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TECHNICAL & SERVICE MANUAL SUZ

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Contents

1. Output to Ambient temperature fan motor CN672 CN932 Fin temperature thermistor RT64 T3 15AL250V J d Fuse F880 T3 15AL250V LEV connector CN724 pum ils AQ ee Tm mI Tm JP715 325 370 VDC Defrost thermistor RT61 JP30 Ambient temperature thermistor RT65 Outdoor heat exchanger temperature thermistor RT68 206 Fin temperature thermistor RT64 Resistance kQ Discharge temperature thermistor RT62 0 gt S 5 a x ER eel SUN 3 0 0 0 20 10 0 10 20 30 40 0 20520730749 190 90 TOBO 901007110120 0 10
2. 2901 14 OCH545 SUZ KA60VA4 TH SUZ KA71VA4 TH 31 7918 S914 8914 2919 198 7 NEED E ei LY LY le zi Hol TW 2 ipp illu ONT LOINNOO 000005 d oll do ol 60606 4 2 SU BUT ITA 104 AUD 9201210002 184002 a5 d 9 1 L9ND ZLINO 9 TLIN 2 on 1115195 10 UPJGPTP 2112819 JUN JOOPUT 01 13431 Ez eti Q BULJIN 2111918 9 15 100p0 84 SILON 6860 E Eu T03 OTONITOS AWA ONTSGASE 1110810199914 MEER Sj ES nz v3X uS3T1081NOO H3MOd 24d p 1 it 5 09 NVJ JW m AV13
3. display and the error code and unit number are displayed alternately as LEE shown below Os If the outdoor unit is malfunctioning the unit number will be 00 TEMP ONOFF In the case of group control for which one remote controller controls V oC multiple refrigerant systems the refrigerant address and error code ofthe sac OMEN ONT eu unit that first experienced trouble i e the unit that transmitted the error pur CA CD o code will be displayed menus X coek f wena Joss To clear the error code press the button Alternating Display l Mim FRRQR foe LILI CA ND 269 CHECK LILI Error code 2 or 4 digits Address 3 digits or unit number 2 digits When using remote local controller combined operation cancel the error code after turning off remote operation During central control by a MELANS controller cancel the error code by pressing the ON OFF button 11 3 4 Self Diagnosis During Maintenance or Service lt PAR 21MAA gt Since each unit has a function that stores error codes the latest check code can be recalled even if it is cancelled by the remote controller or power is turned off Check the error code history for each unit using the remote controller Switch to self diagnosis mode Set the unit num
4. Smoothing Smoothing R V coil DB61 Smoothing capacitor capacitor 721 Back side of unit 200 T VBO capacitor C63 C62 C61 230 VAC Fuse F701 Fuse F801 T3 15AL250V 230 VAC T3 15AL250V N Tod mE Fuse F901 m T3 15AL250V FE a 4 paaa me g ES ERR I Output to T nou VH i pm 1 j my n 4 drive outdoor To pem r He 9 s Z p D fan motor E m 4 A i iHd o U H 5 4 j T CN932 M oe E ul PE Im d 230 Output to i i I d mO 8 AR drive rx i mmi 0 Lv compressor Sy np gus dd ir i B Lik 0 i LDU Ui iii RU n gpl uF 5 i EN Ao M y n z HTH E mt LDW o T miu A D BEND D B ENS AN E Y M T Um mmi LED 55 5 5 5 Jumper wire for Jumper wire 3 Z By changing defrost for pre heat P5 29 ge oD On GE setting JS control setting Frontsideofunit 29 25 26 S85 JK SES 92 55 uc 89 coz SE tuc LO BS 99 cO 52 SS 52 BES 595 ES js 2595 Of SSX Sd GES 9 206 5 Bo mug Defrost thermistor RT61 Ambient temperature thermist
5. 1 E9 Transmitting error Outdoor unit 2 UP Compressor overcurrent interruption 3 03 04 Open short of outdoor unit thermistors 14 Others Other errors Refer to the technical manual for the outdoor unit Notes 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 times continuously beep beep 0 4 0 4 0 4 sec after the initial 2 beeps to confirm the self check start signal was received the specified refrigerant address is incorrect The check code in the parenthesis indicates PAR 30MAA model OCH545 27 11 4 TROUBLE CRITERION OF MAIN PARTS SUZ KA25VA4 TH SUZ KA35VA4 TH 502 4 SUZ KA60VA4 TH SUZ KA71VA4 TH Parts name Check method and criterion Figure Defrost thermistor RT61 Fin temperature thermistor RT64 Measure the resistance with a tester Ambient temperature Refer to 11 6 Test point diagram and voltage 11 6 1 KA25 35 50 or thermistor RT65 11 6 2 KA60 71 Inverter P C board for the chart of thermistor Outdoor heat exchanger temperature thermistor RT68 Measure the resistance with a tester Discharge temperature Before measurement hold the thermistor with your hands to warm it up thermistor RT62 Refer to 11 6 Tes
6. compressor and the intelligent power module KA25 35 50 1 700 KA60 71 IPM P Y Check the voltage between terminals prev See 11 5 Check of open phase Y Are the voltages balanced No Replace the inverter P C board Yes Check the compressor See 11 5 O Check of compressor Check of open phase e 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 130V The voltage may differ according to the tester lt lt 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 Measure AC voltage between the lead wires at 3 points 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 flashes 9 times KA25 35 50 Refer to 11 6 1 KA60 71 11 6 2 O Check of compressor Refer to 11 5 Check of compressor w
7. 8UTITM 104 K UO 190002 9812 BUTJIAJ8S 10 211 28 8 JOOPUT 84 0 BUIIIM 311138 8 ay jnoqy T 5310N Ad 15 1 IN3IENV S91H 1100 3A WA NOISNVdX3 An UOLSIRHSHI 1 7918 01 0m 1109 IATA SNISHAATI 7512 WOISTWUIHI AWL 3OHVHOSIQ 0918 H3MOd 20821 AV Tae IPX COX BOLSINSJHI 1509530 T914 TIMOOW H3N0d e601 02601 01 UaNUOASNVEL TOBI NOllo3l0Nd 1100812 59214 9014 El ISNA 1061 TORY UL X90189 VNIHUSI 8l YOLOW Ji 00827021 3513 194 EOISINU3Hl ANIL U0SS3UdN02 HW 30010 1980 lv3b uooQino 8313 WOLOV3U 191 ONTHLOONS 290190 3HVN 3HVN 3HVN TOMAS Mz O 05 es 1 29 N vaywaua 81 1112019 1 8 031 97 QuvOg 0 4 HdlH3AN LJ r 103 1081 13 OCH545 SUZ KA50VAA TH 9311243102 LINN 0001 OL Ald
8. 9 gt gze poe 4 PACU NOG eoa n IRE Sul PR LUI d d LLL Y ERU KM 5 Si Bg 5 2 E gt HEEE ____ gt E E g lt io pud gi jin 2 Oval holes 10x21 11 OCH545 SUZ KA50VAA TH SUZ KA60VA4 TH SUZ KA71VA4 TH Drain hole 42 Bolt pitch for installation 2 Oval holes 10X 21 500 81 E OCH545 Unit mm Open as a rule 500mm or more if the front and both sides are open REQUIRED SPACE 100mm or more 200mm or more if there are obstacles to both sides SAN V Y NS Open as a rule 500mm or more if the back both sides and top are open Service panel Liquid refrigerant pipe joint Refrigerant pipe flared 2 6 35 SUZ KA50 60VA4 9 52 SUZ KA71VA4 SA M 164 5 99 5 Gas refrigerant pipe joint Refrigerant pipe flared 12 7 SUZ KA50VA4 2 15 88 SUZ KA60 71VA4 12 WIRING DIAGRAM 7 SUZ KA25VA4 TH SUZ KA35VA4 TH 91124302 LINN 80001 OL AlddflS 3804 2405 N NEG
9. 2 7 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
