Fujitsu ARA12LATN Service Instruction page 124

SPLIT TYPE ROOM AIR CONDITIONER
INSTALLATION INSTRUCTION
SHEET
(PART NO. 9377863010)
For authorized service personnel only.
This installation instruction sheet describes how to install the outdoor unit only. To install the indoor unit, refer to the installation instruction sheet included with
the indoor unit.
This mark indicates procedures which, if improperly performed, are most likely to result in the death of or
DANGER
serious injury to the user or service personnel.
This mark indicates procedures which, if improperly performed, might lead to the death or serious injury of
WARNING
the user.
This mark indicates procedures which, if improperly performed, might possibly result in personal harm to
CAUTION
the user, or damage to property.
This air conditioner uses new refrigerant HFC (R410A).
The basic installation work procedures are the same as conventional refrigerant models.
However, pay careful attention to the following points:
1 Since the working pressure is 1.6 times higher than that of conventional refrigerant models, some of the piping and
installation and service tools are special. (See the table below.)
Especially, when replacing a conventional refrigerant model with a new refrigerant R410A model, always replace the
conventional piping and flare nuts with the R410A piping and flare nuts.
2 Models that use refrigerant R410A have a different charging port thread diameter to prevent erroneous charging with
conventional refrigerant and for safety. Therefore, check beforehand. [The charging port thread diameter for R410A is
1/2 UNF 20 threads per inch.]
3 Be more careful that foreign matter (oil, water, etc.) does not enter the piping than with refrigerant models. Also, when
storing the piping, securely seal the openings by pinching, taping, etc.
4 When charging the refrigerant, take into account the slight change in the composition of the gas and liquid phases, and
always charge from the liquid phase side whose composition is stable.
Special tools for R410A
Tool name Contents of change
Pressure is high and cannot be measured with a conventional gauge. To prevent erroneous mixing of other
refrigerants, the diameter of each port has been changed.
Gauge manifold
It is recommended the gauge with seals –0.1 to 5.3 MPa (–76 cmHg to 53 kgf/cm 2 ) for high pressure. –0.1 to
3.8 MPa (–76 cmHg to 38 kgf/cm 2 ) for low pressure.
Charge hose To increase pressure resistance, the hose material and base size were changed.
Vacuum pump A conventional vacuum pump can be used by installing a vacuum pump adapter.
Gas leakage detector Special gas leakage detector for HFC refrigerant R410A.
Copper pipes Thicknesses of Annealed Copper Pipes (R410A)
It is necessary to use seamless copper pipes and it is desirable that the amount of
Pipe outside diameter
residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed,
6.35 mm (1/4 in.)
deformed or discolored portion (especially on the interior surface). Otherwise,
9.52 mm (3/8 in.)
the expansion valve or capillary tube may become blocked with contaminants.
As an air conditioner using R410A incurs pressure higher than when using
12.70 mm (1/2 in.)
conventional refrigerant, it is necessary to choose adequate materials.
15.88 mm (5/8 in.)
Thicknesses of copper pipes used with R410A are as shown in the table. Never
use copper pipes thinner than that in the table even when it is available on 19.05 mm (3/4 in.)
the market.
DANGER
Never touch electrical components immediately after the power supply has been turned off. Electrical shock may occur. After
turning off the power, always wait 5 minutes or more before touching electrical components.
WARNING
1 For the room air conditioner to operate satisfactorily, install it as outlined in this installation instruction sheet.
2 Connect the indoor unit and outdoor unit with the room air conditioner piping and cords available standards parts. This
installation instruction sheet describes the correct connections using the installation set available from our standard
parts.
3 Installation work must be performed in accordance with national wiring standards by authorized personnel only.
4 Also, do not use an extension cord.
5 Do not turn on the power until all installation work is complete.
6 Do not purge the air with refrigerants but use a vacuum pump to vacuum the installation.
7 There is not extra refrigerant in the outdoor unit for air purging.
8
Use a vacuum pump for R410A exclusively.
9 Using the same vacuum pump for different refrigerants may damage the vacuum pump or the unit.
0 Use a clean gauge manifold and charging hose for R410A exclusively.
A If refrigerant leaks while work is being carried out, ventilate the area. If the refrigerant comes in contact with a flame, it
produces a toxic gas.
