with wired remote controller or the remote controller at use is wireless type.

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If operations cannot be completed with the remote controller, diagnose the remote controller with this function.

F1 F2 F3 F4

unem ecivreS

rosruC

:unem niaM

Maintenance password Remote controller check

F1 F2 F3 F4

Remote controller check

:nigeB

Start checking?

Remote controller check

:nigeB

Start checking?

Select "Service" from the Main menu, and press the button.

Select "Remote controller check" with the F1

or F2 button, and press

the

button.

Select "Remote controller check" from the Service menu, and press the but-

ton to start the remote controller check and see the check results.

To cancel the remote controller check and exit the Remote controller check menu screen, press the

or the button.

The remote controller will not reboot itself.

Check the remote controller display and see if anything is displayed (including lines). Nothing will 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 p roblems 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 the other remote controllers.

NG (ALL0, ALL1):

Send-receive circuit fault. Remote controller needs replacing.

ERC:

The number of data errors is the discrepancy between the number of bits in the data transmitted from the remote controller and that of the data that was actually transmitted over the transmission line. If data errors are found, check the transmission line for external noise interference.

Remote controller check results screen

If the button is pressed after the remote controller check results are displayed, remote controller check will end, and the remote controller will automati-

cally reboot itself.

10-3-2. Remote controller check <PAR-32MAA>

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10-3-3. Self-diagnosis <PAC-YT52CRA>

Retrieve the error history of each unit using the Simple MA controller.

1 Switch to the self-diagnosis mode.

When the A button and the button are pressed for 5 seconds or longer, the

figure shown below is

Set the address or refrigerant address No. you want to self-diagnosis.

When the

and

are pressed, the address decreases and increases between 01 and 50 or 00 and 15.

Set it to the address No. or refrigerant address No. you want to self-diagnosis.

OFF

. .

Self-diagnosis address or self-diagnosis refrigerant address

Approximately 3 seconds after the change operation, the self-diagnosis refrigerant address changes from flashing to a steady light and selfdiagnosis begins.

Self-diagnosis result display <error history>

the contents of the check code, refer to 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

(Alternate display)

Error history reset The error history is displayed in 3 self-diagnosis results display. When the

D button is pressed 2 times successi

vely within 3 seconds, the self-

diagnosis object address

When the error history was reset, the display shown below appears. When error history reset is failed, the error contents are displayed again.

Self-diagnosis reset

There are the following 2 ways of resetting self-diagnosis. Press the

A button and the C button simultaneously for 5 seconds or longer.

→

Resets self-diagnosis and returns to the state before self-diagnosis.

Press the

button. → Self-diagnosis resets and indoor units stop.

prohibited, this operation is ineffective.)

OFF

displayed.

manual or service handbook.)

and refrigerant address flash.

(For

(When operation is

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10-3-4. Remote Controller Check <PAC-YT52CRA>

When the air conditioner cannot be controlled from the Simple MA controller, use this function

to check the remote controller.

First, check the power mark.

When normal voltage (12 V DC) is not applied to the remote controller, the power mark goes off. When the power mark is off, check the remote controller wiring and the indoor unit.

Switch to the remote controller check mode. When the B

button and

button are pressed simultaneously for 5 seconds or

longer, the figure

When the

button is pressed, remote controller check begins.

OFF

Remote controller check result <When remote controller is normal>

Since there is no problem at the remote controller, check for other causes.

(Error display 1) “NG” flashes →

Remote controller send/receive circuit abnormal

Remote 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” is the difference between the number of bits of remote controller send data and the number of bits actually sent to the transmission line. In this case, the send d

ata was disturbed by the noise, etc. Check the transmission line.

When data error count is 02

Remote controller send data Send data on transmission line

Remote controller check reset

When the

button and

button are pressed simultaneously for 5 seconds or

longer, remote controller

and run lamp flash for a certain period of time, and then the remote controller returns to its

diagnosis is

reset, the [HO]

shown below is displayed.

