Fujitsu ABYA36LAT Installation Instruction Sheet

Ceiling Type
INSTALLATION
INSTRUCTION SHEET
(PART NO. 9378042018)
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.
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.
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 residual oil is less than 40 mg/10 m. Do not use copper pipes
Pipe outside diameter
having a collapsed, deformed or discolored portion (especially on the interior
6.35 mm (1/4 in.)
surface). Otherwise, the expansion valve or capillary tube may become
blocked with contaminants. 9.52 mm (3/8 in.)
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.
Thicknesses of copper pipes used with R410A are as shown in the table. 15.88 mm (5/8 in.)
Never use copper pipes thinner than that in the table even when it is
19.05 mm (3/4 in.)
available on the market.
CONNECTION PIPE REQUIREMENT
CAUTION
The maximum/minimum lengths of this product, refer to the installation instruction sheet supplied with the outdoor unit. If
the units are further apart than this, correct operation can not be guaranteed.
Diameter
Liquid Gas
9.52 mm (3/8 in.) 15.88 mm (5/8 in.)
• • • • • Use pipe with water-resistant heat insulation.
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. (Reverse 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 expected 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, 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).
ELECTRICAL REQUIREMENT
• • • • • Electric wire size:
Connection cord (mm ) 2
MAX. MIN.
2.5 1.5
• • • • • Use conformed cord with Type 245 IEC57.
• • • • • Install all electrical works in accordance to the standard.
• • • • • Install the disconnect device with a contact gap of at least 3 mm in all poles nearby the units. (Both indoor unit and outdoor unit)
SELECTING THE MOUNTING POSITION
Decide the mounting position with the customer as follows:
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.
INDOOR UNIT
(1) Install the indoor unit level on a strong wall which is not subject to vibration.
(2) The inlet and outlet ports should not be obstructed : the air should be able to blow all over the room.
(3) Do not install the unit where it will be exposed to direct sunlight.
(4) Install the unit where connection to the outdoor unit is easy.
(5) Install the unit where the drain pipe can be easily installed.
(6) Take servicing, etc., into consideration and leave the spaces shown in the figure. Also install the unit where the filter can be removed.
[FOR HALF CONCEALED INSTALLATION]
(Unit : mm)
Ceiling
INDOOR UNIT
INDOOR UNIT
80 or over Ceiling 150 or over Ceiling panel
80 or over
10 or over
Obstruction Obstruction
Floor Floor
INSTALLATION PROCEDURE
STANDARD PARTS
The following installation parts are furnished.
Use them as required.
1
INDOOR UNIT ACCESSORIES
Name and Shape Q'ty Application
Adhesive type 70 × 230
Drain hose insulation
REMOVE THE INTAKE GRILLE AND SIDE COVER
1
(1) Remove the two Air filters.
(2) Remove the two Intake grilles.
• For 4 Left rear drain and 5 Left drain: Remove air filters and intake
VT wire For fixing the drain hose
1 L 280 mm grilles at three places. (Refer to "2 INDOOR UNIT INSTALLATION".)
(3) Remove the Side cover A (Right side) and Side cover B (Right and
Left side).
• For 5 Left drain : Remove both the Side cover A (Right and Left
Coupler heat insulator (large) For indoor side pipe joint
(Gas pipe) side). (Refer to "2 INDOOR UNIT INSTALLATION".)
2
(4) This air conditioner can be set up to intake fresh air. For information
about how to install for fresh-air intake, refer to "7 FRESH-AIR INTAKE".
Coupler heat insulator (small) For indoor side pipe joint
1 (Liquid pipe)
Tapping screw
Large
Nylon fastener For fixing the coupler heat
4
insulator
Small
4
Special nut A For installing indoor unit
(large flange) 4
Special nut B For installing indoor unit
4
(small flange)
Installation For positioning the indoor
template 1 unit
2
Auxiliary pipe assembly For connecting the piping
INDOOR UNIT INSTALLATION
1
You can use the accessory template to help you install the indoor unit.
The template helps you determine the appropriate locations for suspen-
sion bolts and pipe opening (drain pipe and connection cord).
OPTIONAL PARTS
The following options are available.
• • • • • DRAIN PUMP UNIT: UTR-DPB241 (P/N 9034087001)
• • • • • ROUND DUCT: UTD-RF204 (P/N 9093160004)
1. LOCATION OF CEILING SUSPENSION BOLTS
30 mm
Thickness
0.80 mm
0.80 mm
0.80 mm
1.00 mm
1.20 mm
• For 2 Top piping and 3 Right piping connections, use the Auxiliary
2. BENDING PIPES
pipe (Gas pipe) provided.
The pipes are shaped by your hands. Be careful not to collapse them.
°
Do not bend the pipes in an angle more than 90 .
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 the pipes more than three times.
CAUTION
1 To prevent breaking of the pipe, avoid sharp bends.
Bend the pipe with a radius of curvature of 150 mm or
Connection pipe (Gas)
over.
2 If the pipe is bent repeatedly at the same place, it will
break.
(5) When the flare nut is tightened properly by your hand, use a torque
3. CONNECTION PIPES
wrench to finally tighten it.