• • • • • Be careful not to scratch the room air conditioner when handling it.
• • • • • After installation, explain correct operation to the customer, using the operating manual.
• • • • • Let the customer keep this installation instruction sheet because it is used when the room air conditioner is serviced or moved.
STANDARD PARTS
The following installation parts are furnished.
Use them as required.
Name and Shape Q'ty Application
Drain pipe For outdoor unit drain
piping work
1
9377863010_IM.p65 1
1. LIMITATION OF REFRIGERANT PIPING LENGTH INSTALLATION PROCEDURE
CAUTION
1
The total maximum pipe lengths and height difference of
this product are shown in the table.
If the units are further apart than this, correct operation
cannot be guaranteed.
1. OUTDOOR UNIT PROCESSING
Maximum height
Pipe length (1) Outdoor unit to be fasten with bolts at the four places indicated by the
Model Type (between indoor
arrows without fail.
and outdoor)
MAX. MIN.
18,000 BTU/h class 25 m 15 m
5 m
24,000 BTU/h class 30 m 20 m
2. SELECTING PIPE SIZES
The diameters of the connection pipes differ according to the capacity of
(2) Fix securely with bolts on a solid block. (Use 4 sets of commercially
the indoor unit.
available M10 bolt, nut and washer.)
Refer to the following table for the proper diameters of the connection
pipes between the indoor and outdoor units.
Capacity of Gas pipe size Liquid pipe size
indoor unit (thickness) [mm] (thickness) [mm]
18 ø12.7 (0.8) ø6.35 (0.8)
24 ø15.88 (1.0) ø6.35 (0.8)
CAUTION
Operation cannot be guaranteed if the correct combina- (3) Since the drain water flows out of the outdoor unit during heating
tion of pipes, valves, etc., is not used to connect the in- operation, install the drain pipe and connect it to a commercial 16 mm
door and outdoor units.
hose. (Reverse cycle model only)
(4) When installing the drain pipe, plug all the holes other than the drain
pipe mounting hole in the bottom of the outdoor unit with putty so
3. HEAT INSULATION AROUND CONNECTION
there is no water leakage. (Reverse cycle model only)
PIPES REQUIREMENTS
CAUTION
Install heat insulation around both the gas and liquid pipes.
Failure to do so may cause water leaks.
Use heat insulation with heat resistance above 120 °C. (Re-
verse cycle model only)
In addition, if the humidity level at the installation location
of the refrigerant piping is expected to exceed 70%, install
heat insulation around the refrigerant piping. If the ex-
pected humidity level is 70-80%, use heat insulation that
is 15 mm or thicker and if the expected humidity exceeds
80%, use heat insulation that is 20 mm or thicker.
If heat insulation is used that is not as thick as specified,
1 When the outdoor temperature is 0 °C or less, do not
condensation may form on the surface of the insulation.
use the accessory drain pipe and drain cap. If the drain
In addition, use heat insulation with heat conductivity of
pipe and drain cap are used, the drain water in the pipe
0.045 W/(m·K) or less (at 20 °C).
may freeze in extremely cold weather. (Reverse cycle
model only)
Connect the connection pipes according to "2 CONNECTING THE PIP-
ING" in this installation instruction sheet.
2 In the area with heavy snowfall, if the intake and outlet
of outdoor unit is blocked with snow, it might become
4. ELECTRICAL REQUIREMENT
difficult to get warm and it is likely to cause of the break-
• Use conformed cord with Type 245 IEC57.
down. Please construct a canopy and a pedestal or
• Electric wire size and fuse capacity:
place the unit on a high stand (local configured).
MAX. 4.0
Power supply cord (mm 2 )
MIN. 3.5
MAX. 2.5
2
Connection cord (mm )
MIN. 1.5
Thickness
Fuse capacity (A) OUTDOOR UNIT 25
0.80 mm
• • • • • Install the disconnect device with a contact gap of at least 3 mm nearby
0.80 mm
the units.
0.80 mm
• • • • • Always make the air conditioner power supply a special branch circuit
and provide a special breaker. • Set the unit on a strong stand, such as one made of concrete blocks to
1.00 mm
minimize shock and vibration.
1.20 mm
• Do not set the unit directly on the ground because it will cause trouble.