Power mark

state before diagnosis.

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Page 23

• "CHECK" lights, and refrigerant address

"00" flashes.

• Check that the remote controller's

display has stopped before continuing.

• Select the refrigerant address of the

indoor unit for the self-diagnosis.

Note: Set refrigerant address using the

outdoor unit’s DIP switch (SW1). (For more information, see the outdoor unit installation manual.)

• If an air conditioner error occurs, the indoor unit's sensor emits an intermittent

buzzer sound, the operation light flashes, and the check code is output. (It takes 3 seconds at most for check code to appear.)

• The check mode is cancelled.

[Procedure]

1. Press the CHECK button twice.

2. Press the TEMP 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>

10-3-5. Self-diagnosis <Wireless remote controller>

When 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

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

SELECT

TIME

1 Turn ON the power. 2 While pressing both the MODE SELECT button and

TOO COOL button on the remote controller at the same time, press the RESET button.

3 Firstly, release the RESET button. 4 And release the other 2 buttons since all LCD in

operation display section of the remote controller is displayed after 3 seconds. 5 Transmit the signal of remote controller, pressing ON/ OFF button on the remote controller. (The above procedure allows OPERATION INDICATOR lamp to indicate the failure-mode.) 6 Transmit the signal of remote controller, pressing a button other than ON/ OFF button or VANE button to stop the self-check.

[Procedure]

OPERATION INDICATER

10-3-6. Self-diagnosis <Wireless remote controller> <In case of trouble during operation for SLZ model>

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[Output pattern A] Errors detected by indoor unit

[Output pattern B]

1. If the beeper does not sound again after the initial

2 beeps to confirm the self-check start signal was received and

the OPERATION INDICATOR lamp does not come on,

there are no error records.

2. If the beeper sounds 3 times continuously “beep, beep, beep (0.4 + 0.4 + 0.4 seconds)” after the initial 2 beeps to confirm the self-check start signal was received, the specified refrigerant address is incorrect.

Notes:

OPERATION INDICATOR lamp flash pattern

Beep Beep Beep Beep Beep

Beep Beep

Off

Approx. 2.5 sOnApprox. 3 sOn0.5 sOn0.5 sOn0.5 s

0.5 s

Off

Approx. 2.5 sOnApprox. 3 sOn0.5 sOn0.5 s

··· Repeated

Number of blinks/beeps in pattern indicates the check code in the following table (i.e., n=5 for “U2”)

Number of blinks/beeps in pattern indicates the check code in the following table

1st2nd3

1st2

Self-check starts (Start signal received)

Beeper sounds

[Output pattern B]

OPERATION INDICATOR lamp flash pattern

Beep

Beep Beep Beep Beep Beep Beep

Off

Approx. 2.5 s

0.5 sOn0.5 sOn0.5 s

0.5 s

Off

Approx. 2.5 sOn0.5 sOn0.5 s

··· Repeated

Number of blinks/beeps in pattern indicates the check code in the following table (i.e., n=5 for “P5”)

Number of blinks/beeps in pattern indicates the check code in the following table

1st2nd3

1st2

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 flashes Check code

(Number of times)

Wireless remote controller

Wired remote controller

1 P1

Intake sensor error

P9 Pipe (TH5) sensor error

P2 Pipe (TH2) sensor error

3 E6,E7

Indoor/outdoor unit communication error

4 P4 Drain sensor error/Float switch connector (CN4F) open 5

P5 Drain pump error

PA Forced compressor stop (due to water leakage abnormality) 6 P6 Freezing/Overheating protection operation 7 EE Communication error between indoor and outdoor units

9 E4, E5 Remote controller signal receiving error

Errors detected by unit other than indoor unit (outdoor unit, etc.)

Symptom

Indoor/outdoor unit communication error

(Transmitting error) (Outdoor unit)

Open/short of outdoor unit thermistors

UP U3, U4 PL or others

Abnormlity of refrigerant circuit or other errors (Refer to the technical manual for the outdoor unit.)

