ir-onditioners SUZ- K25, K35, K50, K60, K71V INSTLLTION MNUL FOR INSTLLER For safe and orret use, read this manual and the indoor unit installation manual thoroughly efore installing the air-onditioner unit. English
ontents 1. The following should always e oserved for safety... 2 2. Seleting the installation loation... 2 3. Installation diagram... 3 4. Drain piping for outdoor unit... 3 5. Refrigerant piping work... 4 6. Eletrial work... 6 7. Maintenane... 7 1. The following should always e oserved for safety Please provide an exlusive iruit for the air onditioner and do not onnet other eletrial applianes to it. e sure to read The following should always e oserved for safety efore installing the air onditioner. e sure to oserve the autions speified here as they inlude important items related to safety. The indiations and meanings are as follows. ould lead to death, serious injury, et. Do not install it y yourself (ustomer). Inomplete installation ould ause injury due to fire, eletri shok, the unit falling or leakage of water. onsult the dealer from whom you purhased the unit or speial installer. Install the unit seurely in a plae whih an ear the weight of the unit. When installed in an insuffiient strong plae, the unit ould fall ausing injured. Use the speified wires to onnet the indoor and outdoor units seurely and attah the wires firmly to the terminal oard onneting setions so the stress of the wires is not applied to the setions. Inomplete onneting and fixing ould ause fire. Do not use intermediate onnetion of the power ord or the extension ord and do not onnet many devies to one outlet. It ould ause a fire or an eletri shok due to defetive ontat, defetive insulation, exeeding the permissile urrent, et. hek that the refrigerant gas does not leak after installation has ompleted. aution: Perform grounding. Do not onnet the ground wire to a gas pipe, water pipe arrester or telephone ground wire. Defetive grounding ould ause an eletri shok. Do not install the unit in a plae where an inflammale gas leaks. If gas leaks and aumulates in the area surrounding the unit, it ould ause an explosion. Install a ground leakage reaker depending on the installation plae (where it is humid). If a ground leakage reaker is not installed, it ould ause an eletri shok. aution: ould lead to serious injury in partiular environments when operated inorretly. fter reading this manual, e sure to keep it together with the instrution manual in a handy plae on the ustomer s site. : Indiates a part whih must e grounded. arefully read the laels affixed to the main unit. Perform the installation seurely referring to the installation manual. Inomplete installation ould ause a personal injury due to fire, eletri shok, the unit falling or leakage of water. Perform eletrial work aording to the installation manual and e sure to use an exlusive iruit. If the apaity of the power iruit is insuffiient or there is inomplete eletrial work, it ould result in a fire or an eletri shok. ttah the eletrial part over to the indoor unit and the servie panel to the outdoor unit seurely. If the eletrial part over in the indoor unit and/or the servie panel in the outdoor unit are not attahed seurely, it ould result in a fire or an eletri shok due to dust, water, et. e sure to use the part provided or speified parts for the installation work. The use of defetive parts ould ause an injury or leakage of water due to a fire, an eletri shok, the unit falling, et. Ventilate the room if refrigerant leaks during operation. If the refrigerant omes in ontat with a flame, poisonous gases will e released. Perform the drainage/piping work seurely aording to the installation manual. If there is a defet in the drainage/piping work, water ould drop from the unit and household goods ould e wet and damaged. Fasten a flare nut with a torque wrenh as speified in this manual. When fastened too tight, a flare nut may roken after a long period and ause a leakage of refrigerant. 2. Seleting the installation loation 2.1. Outdoor unit Where it is not exposed to strong wind. Where airflow is good and dustless. Where it is not exposed to rain and diret sunshine. Where neighours are not annoyed y operation sound or hot air. Where rigid wall or support is availale to prevent the inrease of operation sound or viration. Where there is no risk of omustile gas leakage. When installing the unit at a high level, e sure to fix the unit legs. Where it is at least 3 m away from the antenna of TV set or radio. (Otherwise, images would e distured or noise would e generated.) Please install it in an area not affeted y snowfall or lowing snow. In areas with heavy snow, please install a anopy, a pedestal and/or some affle oards. Install the unit horizontally. aution: void the following plaes for installation where air onditioner troule is liale to our. Where there is too muh mahine oil. Salty environment as seaside areas. Hot-spring areas. Where sulfide gas exists. Other speial atmospheri areas. 2
