Mitsubishi SUZ-KA09NA, Service Manual

Page 1: ...TION SETTING 32 12 DISASSEMBLY INSTRUCTIONS 35 HFC utilized R410A May 2014 R410A Outdoor unit Model Names Service Ref SUZ KA09NA SUZ KA09NA TH SUZ KA12NA SUZ KA12NA TH SUZ KA15NA SUZ KA15NA TH SUZ KA18NA SUZ KA18NA TH Note This service manual describes service data of the outdoor units only RoHS compliant products have G mark on the spec name plate PARTS CATALOG OCB467 SUZ KA18NA TH Revision Modif...

Page 2: ...ack and side SUZ KA18NA PARTS NAMES AND FUNCTIONS 2 SUZ KA09NA SUZ KA12NA SUZ KA15NA Heat pump type Outdoor unit SUZ Indoor unit Service Manual No Service Ref Heat pump without electric heater KA18NA TH KA15NA TH HWE08020 KA12NA TH KA09NA TH SEZ KD09NA4 TH SEZ KD12NA4 TH SEZ KD15NA4 TH SEZ KD18NA4 TH SLZ KA09NA TH SLZ KA12NA TH SLZ KA15NA TH OCH487 OCB487 OUTDOOR UNIT OCH467C ...

Page 3: ...t Ib 66 77 80 119 External finish Munsell 3Y 7 8 1 1 Control voltage by built in transformer VDC 12 24 Refrigerant piping Not supplied Refrigerant pipe size Min wall thickness Liquid in 1 4 0 0315 Gas in 3 8 0 0315 1 2 0 0315 Connection method Indoor Flared Outdoor Flared Between the indoor outdoor units Height difference ft 40 50 Piping length ft 65 100 Refrigerant charge R410A 1 lb 16 oz 2 lb 9 ...

Page 4: ...he unit 14 in or more 8 in or more 4 in or more 4 in or more Open two sides of left right or rear side SUZ KA18NA 20 9 32 14 3 16 Air in 11 25 32 2 19 32 Air in Air out 19 11 16 33 1 16 13 2 4 25 32 33 7 16 16 15 16 3 3 16 4 3 8 13 16 slot 1 11 32 1 9 16 Drain 3 holes ø1 5 16 3 0 3 5 2 9 16 Liquid 1 4 flared Gas 1 2 flared 3 9 16 8 11 32 Open as a rule 20 inches or more if the front and both sides...

Page 5: ...5 LD S LD62 LD61 6 INVERTER P C BOARD 3 F901 BLU CN721 X63 2 1 1 RT65 CN643 RT62 RT61 CN641 4 1 CIRCUIT BREAKER BRN BLU BRN RED 1 2 S3 S2 S1 TB2 TB1 RT64 RT68 CN642 CN644 2 1 CN932 L61 C62 C63 LD70 LD66 DB61 DB65 TR821 F801 T801 1 3 P N W U V IC802 3 1 V W MS 3 MS MF 3 M LEV MC IPM U WHT RED BLK 3 1 RED WHT BLK BLU YLW ORN LDW LDV LDU CN61 6 CN724 1 21S4 1 1 2 2 1 OPTION PARTS YLW BLK BLK BLK BLK ...

Page 6: ...62 LD61 6 3 BLU CN721 2 1 1 RT65 CN643 RT62 RT61 CN641 4 1 CIRCUIT BREAKER BRN BLU BRN RED 1 2 S3 S2 S1 TB2 TB1 RT64 RT68 CN642 CN644 2 1 L61 T801 1 IC802 BLU YLW ORN 6 CN724 1 21S4 1 1 2 2 1 OPTION PARTS YLW BLK BLK BLK BLK 1 H BLK CN722 3 1 X63 X66 4 t t t t t SMOOTHING CAPACITOR DIODE MODULE FUSE T3 15AL250V DEFROST HEATER OPTION PARTS INTELLIGENT POWER DEVICE INTELLIGENT POWER MODULE REACTOR E...

Page 7: ...S 3 MS M 3 V 1 3 IC802 V U IPM W N P 3 1 HC930 T801 F801 TR821 DB65 DB61 LD66 LD70 C63 C62 C61 L61 CN932 CN644 CN642 RT68 RT64 L2 L1 TB1 TB2 S1 S2 S3 BRN 2 1 RED BRN BLU CIRCUIT BREAKER CN641 RT61 RT62 CN643 RT65 3 X63 CN721 F901 6 LD61 LD62 LD S PTC65 LD E1 BLK PTC64 X64 F701 LD63 NOTES 1 About the indoor side electric wiring refer to the indoor unit electric wiring diagram for servicing 2 Use co...