12 14

Fb (FB)*

Indoor unit control system error (memory error, etc.)

–

E0, E3 – E1, E2 Remote controller control board error

Remote controller transmission error

Abnormality of refrigerant circuit

Compressor overcurrent interruption

As for indoor unit, refer to indoor unit's service manual.

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Page 25

10-4. TROUBLE CRITERION OF MAIN PARTS

Parts name

Figure

Check method and criterion

Outdoor fan motor

R.V. coil (21S4)

Expansion valve coil (LEV)

Measure the resistance between terminals with a tester. (Temperature: −10 to 40°C)

WHT - BLK BLK - RED

RED - WHT

Normal

Measure the resistance between terminals with a tester. (Temperature : −10 to 40°C)

Normal

WHT - RED RED - ORN

YLW - BRN BRN - BLU

Normal

37 to 54 Ω

Measure the resistance with a tester. (Temperature : −10 to 40°C)

Measure the resistance with a tester. 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.

Color of the lead wire

Discharge temperature thermistor (RT62)

Measure the resistance with a tester. Before measurement, hold the thermistor with your hands to warm 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

WHT

RED BLK

WHT

RED BLK

Ambient temperature thermistor (RT65)

Outdoor heat exchanger temperature thermistor(RT68)

SUZ-KA25VA5

2.25 to 3.20 Ω

SUZ-KA35VA5

1.52 to 2.17 Ω

1.19 to 1.78 kΩ

SUZ-KA50/60VA5

0.78 to 1.11 Ω

SUZ-KA71VA5

0.92 to 1.12 Ω

SUZ-KA25/35VA5 SUZ-KA50/60/71VA5

12 to 17 Ω

SUZ-KA25/35VA5

LEV

WHT

RED

YLW

ORN

BLU

Measure the resistance with a tester. (Temperature : −10 to 40°C)

RED - ORN RED - WHT

RED - BLU

RED - YLW

Normal

37 to 54 Ω

Color of the lead wire

SUZ-KA50/60/71VA5

LEV

WHT RED ORN

YLW

BRN

BLU

SUZ-KA25VA5.TH SUZ-KA35VA5.TH SUZ-KA50VA5.TH SUZ-KA25VA5.TH-ET SUZ-KA35VA5.TH-ET SUZ-KA50VA5.TH-ET SUZ-KA60VA5.TH SUZ-KA71VA5.TH SUZ-KA60VA5.TH-ET SUZ-KA71VA5.TH-ET

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A How to check inverter/compressor

Are the voltages balanced?

Disconnect the connector between the compressor and the intelligent power module (KA25/35/50: IC700, KA60/71: IPM) .

Replace the inverter P.C. board.

Check the voltage between terminals.

Check the compressor.

See 10-5. “Check of compressor”.

Yes

See 10-5. “Check of open phase”.

With the connector between the compressor and the intelligent power module disconnected, activate the inverter and check if

the inverter is normal by measuring the voltage balance between the terminals. Output voltage is 50–130 V. (The voltage may differ according to the tester.) << Operation method (Test run operation)>>

• For the PAR-31MAA, select “Service” → “Test Run” from the main menu to start the test run, and 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 of the inverter P.C. board ashes 9 times. (KA25/35/50: Refer to 10-6-1, KA60/71: 10-6-2)

Refer to 10-5. “Check of compressor operation time”. Does the compressor operate continuously?

Yes

Refer to 10-5. “Check of compressor winding”. Is the compressor normal?

Replace the compressor.

Yes

C Check of compressor

B Check of open phase

10-5. TROUBLESHOOTING FLOW

Measure AC voltage between the lead wires at 3 points.

Is the compressor

operation time more than

10 seconds?

Replace the compressor.

Yes

Check the refrigerant circuit.

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Page 27

D Check of compressor winding

Disconnect the connector between the compressor and intelligent power module, and measure the resistance between the

compressor terminals. <<Measurement point>> at 3 points BLK-WHT BLK-RED WHT-RED <<Judgement>> Refer to "10-4. TROUBLE CRITERION OF MAIN PARTS".

