Fuji Electric 9365388044 Installation Instructions

Refrigerant
R410A Cassette Type
SPLIT TYPE AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET
(PART NO. 9365388044)
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 (R22) models.
However, pay careful attention to the following points:
1 Since the working pressure is 1.6 times higher than that of conventional refrigerant (R22) models, some of the piping and
installation and service tools are special. (See the table below.)
Especially, when replacing a conventional refrigerant (R22) 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 con-
ventional refrigerant (R22) 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 (R22) 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
R410A
contaminants. diameter (inch) (mm)
As an air conditioner using R410A incurs pressure higher than when using
3/8 9.52 0.80
R22, it is necessary to choose adequate materials.
5/8 15.88 1.00
Thicknesses of copper pipes used with R410A are as shown in Table 1. Never
use copper pipes thinner than 0.8 mm (Nominal diameter is 3/8 in.), 1.0 mm
(Nominal diameter is 5/8 in.) even when it is available on the market.
For authorized service personnel only.
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 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.
5 Do not use an extension cord.
6 Do not turn on the power until all installation work is complete.
• • • • • 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.

SELECTING THE MOUNTING POSITION

INDOOR UNIT
WARNING
(1) Install the indoor unit on a place having a sufficient strength so that it
Install at a place that can withstand the weight of the in-
withstands against the weight of the indoor unit.
door and outdoor units and install positively so that the
(2) The inlet and outlet ports should not be obstructed; the air should be
units will not topple or fall.
able to blow all over the room.
(3) Leave the space required to service the air conditioner (Fig. 2).
(4) The ceiling rear height as shown in Fig. 3.
CAUTION
(5) A place from where the air can be distributed evenly throughout the
room by the unit.
1 Do not install where there is the danger of combustible
(6) A place from where drainage can be extracted outdoors easily.
gas leakage.
(7) Install the unit where noise and vibrations are not amplified.
2 Do not install near heat sources.
Fig. 2
3 If children under 10 years old may approach the unit,
Strong and durable ceiling
take preventive measures so that they cannot reach
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.
Fig. 1
100 mm (4") or more 100 mm (4") or more 1,000 mm (39") or more
Obstruction
Floor
This mechanism enables the cassette body to move 35 mm down-
(4 directions) (3 directions) (2 directions) (2 directions) ward and realizes installation to the space of 200 mm. No special
Piping position 100 mm (4") or more works and option is needed.
Fig. 3
CAUTION
You can select 2-way setting
Since 2-way outlet as shown below causes performance
problems, do not set it.
(A) Standard setting (B) Slender setting
Pipe
Pipe

INSTALLATION PROCEDURE

STANDARD PARTS
Install the air conditioner as follows:
The following installation parts are furnished. Use them as required.
INDOOR UNIT ACCESSORIES
1
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.
Fig. 5
Blower cover insulation For discharged air
2
Hook wire For installing intake grille.
2
Binder (small) For fixing the remote
controller cord
1
Remote
controller
1
(3) Remove the grille hinge wire.
Tapping screw For installing the remote Fig. 6
(flush heads) controller
2
Remote controller cord For connecting the remote
controller
1
OUTDOOR UNIT ACCESSORIES
Drain pipe
For outdoor unit drain piping
1
work
[Heat & Cool model
(Reverse cycle) only]
Drain cap
1
Thickness (mm)
[ref.] R22
0.80
1.00
OUTDOOR UNIT

CONNECTION PIPE REQUIREMENT

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
9.52 mm (3/8")
to strong wind, fasten it securely.
• • • • • Use pipe with water-resistant heat insulation.
(1) If possible, do not install the unit where it will exposed to direct sun-
light. (If necessary, install a blind that does not interfere with the air
flow.)
(2) Install the outdoor unit in a place where it will be free from being dirty
or getting wet by rain as much as possible.
Install heat insulation around both the gas and liquid pipes.
(3) Install the unit when connection to the indoor unit is easy.
Failure to do so may cause water leaks.
(4) During heating operation, drain water flows from the outdoor unit.
Use heat insulation with heat resistance above 120 °C. (Re-
Therefore, install the outdoor unit in a place where the drain water
flow will not be obstructed. verse cycle model only)
(5) Do not place animals and plants in the path of the warm air. In addition, if the humidity level at the installation location
(6) Take the air conditioner weight into account and select a place where of the refrigerant piping is expected to exceed 70%, install
noise and vibration are small.
heat insulation around the refrigerant piping. If the ex-
(7) Select a place so that the warm air and noise from the air conditioner
pected humidity level is 70-80%, use heat insulation that
do not disturb neighbors.
is 15 mm or thicker and if the expected humidity exceeds
(8) Provide the space shown in Fig. 4 so that the air flow is not blocked.
80%, use heat insulation that is 20 mm or thicker.
Also for efficient operation, leave open three of the four directions
If heat insulation is used that is not as thick as specified,
front, rear, and both sides.
condensation may form on the surface of the insulation.
(9) Do not set the unit directly on the ground because it will cause trou-
In addition, use heat insulation with heat conductivity of
ble.
(10) Set the unit on a strong stand, such as one made of concrete blocks 0.045 W/(m·K) or less (at 20 °C).
to minimize shock and vibration.
Fig. 4

