Fujitsu 9374318117 Installation Instructions

SPLIT TYPE AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET
(PART NO. 9374318117)
For authorized service personnel only.
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 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
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
It is necessary to use seamless copper pipes and it is desirable that the amount
Table 1 Thicknesses of Annealed Copper Pipes
of residual oil is less than 40 mg/10 m. Do not use copper pipes having a
collapsed, deformed or discolored portion (especially on the interior surface).
Otherwise, the expansion valve or capillary tube may become blocked with
Nominal Outer diameter
contaminants.
diameter (inch) (mm)
As an air conditioner using R410A incurs pressure higher than when using
1/4 6.35
R22, it is necessary to choose adequate materials.
3/8 9.52
Thicknesses of copper pipes used with R410A are as shown in Table 1. Never
1/2 12.70
use copper pipes thinner than 0.8 mm (Nominal diameter is 1/4 in., 3/8 in. 1/2
in.), 1.0 mm (Nominal diameter is 5/8 in.) even when it is available on the market. 5/8 15.88
For authorized service personnel only.
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 air conditioner to operate satisfactorily, install it as outlined in this installation instruction sheet.
(2) Connect the indoor unit and outdoor unit with the air conditioner piping and cords available standards parts. This installa-
tion 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) 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.
(10) Use a clean gauge manifold and charging hose for R410A exclusively.
(11) 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.
CAUTION
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.
• • • • • Be careful not to scratch the 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 air conditioner is serviced or moved.
STANDARD ACCESSORIES CONNECTION PIPE REQUIREMENT
The following accessories are supplied with the outdoor unit. Use them as
required.
Install heat insulation around both the gas and liquid pipes.
Name and Shape Q'ty Application Failure to do so may cause water leaks.
Use heat insulation with heat resistance above 120 °C. (Re-
Drain pipe For outdoor unit drain piping
verse cycle model only)
1 work
In addition, if the humidity level at the installation location
[Heat & Cool model
(Reverse cycle) only] of the refrigerant piping is expected to exceed 70%, install
Drain cap
heat insulation around the refrigerant piping. If the ex-
1
pected humidity level is 70-80%, use heat insulation that
is 15 mm or thicker and if the expected humidity exceeds
Adapter assy For use when connecting 80%, use heat insulation that is 20 mm or thicker.
12.7 mm / 9.52 mm
model 12,000 BTU/h
If heat insulation is used that is not as thick as specified,
(1/2" / 3/8")
1
condensation may form on the surface of the insulation.
In addition, use heat insulation with heat conductivity of
0.045 W/(m·K) or less (at 20 °C).
Connect the connection pipes according to "2 CONNECTING THE PIP-
ING" in this installation instruction sheet.
MODEL
Diameter
Maximum length
Maximum Height
(between indoor and outdoor)
• • • • • Use pipe with water-resistant heat insulation.
• • • • • Use pipe that can withstand a pressure of 4,150 kPa.
ELECTRICAL REQUIREMENT
• • • • • Electric wire size and fuse capacity:
Power supply cord (mm
Connection cord (mm
Fuse capacity (A)
• • • • • Install the disconnect device with a contact gap of at least 3 mm nearby
the units.
• • • • • Always make the air conditioner power supply a special branch circuit
and provide a special breaker.
• • • • • Always use H07RN-F or equivalent as the power supply cord and the
connection cord.
Thickness (mm)
R410A
0.80
0.80
0.80
1.00
SELECTING THE MOUNTING POSITION
WARNING
Install at a place that can withstand the weight of the indoor and outdoor units and install positively so that the units will not
topple or fall.
CAUTION
(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, take preventive measures so that they cannot reach the unit.
Decide the mounting position with the customer as follows:
(1) 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
air flow.)
(2) Do not install the unit where a strong wind blows or where it is very
dusty.
(3) Do not install the unit where people pass.
(4) Take your neighbors into consideration so that they are not disturbed
by air blowing into their windows or by noise.