3. Installation diagram SUZ-K25/K35V 3.1. Outdoor unit (Fig. 3-1) Ventilation and servie spae SUZ-K25/K35V 100 mm or more 350 mm or more asially open 100 mm or more without any ostrution in front and on oth sides of the unit. D 200 mm or more (Open two sides of left, right, or rear side.) SUZ-K50/K60/K71V 100 mm or more D 350 mm or more 500 mm or more 800 mm (mm) When the piping is to e attahed to a wall ontaining metals (tin plated) or metal netting, use a hemially treated wooden piee 20 mm or thiker etween the wall and the piping or wrap 7 to 8 turns of insulation vinyl tape around the piping. 150 mm 500 mm ir inlet Units should e installed y liensed ontrator aordingly to loal ode requirement. 344.5 mm 285 mm 2-10 mm 21 mm slot SUZ-K50/K60/K71V ir outlet 40 mm 304-325 mm Note: When operating the air onditioner in low outside temperature, e sure to follow the instrutions desried elow. Never install the outdoor unit in a plae where its air inlet/outlet side may e exposed diretly to wind. To prevent exposure to wind, install the outdoor unit with its air inlet side faing the wall. To prevent exposure to wind, it is reommended to install a affle oard on the air outlet side of the outdoor unit. 515 34 Drainage 3 holes (ø33) 66 299 ir in 40 330 51 ir in 360 ir out 500 Fig. 3-1 4. Drain piping for outdoor unit (Fig. 4-1) SUZ-K25/35V Drain soket 1 (For V type only) Fig. 4-1 Drain hose 3 4.1. essories hek the following parts efore installation. <Outdoor unit> 1 Drain soket (for V type only) 1 3 Drain ap ø33 (for SUZ-K50/K60/K71 only) 2 Provide drain piping efore indoor and outdoor piping onnetion. (It will e hard to install drain soket 1 if indoor and outdoor piping onnetion is onduted prior to drain piping as outdoor unit eomes immovale.) onnet the drain hose 3 (otainale at a store, inside diameter: 15 mm) as shown in the figure for drainage. Make sure to provide drain piping with a downhill grade for easy drain flow. Note: Do not use the drain soket 1 in the old region. Drain may freeze and it makes the fan stop. 3
5. Refrigerant piping work () () Indoor unit Outdoor unit 5.1. Refrigerant pipe (Fig. 5-1) s hek that the differene etween the heights of the indoor and outdoor units, the length of refrigerant pipe, and the numer of ends in the pipe are within the limits shown elow. Models () Pipe length () Height () Numer of (one way) differene ends (one way) SUZ-K25/K35 max. 20 m max. 12 m max. of 10 SUZ-K50/K60/K71 max. 30 m max. 30 m *(15 m) max. of 10 *( ): MFZ () Fig. 5-1 Height differene limitations are inding regardless of whih unit, indoor or outdoor, is positioned higher. Refrigerant adjustment... If pipe length exeeds 7 m, additional refrigerant (R410) harge is required. (The outdoor unit is harged with refrigerant for pipe length up to 7 m.) Pipe length Refrigerant to e added Up to 7 m No additional harge is required. dditional harge is required. Exeeding 7 m (Refer to the tale elow.) SUZ-K25/K35 type 30 g (refrigerant piping length (m) -5) SUZ-K50/K60 type 20 g (refrigerant piping length (m) -7) SUZ-K71 type 55 g (refrigerant piping length (m) -7) ø9.52 ø12.7 ø15.88 ø6.35 ø9.52 Fig. 5-2 Indoor unit Outdoor unit Piping preparation Refrigerant pipes of 3, 5, 7, 10 and 15 m are availale as optional items. (1) Tale elow shows the speifiations of pipes ommerially availale. Model SUZ-K25 SUZ-K35 SUZ-K50 SUZ-K60 SUZ-K71 Pipe Outside diameter mm inh 6.35 1/4 9.52 3/8 6.35 1/4 9.52 3/8 6.35 1/4 12.7 1/2 6.35 1/4 15.88 5/8 9.52 3/8 15.88 5/8 Min. wall thikness 0. 0. 0. 0. 0. 0. 0. 0. 0. 1.0 mm Insulation thikness Insulation material Heat resisting foam plasti 0.045 speifi gravity (2) Ensure that the 2 refrigerant pipes are well insulated to prevent ondensation. (3) Refrigerant pipe ending radius must e 100 mm or more. aution: Using areful insulation of speified thikness. Exessive thikness prevents storage ehind the indoor unit and smaller thikness auses dew drippage. a a 90 d d e Fig. 5-3 Fig. 5-4 f a opper tues Good No good d Tilted e Uneven f urred a urr opper tue/pipe Spare reamer d Pipe utter 5.2. Flaring work Main ause of gas leakage is defet in flaring work. arry out orret flaring work in the following proedure. 