Mitsubishi Electric KA50 Installation manual

Air-Conditioners
SUZ- KA25, KA35, KA50, KA60, KA71VA
INSTALLATION MANUAL
FOR INSTALLER
For safe and correct use, read this manual and the indoor unit installation manual thoroughly before installing
the air-conditioner unit.
English
Contents
1.
2.
3.
4.
5.
6.
7.
The following should always be observed for safety ................................
Selecting the installation location .............................................................
Installation diagram ..................................................................................
Drain piping for outdoor unit .....................................................................
Refrigerant piping work ............................................................................
Electrical work ..........................................................................................
Maintenance ............................................................................................
2
2
3
3
4
6
7
1. The following should always be observed for safety
•
Please provide an exclusive circuit for the air conditioner and do not connect
other electrical appliances to it.
• Be sure to read “The following should always be observed for safety” before
installing the air conditioner.
• Be sure to observe the cautions specified here as they include important
items related to safety.
• The indications and meanings are as follows.
Warning:
Could lead to death, serious injury, etc.
Warning:
• Do not install it by yourself (customer).
Incomplete installation could cause injury due to fire, electric shock, the unit
falling or leakage of water. Consult the dealer from whom you purchased the
unit or special installer.
• Install the unit securely in a place which can bear the weight of the unit.
When installed in an insufficient strong place, the unit could fall causing injured.
• Use the specified wires to connect the indoor and outdoor units securely and
attach the wires firmly to the terminal board connecting sections so the stress
of the wires is not applied to the sections.
Incomplete connecting and fixing could cause fire.
• Do not use intermediate connection of the power cord or the extension cord
and do not connect many devices to one AC outlet.
It could cause a fire or an electric shock due to defective contact, defective
insulation, exceeding the permissible current, etc.
• Check that the refrigerant gas does not leak after installation has completed.
Caution:
• Perform grounding.
Do not connect the ground wire to a gas pipe, water pipe arrester or telephone
ground wire. Defective grounding could cause an electric shock.
• Do not install the unit in a place where an inflammable gas leaks.
If gas leaks and accumulates in the area surrounding the unit, it could cause
an explosion.
• Install a ground leakage breaker depending on the installation place (where it
is humid).
If a ground leakage breaker is not installed, it could cause an electric shock.
Caution:
Could lead to serious injury in particular environments when operated incorrectly.
• After reading this manual, be sure to keep it together with the instruction
manual in a handy place on the customer’s site.
: Indicates a part which must be grounded.
Warning:
Carefully read the labels affixed to the main unit.
• Perform the installation securely referring to the installation manual.
Incomplete installation could cause a personal injury due to fire, electric shock,
the unit falling or leakage of water.
• Perform electrical work according to the installation manual and be sure to
use an exclusive circuit.
If the capacity of the power circuit is insufficient or there is incomplete electrical work, it could result in a fire or an electric shock.
• Attach the electrical part cover to the indoor unit and the service panel to the
outdoor unit securely.
If the electrical part cover in the indoor unit and/or the service panel in the
outdoor unit are not attached securely, it could result in a fire or an electric
shock due to dust, water, etc.
• Be sure to use the part provided or specified parts for the installation work.
The use of defective parts could cause an injury or leakage of water due to a
fire, an electric shock, the unit falling, etc.
• Ventilate the room if refrigerant leaks during operation.
If the refrigerant comes in contact with a flame, poisonous gases will be released.
• Perform the drainage/piping work securely according to the installation
manual.
If there is a defect in the drainage/piping work, water could drop from the unit
and household goods could be wet and damaged.
• Fasten a flare nut with a torque wrench as specified in this manual.
When fastened too tight, a flare nut may broken after a long period and cause
a leakage of refrigerant.
2. Selecting the installation location
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 direct sunshine.
Where neighbours are not annoyed by operation sound or hot air.
Where rigid wall or support is available to prevent the increase of operation sound
or vibration.
Where there is no risk of combustible gas leakage.
When installing the unit at a high level, be 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 be disturbed or noise would be generated.)