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
Hold the torque wrench at its grip, keeping it in the right
with your hand.
angle with the pipe, in order to tighten the flare nut
correctly.
To prevent gas leakage, coat the flare
surface with alkylbenzene oil (HAB).
6.35 mm (1/4 in.) dia.
Do not use mineral oil.
9.52 mm (3/8 in.) dia.
(3) Remove the filter guide.
12.70 mm (1/2 in.) dia.
15.88 mm (5/8 in.) dia.
Indoor unit
19.05 mm (3/4 in.) dia.
Filter guide
(4) Attach the connection pipe.
Connection pipe (Gas)
Connection pipe (Liquid)
Indoor unit
Ceiling panel
150 or over
10 or over
[For Half-Concealed Installation]
• • • • • Suspension-bolt pitch should be as shown in the figure.
40 mm Ceiling Opening: 1580 mm
PREPARING INDOOR UNIT
INSTALLATION
Ceiling Opening: 640 mm
15 mm
Ceiling panel
Suspension bolt should
extend outward 30 to 50 mm.
INDOOR UNIT
2. SELECT PIPING DIRECTION
Air filter
Select connection piping and drain piping directions.
Intake grille
4 Left rear piping 2 Top piping
5 Left piping (Drain pipe only) (Connection pipe only)
(Drain pipe only)
INDOOR UNIT
INDOOR UNIT (TOP VIEW)
Side cover B
(Left side)
Side cover A (Right side)
Side cover B (Right side)
Cut off the piping outlet cutting groove
with a hacksaw, etc.
[FOR 4 Left rear piping, 5 Left piping]
• • • • • Transfer the Drain cap and Drain cap seal.
Drain cap seal
Drain cap
Indoor unit
Drain pan
Drilling position for Suspension bolt
Ceiling
Wall
Push cap all the way on
(as far as it will go).
Template
Drilling position for piping
3. DRILLING THE HOLES AND ATTACHING THE
SUSPENSION BOLTS
(1) Drill ø25 mm holes at the suspension-bolt locations.
Suspension bolt pitch 1600 mm
(2) Install the bolts, then temporarily attach Special nuts A and B and a
30 mm
normal M10 nut to each bolt. (The two special nuts are provided with
Dimensions
the unit. The M10 nut must be obtained locally.) Refer to the figure.
(Space Required
for Installation)
Bolt Strength 980 to 1470 N (100 to 150 kgf)
10 mm
155 mm
Ceiling panel
INDOOR UNIT (TOP VIEW)
300 mm
Special nut A (Included)
10 to 15 mm
Special nut B (Included)
Suspension bolt should
M10 Nut (Obtained locally)
extend outward 30 to 75 mm.
INDOOR UNIT
4. HEAT INSULATION ON THE PIPE JOINTS
(INDOOR SIDE ONLY)
2 Top piping
After checking for gas leaks, insulate by wrapping insulation around the
Connection pipe (Gas)
two parts (Gas and Liquid) 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.
Secure both ends of the heat insulation material using nylon fasteners.
Indoor unit (rear)
And finally fix connection pipe (Liquid) to connection pipe (Gas) by rolling
vinyl tape over coupler heat insulation (Gas) and coupler heat insulation
(Liquid).
Coupler heat insulation (Large)
Auxiliary pipe (Gas pipe)
3 Right piping Connection pipe (Gas)
Indoor unit
Connection pipe (Liquid)
Coupler heat insulation (Small)
Holding spanner Nylon fastener (Large)
Body side
Indoor unit
Torque wrench
Nylon fastener (Small)
Connection pipe (Gas)
Indoor unit
CAUTION
Connection pipe (Liquid)
Vinyl tape
• When using an auxiliary pipe, make sure that the fastener used is insu-
Flare nut Tightening torque
lated in the same way.
14 to 18 N·m (140 to 180 kgf·cm)
CAUTION
33 to 42 N·m (330 to 420 kgf·cm)
50 to 62 N·m (500 to 620 kgf·cm) There should be no gaps between the insulation and the
63 to 77 N·m (630 to 770 kgf·cm) product.
100 to 110 N·m (1000 to 1100 kgf·cm)
4. INSTALLING THE INDOOR UNIT
(1) Lift unit so that suspension bolts pass through the suspension fittings
at the sides (four places), and slide the unit back.
40 mm Arrange the drain pipe
lower than this portion.
Ceiling panel
Ceiling
Bad
Wall
Ceiling panel
(1) Install insulation for the drain pipe.
Cut the included insulation material to an appropriate size and adhere
it to the pipe.
Wall
INDOOR UNIT
(2) Fasten the indoor unit into place by tightening-up the special "B" bolts
1 Right rear piping and the M10 nuts. Make sure that unit is secure and will not shift back
and forth.
Indoor unit (drain port)
[For Half-Concealed Installation]
When installing the indoor unit in a semi-concealed orientation, make sure
3 Right
piping to reinforce the insulation of the unit on all sides. Drops of water may fall
from the unit if it is not thoroughly insulated.