0 [Ω] ················Abnormal [short] Infinite [Ω] ·······Abnormal [open]

NOTE: Be sure to zero the ohmmeter before measurement.

Measure the resistance between the lead wires at 3 points.

E Check of compressor operation time

Compressor starts Abnormal

(IPM failure) (Compressor winding short)

Abnormal (Compressor lock out) (Starting defect)

Abnormal (Poor contact,) (Outdoor P.C. board defect) (Disconnected connector)

Abnormal (Refrigerant circuit defect) (Closed valve)

Normal

0 second 1 second

2 seconds

10 seconds

10 minutes

<<Judgement>>

Connect the compressor and activate the inverter. Then measure the

time until the inverter stops due to overcurrent. <<Operation method>> Start heating or cooling test run. (TEST RUN OPERATION : Refer to 10-5

.) <<Measurement>> 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 connector of thermistor. Turn ON the power supply and press EMERGENCY OPERATION switch.

Yes

F Check of outdoor thermistors

Does the unit operate for 10 minutes or more without showing thermistor abnormality?

Yes

OK (Cause is poor contact.)

Replace the inverter P.C. board.

Thermistor Symbol

Connector, Pin No.

Board

SUZ-KA25/35/50VA5 SUZ-KA60/71VA5

Defrost RT61 Between CN641 pin1 and pin2 Between CN671 pin1 and pin2

Inverter

P.C. board

Discharge temperature RT62 Between CN641 pin3 and pin4 Between CN671 pin3 and pin4 Fin temperature RT64 Between CN642 pin1 and pin2 Between CN673 pin1 and pin2 Ambient temperature RT65 Between CN643 pin1 and pin2 Between CN672 pin1 and pin2 Outdoor heat exchanger temperature RT68 Between CN644 pin1 and pin3 Between CN671 pin5 and pin6

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G Check of R.V. coil

First of all, measure the resistance of R.V. coil to check if the coil is defective. Refer to "10-4. TROUBLE CRITERION OF MAIN PARTS". In case CN721(KA25/35/50)/CN602(KA60/71) is not connected or R.V. coil is open, voltage is generated between the terminal pins of the connector although any signal is not being transmitted to R.V. coil. Check if CN721(KA25/35/50)/CN602(KA60/71) is connected.

Is there 230 VAC between CN721 (KA25/35/50)/CN602(KA60/71)

and on the inverter P.C. board 3 minutes after the power supply is turned ON?

Yes

Replace the inverter P.C. board.

Replace the 4-way valve.

Unit operates COOL mode even if it is set to HEAT mode.

Is there 230 VAC between CN721 (KA25/35/50)/CN602(KA60/71)

and on the inverter P.C. board 3 minutes after the power supply is turned ON?

Yes

Replace the inverter P.C. board.

Replace the 4-way valve.

Unit operates 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 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 resistance between each terminal of outdoor fan motor normal? (Refer to "10-4. TROUBLE CRITERION OF MAIN PARTS". )

Disconnect the connectors CN931 and CN932 from the inverter P.C. board. Check the connection between the connector CN931 and CN932.

Disconnect CN932 from the inverter

P.C. board, and turn on the power sup-

ply.

Rotate the outdoor fan motor manually and measure 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 V DC repeatedly?

Does the outdoor fan motor rotate smoothly?

Replace the outdoor fan motor.

Replace the inverter P.C. board.

Yes

(Fixed to either 5 or 0 V DC)

Yes

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I Check of LEV

Turn on power supply to the outdoor unit after checking

LEV coil is xed to the LEV body securely.

Yes

Disconnect the connector CN724 is there normal resistance to LEV coil?

Replace the inverter P.C. board.

Replace the LEV coil.

Normal

Start

Is "click - click" sound heard? Or, do you feel vibration of the LEV coil with a hand?