SELECTING THE MOUNTING POSITION
WARNING
Select installation locations that can properly support the weight of the indoor and outdoor units. Install the units securely so
that they do not topple or fall.
CAUTION
1 Do not install where there is the danger of combustible gas leakage.
2 Do not install the unit near heat source of heat, steam, or flammable gas.
3 If children under 10 years old may approach the unit, take preventive measures so that they cannot reach the unit.
WARNING
When installing the outdoor unit where it may exposed to strong wind, fasten it securely.
Decide the mounting position with the customer as follows:
(1) Install the outdoor unit in a location which can withstand the weight of the unit and vibration, and which can install horizontally.
(2) Provide the indicated space to ensure good airflow.
(3) If possible, do not install the unit where it will be exposed to direct sunlight.
(If necessary, install a blind that does not interfere with the airflow.)
(4) Do not install the unit near a source of heat, steam, or flammable gas.
(5) During heating operation, drain water flows from the outdoor unit.
Therefore, install the outdoor unit in a place where the drain water flow will not be obstructed. (Reverse cycle model only)
(6) Do not install the unit where strong wind blows or where it is very dusty.
(7) Do not install the unit where people pass.
(8) Install the outdoor unit in a place where it will be free from being dirty or getting wet by rain as much as possible.
(9) Install the unit where connection to the indoor unit is easy.
• • • • • When there are obstacles at the back side. • • • • • When there are obstacles at the back and front sides.
• • • • • When there are obstacles at the back, side(s), and top. • • • • • When there are obstacles at the back side with the installation of
more than one unit.
* If the space is larger than that is stated, the condition will be the
same as that there are no obstacles.
Connector cover removal
• Remove the tapping screws.
Installing the connector cover
(1) After inserting the two front hooks, then insert the rear hook.
OUTDOOR UNIT
(2) Tighten the tapping screws.
INSTALLATION
WARNING
1 Install the unit where it will not be tilted by more than 5°.
2 When installing the outdoor unit where it may exposed
to strong wind, fasten it securely.
54 cm
Tapping screw
Front hooks
Rear hooks
Bolt
Nut
Connector cover
Block
2
CONNECTING THE PIPE
CAUTION
1 Do not use mineral oil on flared part. Prevent mineral
oil from getting into the system as this would reduce
the lifetime of the units.
2 While welding the pipes, be sure to blow dry nitrogen
gas through them.
1. FLARING
(1) Cut the connection pipe to the necessary length with a pipe cutter.
Outdoor
(2) Hold the pipe downward so that cuttings will not enter the pipe and
unit bottom
remove the burrs.
(3) Insert the flare nut (always use the flare nut attached to the indoor
Drain hose
and outdoor units respectively) onto the pipe and perform the flare
processing with a flare tool.
CAUTION Use the special R410A flare tool, or the conventional flare tool.
Check if [L] is flared uniformly
and is not cracked or scratched.
B
Die
A
Pipe
Dimension A (mm)
Pipe outside diameter
Flare tool for R410A, clutch type
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
12.70 mm (1/2 in.) 0 to 0.5
15.88 mm (5/8 in.)
19.05 mm (3/4 in.)
0
Pipe outside diameter Dimension B (mm)
-0.4
6.35 mm (1/4 in.) 9.1
9.52 mm (3/8 in.) 13.2
12.70 mm (1/2 in.) 16.6
15.88 mm (5/8 in.) 19.7
19.05 mm (3/4 in.) 24.0
3
POWER
WARNING
1 The rated voltage of this product is 220-240 V a.c.
50 Hz.
2 Before turning on, verify that the voltage is within the
198 V to 264 V range.
3 Always use a special branch circuit and install a spe-
cial receptacle to supply power to the air conditioner.
4 Use a special branch circuit breaker and receptacle
matched to the capacity of the air conditioner.
(Install in accordance with standard.)
5 Perform wiring work in accordance with standards
so that the air conditioner can be operated safely and
positively.
6 Install a leakage special branch circuit breaker in
accordance with the related laws and regulations
and electric company standards.
7 The circuit breaker is installed in the permanent wir-
ing. Always use a circuit that can trip all the poles of
the wiring and has an isolation distance of at least
3 mm between the contacts of each pole.