5.2.1. Pipe utting (Fig. 5-3) Using a pipe utter ut the opper tue orretly. 5.2.2. urrs removal (Fig. 5-4) ompletely remove all urrs from the ut ross setion of pipe/tue. Put the end of the opper tue/pipe to downward diretion as you remove urrs in order to avoid urrs drop in the tuing. 5.2.3. Putting nut on (Fig. 5-5) Remove flare nuts attahed to indoor and outdoor unit, then put them on pipe/tue having ompleted urr removal. (not possile to put them on after flaring work) a a Fig. 5-5 e d a Flare nut opper tue a Flaring tool Die opper tue d Flare nut e Yoke 5.2.4. Flaring work (Fig. 5-6) arry out flaring work using flaring tool as shown at the right. Dimension Pipe diameter (mm) (mm) When the tool for R410 is used +0-0.4 (mm) luth type 6.35 0-0.5 9.1 9.52 0-0.5 13.2 12.7 0-0.5 16.6 15.88 0-0.5 19.7 Firmly hold opper tue in a die in the dimension shown in the tale at aove. Fig. 5-6 4
5. Refrigerant piping work a d e f g h 5.2.5. hek (Fig. 5-7) ompare the flared work with a figure in right side hand. If flare is noted to e defetive, ut off the flared setion and do flaring work again. i Fig. 5-7 a Smooth all around Inside is shining without any srathes Even length all around d Too muh e Tilted f Srath on flared plane g raked h Uneven i ad examples pply a thin oat of refrigeration oil on the seat surfae of pipe. (Fig. 5-8) For onnetion first align the enter, then tighten the first 3 to 4 turns of flare nut. Use tightening torque tale elow as a guideline for indoor unit side union joint setion, and tighten using two wrenhes. Exessive tightening damages the flare setion. opper pipe O.D. Flare nut O.D. Tightening torque (mm) (mm) (N m) ø6.35 17 14-18 ø9.52 22 34-42 ø12.7 26 49-61 ø15.88 29 68-82 Fig. 5-8 e areful of flying flare nut! (Internally pressurized) Remove the flare nut as follows: 1. Loosen the nut until you hear a hissing noise. 2. Do not remove the nut until the gas has een ompletely released (i.e., hissing noise stops). 3. hek that the gas has een ompletely released, and then remove the nut. 5.5. Purging proedures leak test PURGING PROEDURES onnet the refrigerant pipes (oth the liquid and gas pipes) etween the indoor and the outdoor units. Remove the servie port ap of the stop valve on the side of the outdoor unit gas pipe. (The stop valve will not work in its initial state fresh out of the fatory (totally losed with ap on).) onnet the gage manifold valve and the vauum pump to the servie port of the stop valve on the gas pipe side of the outdoor unit. Run the vauum pump. (Vauumize for more than 15 minutes.) hek the vauum with the gage manifold valve, then lose the gage manifold valve, and stop the vauum pump. Leave it as is for one or two minutes. Make sure the pointer of the gage manifold valve remains in the same position. onfirm that the pressure gage show -0.101 MPa (-760 mmhg) Remove the gage manifold valve quikly from the servie port of the stop valve. fter refrigerant pipes are onneted and evauated, fully open all stop valves on gas and liquid pipe sides. Operating without fully opening lowers the performane and auses troule. Pipe length : 7 m maximum No gas harge is needed. Pipe length exeeding 7 m harge the presried amount of gas. Tighten the ap to the servie port to otain the initial status. Retighten the ap Leak test *lose *Open Hexagonal wrenh *4 to 5 turns Stop valve -0.101 MPa ompound pressure Stop valve (-760 mmhg) gauge (for R410) Pressure gauge (for R410) Servie port Handle Low Stop valve harge hose (for R410) Window Vauum pump dapter for preventing the ak flow Gauge manifold valve (for R410) Handle High harge hose (for R410) (or the vauum pump with the funtion to prevent the ak flow) 5
6. Eletrial work S1 S2 S3 6.1. Outdoor unit (Fig. 6-1, Fig. 6-2, Fig. 6-3, Fig. 6-4) 1 Remove the servie panel. 2 Wire the ales referring to the Fig. 6-1, Fig. 6-2, Fig. 6-3 and the Fig. 6-4. 