(5) Provide the space shown in figure so that the air flow is not blocked.
Also for efficient operation, leave open three of the four directions
front, rear, and both sides.
•
When selecting the installation location of the indoor unit, consult the
customer and refer to the installation instruction sheet included with
the indoor unit.
INSTALLATION PROCEDURE
CAUTION
1
OUTDOOR UNIT INSTALLATION
1. OUTDOOR UNIT PROCESSING
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.
• Set the unit on a strong stand, such as one made of concrete blocks to
minimize shock and vibration.
• Do not set the unit directly on the ground because it will cause trouble.
• Since the drain water flows out of the outdoor unit during heating op-
eration, install the drain pipe and connect it to a commercial 16 mm
hose. (Heat & Cool model (Reverse cycle) only)
• When installing the drain pipe, plug all the holes (• hole at one place)
Table 2
other than the drain pipe mounting hole in the bottom of the outdoor
14000 BTU/h 12000 BTU/h unit with putty so there is no water leakage. (Heat & Cool model (Re-
model model verse cycle) only)
Small 6.35 mm (1/4 in.) 6.35 mm (1/4 in.)
Large 12.70 mm (1/2 in.) 9.52 mm (3/8 in.)
CAUTION
25 m (82 ft) 25 m (82 ft)
Installation in cold regions. Do not use the accessory drain
pipe and drain cap.
15 m (49 ft) 15 m (49 ft) (If the drain pipe and drain cap are used, the drain water in
the pipe may freeze in extremely cold weather.)
Air flow
Bottom
Drain
cap
Table 3
3.0
MAX.
2 )
MIN. 2.0
603 mm
MAX. 2.5
2 )
MIN. 1.5 Drain pipe mounting hole
15
Bottom plate
Drain pipe
3
VACUUM PROCESS
CAUTION
(1) Do not purge the air with refrigerants but use a vacuum
pump to vacuum the installation! There is no extra re-
frigerant in the outdoor unit for air purging!
(2) Use a vacuum pump for R410A exclusively. Using the
same vacuum pump for different refrigerants may dam-
age the vacuum pump or the unit.
1. VACUUM
(1) Remove the cap, and connect the gauge manifold and the vacuum
pump to the charging valve by the service hoses.
(2) Vacuum the indoor unit and the connecting pipes until the pressure
30 cm gauge indicates –0.1 MPa (–76 cmHg).
or over (3) When –0.1 MPa (–76 cmHg) is reached, operate the vacuum pump
for at least 15 minutes.
(4) Disconnect the service hoses and fit the cap to the charging valve to
the specified torque.
(5) 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
30 cm 30 cm
kgf · cm).
Air
or over or over
(6) Tighten the blank caps of the 2-way valve and 3-way valve to the
specified torque.
60 cm
or over
Table 6
Tightening torque
Blank cap (2-way valve) 20 to 25 N · m (200 to 250 kgf · cm)
60 cm
Blank cap 12.70 mm (1/2 in.) 25 to 30 N · m (250 to 300 kgf · cm)
or over
(3-way valve) 15.88 mm (5/8 in.) 30 to 35 N · m (300 to 350 kgf · cm)
Charging port cap 10 to 12 N · m (100 to 120 kgf · cm)
Connecting pipe
Blank cap
Hexagon wrench
Outdoor unit
Use a 4 mm
hexagon wrench.
3-way valve
Service hose
with valve core
Charging port
Cap
CAUTION
Use a clean gauge mani-
fold and charging hose
for R410A exclusively.
Gauge manifold
LO
HI
Vacuum pump
Service hose
2
CONNECTING THE PIPING
2. OUTDOOR UNIT CONNECTION CORD AND
PIPE CONNECTION PREPARATIONS
Remove outdoor unit valve cover.
WARNING
Do not use the existing piping and flare nuts.
• If the existing materials are used, the pressure inside the
refrigerant cycle will rise and cause breakage, injury, etc.
(Use the special R410A materials.)
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.
