Fujitsu R410A 9370937022 Installation Instruction Sheet

Refrigerant
R410A Cassette Type
SPLIT TYPE AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET
(PART NO. 9370937022)
IMPORTANT!
Please Read Before Starting
When Transporting
This air conditioning system meets strict safety and operating standards.
As the installer or service person, it is an important part of your job to
Be careful when picking up and moving the indoor and outdoor units. Get
install or service the system so it operates safely and efficiently. a partner to help, and bend your knees when lifting to reduce strain on
your back. Sharp edges or thin aluminum fins on the air conditioner can
For safe installation and trouble-free operation, you must:
cut your fingers.
• Carefully read this instruction booklet before beginning.
When Installing...
• Follow each installation or repair step exactly as shown.
• Observe all local, state, and national electrical codes.
...In a Ceiling or Wall
• Pay close attention to all danger, warning, and caution notices given in
Make sure the ceiling/wall is strong enough to hold the unit's weight. It
this manual. may be necessary to construct a strong wood or metal frame to provide
added support.
This symbol refers to a hazard or unsafe practice which
WARNING:
can result in severe personal injury or death.
...In a Room
Properly insulate any tubing run inside a room to prevent "sweating" that
This symbol refers to a hazard or unsafe practice which
can cause dripping and water damage to walls and floors.
CAUTION: can result in personal injury and the potential for
product or property damage.
...In Moist or Uneven Locations
• Use a raised concrete pad or concrete blocks to provide a solid, level
Hazel alerting symbols
foundation for the outdoor unit. This prevents water damage and abnor-
mal vibration.
Electrical
...In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a metal frame.
Provide a suitable air baffle.
...In a Snowy Area (for Heat Pump-type Systems)
Safety / alert
Install the outdoor unit on a raised platform that is higher than drifting
snow. Provide snow vents.
If Necessary, Get Help
When Connecting Refrigerant Tubing
These instructions are all you need for most installation sites and mainte-
• Keep all tubing runs as short as possible.
nance conditions. If you require help for a special problem, contact our
•
Use the flare method for connecting tubing.
sales/service outlet or your certified dealer for additional instructions.
•
Apply refrigerant lubricant to the matching surfaces of the flare and
In Case of Improper Installation union tubes before connecting them, then tighten the nut with a torque
wrench for a leak-free connection.
The manufacturer shall in no way be responsible for improper installation
or maintenance service, including failure to follow the instructions in this • Check carefully for leaks before starting the test run.
document.
NOTE:
Depending on the system type, liquid and gas lines may be either narrow
SPECIAL PRECAUTIONS
or wide. Therefore, to avoid confusion the refrigerant tubing for your
particular model is specified as either "small" or "large" rather than as
When Wiring
"liquid" or "gas".
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR
DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD When Servicing
ATTEMPT TO WIRE THIS SYSTEM. •
Turn the power OFF at the main circuit breaker panel before opening
the unit to check or repair electrical parts and wiring.
• Do not supply power to the unit until all wiring and tubing are completed
•
Keep your fingers and clothing away from any moving parts.
or reconnected and checked.
• Clean up the site after you finish, remembering to check that no metal
•
Highly dangerous electrical voltages are used in this system. Carefully
scraps or bits of wiring have been left inside the unit being serviced.
refer to the wiring diagram and these instructions when wiring. Improper
•
After installation, explain correct operation to the customer, using the
connections and inadequate grounding can cause accidental injury or
operating manual.
death.
•
Ground the unit following local electrical codes.
•
Connect all wiring tightly. Loose wiring may cause overheating at con-
nection points and a possible fire hazard.
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 instal-
lation 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 con-
ventional 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 con-
ventional 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
residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed,
Pipe outside diameter
deformed or discolored portion (especially on the interior surface). Otherwise, the
6.35 mm (1/4 in.) 0.80 mm (0.0315 in.)
expansion valve or capillary tube may become blocked with contaminants.
0.80 mm (0.0315 in.)
As an air conditioner using R410A incurs pressure higher than when using 9.52 mm (3/8 in.)
conventional refrigerant, it is necessary to choose adequate materials.
12.70 mm (1/2 in.) 0.80 mm (0.0315 in.)