Page 8: ...ervice port Service port Muffler SUZ KA12NA SUZ KA15NA Outdoor heat exchanger Flared connection Defrost thermistor RT61 Discharge temperature thermistor RT62 Flared connection Stop valve with strainar Stop valve with service port Refrigerant flow in cooling Compressor 4 way valve Refrigerant flow in heating Refrigerant pipe ø3 8 KA12 Refrigerant pipe ø1 2 KA15 with heat insulator Refrigerant pipe ...

Page 9: ...V R V coil heating ON cooling OFF Muffler 100 Receiver Outdoor heat exchanger temperature thermistor RT68 Ambient temperature thermistor RT65 Strainer 100 Service port Service port Max Length A Max Height difference B Indoor unit Outdoor unit MAX REFRIGERANT PIPING LENGTH and MAX HEIGHT DIFFERENCE Model Refrigerant piping ft Piping size O D in Max Length A Max Height difference B Gas Liquid SUZ KA...

Page 10: ...62 4 86 8 10 11 34 12 96 SUZ KA12NA 2 lb 9 oz SUZ KA15NA Calculation X oz 1 62 5 oz ft Refrigerant piping length ft 25 Model Outdoor unit precharged Refrigerant piping length one way ft 25 30 40 50 60 70 80 90 100 SUZ KA18NA 3 lb 16 oz 0 1 08 3 24 5 40 7 56 9 72 11 88 14 04 16 20 Calculation X oz 1 08 5 oz ft Refrigerant piping length ft 25 NOTE Refrigerant piping exceeding 25 ft requires addition...

Page 11: ...KA12NA SUZ KA15NA SUZ KA18NA Power supply V phase Hz 230 1 60 Input kW 0 61 0 98 0 85 1 09 1 08 1 43 1 39 1 63 Current A 2 80 4 33 3 64 4 65 4 45 5 96 5 38 6 91 Refrigerant circuit Condensing pressure PSIG 398 448 387 386 399 389 373 397 Suction pressure PSIG 135 97 135 104 133 96 142 100 Discharge temperature F 148 170 162 165 159 182 150 172 Condensing temperature F 116 125 114 114 116 115 112 1...

Page 12: ...Z KA15NA Power supply V phase Hz 230 1 60 Input kW 0 63 0 86 0 84 1 10 1 38 1 87 Current A 3 12 4 02 3 82 4 93 5 98 8 10 Refrigerant circuit Condensing pressure PSIG 401 406 379 418 422 475 Suction pressure PSIG 147 104 139 106 128 98 Discharge temperature F 154 169 152 173 174 188 Condensing temperature F 116 117 111 118 118 128 Suction temperature F 52 34 51 36 51 31 Ref pipe length ft 25 Refrig...

Page 13: ...pped running ON OFF Compressor Outdoor fan motor R V coil ON OFF ON OFF COOL 5 seconds HEAT 5 seconds 8 3 RELATION BETWEEN MAIN SENSOR AND ACTUATOR 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 protec tion Defrost thermistor Heating...

Page 14: ... 1 Check the power supply voltage 2 Check the indoor outdoor connecting wire for miswiring 2 Take care of the following during servicing 1 Before servicing the air conditioner be sure to turn OFF the main unit first with the remote controller and turn off the breaker 2 Be sure to turn OFF the power supply before removing the front panel the cabinet the top panel and the electronic control P C boar...

Page 15: ...phase current of compressor cannot be detected nor mally Refer to 10 5 A verter 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 16...

Page 16: ...he check code by pressing the ON OFF button Since each unit has a function that stores check 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 history for each unit using the remote controller 1 Switch to self diagnosis mode Press the CHECK button H in the picture above twice within 3 seconds The display content will...

Page 17: ...w Press the FILTER button A in the picture in the previous page 3 Remote controller self diagnosis result When the remote controller is functioning correctly Check for other possible causes as there is no problem with the remote controller When the remote controller malfunctions Error display 1 NG blinks The remote controller s transmitting receiv ing circuit is defective The remote controller mus...