Please install it in an area not affected by snowfall or blowing snow. In areas with
heavy snow, please install a canopy, a pedestal and/or some baffle boards.
2
• Install the unit horizontally.
Caution:
Avoid the following places for installation where air conditioner trouble is liable to occur.
• Where there is too much machine oil.
• Salty environment as seaside areas.
• Hot-spring areas.
• Where sulfide gas exists.
• Other special atmospheric areas.
3. Installation diagram
■ SUZ-KA25/KA35VA
3.1. Outdoor unit (Fig. 3-1)
Ventilation and service space
C
■ SUZ-KA25/KA35VA
A
B
C
D
A
A
100 mm or more
350 mm or more
Basically open 100 mm or more without any obstruction in front and on both sides of the unit.
200 mm or more (Open two sides of left, right, or rear side.)
■ SUZ-KA50/KA60/KA71VA
A 100 mm or more
B 350 mm or more
C 500 mm or more
B
D
(mm)
800 mm
150
mm
500 mm
Units should be installed by licensed contractor accordingly to local code requirement.
285 mm
304 - 325 mm
Air inlet
344.5 mm
When the piping is to be attached to a wall containing metals (tin plated) or metal
netting, use a chemically treated wooden piece 20 mm or thicker between the wall
and the piping or wrap 7 to 8 turns of insulation vinyl tape around the piping.
Air outlet
Note:
When operating the air conditioner in low outside temperature, be sure to follow the instructions described below.
• Never install the outdoor unit in a place where its air inlet/outlet side may be exposed directly to wind.
• To prevent exposure to wind, install the outdoor unit with its air inlet side facing the
wall.
• To prevent exposure to wind, it is recommended to install a baffle board on the air
outlet side of the outdoor unit.
40 mm
2-10 mm × 21 mm slot
■ SUZ-KA50/KA60/KA71VA
C
A
A
C
34
B
515
Drainage 3 holes
(ø33)
299
40
Air in
Air in
360
330
51
66
Air out
500
Fig. 3-1
4. Drain piping for outdoor unit (Fig. 4-1)
■ SUZ-KA25/35VA
4.1. Accessories
Check the following parts before installation.
<Outdoor unit>
1
3
Drain hose 3
Drain socket 1
(For VA type only)
Fig. 4-1
Drain socket (for VA type only)
Drain cap ø33 (for SUZ-KA50/KA60/KA71 only)
1
2
• Provide drain piping before indoor and outdoor piping connection. (It will be hard to
install drain socket 1 if indoor and outdoor piping connection is conducted prior to
drain piping as outdoor unit becomes immovable.)
• Connect the drain hose 3 (obtainable 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 socket 1 in the cold region. Drain may freeze and it makes
the fan stop.
3
5. Refrigerant piping work
5.1. Refrigerant pipe (Fig. 5-1)
s Check that the difference between the heights of the indoor and outdoor
units, the length of refrigerant pipe, and the number of bends in the pipe are
within the limits shown below.
(A)
A
A Indoor unit
B Outdoor unit
Models
(B)
SUZ-KA25/KA35
SUZ-KA50/KA60/KA71
B
(A) Pipe length
(one way)
max. 20 m
max. 30 m
(B) Height
difference
max. 12 m
max. 30 m *(15 m)
*(
): MFZ
(C) Number of
bends (one way)
max. of 10
max. of 10
• Height difference limitations are binding regardless of which unit, indoor or outdoor,
is positioned higher.
(C)
• Refrigerant adjustment ... If pipe length exceeds 7 m, additional refrigerant (R410A)
charge is required.
(The outdoor unit is charged with refrigerant for pipe length up to 7 m.)
Fig. 5-1
Up to 7 m
Pipe length
Exceeding 7 m
No additional charge is required.
Additional charge is required.
(Refer to the table below.)