10. FAN SPEED FUNCTION SPL dB A LINE High COOLING 47 Med HEATING 48 0 0 X 90 i 3 1 I d d x 3 o T 3 80 1 I E e I 1 e I J e x 1 o 70 t 2 J m i 1 5 ai J 60 4 1 gt RE 3 1 d d ul F 3 x 50 1 2 I 3 an j x 40 3 NC 40 a A s GUT 5 EN O 30 d NC 30 a N T 3 20 1 lt i i 10 i 63 125 250 500 1000 2000 4000 8000 BAND CENTER FREQUENCIES Hz FAN SPEED FUNCTION SPL dB A LINE COOLING 52 e High HEATING 52 O V lt E I 3 3 r4 T I i F I N 247 SL A a SI S RS Po i gt 70 1 5 p E NC 70 AM E m F zr 60 1 E gt i NC 60 F 50 x 5 EDY NC 50 o 0 40 NC 40 3 I cnp a IT iw E 30 T b NC 30 Es 2 20 a i u j T NC 20 2 i i NC 10 i 5 10 6 63 125 250 500 1000 2000 4000 8000 BAND CENTER FREQUENCIES Hz OCH545 Test conditions SUZ KA35VA4 TH FAN SPEED FUNCTION SPL dB A LINE High COOLING
11. Yes Refer to 11 4 i No Disconnect CN932 from the inverter P C board and turn on the power sup ply Y Rotate the outdoor fan motor manually and measure the voltage of CN931 Between 1 and 5 Between 2 and 5 Between 3 and 5 Y Fixed to either 5 or 0 VDC Does the voltage between each terminal become 5 and 0 No VDC repeatedly yes No Does the outdoor fan motor rotate smoothly Yes lt Y Y Replace the outdoor fan motor Replace the inverter P C board OCH545 31 D Check of LEV Turn on power supply to the outdoor unit after checking Yes Normal LEV coil is fixed to the LEV body securely Normal Is click click sound heard Or do you feel vibration of the LEV coil with a hand Yes n Nie his here nor the inverter P C board No Replace the LEV coil J Check of inverter P C board Check the outdoor fan motor Refer to 6 Y verter P C board Yes No 8 the fuse F901 blown on the in Y 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 Check the cor
12. coil to check if the coil is defective Refer to 11 4 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 Unit operates COOL mode even if it is set to HEAT mode Disconnect connector between the compressor and the intelligent Is there 230 VAC between CN721 power module KA25 35 50 CN602 KA60 71 and Replace the inverter Turn ON the power supply and start on the inverter P C board 3 minutes after P C board heating test run the power supply is turned ON TEST RUN OPERATION Refer to Yes 11 5 Unit operates HEAT mode even if it is set to COOL mode Disconnect connector between the compressor and the intelligent Is there 230 VAC between CN721 power module KA25 35 50 CN602 KA60 71 and Replace the inverter Turn ON the power supply and start on the inverter P C board 3 minutes after Yes P C board cooling test run the power supply is turned ON TEST RUN OPERATION Refer to No 11 5 Replace the 4 way valve H Check of outdoor fan motor Disconnect the connectors CN931 and CN932 from the inverter P C board Check the connection between the connector CN931 and CN932 Is the resistance between each ter minal of outdoor fan motor normal
13. 20 30 40 50 T 70 8 80 Temperature C Temperature C Temperature C OCH545 35 12 DISASSEMBLY INSTRUCTIONS Terminal with locking mechanism Detaching points 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 1 Slide the sleeve and check if there is a locking lever or not lever SUZ KA25VA4 TH OUTDOOR UNIT OPERATING PROCEDURE SUZ KA35VA4 TH Slide the sleeve GPull the terminal while pushing the locking 2 The terminal with this connector has the locking mechanism Hold the sleeve and pull out the terminal slowly Connector NOTE Turn OFF power supply before disassembling PHOTOS 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 OCH545 Photo 1 Screws of the top panel Screws of the top panel Back panel Screws of the cabinet Service Photo 2 panel Screw of
14. 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 Removing outdoor fan motor 1 Remove the top panel cabinet and service panel Refer to 1 2 Disconnect the following connectors Defrost thermistor Inverter P C board Photo 6 CN931 and CN932 Fan motor 3 Remove the propeller 4 Remove the screws fixing the fan motor 5 Remove the fan motor Screws of the outdoor fan motor Removing the compressor and 4 way valve Photo 7 1 Remove the top panel cabinet and service panel Refer to procedure 1 Discharge temperature 2 Remove the back panel Refer to procedure 1 die hadas the thermistor 3 Remove the inverter assembly Refer to procedure 2 gt 4 Recover gas from the refrigerant circuit R NOTE Recover gas from the pipes until the pressure gauge shows 0 kg cm 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 D Welded part of the suction pipe OCH545 44 OCH545 45 Mir SLIM MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE TOKYO BLDG
15. TH SUZ KA50VA4 TH SUZ KA60VA4 TH SUZ KA71VA4 TH Smoothing capacitor C61 6201 420V C62 C63 6201 420V 6201 420V 6201 420 2 3 5601 450V 560yF 350V Diode module DB61 15A 600V 15A 600V 25 600V F61 T20A L250V T20A L250V T20A L250V F62 T20A L250V T20A L250V T3 15A L250V T3 15A L250V T3 15A L250V IC700 15A 600V 15A 600V 20A 600V Inteligent power module IPM 20A 600V 12932 8A 600V 8A 600V 8A 600V 5A 600V 5A 600V Power factor controller PFC 20A 600V 20A 600V F701 F801 F901 IC820 20A 600 20A 600V 20A 600V Expansion valve coil LEV DC12V Reactor L61 23mH L 340pH 20A 340pH 20A Current Limiting PTC thermistoe PTC64 PTC65 Terminal block 5P 5P 5P Relay 3A 250V 3A 250V 3A 250V 20A 250V 3A 250V 3A 250V 3A 250V 3A 250V R V coil OCH545 AC220 240V 5 NOISE CRITERIA CURVES
16. inverter P C board 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 5 How to check in verter compressor 13 time flash 2 5 seconds OFF DC voltage DC voltage of inverter cannot be detected normally Refer to 11 5 9 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 frequency lowers The unit is normal but check the following Check if indoor filters are clogged 3 time flash 2 5 seconds OFF Frequency drop by high pressure pro tection Temperature of indoor coil thermistor exceeds 55 in HEAT mode compressor frequency lowers Check if refrigerant is short Check if indoor outdoor unit air circulation is short cycled Frequency drop by defrosting in COOL mode Indoor coil thermistor reads 8 C or less in COOL mode com pressor frequency lowers 4 time flash 2 5 seconds OFF Frequency drop by discharge tempera ture protection Temperature of discharge temperature thermistor exceeds 111 C compressor frequency lowers Check refrigerant circuit and refrig erant amount Refer to 11 5 D Check of LEV Refer to 11 5 O Check of outdoor thermistors 7 time flas