Yes

Check the outdoor fan motor. (Refer to .)

Is the fuse (F901) blown on the inverter P.C. board?

Check the connection of the connectors (CN931, CN932) of the outdoor fan motor. If the connection is poor, make it correct.

Operate the outdoor unit by starting EMERGENCY OPERATION.

Check the LED indication on the inverter P.C. board.

Does the LED ash 10 times?

Replace the inverter P.C. board.

Check the corresponding parts following LED indication. (Refer to "10-3. HOW TO PROCEED "SELF-DIAGNOSIS"".)

Yes

(10-time ash)

J Check of inverter P.C. board

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Page 30

Electromagnetic noise enters into TV sets or radios

Yes

Is the unit earthed?

Earth the unit.

Yes

Is the distance between the antennas and the indoor unit within 3 m, or is the distance between the antennas and the outdoor unit within 3 m?

Extend the distance between the antennas and the indoor unit, and/or the antennas and the outdoor unit.

Is the distance between the TV sets or radios and the indoor unit within 1 m, or is the distance between the TV sets or radios and the outdoor unit within 3 m?

Yes

Extend the distance between the TV sets and/or radios and the indoor unit, or the TV sets or radios and the outdoor unit.

Are the antennas damaged? Is the coaxial cable damaged? Is there any poor contact in the antenna wiring?

Yes

Replace or repair the antenna. Replace or repair the coaxial cable.

Is the indoor/outdoor connecting wire of the air conditioner and the wiring of the antennas close?

Yes

Extend the distance between the indoor/outdoor connecting wire of the air conditioner and the wiring of the antennas.

Even if all of the above conditions are fullled, the electromagnetic noise may enter, depending on the electric eld strength or the installation condition (combination of specic 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 the air conditioner, indoor/outdoor wiring, earth wire, antennas, wiring from antennas, receiver

5. Electric eld intensity of the broadcast station affected by the electromagnetic noise

6. Presence or absence of amplier such as booster

7. Operation condition of air conditioner when the electromagnetic noise enters in

1) Turn OFF the power supply once, and then turn ON the power supply. In this situation, check for the electromagnetic noise.

2) Within 3 minutes after turning ON the power supply, press OPERATE/STOP (ON/OFF) button on the remote controller for power ON, and check for the electromagnetic noise.

3) After a short time (3 minutes later after turning ON), the outdoor unit starts running. During operation, check for the electromagnetic noise.

4) Press OPERATE/STOP (ON/OFF) button on the remote controller for power OFF, when the outdoor unit stops but the indoor/outdoor communication still runs on. In this situation, check for the electromagnetic noise.

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Check of outdoor refrigerant circuit

The unit occasionally stops when the stop valve is opened or closed during operation. Open the stop valve and start the cooling operation again.

Has the operation stopped during pump down?

Yes

Was the operation started with the stop valve closed, and was it opened during operation?

Yes

The refrigerant gas amount may be 60% or less than the normal amount. Identify where the gas is

leaking from, and x the leak.

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 be reset with remote controllers, it is

detected in the connected indoor unit. Please refer to the indoor

unit's service manual.

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Page 32

10-6. TEST POINT DIAGRAM AND VOLTAGE

10-6-1. Inverter P.C. board

SUZ-KA25VA5.TH SUZ-KA35VA5.TH SUZ-KA50VA5.TH SUZ-KA25VA5.TH-ET SUZ-KA35VA5.TH-ET SUZ-KA50VA5.TH-ET

−20 −10 0 10 20 30 40

100

Temperature( )

Defrost thermistor(RT61) Ambient temperature thermistor(RT65) Outdoor heat exchanger temperature thermistor(RT68)

Temperature( )

Discharge temperature thermistor(RT62)

0 10 20 30 40 50 60 70 80 90 100 110 120

100

200

300

400

500

600

700

0 10 20 30 40 50 60 70 80

100

120

140

160

180

200

Temperature( )

Fin temperature thermistor(RT64)