Thicknesses of copper pipes used with R410A are as shown in the table. Never
15.88 mm (5/8 in.) 1.00 mm (0.0394 in.)
use copper pipes thinner than that in the table even when it is available on
the market.
CAUTION
This installation instruction sheet describes how to install the indoor unit only.
To install the outdoor unit, refer to the installation instruction sheet included with the outdoor unit.
INSTALLATION PROCEDURE
STANDARD PARTS
Install the air conditioner as follows:
The following installation parts are furnished. Use them as required.
INDOOR UNIT ACCESSORIES
1
INDOOR UNIT INSTALLATION
Name and Shape Q'ty Application
Coupler heat insulation For indoor side pipe joint
2
G Install the air conditioner in a location which can with-
Special nut A (large flange) For installing indoor unit stand a load do at least five times the weight of the
main unit and which will not amplify sound or vibra-
4
tion. If the installation location is not strong enough,
the indoor unit may fall and cause injuries.
G If the job is done with the panel frame only, there is a
Special nut B (small flange) For installing indoor unit
risk that the unit will come loose. Please take care.
4
REMOVING THE INTAKE GRILLE
Template For ceiling hole cutting
(1) Push the intake grille pushbuttons (two places).
1 (2) Open the intake grille.
Blower cover insulation For discharged air PUSH
2
Hook wire For installing intake grille.
2
Binder (small) For fixing the remote
1 controller cord
Remote
controller
1
(3) Remove the grille hinge wire.
Tapping screw For installing the remote
(flush heads) 2 controller
Remote controller cord For connecting the remote
controller
1
SELECTING THE MOUNTING POSITION
WARNING
This mechanism enables the cassette body to move 35 mm (1-3/8")
downward and realizes installation to the space of 215 or 265 mm
Install at a place that can withstand the weight of the in-
(8-15/32" or 10-15/32"). No special works and option is needed.
door and outdoor units and install positively so that the
units will not topple or fall.
[18 to 24 type]
CAUTION
(A) Standard setting
1 Do not install where there is the danger of combustible
gas leakage.
2 Do not install near heat sources.
3 If children under 10 years old may approach the unit,
[30 to 54 type]
take preventive measures so that they cannot reach
(A) Standard setting
the unit.
Especially, the installation place is very important for the split type air
conditioner because it is very difficult to move from place to place after the
first installation.
Decide the mounting position together with the customer as follows:
The discharge direction can be selected as shown below.
100 mm (4") or more 100 mm (4") or more 100 mm (4") or more
CONNECTION PIPE REQUIREMENT
GENERAL
This INSTALLATION INSTRUCTION SHEET briefly outlines where and
how to install the air conditioning system. Please read over the entire set
(4 directions)
(3 directions) (2 directions) (2 directions) of instructions for the indoor and outdoor units and make sure all acces-
Piping position 100 mm (4") or more sory parts listed are with the system before beginning.
Thickness CAUTION
MODEL
Since 2-way outlet as shown below causes performance
Diameter
problems, do not set it.
• • • • • Use pipe with water-resistant heat insulation.
Pipe
Pipe
Install heat insulation around both the gas and liquid pipes.
INDOOR UNIT
Failure to do so may cause water leaks.
Use heat insulation with heat resistance above 248 °F. (Re-
(1) Install the indoor unit on a place having a sufficient strength so that it
withstands against the weight of the indoor unit. verse cycle model only)
(2) The inlet and outlet ports should not be obstructed; the air should be In addition, if the humidity level at the installation location
able to blow all over the room. of the refrigerant piping is expected to exceed 70%, install
(3) Leave the space required to service the air conditioner.
heat insulation around the refrigerant piping. If the ex-
(4) The ceiling rear height as shown in figure.
pected humidity level is 70-80%, use heat insulation that
(5) A place from where the air can be distributed evenly throughout the
is 15 mm (19/32") or thicker and if the expected humidity
room by the unit.
exceeds 80%, use heat insulation that is 20 mm (3/4") or
(6) A place from where drainage can be extracted outdoors easily.
thicker.
(7) Install the unit where noise and vibrations are not amplified.
If heat insulation is used that is not as thick as specified,
condensation may form on the surface of the insulation.
Strong and durable ceiling
In addition, use heat insulation with heat conductivity of
0.045 W/(m·K) or less (at 68 °F).
ELECTRICAL REQUIREMENT
• • • • • Electric wire size:
Connection cord (mm
1,000 mm (39")
or more
• • • • • Install all electrical works in accordance to the standard.