17. j Y Pf received Number of blinks beeps in pattern indicates the check Number of blinks beeps in pattern indicates code in the following table i e 5 for U2 the check code in the following table Output pattern A Errors detected by indoor unit Wireless remote controller Wired remote controller Beeper sounds OPERATION enm Boma INDICATOR lamp flashes Check code Number of times 1 P1 Intake sensor error 2 P2 Pipe TH2 sensor error P9 Pipe TH5 sensor error 3 E6 E7 Indoor outdoor unit communication error 4 P4 Drain sensor error Float switch connector CN4F open P5 Drain pump error i PA Forced compressor stop due to water leakage abnormality As for indoor 6 P6 Freezing Overheating protection operation unit refer to 7 EE Communication error between indoor and outdoor units indoor unit s 9 E4 E5 Remote controller signal receiving error servic amp manual 12 Fb FB Indoor unit control system error memory error etc 14 PL Abnormality of refrigerant circuit EO Remote controller transmission error E1 E2 Remote controller control board error Output pattern B Errors detected by unit other than indoor unit outdoor unit etc Wireless remote controller Wired remote controller Beeper sounds OPERATION INDICATOR lamp flashes Check code Number of times Symptom Indoor outdoor unit communication error
18. or more The display content will change as shown below to start self diagnosis SELF CHECK 2 Remote controller self diagnosis result When the remote controller is functioning correctly When the remote controller malfunctions Error display 1 blinks The remote controller s transmitting receiv ing circuit is defective SELF CHECK SELF CHECK E KE ll Check for other possible causes as there is no problem with the remote The remote controller must be replaced with a new one controller Where the remote controller is not defective but cannot be operated Error display 2 6833 or 6832 blinks Transmission is not possible Error display 3 and the number of data errors are displayed Data error has occurred E35 RE EX There might be noise or interference on the transmission path or the indoor unit or other remote controllers are defective Check the transmission path and other controllers SELF r gas 4 ERL The number of data errors is the difference between the number of bits sent from the remote controller and the number actually transmitted through the transmis sion path If such a problem is occurring the transmitted data is affected by noise etc Check the transmission path When the number of data errors is 02 Transmission data from remote contro
19. 1 Photo 6 Outdoor heat exchanger tempera ture thermistor Ambient tem perature thermistor AA AVA rN NL CO CN YN Photo 7 Screws of the outdoor fan motor Discharge temperature Brazed part of the thermistor discharge pipe Brazed part of suction pipe SUZ KA60VA4 TH SUZ KA71VA4 TH NOTE Turn OFF power supply before disassembling OPERATING PROCEDURE PHOTOS 1 Removing the cabinet Photo 1 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 Screws of the top panel Scr ws of the Screws of the cabinet cabinet Photo 2 Screw of the back panel Screws of the top panel Screws of the cabinet of the cabinet Screws of the back panel Screws of the service panel Screw of the valve cover OCH545 42 OPERATING PROCEDURE PHOTOS 2 Removing the inverter assembly inverter P C board 1 Remove the cabinet and panels Refer to procedure 1 Screw of the 2 Disconnect the lead wire to the reactor and the following con relay panel Screws of the nectors PB suppo
20. 49 e Med HEATING 50 o o amp mo i 1 s 9 o 80 N e e e e 70 m ap 60 gt al 50 2 o 2 40 a a z o RE a POI F i 1 amp 2 f F ken gt r 1 10 1 o N i 4 o 63 125 250 500 1000 2000 4000 8000 BAND CENTER FREQUENCIES Hz SUZ KA60VA4 TH SUZ KA71VA4 TH FAN SPEED FUNCTION SPL dB A LINE COOLING 55 e e High HEATING 55 o o E ai 90 7 ioi d i 1 x o 80 N e S px 70 i m T 60 gt al 50 x 2 o ij 2 40 a a E o 30 o a 3 lt 20 T ME i 20 8 63 125 250 500 1000 2000 4000 8000 BAND CENTER FREQUENCIES Hz Cooling Dry bulb temperature 35 Heating Dry bulb temperature 7 C 10 Wet bulb temperature 6 OUTDOOR UNIT 1m MICROPHONE Unit mm OUTLINES AND DIMENSIONS 6 SUZ KA25VA4 TH SUZ KA35VA4 TH Basically open 100mm or more without any obstruction in front and on both sides of the unit 9 S 5 5 LEN 5 gs 55 TAXI De i i 25 58 E 2 S c 25 e DE n OZ gl 55 X 5 o amp L oj S GE m 255 72 9 Z 5 LLI nc
21. 50 180 210 Calculation Xg 30g mx Refrigerant piping length m 7 Outdoor unit Refrigerant piping length one way precharged 15m 20m 25m SUZ KA50VA4 TH 1 600 160 260 360 SUZ KA60VA4 TH 1 800 160 260 360 Calculation Xg 20g m x Refrigerant piping length m 7 Model Outdoor unit Refrigerant piping length one way Model precharged 10m 15m 20m 25m SUZ KA71VA4 TH 1 800 440 715 990 Calculation Xg 55g m x Refrigerant piping length m 7 OCH545 18 9 ACTUATOR CONTROL SUZ KA25VA4 TH SUZ KA35VA4 TH SUZ KA50VA4 TH SUZ KA60VA4 TH SUZ KA71VA4 TH 9 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 5 seconds 15 seconds ON x x x Compressor OFF ON Outdoor fan OFF 9 2 R V COIL CONTROL Heating ON NOTE The 4 way valve reverses for 5 seconds OFF right before start up of the compressor Dry COOL HEAT 5 seconds 5 seconds SN a ompressor opp R V coi ON i d Outdoor fan ON DEN cum MER motor OFF 9 3 RELATION BETWEEN MAIN SENSOR AND ACTUATOR Actuator Outdoor fa
22. D 11 3 HOW TO PROCEED SELF DIAGNOSIS 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 11 3 1 Self diagnosis lt PAR 30MAA gt lt PAR 31MAA gt Select Service from the Main menu and press the 2 button Cw Select Self check with the F1 or 22 button and press the button Service menu 12 Test run Input maintenance info Function setting Check Self check Main menu 5 ES 000 With the F1 22 button enter the refrigerant address and press the 2 button Self check Ref address Select Y 5 3 Error code unit number attribute will appear will appear if no error history is available Self check Ref address B Error Unt 1 Grp IC Return gt Reset When there is no error history Self check M NET address 1 4 Resetting the error history Press the F4 button Reset on the screen that shows the error history Cw A confirmation screen will appear asking if you want to delete the error history Cw Press the F4 button OK to delete the error history If deletion fa
23. Hz Model 7 KNB092FFAMC SNB130FGBMT SNB172FEKMT Output 550 650 900 1 200 Compressor Cooling 2 76 4 06 5 58 6 62 8 02 Current Heating 3 24 4 09 5 75 6 37 8 13 Refrigeration oil 0 31 FV50S 0 27 FV50S 0 35 FV50S 0 4 FV50S Model Model RC0J50 FA RC0J60 BD 0 84 0 93 RC0J60 BC 0 24 0 29 0 27 0 28 800 x 550 x 285 30 35 0 84 0 93 840 x 880 x 330 50 3 492 3 066 1 692 2 952 2 952 2 226 0 83 0 82 Fan motor Cooling Current Heating Dimensions WxH xD Weight 54 53 1 806 1 806 Cooling 1 170 1 038 2 106 Med 1 806 1 452 1 770 1 326 49 50 Heating Cooling Heating High Med Low Cooling Special remarks High Med Low Heating Fan speed regulator Refrigerant filling capacity 410 NOTE Test conditions are based on ISO 5151 Cooling Indoor D B 27 C W B 19 Outdoor D B 35 C Heating Indoor D B 20 C Outdoor D B 7 C W B 6 Refrigerant piping length one way 5 m Measured under rated operating frequency OCH545 8 Specifications and rating conditions of main electric parts SUZ KA35VA4 TH SUZ KA25VA4 TH 502 4 SUZ KA71VA4 TH Item SUZ KA60VA4 TH SUZ KA25VA4 TH SUZKA35VA4