ELECTRICAL REQUIREMENT

• • • • • Electric wire size and fuse/breaker capacity:
30 cm (1') or over
Power supply cord (mm
30 cm (1')
30 cm (1') Connection cord (mm
Air
or over
or over
Fuse/Breaker capacity (A)
60 cm (2')
or over
• • • • • Always use H07RN-F or equivalent to the connection cord.
• • • • • Install the disconnect device with a contact gap of at least 3 mm nearby
the units (both indoor unit and outdoor unit).
60 cm (2') or over
1,000 mm (39")
or more
• Pull up while pressing the B section (Fig. 7).
Fig. 7 Part A detail view Fig. 8 Part A section view

INDOOR UNIT INSTALLATION

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
Fig. 9 (4 locations).
Fig. 9 Part A detail view
A
PUSH
OPEN
A
B
A
A
• Pull up in the direction of the arrow while holding down the C
section of Fig. 10 (4 locations).
Fig. 10 Part B detail view
C
2
INSTALLING DRAIN PIPE
Table 2
Maximum Height CAUTION
Diameter
Maximum
(between indoor
length
Install the drain pipe in accordance with the instructions
Small Large and outdoor)
in this installation instruction sheet and keep the area warm
15.88 mm (5/8") 25 m (82 ft) 15 m (50 ft)
enough to prevent condensation. Problems with the pip-
ing may lead to water leaks.
NOTE: Install the drain pipe.
• • • • •
Install the drain pipe with downward gradient (1/50 to 1/100) and so
CAUTION
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.
• • • • •
Always heat insulate the indoor side of the drain pipe.
• • • • •
When desiring a high drain pipe height, raise 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.
Fig. 20 Supporter
Rise
Trap
150 mm (6") or less
Air bleeding
Max. 800 mm (31")
Table 3
MAX. 4.0
3
2 )
MIN. 3.5 OUTDOOR UNIT INSTALLATION
MAX.
2.5
2 )
MIN. 1.5
30

1. OUTDOOR UNIT PROCESSING

When the outdoor unit will be exposed to strong wind, fasten it with bolts
at the four places indicated by the arrows (Fig. 21).
Fig. 21
Air flow
Bottom
Drain cap
603 mm
Drain pipe mounting hole
Drain pipe mounting hole
Bottom plate
Drain pipe
CAUTION
If this product is used in an area where the temperature
falls below freezing for long periods of time, do not con-
nect the drain pipe. Instead, allow the water to drain into a
drain pan.
Fig. 14
Fig. 11
Panel frame (A) Standard setting
Panel base
(B) Slender setting
CAUTION
Always remove the panel frame after removing the intake
grille.
3. BODY INSTALLATION
A [The ceiling rear height is 235 mm (9-1/4") or more.] [Standard setting]
1. POSITION THE CEILING HOLE AND HANGING
[The ceiling rear height is 200 mm (7-7/8") or more.] [Slender setting]
BOLTS
(1) Install special nut A, then special nut B onto the hanging bolt (Fig. 15).
(2) Raise the body and mount its hooks onto the hanging bolt between
the special nuts (Fig. 15).
Fig. 12
(3) Turn special nut B to adjust the height of the body (Fig. 15).
940 mm ( 37") (4) Leveling
Using a level, or vinyl hose filled with water, fine adjust so that the
(Grille measurement)
body is level.
Perform final tightening by tightening the double nut firmly.
Fig. 15
Special nut B
Hanging bolt
750 mm (29-17/32")
(Hanging bolt position)
2. HANGING PREPARATIONS
• Firmly fasten the hanging bolts as shown in Fig. 13 or by another method.
Fig. 16
• Install the hanging bolts at a place where they would be capable of
holding a weight of at least 50 kgf per bolt.
Fig. 13
Hole-in anchor
Hole-in plug
Concrete Insert
* Allowable space between the unit and the ceiling 5 mm or less
Hanging bolt M10
2. OUTDOOR UNIT CONNECTION CORD AND 2. BENDING PIPES
PIPE CONNECTION PREPARATIONS
The pipes are shaped by your hands. Be careful not to collapse them.
(1) Remove outdoor unit terminal cover.
Fig. 24
Fig. 22
Terminal cover
Do not bend the pipes in an angle more than 90°.
When pipes are repeatedly bent or stretched, the material will harden,
making it difficult to bend or stretch them any more. Do not bend or stretch
the pipes more than three times.
* After removing the screws,
remove terminal cover.
When bending the pipe, do not bend it as is. The pipe will be collapsed. In
this case, cut the heat insulating pipe with a sharp cutter as shown in Fig.
25, and bend it after exposing the pipe. After bending the pipe as you
want, be sure to put the heat insulating pipe back on the pipe, and secure
(2) Connect the piping, connection cord and power supply cord.
it with tape.
Fig. 25
4
CONNECTING THE PIPING
Heat insulating pipe
1.5 to 2.0 m (5 to 6.5 ft)
WARNING
Do not use the existing (for R22) 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 To prevent breaking of the pipe, avoid sharp bends.
1 Do not use mineral oil on flared part. Bend the pipe with a radius of curvature of 150 mm or
Prevent mineral oil from getting into the system as this
over.
would reduce the lifetime of the units.
2 If the pipe is bent repeatedly at the same place, it will
2 While welding the pipes, be sure to blow dry nitrogen break.
gas through them.
3 The maximum lengths of this product are shown in ta-