SUZ-KA25/KA35 type 30 g × (refrigerant piping length (m) -5)
Refrigerant to be
SUZ-KA50/KA60 type 20 g × (refrigerant piping length (m) -7)
added
SUZ-KA71 type 55 g × (refrigerant piping length (m) -7)
A Indoor unit
B Outdoor unit
ø6.35
ø9.52
A
Piping preparation
• Refrigerant pipes of 3, 5, 7, 10 and 15 m are available as optional items.
(1) Table below shows the specifications of pipes commercially available.
ø9.52
ø12.7
ø15.88
B
SUZ-KA25
Fig. 5-2
SUZ-KA35
SUZ-KA50
SUZ-KA60
SUZ-KA71
Outside diameter
mm
inch
Pipe
Model
For liquid
For gas
For liquid
For gas
For liquid
For gas
For liquid
For gas
For liquid
For gas
6.35
9.52
6.35
9.52
6.35
12.7
6.35
15.88
9.52
15.88
1/4
3/8
1/4
3/8
1/4
1/2
1/4
5/8
3/8
5/8
Min. wall
thickness
Insulation
thickness
Insulation
material
0.8 mm
0.8 mm
0.8 mm
0.8 mm
0.8 mm
0.8 mm
0.8 mm
0.8 mm
0.8 mm
1.0 mm
8 mm
8 mm
8 mm
8 mm
8 mm
8 mm
8 mm
8 mm
8 mm
8 mm
Heat resisting
foam plastic
0.045 specific
gravity
(2) Ensure that the 2 refrigerant pipes are well insulated to prevent condensation.
(3) Refrigerant pipe bending radius must be 100 mm or more.
Caution:
Using careful insulation of specified thickness. Excessive thickness prevents
storage behind the indoor unit and smaller thickness causes dew drippage.
b
a
c
d
90°
e
f
a
b
c
d
e
f
Copper tubes
Good
No good
Tilted
Uneven
Burred
Fig. 5-3
a
b
c
d
c
d
Burr
Copper tube/pipe
Spare reamer
Pipe cutter
Fig. 5-4
a Flare nut
b Copper tube
Fig. 5-5
A
e
b
d
c
Fig. 5-6
4
• Using a pipe cutter cut the copper tube correctly.
• Completely remove all burrs from the cut cross section of pipe/tube.
• Put the end of the copper tube/pipe to downward direction as you remove burrs in
order to avoid burrs drop in the tubing.
5.2.3. Putting nut on (Fig. 5-5)
• Remove flare nuts attached to indoor and outdoor unit, then put them on pipe/tube
having completed burr removal.
(not possible to put them on after flaring work)
• Carry out flaring work using flaring tool as shown at the right.
Pipe diameter
(mm)
b
b
c
5.2.1. Pipe cutting (Fig. 5-3)
5.2.4. Flaring work (Fig. 5-6)
a
a
• Main cause of gas leakage is defect in flaring work.
Carry out correct flaring work in the following procedure.
5.2.2. Burrs removal (Fig. 5-4)
b
a
5.2. Flaring work
a
b
c
d
e
Flaring tool
Die
Copper tube
Flare nut
Yoke
6.35
9.52
12.7
15.88
Dimension
A (mm)
When the tool for R410A is used
Clutch type
0 - 0.5
0 - 0.5
0 - 0.5
0 - 0.5
+0
B -0.4 (mm)
9.1
13.2
16.6
19.7
Firmly hold copper tube in a die in the dimension shown in the table at above.
5. Refrigerant piping work
a B
b
5.2.5. Check (Fig. 5-7)
d
e
f
g
h
c
i
Fig. 5-7
• Compare the flared work with a figure in right side hand.
• If flare is noted to be defective, cut off the flared section and do flaring work again.
a
b
c
d
e
Smooth all around
Inside is shining without any scratches
Even length all around
Too much
Tilted
f
g
h
i
Scratch on flared plane
Cracked
Uneven
Bad examples
• Apply a thin coat of refrigeration oil on the seat surface of pipe. (Fig. 5-8)
• For connection first align the center, then tighten the first 3 to 4 turns of flare nut.