• • • • • Install the disconnect device with a contact gap of at least 3 mm (1/8")
Obstruction in all poles nearby the units. (Both indoor unit and outdoor unit)
• • • • • Install the circuit breaker nearby the units.
Floor
• Pull up while pressing the B section.
Part A detail view Part A section view
B
WARNING
Grille hinge wire
(4) Remove the intake grille.
REMOVING THE PANEL FRAME
• Pull up the corner sections (A) of the panel frame as shown in
figure (4 locations).
Part A detail view
OPEN
A
A A
B
A
A
• Pull up in the direction of the arrow while holding down the C
section of figure (4 locations).
Part B detail view
C
2
INSTALLING DRAIN PIPE
CAUTION
Install the drain pipe in accordance with the instructions
in this installation instruction sheet and keep the area warm
You can select 2-way setting
enough to prevent condensation. Problems with the pip-
ing may lead to water leaks.
(B) Slender setting
NOTE: Install the drain pipe.
• • • • •
Install the drain pipe with downward gradient (1/50 to 1/100) and so
there are no rises or traps in the pipe.
• • • • •
Use general hard polyvinyl chloride pipe (VP25) [outside diameter
32 mm (1-1/4")] and connect it with adhesive (polyvinyl chloride) so
that there is no leakage.
• • • • •
When the pipe is long, install supporters.
• • • • •
Do not perform air bleeding.
(B) Slender setting • • • • •
Always heat insulate the indoor side of the drain pipe.
• • • • •
When desiring a high drain pipe height, rise it up to 800 mm (31") or
less from the ceiling within a range of 150 mm (6") from the body. A
rise dimension over this range will cause leakage.
Supporter
Rise
Trap
1.5 to 2.0 m (5 to 6.5 ft)
150 mm (6") or less
Air bleeding
Max. 800 mm (31")
14000, 18000 BTU/h 24000, 36000, 3
model 42000 BTU/h model CONNECTING THE PIPING
Liquid
6.35 mm (1/4 in.) 9.52 mm (3/8 in.)
Gas 12.70 mm (1/2 in.) 15.88 mm (5/8 in.)
CAUTION
1 Do not use mineral oil on flared part.
CAUTION 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.
(2) Hold the pipe downward so that cuttings will not enter the pipe and
remove the burrs.
(3) Insert the flare nut (always use the flare nut attached to the indoor
and outdoor units respectively) onto the pipe and perform the flare
processing with a flare tool.
Use the special R410A flare tool, or the conventional flare tool.
Check if [L] is flared uniformly
and is not cracked or scratched.
Die
A
Pipe
Dimension A
Pipe outside diameter
2.5 Flare tool for R410A, clutch type
MAX.
2 )
MIN. 1.5 6.35 mm (1/4 in.)
9.52 mm (3/8 in.) 0 to 0.5 mm
(0 to 0.0197 in.)
12.70 mm (1/2 in.)
15.88 mm (5/8 in.)
(A) Standard setting
Panel frame
Drain pipe (I.D. 32 mm)
305.5 mm (12")
Panel base
(B) Slender setting
Drain pipe (I.D. 32 mm)
305.5 mm (12")
CAUTION
Always remove the panel frame after removing the intake
3. BODY INSTALLATION
grille.
As for the dimension of the ceiling rear hight is above figure or more.
(1) Install special nut A, then special nut B onto the hanging bolt.
1. POSITION THE CEILING HOLE AND HANGING (2) Raise the body and mount its hooks onto the hanging bolt between
the special nuts.
BOLTS
(3) Turn special nut B to adjust the height of the body.
(4) Leveling
Using a level, or vinyl hose filled with water, fine adjust so that the
940 mm ( 37")
body is level.
(Grille measurement)
Perform final tightening by tightening the double nut firmly.
Special nut B
Hanging bolt
750 mm (29-17/32")
(Hanging bolt position)
2. HANGING PREPARATIONS
• Firmly fasten the hanging bolts as shown in figure or by another method.
• Install the hanging bolts at a place where they would be capable of
holding a weight of at least 50 kgf per bolt.