24. MITSUBISHI ELECTRIC SPLIT TYPE HEAT PUMP AIR CONDITIONERS TECHNICAL amp SERVICE MANUAL R410A Outdoor unit Model Name SUZ KA25VA4 SUZ KA35VA4 SUZ KA50VA4 SUZ KA60VA4 SUZ KA71VA4 Service Ref SUZ KA25VA4 TH SUZ KA35VA4 TH SUZ KA50VA4 TH SUZ KA60VA4 TH SUZ KA71VA4 TH Changes for the Better August 2013 No OCH545 utilized R410A Note This service manual describes technical data of the outdoor units SUZ KA25VA4 TH SUZ KA35VA4 TH CONTENTS 1 COMBINATION OF INDOOR AND OUTDOOR UNITS 2 2 TECHNICAL CHANGES 3 3 PARTS NAMES AND FUNCTIONS 7 SPECIEICATION R n n nan 8 RA 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 PARTS CATALOG OCB545 1 COMBINATION OF INDOOR AND OUTDOOR UNITS INDOOR UNIT SERVICE MANUAL Outdoor unit Heat pump type Indoor unit x o o o 5 z 3 o SUZ Se
25. RA10A Yes Substitutable for R410A OCH545 4 2 Refrigerant piping Specifications Use the refrigerant pipes that meet the following specifications Outside diameter Wall thickness Insulation material em Ls Heat resisting foam plastic s s gray 0095 For gas 0 8 Thickness 8 mm 1588 88 1 0 Use a copper pipe or a copper alloy seamless pipe with a thickness of 0 8 mm Never use any pipe with a thickness less than 0 8mm as the pressure resistance is insufficient 2 Flaring work and flare nut Flaring work for R410A pipe differs from that for R22 pipe For details of flaring work refer to Installation manual FLARING WORK Dimension of flare nut mm RATOA Pipe diameter mm 15 88 3 Refrigerant oil Apply the special refrigerant oil accessories packed with indoor unit to the flare and the union seat surfaces 4 Air 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 charged from the gas phase composition change may occur in the refrigerant inside the cylinder and the outdoor unit In this case
26. U 09 HOSSiUdW02 2M pes 063 0883 S L rs L U3NHUOJSNvUI 1081 1102 JAVA NOISNVdX3 A31 ZEN 18 1 10 39018 IWNIWYSI EL 181 eal UOLSTRUIHL NAL gg HIMOA INSOITHINI WaT 1 1 4000110 TINGOW E3NOd 1N39ITHIMI 26 821 E e HOISINUSHL INSIGNV 59184 AOSZTVST 1 354 1064 m UDISIWHSHI dW3 NIJ v91H A062 3909 0883 WOISINHSHI dW3l 3OUVEOSIQ 2918 A0S21V21 3Snd 293 gt amp L UDISINH3HI 1508330 1914 A0S21VS1 61 3504 1094 eo 1100812 59218 ONTHLOOWS 182 5 1 318 Yu 3AVN 108NAS JWYN 10845 TT 25 Hdl 3m 1 pone MR ORIENTEM NEL ss 181 TINNI 1805 ADS N 1805 H3W0d 15 OCH545 8 REFRIGERANT SYSTEM DIAGRAM SUZ KA25VA4 TH Unit mm Refrigerant pipe 09 52 with heat insulator A way valve lt gt Outdoor heat exchanger Stop og temperature with service Muffler Outdoor thermistor Flared connection Am heat RT68 temperature exchanger I thermistor RT62 Compressor Ambient temperature thermistor RT65 Defrost NI thermistor RT61 4 Strainer 100 Flared connection Capillary tube LEV X 03 0 02 0 240 P lt R V coil mE heating ON F gt lt 000 gt lt cooling OFF Stop valve with strainer Refrigerant pipe 26 35 gt Refrigerant flow in c
27. ability of the refrigerating cycle decreases or normal operation can be impossible However charging the liquid refrigerant all at once may cause the compressor to be locked Thus charge the refrigerant slowly Indoor unit Refrigerant gas cylinder operating valve Union Stop valve Outdoor unit Service PTPN Gauge manifold valve for R410A Refrigerant gas cylinder for R410A with siphon Refrigerant liquid Electronic scale for refrigerant charging OCH545 5 6 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 QD Turn off the power supply circuit breaker Connect the gauge manifold valve to the service port of the stop valve on the gas pipe side of the outdoor unit Fully close the stop valve on the liquid pipe side of the outdoor unit Supply power circuit breaker 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 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 app
28. als specifically designed for Refer to 2 Refrigerant piping 4 Composition change may occur in R410A since it is a mixed refrigerant When charging charge liquid refrigerant to prevent composition change TO Now Provous Saturated steam density 25 CJKg m 0 UNA us c D 14 1 Ozone Depletion Potential based on CFC 11 2 Global Warming Potential based on CO New Specification Current Specification The incompatible refrigerant oil easily separates from Since refrigerant and refrigerant oil are compatible with refrigerant and is in the upper layer inside the suction muffler each other refrigerant oil backs to the compressor through Raising position of the oil back hole enables to back the the lower position oil back hole refrigerant oil of the upper layer to flow back to the compressor Suction muffler Suction muffler o o Compressor Oil back hole Compressor 1 Refrigerant oil Oil back hole Refrigerant Refrigerant oil Refrigerant NOTE The unit of pressure has been changed to MPa on the international system of units SI unit system The conversion factor is 1 MPa Gauge 710 2 kgf cm Gauge OCH545 3 Conversion chart of refrigerant temperature and pressure MPa Gauge 4 0 3 5 410 NOTE The unit of pressure has been changed to MPa on the international sy
29. ber or refrigerant address you want to diagnose Press the CHECK button 6 in the picture above twice within 3 seconds Press the TEMP buttons and CA in the picture above to select the desired number or address The number address changes between 01 and 50 or 00 and 15 The display content will change as shown below e gt The refrigerant address will begin to blink Unit number or refrigerant address approximately 3 seconds after being to be diagnosed selected and the self diagnosis process will begin 9 Display self diagnosis results When there is error code history For the definition of each error code refer to the indoor unit s installation manual or service handbook Alternating Display pa SELF SELF CHECK ae eo cue NN nn LILI 2 4 uem Address 3 digits or unit number 2 digits When there is no error code history When there is no corresponding unit SELFCHECK 207 SELFCHECK ERROR TEN _ ERROR qoem nn LILI uu Reset the error history Display the error history in the diagnosis result display screen see step 9 SELF CHECK 1 lt y CS OCH545 24 Press the ON OFF button in the picture in the previous page twice When the error history is
30. cedure 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 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 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 cm 0 MPa 5 Detach the brazed part of the suction and the discharge pipe connected with compressor 6 Remove the rieCONNECTOR Yellow nuts 7 Remove the compressor 8 Detach the brazed part of 4 way valve and pipe Photo 5 OCH545 4