Indoor unit
Glass wool insulate
(10 to 20 mm thick)
(2) If "1 Right rear piping" : fasten the drain pipe with VT wire so that the
pipe slopes correctly within the indoor unit.
INDOOR UNIT
(Top view)
Wall
Drain cap seal
Drain cap
Ceiling panel
CAUTION
Indoor unit (rear view)
In order to check the drainage, be sure to use a level
(3) If the drain hose will not be connected to the right rear piping, cut the
during installation of the indoor unit. If the installation site
hole cover at the points indicated in Fig. (a), and attach it to the piping
of the indoor unit is not level, water leakage may occur.
hole as shown in Fig. (b).
5. DRAIN PIPING (a)
CAUTION
Install the drain pipe in accordance with the instructions
in this installation instruction sheet and keep the area
Cut x 5
warm enough to prevent condensation. Problems with the
piping may lead to water leaks.
(b)
• • • • • 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
38 mm].
• • • • • During installation of the drain pipe, be careful to avoid applying
pressure to the drain port of the indoor unit.
• • • • • When the pipe is long, install supporters.
• • • • • Do not perform air bleeding.
• • • • • Always heat insulate (8 mm or over thick) the indoor side of the drain
pipe.
4
ELECTRICAL WIRING 1. CONNECTION DIAGRAMS
Wired remote controller (option)
WARNING
Red
1 Before starting work, check that power is not being White
supplied to the indoor unit and outdoor unit. Black
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
* Ground the remote controller if it has ground wire.
cord with the cord clamp. (If the insulator is chafed,
electric leakage may occur.)
2. CONNECTION CORD PREPARATION
5 Always connect the ground wire.
No gap
6 Install the remote controller wires so as not to be di-
rect touched with your hand.
For earth
Coupler heat
insulation
HOW TO CONNECT WIRING TO THE
TERMINALS
3. INDOOR UNIT
A. For solid core wiring
(1) Cut the wire end with a wire cutter or wire-cutting pliers, then strip
the insulation to about 25 mm to expose the solid wire.
(2) Using a screwdriver, remove the terminal screw(s) on the terminal
Use care not to mistake the power supply cord and
board.
connection wires when installing.
(3) Using pliers, bend the solid wire to form a loop suitable for the
terminal screw.
(1) Remove the two tapping screws and pull the control box downward.
(4) Shape the loop wire properly, place it on the terminal board and
tighten securely with the terminal screw using a screwdriver.
B. For strand wiring
(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.
(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
terminal screw using a screwdriver.
Round
A. Solid wire B. Strand wire
terminal
(2) Remove the Cover A and install the Connection cord.
(3) Reattach Cover A. Then fasten the control box back into its original
Loop position using the two tapping screws.
Insulation
Screw with
special washer
Screw with
Round terminal special washer
Terminal Round
Wire
board
terminal
Wire
(4) After wiring is complete, clamp the Connection cord with the Cord
clamp.
Terminal block
3
CONNECTING THE PIPE
Drain pipe
Good
CAUTION
1 Do not use mineral oil on flared part. Prevent mineral
oil from getting into the system as this would reduce
Lifted up
the lifetime of the units.
Wave 2 While welding the pipes, be sure to blow dry nitrogen
Bad
gas through them.
End in water 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
Supporter
remove the burrs.
1.5 to 2 m
(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.
Drain pipe
Insulation for drain pipe Die
(To be obtained locally. Length
A
should be at least 8 mm.)
Pipe
Drain pipe insulation (accessories)
Dimension A (mm)
Pipe outside diameter
Flare tool for R410A, clutch type
Drain pipe insulation
6.35 mm (1/4 in.)
Drain pipe
9.52 mm (3/8 in.)
12.70 mm (1/2 in.) 0 to 0.5
10 mm or over
No gap
15.88 mm (5/8 in.)
19.05 mm (3/4 in.)
VT wire
Pipe outside diameter Dimension B 0 (mm)
-0.4
6.35 mm (1/4 in.) 9.1
9.52 mm (3/8 in.) 13.2
Drain hose
12.70 mm (1/2 in.) 16.6
15.88 mm (5/8 in.) 19.7
19.05 mm (3/4 in.) 24.0
When using conventional flare tools to flare R410A pipes, the dimension
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-
ness gauge to measure the dimension A.
Width across flats Pipe outside Width across flats
diameter of Flare nut
6.35 mm (1/4 in.) 17 mm
Hole cover
9.52 mm (3/8 in.) 22 mm
12.70 mm (1/2 in.) 26 mm
15.88 mm (5/8 in.) 29 mm
19.05 mm (3/4 in.) 36 mm
(5) Attach the connection cord and cable clips. Make sure that they are
positioned so that they will not interfere with opening and closing of
the intake grille or with removal and installation of the air filters.
*
3
Power
2
1 2 3
1 Control line
Power line
Red Remote
3
White
2
Outdoor unit
Black
1
Indoor unit
side terminal
Connection cord Wired remote controller cord
(To outdoor unit) (Option)
Connection cord
Power supply cord
or connection cord
Wired remote controller cord
Cable clip
CAUTION
Indoor unit
Control box
Tapping screw
Control box
Cover A
- Continued on back -
B