CAUTION
1 The power source capacity must be the sum of the air
conditioner current and the current of other electrical
appliances. When the current contracted capacity is
insufficient, change the contracted capacity.
2 When the voltage is low and the air conditioner is
difficult to start, contact the power company the
voltage raised.
AIR
4
ELECTRICAL WIRING
WARNING
1 Before starting work, check that power is not being
supplied to the indoor unit and outdoor unit.
2 Match the terminal board numbers and connection
cord colors with those of the outdoor unit.
Erroneous wiring may cause burning of the electric
parts.
3 Connect the connection cords firmly to the terminal
board. Imperfect installation may cause a fire.
4 Always fasten the outside covering of the connection
cord with the cord clamp. (If the insulator is chafed,
electric leakage may occur.)
5 Always connect the ground wire.
28/7/06, 15:26
When using conventional flare tools to flare R410A pipes, the dimension
CAUTION
A should be approximately 0.5 mm more than indicated in the table (for
flaring with R410A flare tools) to achieve the specified flaring. Use a thick-
Hold the torque wrench at its grip, keeping it in the right
ness gauge to measure the dimension A.
angle with the pipe, in order to tighten the flare nut
correctly.
Width across flats Pipe outside Width across flats
diameter of Flare nut
Flare nut Tightening torque
6.35 mm (1/4 in.) 17 mm
16 to 18 N·m (160 to 180 kgf·cm)
6.35 mm (1/4 in.) dia.
9.52 mm (3/8 in.) 22 mm
9.52 mm (3/8 in.) dia. 30 to 42 N·m (300 to 420 kgf·cm)
12.70 mm (1/2 in.)
26 mm
12.70 mm (1/2 in.) dia. 49 to 61 N·m (490 to 610 kgf·cm)
15.88 mm (5/8 in.) 29 mm
15.88 mm (5/8 in.) dia. 63 to 75 N·m (630 to 750 kgf·cm)
19.05 mm (3/4 in.) 36 mm
19.05 mm (3/4 in.) dia.
90 to 110 N·m (900 to 1100 kgf·cm)
2. BENDING PIPES
4. VACUUM
The pipes are shaped by your hands. Be careful not to collapse them.
Do not bend the pipes in an angle more than 90°. CAUTION
When pipes are repeatedly bend or stretched, the material will harden,
making it difficult to bend or stretch them any more. Do not bend or stretch 1 Always use a vacuum pump to purge the air.
the pipes more than three times.
2 Refrigerant for purging the air is not charged in the
outdoor unit at the factory.
CAUTION
3 Refrigerant must not be discharged into atmosphere.
1 To prevent breaking of the pipe, avoid sharp bends.
Bend the pipe with a radius of curvature of 150 mm or
4 Use a vacuum pump, gauge manifold and charge hose
over.
for R410A exclusively. Using the same vacuum for dif-
ferent refrigerants may damage the vacuum pump or
2 If the pipe is bent repeatedly at the same place, it will
the unit.
break.
5 After connecting the piping, check the joints for gas
3. CONNECTION PIPES leakage with gas leak detector or soapy water.
Outdoor unit
CHECKING GAS LEAKAGE AND PURGING AIR
(1) Detach the caps and plugs from the pipes.
Gas leak checks are performed using either vacuum or nitrogen gas, so
CAUTION
select the proper one depending on the situation.
Checking gas leaks with vacuum:
1 Be sure to apply the pipe against the port on the in-
door unit and outdoor unit correctly. If the centering is
(1) Check if the piping connections are secure.
improper, the flare nut cannot be tightened smoothly. If
(2) Remove the cap of 3-way valve, and connect the gauge manifold
the flare nut is forced to turn, the threads will be dam-
charge hoses to the charging port of the 3-way valve.
(3) Open the valve of the gauge manifold fully.
aged.
(4) Operate the vacuum pump and start pump down.
2 Do not remove the flare nut from the indoor unit pipe (5) Check that the compound pressure gauge reads -0.1 MPa (76 cmHg),
operate the vacuum pump for at least 1 hour.
until immediately before connecting the connection
(6) At the end of pump down, close the valve of the gauge manifold fully
pipe.
and stop the vacuum pump.