31. dfiS U3N0d 2109 ADE M WOISIWEJHI 1103 JANA NOISNVOXI An 151 1 T91H an am BULTIM PISTE 104 1100 JAWA SNISUIAGU Sie BUISINU3HI 2918 20801 Al uo Ley 2 AV 8 SSX TX ___ 5 __ 508430 1918 FMOOW UINOd 901 121 U3WUD3SNVUL 1081 1102912 5901d TSOld 95094 1063 08 Sa s E 30018 TWNIWUSL Bl NJ di 38d 193 513 184 ANIL H0SS3UdWD2 TINGOW 30010 1980 31133818 SUY 1109071 _ 8518 HOLE T WOITOVdVJ ONTHIOONS 290229 S310N 09 TOERAS TORWAS 194 Nua 31 zn 891g Z914 T914 998 1318 Lp Le ot D of 2 oly lNO 9 y code 13 01 o wg Kee 25 awaya 8 1109113 L o HE 99019 um 031 A 1901 davo 2 d L J 509 1083
32. e the cabinet and panels Refer to procedure 1 2 Disconnect the lead wire to the reactor and the following con nectors lt Inverter P C board gt 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 OCH545 37 OPERATING PROCEDURE PHOTOS 5 Removing outdoor fan motor Photo 6 1 Remove the cabinet and panels Refer to procedure 1 rE 2 Disconnect the following connectors Outdoor heat Inverter P C board a exchanger tempera CN932 Fan motor ture thermistor 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 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 cm 0 MPa 4 Detach the welded part of the sucti
33. h 2 5 seconds OFF Low discharge tem perature protection Temperature of discharge temperature thermistor has been 50 C or less for 20 minutes Refer to 11 5 Check of LEV Check refrigerant circuit and refrig erant amount 8 time flash 2 5 seconds OFF KA25 35 50 PAM protection PAM Pulse Ampli tude 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 pro tection will be activated in the fol lowing cases 1 Instantaneous power voltage drop Short time power failure KA60 71 Zero cross detecting circuit Zero cross signal for PAM control cannot be detected 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 NOTE 1 The location of LED is illustrated at the right figure Refer to 11 6 1 2 LED is lighted during normal operation The flashing frequenc Example When the OFF OCH545 2 5 second OFF y shows the number of times the LED blinks after every 2 5 second OFF lashing frequency is 2 zi 0 5 second ON E 0 5 second ON 2 5 second OFF Check if the connector of the com pressor is correctly connected Refer to 11 5 How to check inverter compressor Inverter P C board Flashing gt LE
34. h heat insulator 215 88 Muffler 4 way valve 100 M d Stop valve with service port Outdoor Flared connection Discharge neat Ambient emperature exchanger temperature thermistor Defrost thermistor ermistor RT65 RT61 Compressor Outdoor heat exchanger temperature thermistor RT68 Flared connection LEV Strainer Strainer 100 100 R V Coil heating ON ER Capillary tube cooling OFF 04 0 02 4 100 Refrigerant pipe gt Refrigerant flow in cooling with heat insulator Refrigerant flow in heating 6 35 SUZ KA60VA4 9 52 SUZ KA71VA4 OCH545 17 SUZ KA25VA4 TH SUZ KA35VA4 TH SUZ KA50VAA TH SUZ KA60VA4 TH SUZ KA71VA4 TH MAX REFRIGERANT PIPING LENGTH Refrigerant piping m Piping size O D mm Max Length A Max Height difference B Gas Liquid Model SUZ KA25VA4 TH SUZ KA35VA4 TH 20 12 9 52 SUZ KA50VA4 TH x SUZ KA60VA4 TH 30 SUZ KA71VA4 TH 6 35 15 88 MAX HEIGHT DIFFERENCE Max Height difference B Max Length A Outdoor unit Height difference limitations are binding regardless of which unit indoor or outdoor is position high ADDITIONAL REFRIGERANT CHARGE 410 Outdoor unit Refrigerant piping length one way precharged 10m 11m 12m 13m 14m Model SUZ KA25VA4 TH 800 90 120 150 180 210 SUZ KA35VA4 TH 1 150 90 120 1
35. ils Request rejected will appear Unit not exist will appear if no indoor units that are correspond to the entered address are found E through the screens To go back to the Main menu button To return to the previous screen 5 button OCH545 22 Eron cc a Orpa Contact OFF Return gt Self check Ref address Delete error history Self check Ref address 0 Error history deleted Return 11 3 2 Remote controller check lt PAR 30MAA gt lt PAR 31MAA gt If operations cannot be completed with the remote controller diagnose the remote controller with this function Select Service from the Main menu and press the 2 button Service menu 2 2 Maintenance password Cw Remote controller check Select Remote controller check with the F1 or F2 button and press the 2 button Main menu 1 000 2 Select Remote controller check from the Service menu and press the but Remote controller check ton to start the remote controller check and see the check results Cw Start checking To cancel the remote controller check and exit the Remote controller check menu screen press the or the 5 button mnmm C D The remote controller will not reboot itself Begin Y No problems are found with the remote controller Check other hompt conroller check resu
36. inding No Replace the compressor Is the compressor normal pes Refer to 11 5 Check of compressor the compressor ion time operation time more than operation time No 10 healer ies Replace the compressor Does the compressor operate continuously Yes OCH545 29 D Check of compressor winding e 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 lt lt Judgement gt gt Refer to 11 4 0 Q Abnormal short Infinite 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 lt lt Judgement gt gt Compressor starts Abnormal IPM failure Compressor winding short eConnect the compressor and activate the inverter Then measure the time until the inverter stops due to over current Operation method gt gt Start heating or cooling test run TEST RUN OPERATION Refer to 11 5 lt lt Measurement gt gt Measure the time from the start of compressor to the stop of compressor due to overcurrent Abnormal Compressor lock out Starting defect Abnormal Poor contact Outdoor P C board defect Disconnected co
37. it and indoor unit s sensor emits an intermittent CHECK OER h press the HOUR button buzzer sound the operation light CHECK m flashes and the error code is output button It takes 3 seconds at most for error ser reser 0 4 Point the remote controller the The check mode is cancelled sensor on the indoor unit and press the ON OFF button OCH545 26 Refer to the following tables for details on the check codes Output pattern A Beepersounds Beep Beep Beep Beep Beep Beep OPERATION Jar a N nel aed fet 2nd Repeated INDICATOR oy lamp flash Off On On Off On On pattern Self check Approx 2 5 sec 0 5 sec 0 5 sec 0 5 sec 0 5 sec Approx 2 5 0 5 sec 0 5 sec starts N J Start signal dios received Number of blinks beeps in pattern indicates the check Number of blinks beeps in pattern indicates code in the following table i e n 5 for P5 the check code in the following table Output pattern B Beepersounds Beep Beep Beep Beep Beep Beep OPERATION xcd Ye qst 2nd 3 n E y xx 1st 2nd Repeated INDICATOR d gt x lamp flash Off On On On Off On On On pattern Self check 2 5 sec Approx 3 sec 0 5 sec 0 5 sec 0 5 sec 0 5 sec Approx 2 5 sec Approx 3 sec 0 5 0 5 starts N Start signal