Page 18: ...e is cancelled Procedure 1 Press the CHECK button twice 2 Press the temperature buttons 3 Point the remote controller at the sensor on the indoor unit and press the HOUR button 4 Point the remote controller at the sensor on the indoor unit and press the ON OFF button Malfunction diagnosis method at maintenance service 10 3 4 Self diagnosis Wireless remote controller In case of trouble during opera...

Page 19: ...Number of blinks beeps in pattern indicates the check code in the following table nth 1st 2nd 3rd 1st 2nd Self check starts Start signal received Beeper sounds Refer to the following tables for details on the check codes Output pattern A Notes Beeper sounds OPERATION INDICATOR lamp flashes Check code Symptom Remark Number of times Wireless remote controller Wired remote controller Beeper sounds OP...

Page 20: ... 10 6 TEST POINT DIAGRAM AND VOLTAGE for the chart of thermistor Compressor Measure the resistance between terminals with a tester Temperature 14 to 104 F 10 to 40 C Normal Ω KA09 KA12 KA15 18 U V U W V W 1 36 to 1 93 1 52 to 2 17 0 78 to 1 11 Outdoor fan motor Measure the resistance between lead wires with a tester Temperature 14 to 104 F 10 to 40 C Color of lead wire Normal Ω KA09 12 15 KA18 RED...

Page 21: ... the COOL or HEAT mode 3 Compressor starts at rated frequency in COOL mode or 58 Hz in HEAT mode 4 Indoor fan operates at High speed 5 To cancel test run operation press the ON OFF button on remote controller Measurement point at 3 points BLK U WHT V BLK U RED W WHT V RED W NOTE 1 Output voltage varies according to power supply voltage 2 Measure the voltage by analog type tester 3 During this chec...

Page 22: ...lectrical circuit check 1 Contact of the compressor connector including CN61 2 Output voltage of inverter P C board and balance of them See 10 5 3 Direct current voltage between DB61 and on the inverter P C board 4 Voltage between outdoor terminal block S1 S2 1 Heat the compressor with a drier for about 20 minutes Do not recover refrigerant gas while heating Heating part Connect the compressor and...

Page 23: ...BLE CRITERION OF MAIN PARTS In case CN721 is disconnected or R V coil is open voltage is generated between the terminal pins of the connector although no signal is being transmitted to R V coil Check if CN721 is connected Is there 208 230 VAC between CN721 and on the inverter P C board 3 minutes after the power supply is turned ON No Yes Replace the inverter P C board Replace the 4 way valve Unit ...

Page 24: ...or fan motor normal Refer to 10 4 TROUBLE CRITERION OF MAIN PARTS Check the connection between the connector CN931 and CN932 Disconnect CN932 from the inverter P C board and turn on the power supply 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 VDC repeatedly Does the outd...

Page 25: ...ght up Does LED on the inverter P C board light up or flash Refer to 10 6 TEST POINT DIAGRAM AND VOLTAGE No Replace the inverter P C board Is there bus bar voltage 260 325 VDC between DB61 and DB61 on the inverter P C board Refer to 10 6 TEST POINT DIAGRAM AND VOLTAGE No Check the electric parts in main circuit Yes Yes No Disconnect the connector CN61 between compressor and intelligent power modul...

Page 26: ... between connector pins of CN724 on the inverter P C board 1 Pin Pin 2 Pin Pin 3 Pin Pin 4 Pin Pin Is there about 3 5 VAC between each NOTE Measure the voltage with an analog tester Properly fix the LEV coil to the expansion valve Replace the LEV coil Replace the expansion valve Is LEV coil properly fixed to the expansion valve Does the resistance of LEV coil have the characteristics Do you hear t...

Page 27: ...f the connectors CN931 CN932 of the outdoor fan motor If the connection is poor make it correct Operate the outdoor unit by starting TEST RUN Check the LED indication on the in verter P C board Does the LED flash 10 times Replace the inverter P C board Check the remedy following LED indication Refer to 10 3 HOW TO PRO CEED SELF DIAGNOSIS Yes No Yes 10 time flash No OCH467C ...

Page 28: ... of the residual voltage of smoothing capacitor Yes 3 Be sure to check this within 3 minutes after turning ON After 3 minutes LED blinks 6 times Even when the inverter P C board or the outdoor electronic control P C board is normal LED blinks 6 times after 3 minutes Is the bus bar voltage of the inverter P C board or the outdoor electronic control P C board normal Refer to 10 6 TEST POINT DIAGRAM ...