(It checks that leave as it is for about 10 minutes, and a needle does
(2) Centering the pipe against port on the indoor unit, turn the flare nut
not return.)
with your hand.
(7) Disconnect the charge hose from the 3-way valve charging port.
(8) Remove the blank caps, and fully open the spindles of the 2-way and
3-way valves with a hexagon wrench.
[torque: 6 to 7 N . m (60 to 70 kgf . cm)].
To prevent gas leakage, coat the flare (9) Tighten the blank caps and charging port cap of the 2-way valve and
surface with alkylbenzene oil (HAB).
3-way valve to the specified torque.
Do not use mineral oil.
Checking gas leaks with nitrogen gas:
(3) When the flare nut is tightened properly by your hand, use a torque
(1) Check if the piping connections are secure.
wrench to finally tighten it.
(2) Remove the cap of 3-way valve, and connect the gauge manifold
charge hoses to the charging port of the 3-way valve.
Holding spanner
(3) Pressurize with nitrogen gas using the 3-way valve charging port.
(4) Do not pressurize up to the specified pressure all at once but do so
gradually.
1 Increase the pressure up to 0.5 Mpa (5 kgf/cm
Body side
five minutes and then check for any decrease in pressure.
2 Increase the pressure up to 1.5 Mpa (15 kgf/cm
about five minutes and then check for any decrease in pressure.
3 Increase the pressure up to the specified pressure (the pressure
Torque wrench
designed for the product) and then make a note of it.
(5) Let it sit at the specified pressure and if there is no decrease in pres-
sure then it is satisfactory. If a pressure decrease is confirmed, there
is a leak, so it is necessary to specify the leak location and make
minor adjustments.
3. OUTDOOR UNIT
HOW TO CONNECT WIRING TO THE
(1) Remove the outdoor unit connector cover.
TERMINALS
(2) Bend the end of the cord as shown in the figure.
(3) Connect the end of the connection cord fully into the terminal block.
For strand wiring (4) Fasten the sheath with a cord clamp.
(5) Install the connector cover.
(1) Cut the wire end with a wire cutter or wire-cutting pliers, then strip
the insulation to about 10 mm to expose the strand wiring.
Control box
(2) Using a screwdriver, remove the terminal screw(s) on the terminal
board.
(3) Using a round terminal fastener or pliers, securely clamp a round
terminal to each stripped wire end.
(4) Position the round terminal wire, and replace and tighten the
Connection cord
terminal screw using a screwdriver.
Round
Earth
terminal
screw
Earth
screw
Screw with
special washer
Screw with
Cord clamp Sheath
Round terminal special washer
Terminal
Wire Round Connection cord wiring
board terminal
Run the connection cord to the rear of the outdoor unit within the A range
Wire
of the arrows shown in the figure.
(The connector cover becomes difficult to install.)
Terminal block
1. CONNECTION DIAGRAMS
Power supply
Connection cord
EARTH
Indoor unit terminal block Outdoor unit terminal block
N
Power line
L 1 2 4
3
Connection cord
3 3 Earth screw
2 2
1 1
EARTH
Indoor unit Outdoor unit
side terminal
side terminal
CAUTION
2. CORD PREPARATION
1 Match the terminal block numbers and connection cord
colors with those of the indoor unit.
Keep the earth wire longer than the other wires.
Erroneous wiring may cause burning of the electric
parts.
2 Connect the connection cords firmly to the terminal
block. Imperfect installation may cause a fire.
Connection cord
and power cord 3 Always fasten the outside covering of the connection
Earth wire
cord with the cord clamp. (If the insulator is chafed,
electric leakage may occur.)
4 Securely earth the power cord plug.
5 Do not use the earth screw for an external connector.
Only use for interconnection between two units.
(6) Discharge the nitrogen gas and starting removing the gas with a
vacuum pump.
(7) Open the valve of the gauge manifold fully.
(8) Operate the vacuum pump and start pump down.
(9) Check that the compound pressure gauge reads -0.1 MPa (76 cmHg),
operate the vacuum pump for at least 1 hour.
(10) At the end of pump down, close the valve of the gauge manifold fully
and stop the vacuum pump.
(11) Disconnect the charge hose from the 3-way valve charging port.