38. k stop valve flash 2 5 seconds OFF Discharge tempera ture overheat pro tection 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 refrig erant amount Refer to 11 5 Check of LEV 4 time flash 2 5 seconds OFF Fin temperature P C board tem perature thermistor overheat protection Temperature of fin temperature thermistor on the heat sink exceeds 72 86 or temperature of P C board temperature thermistor on the inverter P C board exceeds 72 85 Check around outdoor unit Check outdoor unit air passage Refer to 11 59 Check of outdoor fan motor 5 time flash 2 5 seconds OFF High pressure pro tection Indoor coil thermistor exceeds 70 in HEAT mode Defrost thermistor exceeds 70 in COOL mode Check refrigerant circuit and refrig erant amount Check stop valve 8 time flash 2 5 seconds OFF Compressor syn chronous abnormal ity The waveform of compressor current is distorted Reconnect connector of compressor Refer to 11 5 9 How to check in verter 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 11 5 Check of outdoor fan motor Refer to 11 5 Check of
39. ller Transmission data on transmission path To cancel remote controller diagnosis Press the CHECK button in the picture in the previous page for 5 seconds or more Remote controller diagnosis will be cancelled PLEASE WAIT and operation lamp will blink Afterapproximately 30 seconds the state in effect before the diagnosis will be restored OCH545 25 11 3 6 Self diagnosis Wireless remote controller n case of trouble during operation When a malfunction occurs to air conditioner both indoor unit and outdoor unit will stop and operation lamp blinks to inform unusual stop lt Malfunction diagnosis method at maintenance service Procedure 1 Press the CHECK button twice CHECK lights and refrigerant address Refrigerant 00 flashes OMEN display Check that the remote controller s CHECK 5 CHECK display has stopped before continuing display 2 Press the temperature 0 Select the refrigerant address of the Temperature buttons indoor unit for the self diagnosis ON OFF amp TEMP Note Set refrigerant address using the outdoor unit s DIP switch SW1 ON OFF For more information see the button d outdoor unit installation manual e FAN AUTOSTOP 6 0 MODE VANE AUTOSTAR 3 Point the remote controller at the If an air conditioner error occurs the PUES sensor on the indoor un
40. lts screen parts for problems Remote controller check 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 Start checking other remote controllers ALL 1 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 inter ference Begin V Cw If the button is pressed after the remote controller check results are dis played remote controller check will end and the remote controller will automati cally 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 12 VDC is not supplied to the remote con troller If this is the case check the remote controller wiring and indoor units OCH545 23 11 3 3 Self diagnosis lt PAR 21MAA gt Whena problem occurs to the air conditioner the indoor and outdoor units will stop and the problem is shown in the remote controller display CHECK and the refrigerant address are displayed on the temperature D
41. me flash every 2 5 seconds UP Outdoor power sys tem Overcurrent protection cut out operates 3 consecutive times within 1 minute after the compressor gets started Reconnect connector of compres Sor Refer to 11 5 amp to check in verter compressor Check stop valve Outdoor thermistors Discharge temperature thermistor shorts or opens during compressor running Refer to 11 5 Check of outdoor thermistors Fin temperature thermistor defrost thermistor board temperature thermistor outdoor heat exchanger temperature thermistor or ambient temperature thermistor shorts or opens during compressor running Outdoor control sys tem 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 Check of indoor outdoor connecting wire Replace indoor or outdoor P C board if abnormality is displayed again 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 protec tion Large current flows into intelligent power module Reconnect connector of compressor Refer to 11 5 How to check in verter compressor Chec
42. n Indoor fan motor motor Sensor Purpose Compressor Discharge temperature thermistor Indoor coil temperature Cooling Coil frost prevention thermistor Heating High pressure protection Protection Q Defrost thermistor Heating Defrosting Fin temperature thermistor Protection Ambient temperature thermistor Cooling Low ambient temperature operation Outdoor heat exchanger Cooling Low ambient temperature operation temperature thermistor Cooling High pressure protection OCH545 19 10 SERVICE FUNCTIONS SUZ KA25VA4 TH SUZ KA35VA4 TH 502 4 SUZ KA60VA4 TH SUZ KA71VA4 TH CHANGE IN DEFROST SETTING Changing defrost finish temperature lt JS gt To change the defrost finish temperature cut solder the JS wire of the outdoor inverter P C board Refer to 11 6 1 Defrost finish temperature C Jumper wire SUZ KA25VA4 TH SUZ KA60VA4 TH SUZ KA35VA4 TH SUZ Aen SUZ KA71VA4 TH Soldered Initial setting 5 9 10 None cut 10 18 18 11 TROUBLESHOOTING SUZ KA25VA4 TH SUZ KA35VA4 TH SUZ KA50VA4 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
43. nd the separator oe support and the nectors ack panel lt Inverter P C board gt 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 Heat sink Heat sink support P C board 3 Removing R V coil 1 Remove the cabinet and panels Refer to procedure 1 2 Disconnect the following connector lt Inverter P C board gt CN721 R V coil 3 Remove the R V coil N J Screwof d the inverter S P C board Screws of the earth wire terminal block support Photo 5 parts of 4 way valve OCH545 40 OPERATING PROCEDURE PHOTOS 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 pro