Page 29: ...h or the installation condition combination of specific conditions such as antennas or wiring Check the followings 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 indo...

Page 30: ...15NA 10 6 TEST POINT DIAGRAM AND VOLTAGE Back side of unit Fin temperature thermistor RT64 CN642 Ambient temperature thermistor RT65 CN643 Discharge temperature thermistor RT62 CN641 Defrost thermistor RT61 CN641 LEV connector CN724 Bus bar voltage DB61 DC 260 325 V Front side of unit AC 208 230 V Smoothing capacitor C62 Output to drive compressor LDU LDV LDW Fuse F701 T3 15 AL 250 V Smoothing cap...

Page 31: ...it Fin temperature thermistor RT64 CN642 Ambient temperature thermistor RT65 CN643 Discharge temperature thermistor RT62 CN641 Defrost thermistor RT61 CN641 LEV connector CN724 Bus bar voltage DB61 DC 260 325 V Front side of unit AC 208 230 V Smoothing capacitor C62 Output to drive compressor LDU LDV LDW Fuse F701 T3 15 AL 250 V Smoothing capacitor C61 Smoothing capacitor C63 Fuse F801 250 V 3 15 ...

Page 32: ...system Check Wired remote controller RF thermostat 2 Functions are available when setting the unit number to 01 Function Settings No Mode No Setting Initial setting Factory setting Filter sign 100h 1 2500h 07 107 2 No filter sign indicator 3 External static pressure 5 15 35 50Pa 0 02 0 06 0 14 0 20in WG 08 108 10 110 1 2 Extra low 3 Fan speed during the heating thermo OFF Stop 25 125 1 Set fan spe...

Page 33: ...ing Press E Specified indoor unit FAN operation Change refrigerant address or unit No 2 Switch to function setting mode Press A and B at the same time with stop the remote controller 11 1 1 Selecting functions using the wired remote controller First try to familiarize yourself with the flow of the function selection procedure In this section an example of setting the room temperature detection pos...

Page 34: ...flash the mode No and setting No and to start registration The mode No and setting No stop flashing to confirm the settings If the mode No or setting No shows and the temperature shows this seems to be a transmission error Check for noise source or interference around the transmission path To make additional settings in the FUNCTION SELECTION screen repeat the steps 3 through 8 Note After setting ...

Page 35: ...el Service panel Screws of the top panel Screw of the cabinet Screws of the top panel Hooks Screw of the service panel Screw of the conduit cover Conduit plate Conduit cover 1 Slide the sleeve and check if there is a locking lever or not 2 The terminal with this connector has the locking mechanism Slide the sleeve Pull the terminal while pushing the locking lever Hold the sleeve and pull out the t...

Page 36: ...llowing connectors Inverter P C board CN721 R V coil 3 Remove the R V coil See Photo 5 4 Removing the discharge temperature thermistor defrost thermistor outdoor heat exchanger tempera ture thermistor and ambient temperature thermistor 1 Remove the cabinet and panels Refer to procedure 1 2 Disconnect the lead wire to the reactor and the following connectors Inverter P C board CN641 Defrost thermis...

Page 37: ...et 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 PSIG 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...

Page 38: ...he 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 38 Screws of the cabinet Screws of the back panel Screw of the top panel Screws of the cabinet Screws of the cabinet Screw of the valve cover Screw of the servi...

Page 39: ...assembly See Photo 4 6 Remove the screw of the ground wire and screw of the T B support See Photo 4 7 Remove the screw of the PB fixture 8 Remove the relay panel from the PB support 9 Remove the inverter P C board from the inverter assembly Photo 3 Photo 4 Inverter assembly Photo5 3 Removing R V coil 1 Remove the cabinet and panels Refer to procedure 1 2 Disconnect the following connectors Inverte...

Page 40: ...tdoor 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 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...

Page 41: ...41 OCH467C ...

Page 42: ...ORPORATION Distributed in May 2014 No OCH467 REVISED EDITION C Distributed in Aug 2011 No OCH467 REVISED EDITION B Distributed in Jul 2011 No OCH467 REVISED EDITION A Distributed in Jan 2010 No OCH467 PDF 4 Made in Japan New publication effective May 2014 Specifications are subject to change without notice TM ...