(12) Remove the blank caps, and fully open the spindles of the 2-way and
3-way valves with a hexagon wrench.
[torque: 6 to 7 N . m (60 to 70 kgf . cm)].
(13) Tighten the blank caps and charging port cap of the 2-way valve and
3-way valve to the specified torque.
Tightening torque
6.35 mm (1/4 in.)
20 to 25 N·m (200 to 250 kgf·cm)
9.52 mm (3/8 in.)
20 to 25 N·m (200 to 250 kgf·cm)
Blank cap 12.70 mm (1/2 in.)
28 to 32 N·m (280 to 320 kgf·cm)
15.88 mm (5/8 in.) 30 to 35 N·m (300 to 350 kgf·cm)
19.05 mm (3/4 in.) 35 to 40 N·m (350 to 400 kgf·cm)
Charging port cap
12.5 to 16 N·m (125 to 160 kgf·cm)
Gauge manifold
Compound pressure gauge
Pressure gauge
3-way valve 2-way valve -0.1 MPa
LO
(76 cmHg) HI
Flare nut
High
pressure
Low pressure
side valve
side valve
(closed)
Valve stem
Charge
hose
Blank cap
Charge hose
Charging port
Charging port cap
Vacuum pump
5. ADDITIONAL CHARGE
Refrigerant suitable for a piping length of 15 m is charged in the outdoor
unit at the factory.
When the piping is longer than 15 m, additional charging is necessary.
For the additional amount, see the table below.
Pipe length
15 m 20 m 25 m 30 m
Model type
18,000 BTU/h class None 100 g 200 g –
24,000 BTU/h class None 100 g 200 g 300 g
CAUTION
1 When moving and installing the air conditioner, do not
mix gas other than the specified refrigerant (R410A)
inside the refrigerant cycle.
2 When charging the refrigerant R410A, always use an
electronic balance for refrigerant charging (to meas-
ure the refrigerant by weight).
3 When charging the refrigerant, take
Gas
into account the slight change in the
composition of the gas and liquid R410A
2 ), let it sit for about
phases, and always charge from the
liquid phase side whose composi-
2 ), let it sit for
tion is stable. Liquid
4 Add refrigerant from the charging valve after the com-
pletion of the work.
5 If the units are further apart than the maximum pipe
length, correct operation can not be guaranteed.
5
TEST RUNNING
1. Make a TEST RUN in accordance with the
installation instruction sheet for the indoor unit.
CHECK ITEMS
(1) INDOOR UNIT
Cord clamp
(1) Is operation of each button on the remote control unit normal?
(2) Does each lamp light normally?
(3) Do the air flow-direction louver operate normally?
(4) Is the drain normal?
(5) Is there any abnormal noise and vibration during operation?
(2) OUTDOOR UNIT
(1) Is there any abnormal noise and vibration during operation?
(2) Will noise, wind, or drain water from the unit disturb the neighbors?
(3) Is there any gas leakage?
• Do not operate the air conditioner in the test running state for a long
time.
• For the operation method, refer to the operating manual and perform
operation check.
2. OUTDOOR UNIT LEDS
When a malfunction occurs in the outdoor unit, the LED on the circuit
board lights to indicate the error. Refer to the following table for the
description of each error according to the LED.
Error contents LED
Thermistor malfunction on 0.1 sec/off 0.1 sec
Abnormal discharge temperature on
Current surge protection on 0.5 sec/off 0.5 sec
CT abnormality on 2.0 sec/off 2.0 sec
Compressor position detection malfunction on 0.1 sec/off 2.0 sec
Fan malfunction on 5.0 sec/off 5.0 sec
PAM voltage abnormality on 5.0 sec/off 0.1 sec
Timer short on 1.0 sec/off 1.0 sec
1 2 3 L N Compressor temperature protection (permanent stop) on 2.0 sec/off 5.0 sec
Earth screw
PFC surge protection (permanent stop) on 5.0 sec/off 2.0 sec
6
CUSTOMER GUIDANCE
Explain the following to the customer in accordance with the operating
manual:
(1) Starting and stopping method, operation switching, temperature
adjustment, timer, air flow adjustment, and other remote control unit
operations.
(2) Air filter removal and cleaning.
(3) Give the operating manual and installation instruction sheet to the
customer.