(3) The maximum lengths of this product are shown in ta-
ble 2. If the units are further apart than this, correct
operation can not be guaranteed.
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.
Valve cover
Use the special R410A flare tool, or the conventional flare tool.
When using the conventional flare tool, always use an allowance ad-
justment gauge and secure the A dimension shown in table 4.
Remove outdoor unit terminal cover. Check if [L] is flared uniformly
and is not cracked or scratched.
* After removing the screws,
remove terminal cover.
Die
L
Terminal cover
Table 4 Pipe outside diameter
A (mm)
Pipe outside diameter
Flare tool for R410A, clutch type
6.35 mm (1/4 in.) 0 to 0.5
9.52 mm (3/8 in.) 0 to 0.5
12.70 mm (1/2 in.) 0 to 0.5
15.88 mm (5/8 in.) 0 to 0.5
2. BENDING PIPES
(1) When bending the pipe, be careful not to crush it.
(2) To prevent breaking of the pipe, avoid sharp bends. Bend the pipe
with a radius of curvature of 150 mm or over.
(3) If the copper pipe is bend the pipe or pulled to often, it will become
stiff. Do not bend the pipes more than three times at one place.
2. ADDITIONAL CHARGE
Refrigerant suitable for a piping length of 10 m is charged in the outdoor
unit at the factory.
When the piping is longer than 10 m, additional charging is necessary.
For the additional amount, see the table below.
Table 7
g/m
Pipe length 10 m 15 m 20 m 25 m
Additional
(oz/ft)
refrigerant (33 ft) (49 ft) (66 ft) (82 ft)
Heat &
Cool
12,000 BTU/h
100 g 200 g 300 g 20 g/m
model
14,000 BTU/h None
(3-17/ 32 oz) (7-1/16 oz) (10-19/32 oz) (7/32 oz/ft)
(Reverse class
cycle)
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
into account the slight change in the Gas
composition of the gas and liquid
R410A
phases, and always charge from the
liquid phase side whose composi-
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.
3. GAS LEAKAGE INSPECTION
CAUTION
After connecting the piping, check the joints for gas leak-
age with gas leak detector.
3. CONNECTION
(1) Install the outdoor unit wall cap (supplied with the optional installation
set or procured at the site) to the wall hole pipe.
(2) Connect the outdoor unit and indoor unit piping.
(3) After matching the center of the flare surface and tightening the nut
hand tight, tighten the nut to the specified tightening torque with a
torque wrench.
Tighten with two wrenches.
Wrench (fixed)
Flare nut
Torque wrench
Indoor unit
To prevent gas leakage,
pipe Connection pipe
coat the flare surface with
alkylbenzene oil (HAB).
Do not use mineral oil.
Table 5 Flare nut tightening torque
Flare nut Tightening torque
6.35 mm (1/4 in.) dia. 14 to 18 N · m (140 to 180 kgf · cm)
9.52 mm (3/8 in.) dia. 33 to 42 N · m (330 to 420 kgf · cm)
50 to 62 N · m (500 to 620 kgf · cm)
12.70 mm (1/2 in.) dia.
63 to 77 N · m (630 to 770 kgf · cm)
15.88 mm (5/8 in.) dia.
Do not remove the cap from the connection pipe before connecting
the pipe.
4. HOW TO USE ADAPTER (Connection ports of
12,000 BTU/h model outdoor unit)
• When using the ADAPTER, be careful not to overtighten the nut, or the
smaller pipe may be damaged.
• Apply a coat of refrigeration oil to the threaded connection port of the
outdoor unit where the flare nut comes in.
A
• Use appropriate wrenches to avoid damaging the connection thread by
Pipe overtightening the flare nut.
• Apply wrenches on both of flare nut (local part), and ADAPTER to tighten
them.
Adapter tightening torque
Adapter type Tightening torque
ø12.7 mm / ø9.52 mm
50 to 62 [N·m] (500 to 620 kgf·cm)
ø12.7 / ø9.52 (1/2" / 3/8")
ADAPTER
- Continued on back -