Hole-in anchor
Hole-in plug
Concrete Insert
Hanging bolt M10
* Allowable space between the unit and the ceiling 5 mm (3/16") or less
(3) When the flare nut is tightened properly by your hand, use a torque
Pipe outside diameter Dimension B
wrench to finally tighten it.
6.35 mm (1/4 in.) 9.1 mm (0.3583 in.)
9.52 mm (3/8 in.) 13.2 mm (0.5197 in.)
12.70 mm (1/2 in.) 16.6 mm (0.6536 in.)
15.88 mm (5/8 in.) 19.7 mm (0.7756 in.) Body side
When using conventional flare tools to flare R410A pipes, the dimension
A should be approximately 0.5 mm (1/32") more than indicated in the
table (for flaring with R410A flare tools) to achieve the specified flaring.
Use a thickness gauge to measure the dimension A.
Width across flats
Pipe outside Width across flats
diameter of Flare nut
Hold the torque wrench at its grip, keeping it in the right
6.35 mm (1/4 in.) 17 mm (0.6693 in.)
angle with the pipe, in order to tighten the flare nut
9.52 mm (3/8 in.) 22 mm (0.8661 in.)
correctly.
12.70 mm (1/2 in.) 26 mm (1.0236 in.)
15.88 mm (5/8 in.) 29 mm (1.1417 in.)
Flare nut
6.35 mm (1/4 in.) dia.
2. BENDING PIPES 9.52 mm (3/8 in.) dia.
12.70 mm (1/2 in.) dia.
The pipes are shaped by your hands. Be careful not to collapse them.
15.88 mm (5/8 in.) dia.
Do not bend the pipes in an angle more than 90 ° .
When pipes are repeatedly bend or stretched, the material will harden,
Do not remove the cap from the connection pipe before connecting
making it difficult to bend or stretch them any more. Do not bend or
the pipe.
stretch the pipes more than three times.
CAUTION
Be sure to connect the large pipe after connecting the small
1 To prevent breaking of the pipe, avoid sharp bends.
pipe completely.
Bend the pipe with a radius of curvature of 150 mm (6")
or over.
2 If the pipe is bent repeatedly at the same place, it will
break.
3. CONNECTION PIPES
Indoor unit
(1) Detach the caps and plugs from the pipes.
CAUTION
1 Be sure to apply the pipe against the port on the in-
door unit correctly. If the centering is improper, the flare
nut cannot be tightened smoothly. If the flare nut is
forced to turn, the threads will be damaged.
2 Do not remove the flare nut from the indoor unit pipe
until immediately before connecting the connection pipe.
(2) Centering the pipe against port on the indoor unit, turn the flare nut
with your hand.
To prevent gas leakage, coat the flare
surface with alkylbenzene oil (HAB).
Do not use mineral oil.
B
Connection pipe
(Gas)
Indoor unit
Connection pipe
(Liquid)
INSTALLING THE PANEL FRAME
298.5 mm (11-3/4")
248.5 mm
(9-25/32")
Panel base
298.5 mm (11-3/4")
248.5 mm
*90° Turn
(9-25/32")
Panel frame
* With slender setting, turn the panel frame 90° as shown in the dia-
gram above.
Grille setting method has been changed at the marked posi-
tions on the panel frame and panel base.
(A) Standard setting (B) Slender setting
WARNING
Mark
Special nut A No mark
Panel frame
After installing the body,
Hook
tighten the nuts.
30 mm (1-3/16")
or more
(Example)
Ceiling
* Must fit tightly against ceiling
without any gap.
* Appearance of slender setting
Vinyl hose
4
INSTALLING THE COUPLER
HEAT INSULATION
Holding spanner
After checking for gas leaks, insulate by wrapping insulation around the
two parts (large and small) of the indoor unit coupling, using the coupler
heat insulation.
After installing the coupler heat insulation, wrap both ends with vinyl tape
so that there is no gap.
Torque wrench
Coupler heat insulation
CAUTION Body
Be sure to overlap the
insulation
CAUTION
Tightening torque
16 to 18 N·m (160 to 180 kgf·cm) Must fit tightly against body without any gap.
30 to 42 N·m (300 to 420 kgf·cm)
49 to 61 N·m (490 to 610 kgf·cm)
No gap
63 to 75 N·m (630 to 750 kgf·cm)
Coupler heat insulation
CAUTION
- Continued on back -