• Use tightening torque table below as a guideline for indoor unit side union joint section,
and tighten using two wrenches. Excessive tightening damages the flare section.
Copper pipe O.D.
(mm)
ø6.35
ø9.52
ø12.7
ø15.88
Fig. 5-8
Flare nut O.D.
(mm)
17
22
26
29
Tightening torque
(N·m)
14 - 18
34 - 42
49 - 61
68 - 82
Warning:
Be careful 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 been completely released (i.e., hissing noise stops).
3. Check that the gas has been completely released, and then remove the nut.
5.5. Purging procedures leak test
PURGING PROCEDURES
Connect the refrigerant pipes (both the liquid and gas pipes) between the indoor
and the outdoor units.
Remove the service port cap 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 factory (totally closed
with cap on).)
Connect the gage manifold valve and the vacuum pump to the service port of the
stop valve on the gas pipe side of the outdoor unit.
Remove the gage manifold valve quickly from the service port of the stop valve.
After refrigerant pipes are connected and evacuated, fully open all stop valves on
gas and liquid pipe sides.
Operating without fully opening lowers the performance and causes trouble.
Pipe length :
7 m maximum
No gas charge is needed.
Pipe length exceeding 7 m
Charge the prescribed
amount of gas.
Run the vacuum pump. (Vacuumize for more than 15 minutes.)
Tighten the cap to the service port to obtain the initial status.
Check the vacuum with the gage manifold valve, then close the gage manifold valve,
and stop the vacuum pump.
Leave it as is for one or two minutes. Make sure the pointer of the gage manifold
valve remains in the same position. Confirm that the pressure gage show -0.101
MPa (-760 mmHg)
*Close
*Open
Hexagonal wrench
*4 to 5 turns
Stop valve
Retighten the cap
Leak test
-0.101 MPa Compound pressure
Stop valve (-760 mmHg) gauge (for R410A)
Pressure gauge
(for R410A)
Gauge manifold
valve (for R410A)
Handle High
Handle
Low
Charge hose
Stop
(for R410A)
valve
Vacuum
(or the vacuum
Service port
pump
pump with the
Window
function to
Adapter for
prevent the back
Charge hose preventing
flow)
(for R410A)
the back flow
5
6. Electrical work
6.1. Outdoor unit (Fig. 6-1, Fig. 6-2, Fig. 6-3, Fig. 6-4)
A
S1
S2
S3
1 Remove the service panel.
2 Wire the cables referring to the Fig. 6-1, Fig. 6-2, Fig. 6-3 and the Fig. 6-4.
12
B
L N
S1 S2 S3
D
A
B
C
D
C
Indoor unit
Outdoor unit
Wired main switch/fuse
Grounding
For Power supply
Fig. 6-1
Indoor terminal block
B
Earth wire (green/yellow)
A
Indoor/outdoor unit
connecting wire
3-core 1.5 mm2 or more
D
C
L N
C
Outdoor terminal block
E
Power supply cord SUZ-KA25/KA35: 1.5 mm2 or more
SUZ-KA50/KA60/KA71: 2.5 mm2 or more
• Perform wiring as shown in the diagram to the lower left. (Procure the cable locally)
(Fig. 6-2)
Make sure to use cables of the correct polarity only.
A
B
C
D
E
Connecting cable
Indoor terminal block
Outdoor terminal block
Always install an earth wire longer than other cables.
Power supply cord
Caution:
• Use care not to make miswiring.
• Firmly tighten the terminal screws to prevent then from loosening.
• After tightening, pull the wires lightly to confirm that they do not move.
Fig. 6-2
• Connect cable from the indoor unit correctly on the terminal-block.
• Use the same terminal block and polarity as is used with the indoor unit.
• For aftercare maintenance, give extra length to connecting cable.
Service panel
Remove one fixing
screw to open the
service panel.
Be sure to fix the
indoor/outdoor unit
connecting wire using
this cord clamp.
A
B
Fig. 6-4
6
Caution:
• Use care not to make miswiring. (Fig. 6-4)
• Firmly tighten the terminal screws to prevent them from loosening.