1 2 L N S1 S2 S3 D Indoor unit Outdoor unit Wired main swith/fuse D Grounding For Power supply Fig. 6-1 Indoor terminal lok L N Outdoor terminal lok E Fig. 6-2 Indoor/outdoor unit onneting wire 3-ore 1.5 mm 2 or more D Earth wire (green/yellow) Power supply ord SUZ-K25/K35: 1.5 mm 2 or more SUZ-K50/K60/K71: 2.5 mm 2 or more Perform wiring as shown in the diagram to the lower left. (Proure the ale loally) (Fig. 6-2) Make sure to use ales of the orret polarity only. onneting ale Indoor terminal lok Outdoor terminal lok D lways install an earth wire longer than other ales. E Power supply ord aution: Use are not to make miswiring. Firmly tighten the terminal srews to prevent then from loosening. fter tightening, pull the wires lightly to onfirm that they do not move. onnet ale from the indoor unit orretly on the terminal-lok. Use the same terminal lok and polarity as is used with the indoor unit. For afterare maintenane, give extra length to onneting ale. Servie panel oth end of onneting ale (extension wire) are peeled off. When too long, or onneted y utting off the middle, peel off power supply ale to the size given in the figure. e areful not to ontat onneting ale with piping. e sure to fix the indoor/outdoor unit onneting wire using this ord lamp. Remove one fixing srew to open the servie panel. aution: Use are not to make miswiring. (Fig. 6-4) Firmly tighten the terminal srews to prevent them from loosening. fter tightening, pull the wires lightly to onfirm that they do not move. Fig. 6-3 Fig. 6-4 Loosen terminal srew Terminal lok Lead wire e sure to attah the servie panel of the outdoor unit seurely. If it is not attahed orretly, it ould result in a fire or an eletri shok due to dust, water, et. Tighten terminal srews seurely. Wiring should e done so that the power lines are not sujet to tension. Otherwise, heat may e generated or fire may our. 6
6. Eletrial work 6.2. Field eletrial wiring Outdoor unit model Outdoor unit power supply Outdoor unit input apaity *1 Main swith (reaker) Outdoor unit power supply Outdoor unit power supply earth Wiring Wire No. size (mm 2 ) iruit rating Indoor unit-outdoor unit Indoor unit-outdoor unit earth Outdoor unit L-N *2 Indoor unit-outdoor unit S1-S2 *2 Indoor unit-outdoor unit S2-S3 *2 SUZ-K25/K35 SUZ-K50/K60/K71 ~/N (single), 50 Hz, ~/N (single), 50 Hz, 230 V 230 V 10 20 2 Min. 1.5 2 Min. 2.5 1 Min. 1.5 1 Min. 2.5 3 1.5 (Polar) 3 1.5 (Polar) 1 Min. 1.5 1 Min. 1.5 230 V 230 V 230 V 230 V D 12 V ~ D 24 V D 12 V ~ D 24 V *1. reaker with at least 3 mm ontat separation in eah poles shall e provided. Use non-fuse reaker (NF) or earth leakage reaker (NV). *2. The figures are NOT always against the ground. S3 terminal has D 24 V against S2 terminal. However etween S3 and S1, these terminals are NOT eletrially insulated y the transformer or other devie. Notes: 1. Wiring size must omply with the appliale loal and national ode. 2. Power supply ords and Indoor/Outdoor unit onneting ords shall not e lighter than polyhloroprene sheathed flexile ord. (Design 60245 IE 57) 3. Install an earth longer than other ales. 230V Single phase Isolator 3 poles isolator S1 S1 Outdoor Unit S2 S2 Indoor Unit S3 S3 There is high voltage potential on the S3 terminal aused y eletrial iruit design that has no eletrial insulation etween power line and ommuniation signal line. Therefore, please turn off the main power supply when serviing. nd do not touh the S1, S2, S3 terminals when the power is energized. If isolator should e used etween indoor unit and outdoor unit, please use 3-poles type. 7. Maintenane G K H I J Indoor unit Union Liquid pipe D Gas pipe E Stop valve F Outdoor unit G Refrigerant gas ylinder operating valve L D M E F H Refrigerant gas ylinder for R410 with siphon I Refrigerant (liquid) J Eletroni sale for refrigerant harging K harge hose (for R410) L Gauge manifold valve (for R410) M Servie port 7.1. Gas harge (Fig. 7-1) 1. onnet gas ylinder to the servie port of stop valve (3-way). 2. Exeute air purge of the pipe (or hose) oming from refrigerant gas ylinder. 3. Replenish speified amount of refrigerant, while running the air onditioner for ooling. Note: In ase of adding refrigerant, omply with the quantity speified for the refrigerating yle. aution: Do not disharge the refrigerant into the atmosphere. Take are not to disharge refrigerant into the atmosphere during installation, reinstallation, or repairs to the refrigerant iruit. For additional harging, harge the refrigerant from liquid phase of the gas ylinder. If the refrigerant is harged from the gas phase, omposition hange may our in the refrigerant inside the ylinder and the outdoor unit. In this ase, aility of the refrigerating yle dereases or normal operation an e impossile. However, harging the liquid refrigerant all at one may ause the ompressor to e loked. Thus, harge the refrigerant slowly. To maintain the high pressure of the gas ylinder, warm the gas ylinder with warm water (under 40 ) during old season. ut never use naked fire or steam. Fig. 7-1 7
Please e sure to put the ontat address/telephone numer on this manual efore handing it to the ustomer. HED OFFIE: TOKYO LDG., 2-7-3, MRUNOUHI, HIYOD-KU, TOKYO 100-8310, JPN G79U686K01 Printed in Thailand