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 V AC

Smoothing capacitor (C62)

Output to drive compressor (LDU, LDV, LDW)

(+)

(−)

Fuse (F701) T3.15AL 250 V

Smoothing capacitor (C61)

Smoothing capacitor (C63)

Fuse (F901) T3.15AL 250 V

R.V.coil (CN721) 230 V AC

Jumper wire for changing defrost setting (JS)

Signal of outdoor

fan motor (CN931)

230 V AC

Outdoor heat exchanger

temperature thermistor

/RT68 (CN644)

Heater connector (CN722)

Fuse (F801) T3.15AL 250 V

Back side of unit

LEV connector

(CN724)

Output to drive outdoor fan motor (CN932)

LED

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Page 33

10-6-2. Inverter P.C. board SUZ-KA60VA5.TH SUZ-KA71VA5.TH SUZ-KA60VA5.TH-ET SUZ-KA71VA5.TH-ET

−20 −10 0 10 20 30 40

100

Temperature( )

Defrost thermistor(RT61) Ambient temperature thermistor(RT65) Outdoor heat exchanger temperature thermistor(RT68)

Temperature( )

Discharge temperature thermistor(RT62)

0 10 20 30 40 50 60 70 80 90 100 110 120

100

200

300

400

500

600

700

0 10 20 30 40 50 60 70 80

100

120

140

160

180

200

Temperature( )

Fin temperature thermistor(RT64)

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 (F880) T3.15AL 250 V

LEV connector (CN724)

Jumper wire for changing defrost setting (JS)

Fuse (F62) T2.0AL 250 V

Fuse (F601) T3.15AL 250 V

Signal of outdoor fan motor (CN931)

R.V. coil (CN602) 230 V AC

325–370 V DC

JP715 (+)

JP30 (−)

LED

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Page 34

DISASSEMBLY PROCEDURE

(1) Slide the sleeve and check if there is a locking lever or not. (2) The terminal with this connector has the

locking mechanism.

1Slide the sleeve. 2Pull the terminal while

pushing the locking lever.

1Hold the sleeve, and pull out the terminal slowly.

The terminal which has the locking mechanism can be detached as shown below. There are two types (Refer to (1) and (2)) of the terminal with locking mechanism. The terminal without locking mechanism can be detached by pulling it out. Check the shape of the terminal before detaching.

<"Terminal with locking mechanism" Detaching points>

Connector

Sleeve

Locking lever

NOTE: Turn OFF power supply before disassembling.

SOTOPERUDECORP GNITAREPO

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 cabinet. (7) Remove the cabinet. (8) Remove the screws fixing the back panel. (9) Remove the back panel.

Photo 1

Photo 2

Back panel

Screws of the 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

Screw of the cabinet

SUZ-KA25VA5.TH SUZ-KA35VA5.TH SUZ-KA25VA5.TH-ET SUZ-KA35VA5.TH-ET

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Page 35

3535

OPERATING PROCEDURE

PHOTOS

2. Removing the inverter assembly, inverter P.C. board

(1) Remove the cabinet and panels. (Refer to procedure 1.) (2) Disconnect the lead wire to the reactor and the following con-

nectors:

CN721 (R.V. coil) CN932 (Fan motor) CN641 (Defrost thermistor and discharge temperature ther-

mistor) CN643 (Ambient temperature thermistor) CN644 (Outdoor heat exchanger temperature thermistor) CN724 (LEV)

(3) Remove the compressor connector (CN61). (4) Remove the screws fixing the relay panel. (Photo 3) (5) Remove the inverter assembly. (Photo 4) (6) Remove the screw of the earth wire and screw of the

T.B.support. (Photo 4)

(7) Remove the relay panel from the inverter assembly. (8) Remove the inverter P.C. board from the relay panel.