3. CONNECTION PIPES

ble 2. If the units are further apart than this, correct
operation can not be guaranteed. (1) Indoor unit side
Fig. 26
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 (for R22) flare tool.
When using the conventional flare tool, always use an allowance ad-
justment gauge and secure the A dimension shown in table 4.
Fig. 23
Check if [L] is flared uniformly
and is not cracked or scratched.
1 Be sure to apply the pipe against the port on the in-
door unit correctly. If the centering is improper, the flare
Die nut cannot be tightened smoothly. If the flare nut is
forced to turn, the threads will be damaged.
A
L
Pipe 2 Do not remove the flare nut from the indoor unit pipe
until immediately before connecting the connection
Table 4 Pipe outside diameter
pipe.
A (mm)
Pipe outside
Flare tool for Conventional (R22) flare tool
diameter
R410A, clutch type Clutch type Wing nut type
9.52 mm (3/8 in.)
0 to 0.5 1.0 to 1.5 1.5 to 2.0
15.88 mm (5/8 in.) 0 to 0.5 1.0 to 1.5 2.0 to 2.5

INSTALLING THE PANEL FRAME

Fig. 17
Drain pipe (I.D. 32 mm)
298.5 mm (11-3/4")
248.5 mm
305.5 mm (12") (9-25/32")
Panel base
Drain pipe (I.D. 32 mm)
11-3/4" (298.5 mm)
248.5 mm *90° Turn
305.5 mm (12") (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.
Fig. 18
(A) Standard setting (B) Slender setting
WARNING
Special nut A
Mark
No mark
Panel frame
After installing the body,
Hook
tighten the nuts.
30 mm or
more
Fig. 19
(Example)
Ceiling
* Must fit tightly against ceiling
without any gap.
* Appearance of slender setting
Vinyl hose
When the flare nut is tightened properly by your hand, hold the body
side coupling with a separate spanner, then tighten with a torque wrench
(Fig. 27).
Fig. 27
Holding spanner
Body side
Extend the pipe
by unwinding it.
Torque wrench
To prevent gas leakage, coat the flare
surface with alkylbenzene oil (HAB).
Do not use mineral oil.
Pipe
CAUTION
Cutter
Hold the torque wrench at its grip, keeping it in the right
angle with the pipe as shown in Fig. 27, in order to tighten
the flare nut correctly.
Cut line
Table 5 Flare nut tightening torque
CAUTION
Flare nut Tightening torque
9.52 mm (3/8 in.) dia. 33 to 42 N·m (330 to 420 kgf·cm)
15.88 mm (5/8 in.) dia. 63 to 77 N·m (630 to 770 kgf·cm)
Do not remove the cap from the connection pipe before connecting
the pipe.
CAUTION
Be sure to connect the large pipe after connecting the small
pipe completely.
(2) Outdoor unit side
Tighten the flare nut of the connection pipe at the outdoor unit valve
connector. The tightening method is the same as that as at the indoor
Large pipe
side.
Indoor unit
Fig. 28
Small pipe
(Small pipe)
Connection pipe
CAUTION
(Large pipe)
2-Way valve
Flare nut
3-Way valve
- Continued on back -