44. nnector 10 seconds Abnormal Refrigerant circuit defect Closed valve 10 minutes Normal Check of outdoor thermistors Disconnect the connector of thermistor in the outdoor P C board see below table and measure the resistance of thermistor Y Is the resistance of thermistor normal Replace the thermistor except RT64 KA25 35 50 Refer to 11 6 1 KA60 71 11 6 2 No When RT64 is abnormal replace the inverter Yes P C board Y Reconnect the connector of thermistor Turn ON the power supply and press EMERGENCY OPERATION switch Does the unit operate for 10 minutes or more without showing thermistor abnormality v Yes Du Replace the inverter P C board OK Cause is poor contact Connector Pin No Thermistor SUZ KA25 35 50VA4 TH SUZ KA60 71VA4 TH Defrost Between CN641 pin1 and pin2 Between CN671 pin1 and pin2 Discharge temperature Between 641 pin3 and pin4 Between CN671 pin3 and pin4 Fin temperature Between CN642 pin1 and 2 Between CN673 pin1 and pin2 Ambient temperature Between CN643 pin1 and pin2 Between CN672 pin1 and pin2 Outdoor heat exchanger temperature OCH545 Between CN644 pin1 and pin3 30 Between CN671 pind and Inverter P C board 6 Check of R V coil First of all measure the resistance of R V
45. on 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 Propeller Propeller nut Photo 8 Welded parts of 4 way valve OCH545 38 SUZ KA50VA4 TH NOTE Turn OFF power supply before disassembly OPERATING PROCEDURE PHOTOS Photo 1 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 of the ing wire cabinet 8 Remove the screws of the cabinet 9 Remove the cabinet 10 Remove the screws of the back panel 11 Remove the back panel Screws of the top panel Scr ws of the Screws of the cabinet cabinet Photo 2 Screw of the back panel Screws of the cabinet 1 Screws of the top panel of the cabinet Screws of the Screws of the back panel service panel Screw of the valve cover OCH545 39 OPERATING PROCEDURE PHOTOS 2 Removing the inverter assembly inverter P C board Photo 3 1 Remove the cabinet and panels Refer to procedure 1 Screw of the heat sink Screw of the terminal 2 Disconnect the lead wire to the reactor and the following con support a
46. ooling with heat insulator gt Refrigerant flow in heating SUZ KA35VA4 TH Unit mm Refrigerant pipe 29 52 T with heat insulator sway valve 5 lt heat exchanger nb WIS jo temperature Muffler Outdoor ermistor Flared connection Discharge heat RT68 temperature exchanger thermistor RT62 i Compressor Ambient temperature thermistor RT65 Defrost Qo thermistor RT61 lt lt Capillary tube 03 0 01 8 600 2 a Strainer Flared connection 100 Capillary tube LEV N 03 0 02 0 240 gt lt R V coil heating ON H 000 cooling OFF Stop valve th strai Refrigerant pipe 06 35 with heat insulator OCH545 Refrigerant flow in cooling gt Refrigerant flow in heating 16 502 4 Unit mm Refrigerant pipe 212 7 Mamer with heat insulator 4 way valve EE Stop valve with service port Flared connection Discharge Ambient temperature temperature thermistor Defrost thermistor ermistor RT65 RT61 Compressor Outdoor heat exchanger temperature thermistor Flared connection N Strainer Ley Strainer 1 100 100 R V coil heating ON Stop valve Capillary tube cooling OFF 04 0 02 4 100 Refrigerant pipe 26 35 gt Refrigerant flow in cooling with heat insulator Refrigerant flow in heating SUZ KA60VA4 TH SUZ KA71VA4 TH nlt mam Refrigerant pipe wit
47. or RT65 Outdoor heat exchanger temperature thermistor RT68 Discharge temperature thermistor RT62 0 Resistance kC PINT PITT NTT TTT 00 10 20 30 40 50 60 70 80 90 100 110 120 Temperature C 10 0 10 20 Temperature C OCH545 34 Fin temperature thermistor RT64 Vet ALERT ARE E AEST 0 0 10 20 30 40 50 60 70 80 Temperature C 11 6 2 Inverter P C board SUZ KA60VA4 TH Signal of out door fan motor CN931 LED SUZ KA71VA4 TH Fuse F62 Fuse F601 R V coil CN602 T2 0AL250V 1T3 15AL250V 230VAC 8 ET Jumper wire for Pes 9 changing defrost E setting JS oTo ia 0 Vut gt 8 Jumper wire for pre heat control setting Defrost thermistor RT61 CN671 Discharge temperature m d thermistor RT62 C 2 _ CN671 i rz Outdoor heat exchanger temperature thermistor RT68 CN671
48. re asking for service 1 2 3 4 Devices affected by the electromagnetic noise TV sets radios FM AM broadcast shortwave Channel frequency broadcast station affected by the electromagnetic noise Channel frequency broadcast station unaffected by the electromagnetic noise Layout of indoor outdoor unit of the air conditioner indoor outdoor wiring earth wire antennas wiring from antennas receiver Electric field intensity of the broadcast station affected by the electromagnetic noise Presence or absence of amplifier such as booster 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 OCH545 33 11 6 TEST POINT DIAGRAM AND VOLTAGE 11 6 1 Inverter P C board SUZ KA25VA4 TH SUZ KA35VA4 TH SUZ KA50VA4 TH
49. reset the display will look like the one shown below within 3 seconds The self diagnosis address or refrigerant address will blink However if you fail to reset the error history the error content will be displayed again SELFCHECK HER SELF E gt ERROR GORE nn i LILI Cancel self diagnosis Self diagnosis can be cancelled by the following 2 methods Press the CHECK button in the picture in the previous page Self diagnosis will be cancelled and the screen will return to the previous state in effect twice within 3 seconds before the start of self diagnosis Press the ON OFF button in the picture in the previous page Self diagnosis will be cancelled and the indoor unit will stop 11 3 5 Remote controller check PAR 21MAA If the air conditioner cannot be operated from the remote controller diagnose the remote controller as explained below If the correct voltage DC12 V is not supplied to the remote controller the SELF CHECK indicator will not light If this occurs check the remote controller s wiring and the indoor unit First check that the power on indicator is lit Power on indicator Switch to the remote controller self diagnosis mode Press the CHECK button amp in the picture in the previous page Press the FILTER button in the picture in the previous page for 5 seconds
50. responding parts verter P C board N following LED indication Does the LED flash 10 times Refer to 11 3 Yes 10 time flash Replace the inverter P C board lt OCH545 32 K Elect romagnetic noise enters into TV sets or radios Is the unit earthed No Earth the unit Yes bbs E ni Extend the distance between the antennas and the indoor unit and or the antennas and the distance between the antennas and the Yes outdoor unit outdoor unit within 3 m V OMNES in Extend the distance between the TV sets and or is the distance between the TV sets Yes js er radios and the outdoor unit within 3 m l Are the antennas damaged Is the coaxial cable damaged Replace or repair the antenna Is there any poor contact in the anten Yes Replace or repair the coaxial cable na wiring i Is the indoor outdoor connecting wire Extend the distance between the indoor outdoor of the air conditioner and the wiring of connecting wire of the air conditioner and the wir the antennas close Yes ing of the antennas Even if all of the above conditions are fulfilled the electromagnetic noise may enter depending on the electric field strength r the installation condition combination of specific conditions such as antennas or wiring Check the following befo