• After tightening, pull the wires lightly to confirm that they do not move.
Warning:
• Be sure to attach the service panel of the outdoor unit securely. If it is not
attached correctly, it could result in a fire or an electric shock due to dust,
water, etc.
• Tighten terminal screws securely.
• Wiring should be done so that the power lines are not subject to tension.
Otherwise, heat may be generated or fire may occur.
Fig. 6-3
C
• Both end of connecting cable (extension wire) are peeled off. When too long,
or connected by cutting off the middle, peel off power supply cable to the size
given in the figure.
• Be careful not to contact connecting cable with piping.
A Loosen terminal screw
B Terminal block
C Lead wire
6. Electrical work
6.2. Field electrical wiring
Outdoor unit model
Outdoor unit power supply
SUZ-KA25/KA35
~/N (single), 50 Hz,
230 V
*1
Wiring
Circuit
Wire No. ×
rating
size (mm2)
Outdoor unit input capacity
Main switch (Breaker)
Outdoor unit power supply
Outdoor unit power supply earth
Indoor unit-Outdoor unit
Indoor unit-Outdoor unit earth
Outdoor unit L-N
Indoor unit-Outdoor unit S1-S2
Indoor unit-Outdoor unit S2-S3
*2
*2
*2
SUZ-KA50/KA60/KA71
~/N (single), 50 Hz,
230 V
10 A
20 A
2 × Min. 1.5
1 × Min. 1.5
3 × 1.5 (Polar)
1 × Min. 1.5
AC 230 V
AC 230 V
DC 12 V ~ DC 24 V
2 × Min. 2.5
1 × Min. 2.5
3 × 1.5 (Polar)
1 × Min. 1.5
AC 230 V
AC 230 V
DC 12 V ~ DC 24 V
*1. A breaker with at least 3 mm contact separation in each poles shall be provided. Use non-fuse breaker (NF) or earth leakage breaker (NV).
*2. The figures are NOT always against the ground.
S3 terminal has DC 24 V against S2 terminal. However between S3 and S1, these terminals are NOT electrically insulated by the transformer or other device.
Notes: 1. Wiring size must comply with the applicable local and national code.
2. Power supply cords and Indoor/Outdoor unit connecting cords shall not be lighter than polychloroprene sheathed flexible cord. (Design 60245 IEC 57)
3. Install an earth longer than other cables.
230V
Single phase
Isolator
Outdoor
Unit
3 poles isolator
S1
S1
S2
S2
S3
S3
Indoor
Unit
Warning:
There is high voltage potential on the S3 terminal caused by electrical circuit design that has no electrical insulation between power line and communication
signal line. Therefore, please turn off the main power supply when servicing. And do not touch the S1, S2, S3 terminals when the power is energized. If isolator
should be used between indoor unit and outdoor unit, please use 3-poles type.
7. Maintenance
7.1.
B
E
A
C
D
F
M
G
L
K
H
I
J
A
B
C
D
E
F
G
Indoor unit
Union
Liquid pipe
Gas pipe
Stop valve
Outdoor unit
Refrigerant gas cylinder operating valve
H Refrigerant gas cylinder for R410A with
siphon
I Refrigerant (liquid)
J Electronic scale for refrigerant charging
K Charge hose (for R410A)
L Gauge manifold valve (for R410A)
M Service port
Gas charge (Fig. 7-1)
1. Connect gas cylinder to the service port of stop valve (3-way).
2. Execute air purge of the pipe (or hose) coming from refrigerant gas cylinder.
3. Replenish specified amount of refrigerant, while running the air conditioner
for cooling.
Note:
In case of adding refrigerant, comply with the quantity specified for the refrigerating cycle.
Caution:
• 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.
• 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,
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.
To maintain the high pressure of the gas cylinder, warm the gas cylinder with warm
water (under 40°C) during cold season. But never use naked fire or steam.
Fig. 7-1
7
Please be sure to put the contact address/telephone number on
this manual before handing it to the customer.
HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
BG79U686K01
Printed in Thailand