Photo 3

Photo 4 (Inverter assembly)

Photo 5

3. Removing R.V. coil

(1) Remove the cabinet and panels. (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 temperature 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: <Inverter P.C. board> CN641 (Defrost thermistor and discharge temperature ther-

mistor)

CN643

(Ambient temperature thermistor)

CN644 (Outdoor heat exchanger temperature thermistor)

(3) Pull out the discharge temperature thermistor from its holder.

(Photo 5) (4) Pull out the defrost thermistor from its holder. (Photo 6) (5) Pull out the outdoor heat exchanger temperature thermistor

from its holder. (Photo 6) (6) Pull out the ambient temperature thermistor from its holder.

Discharge temperature thermistor

R.V. coil

Screws of the relay panel

Heat sink

Inverter P.C. board

Screw of the earth wire

T.B.support

Screw of the T.B.support

Relay panel

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Page 36

OPERATING PROCEDURE

PHOTOS

5. Removing outdoor fan motor

(1) Remove the cabinet and panels. (Refer to procedure 1.) (2) Disconnect the following connectors: <Inverter P.C. board>

CN932 (Fan motor) (3) Remove the propeller nut. (Photo 7) (4) Remove the propeller. (Photo 7) (5) Remove the screws fixing the fan motor. (Photo 7) (6) Remove the fan motor.

Photo 6

Photo 7

Photo 8

6. Removing the compressor and 4-way valve

(1) Remove 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/cm² (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 pipes connected with 4-way valve.

(Photo 8)

Defrost thermistor

Outdoor heat exchanger temperature thermistor

Propeller nut

Screws of the outdoor fan motor

Propeller

Welded parts of 4-way valve

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Page 37

SUZ-KA50VA5.TH SUZ-KA50VA5.TH-ET

NOTE: Turn OFF power supply before disassembly.

OPERATING PROCEDURE

PHOTOS

1. Removing the cabinet

(1) Remove the screws of the service panel. (2) Remove the screws of the top panel. (3) Remove the screw of the valve cover. (4) Remove the service panel. (5) Remove the top 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 1

Photo 2

Screws of the cabinet

Screws of the top panel

Screw of the back panel

Screws of the cabinet

Screws of the service panel

Screw of the valve cover

Screws of the cabinet

Screws of the back panel

Screws of the cabinet

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Page 38

OPERATING PROCEDURE

PHOTOS

2. Removing the inverter assembly, inverter P.C. board

(1) Remove the cabinet and panels. (Refer to procedure 1.) (2) Disconnect the lead wire to the reactor and the following con-

nectors: <Inverter P.C. board> CN721 (R.V. coil) CN931, CN932 (Fan motor) CN641 (Defrost thermistor and discharge temperature ther-

mistor) CN643 (Ambient temperature thermistor) CN644 (Outdoor heat exchanger temperature thermistor) CN724 (LEV)

(3) Remove the compressor connector. (4) Remove the screws fixing the heat sink support and the sep-

arator.

(5) Remove the fixing screws of the terminal block support and

the back panel.

(6) Remove 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 the following connector: <Inverter P.C. board>

CN721 (R.V. coil)

(3) Remove the R.V. coil.

Screw of the heat sink support and the separator

Brazed parts of 4-way valve

Screw of the R.V. coil

Heat sink

Screw of the inverter P.C. board

Screw of the earth wire

Screws of the terminal block support

Screw of the

P.C. board cover

Screw of the terminal block support and the back panel

P.C. board support

Heat sink support

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Page 39

OPERATING PROCEDURE PHOTOS

4. Removing the discharge temperature thermistor, defrost thermistor, outdoor heat exchanger temperature 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

connectors: <Inverter P.C. board> CN641 (Defrost thermistor and discharge temperature ther-

mistor) CN643 (Ambient temperature thermistor) CN644 (Outdoor heat exchanger temperature thermistor)

(3)

Pull out the discharge temperature thermistor from its holder.

(4) Pull out the defrost thermistor from its holder. (5) Pull out the outdoor heat exchanger temperature thermistor

from its holder.

(6) Pull out the ambient temperature thermistor from its holder.