51. rox 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 operation In this case use refrigerant recovery equipment to collect all of the refrigerant in the system Turn off the power supply circuit breaker remove the gauge manifold valve and then disconnect the refrigerant pipes A 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 OCH545 6 3 PARTS NAMES AND FUNCTIONS SUZ KA25VA4 TH SUZ KA35VA4 TH back and side Air outlet Drain outlet SUZ KA50VA4 TH SUZ KA60VA4 TH SUZ KA71VA4 TH back and side iw Piping 4 4 Orain hose Drain outlet Model SUZKAVAATH OCH545 7 SPECIFICATION Outdoor model SUZ KA25VA4 TH SUZ KA35VA4 TH SUZ KA50VA4 TH SUZ KA60VA4 TH SUZ KA71VA4 TH Power supply Single phase 230V 50
52. rt Inverter P C board Inverter P C Earth wires 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 screw of the PB support 8 Remove the inverter P C board from the relay panel Screws of the PB support i Screws of 3 Removing R V coil the relay 1 Remove the cabinet and panels Refer to procedure 1 panel 2 Disconnect the following connector Inverter P C board CN602 R V coil 3 Remove the R V coil Photo 4 Screw of the RN coil gt Welded parts of 4 way valve OCH545 43 OPERATING PROCEDURE PHOTOS 4 Removing the discharge temperature thermistor Photo 5 defrost thermistor outdoor heat exchanger tempera Outdoor heat Ambient tem ture thermistor and ambient temperature thermistor exchanger tempera perature 1 Remove the cabinet and panels Refer to procedure 1 ture thermistor thermistor 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 ther mistor CN672
53. rvice Ref SLZ KA25VAL2 TH SLZ KA35VALR3 TH SLZ KA50VALR3 TH Service Manual No KA25VA4 TH KA35VA4 TH 5 4 4 KA71A4 TH SLZ KA25VAQ2 TH SLZ KA35VAQR2 TH SLZ KA50VAQR2 TH OCH493 SEZ KD25VA L R2 TH SEZ KD35VA L R2 TH SEZ KD50VA L R2 TH SEZ KD60VA L R2 TH SEZ KD71VA L R2 TH HWE0711 BWE102050 SEZ KD25VAQR2 TH SEZ KD35VAQR2 TH SEZ KD50VAQR2 TH SEZ KD60VAQR2 TH SEZ KD71VAQR2 TH HWE1008 BWE102040 Note Please refer to the service manual of indoor unit or the technical data book for the combination data OCH545 2 TECHNICAL CHANGES INFORMATION FOR THE AIR CONDITIONER WITH R410A REFRIGERANT This room air conditioner adopts an HFC refrigerant R410A which never destroys the ozone layer Pay particular attention to the following points though the basic installation procedure is same as that for R22 conditioners D As R410A has working pressure approximate 1 6 times as high as that of R22 some special tools and piping parts materi als are required Refer to the table below 2 Take sufficient care not to allow water and other contaminations to enter the 410 refrigerant during storage and installa tion since it is more susceptible to contaminations than R22 3 For refrigerant piping use clean pressure proof parts materi
54. stem of units SI unit system The conversion factor is 1 MPa Gauge 710 2 kgf cm Gauge Saturated liquid pressure 5 30 20 10 0 10 20 30 40 50 60 C 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 of the service port on the stop valve in outdoor unit has been changed to prevent any other refrigerant being charged into the unit Cap size has been changed from 7 16 UNF with 20 threads to 1 2 UNF with 20 threads R410A tools Can R22 tools be used Description has high pressures beyond the measurement range of existing Gauge manifold gauges Port diameters have been changed to prevent any other refrigerant from being charged into the unit Hose material and cap size have been changed to improve the pressure Charge hose resistance Gas leak detector E Dedicated for HFC refrigerant Les __ 952 Torque wrench Flare tool ERE CR E bar hole has been enlarged to reinforce the spring strength in the tool Flare gauge New Provided for flaring work to be used with R22 flare tool Provided to prevent the back flow of oil This adapter enables you to use adapter vacuum pumps It is difficult to measure R410A with a charging cylinder because the refrigerant charging refrigerant bubbles due to high pressure and high speed vaporization No Not substitutable for
55. t 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 Measure the resistance between terminals with a tester Temperature 10 C 40 C WHT RED BLK Normal W Compressor SUZ KA25VA4 TH SUZ KA35VA4 TH SUZ KA50 60VA4 TH SUZ KA71VA4 TH U V V T U W 4 1520 2470 0780 1110 0920 1120 VW 1360 1930 Measure the resistance between terminals with a tester Temperature 10 C 40 C WHT RED BLK Color of the lead wi NORIS W Outdoor fan motor i dic SUZ KA25 35VA4 TH SUZ KA50 60 71VA4 TH WHT BLK V BLK RED 290 420 120 170 RED WHT R V coil 2194 Measure the resistance between terminals with a tester Temperature 10 C 40 Normal 1 19 1 78 Expansion valve coil LEV OCH545 Measure the resistance with a tester Temperature 10 C 40 C SUZ KA25 35VA4 TH WHT ORN Color of the lead wire Normal WHT RED ign RED ORN 370 540 z gt YLW BRN BRN BLU Measure the resistance with a tester Temperature 10 C 40 SUZ KA50 60 71VA4 TH Color of the lead wire Normal RED ORN RED WHT 370 540 RED RED BLU YLW BLU RED YLW 28 11 5 TROUBLESHOOTING FLOW How to check inverter compressor Disconnect the connector between the
56. the cabinet Screw of the service panel Screws of the cabinet 36 OPERATING PROCEDURE PHOTOS 2 Removing the inverter assembly inverter P C board Photo 3 1 Remove the cabinet and panels Refer to procedure 1 2 Disconnect the lead wire to the reactor and the following con Screws of the nectors relay panel Inverter P C board 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 inniti Photo 4 Inverter assembly Inverter Screw of the Heat sink P C board T B support 3 Removing R V coil T B support 1 Remove the cabinet and panels Refer to procedure 1 2 Disconnect the following connectors Inverter P C board CN721 coil 3 Remove the R V coil Photo 5 Screw of the Relay panel earth wire 4 Removing the discharge temperature thermistor Photo 5 RV coil defrost thermistor outdoor heat exchanger tempera ture thermistor and ambient temperature thermistor 1 Remov
57. 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 X Es Lead wire Housing point 3 Troubleshooting procedure 1 Check if the OPERATION INDICATOR lamp on the outdoor P C board is blinking on and off to indicate an abnormal ity 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 11 2 and 11 3 OCH545 20 11 2 TROUBLE SHOOTING CHECK TABLE SUZ KA25VA4 TH SUZ KA35VA4 TH 502 4 SUZ KA60VA4 TH SUZ KA71VA4 TH Symptoms LED indication check code Abnormal point Condition Condition Remedy Outdoor unit does not op erate 1 ti

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