Photo 6

Photo 7

Photo 8

5. Removing outdoor fan motor

(1)

Remove the top panel, cabinet 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) Remove the inverter assembly. (Refer to procedure 2.) (4) Recover gas from the refrigerant circuit.

NOTE: Recover gas from the pipes until the pressure gauge

shows 0 kg/cm² (0 MPa).

(5) Detach the brazed part of the suction and the discharge

pipe connected with compressor. (6) Remove the compressor nuts. (7) Remove the compressor. (8) Detach the brazed part of 4-way valve and pipe. (Photo 5)

Screws of the outdoor fan motor

Brazed part of the discharge pipe

Brazed part of the suction pipe

Discharge temperature thermistor

Outdoor heat exchanger temperature thermistor

Ambient tem-

perature

thermistor

Defrost thermistor

Propeller nut

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Page 40

NOTE: Turn OFF power supply before disassembling.

OPERATING PROCEDURE

PHOTOS

1. Removing the cabinet

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

Screw of the back panel

Screws of the cabinet

Screws of the service panel

Screw of the valve cover

Screws of the cabinet

Screws of the back panel

SUZ-KA60VA5.TH SUZ-KA71VA5.TH SUZ-KA60VA5.TH-ET SUZ-KA71VA5.TH-ET

OCH603

Page 41

OPERATING PROCEDURE

PHOTOS

2. Removing the inverter assembly, inverter P.C. board

(1) Remove the cabinet and panels. (Refer to procedure 1.) (2) Disconnect the lead wire to the reactor and the following con-

nectors: <Inverter P.C. board> CN602 (R.V. coil) CN931, CN932 (Fan motor) CN671 (Defrost thermistor, discharge temperature thermistor

and outdoor heat exchanger temperature thermistor) CN672 (Ambient temperature thermistor) CN724 (LEV)

(3) Remove 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>

CN602 (R.V. coil)

(3) Remove the R.V. coil.

Screws of the PB support

Screws of the relay panel

Inverter P.C board

Earth wires

Screw of the relay panel

Screws of the PB support

Welded parts of 4-way valve

Screw of the R.V. coil

OCH603

Page 42

OPERATING PROCEDURE PHOTOS

4. Removing the discharge temperature thermistor, defrost thermistor, outdoor heat exchanger temperature 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

connectors: <Inverter P.C. board> CN671 (Defrost thermistor, discharge temperature thermis-

tor and outdoor heart exchanger temperature thermistor)

CN672 (Ambient temperature thermistor)

(3) Pull out the discharge temperature thermistor from its hold-

er. (Photo 7) (4) Pull out the defrost thermistor from its holder. (5) Pull out the outdoor heat exchanger temperature thermistor

from its holder. (6) Pull out the ambient temperature thermistor from its holder.

Photo 5

Photo 6

Photo 7

5. Removing outdoor fan motor

(1)

Remove the top panel, cabinet and service panel. (Refer to 1.) (2) Disconnect the following connectors:

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 inverter assembly. (Refer to procedure 2.) (4) Recover gas from the refrigerant circuit.

NOTE: Recover gas from the pipes until the pressure gauge

shows 0 kg/cm² (0 MPa).

(5) Detach the welded part of the suction and the discharge

pipe connected with compressor. (6) Remove the compressor nuts. (7) Remove the compressor. (8) Detach the welded part of 4-way valve and pipe. (Photo 4)

Screws of the outdoor fan motor

Welded part of the discharge pipe

Welded part of the suction pipe

Discharge temperature thermistor

Outdoor heat exchanger temperature thermistor

Ambient temperature thermistor

Defrost thermistor

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Page 43

OCH603

Page 44

HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO100-8310, JAPAN

New publication, effective Oct. 2015 Specifications are subject to change without notice.

Mitsubishi Electric SUZ-KA25VA5, SUZ-KA60VA5, SUZ-KA50VA5, SUZ-KA35VA5, SUZ-KA71VA5 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual