Fujitsu AB*30LBAG series Service Instruction page 89

Refrigerant
R410A Ceiling Suspension Type
SPLIT TYPE AIR CONDITIONER
INSTALLATION INSTRUCTION
SHEET
(PART NO. 9366160052)
For authorized service personnel only.
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.
5 When moving, if the compressor stops during pump down, close the valve immediately.
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.)
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
conventional refrigerant, it is necessary to choose adequate materials. 12.70 mm (1/2 in.)
Thicknesses of copper pipes used with R410A are as shown in the table. Never
15.88 mm (5/8 in.)
use copper pipes thinner than that in the table even when it is available on
the market. 19.05 mm (3/4 in.)
CONNECTION PIPE REQUIREMENT
CAUTION
The maximum lengths of this product are shown in the following table. If the units are further apart than this, correct opera-
tion 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 1.0
• • • • • Always use H07RN-F or equivalent to the connection cord.
• • • • • 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
[FOR HALF CONCEALED INSTALLATION]
(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
INDOOR UNIT
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.
Ceiling panel
(6) Take servicing, etc., into consideration and leave the spaces shown
80 mm
in the figure. Also install the unit where the filter can be removed.
or over
Ceiling
INDOOR UNIT
Ceiling
80 mm 150 mm
or over or over
10 mm
or over
9366160052_IM_front.p65 1
STANDARD PARTS INSTALLATION PROCEDURE
The following installation parts are furnished.
Use them as required.
1
PREPARING INDOOR UNIT
INDOOR UNIT ACCESSORIES
Name and Shape Q'ty Application
Remote Use for air conditioner
REMOVE THE INTAKE GRILLE AND SIDE COVER
control unit operation
(1) Remove the two Air filters.
1
(2) Remove the two Intake grilles.
• For 4 Left rear drain and 5 Left drain: Remove air filters and intake
grilles at three places. (Refer to "2 INDOOR UNIT INSTALLATION".)
(3) Remove the Side cover A (Right side) and Side cover B (Right and
Battery (penlight) For remote control unit Left side).
• For 5 Left drain : Remove both the Side cover A (Right and Left
2
side). (Refer to "2 INDOOR UNIT INSTALLATION".)
(4) This air conditioner can be set up to intake fresh air. For information
Remote For mounting the remote about how to install for fresh-air intake, refer to "0 FRESH-AIR INT AKE".
control control unit
unit holder
1
Tapping screw
Tapping screw For remote control unit
(ø3 × 12)
2 holder installation
Adhesive type 70 × 230
Drain hose insulation
1
VT wire For fixing the drain hose
1 L 280 mm
Side cover B (Right side)
Coupler heat insulator (large) For indoor side pipe joint
(Gas pipe)
2 2
INDOOR UNIT INSTALLATION
Coupler heat insulator (small) For indoor side pipe joint
You can use the accessory template to help you install the indoor unit.
1 (Liquid pipe)
The template helps you determine the appropriate locations for suspen-
sion bolts and pipe opening (drain pipe and connection cord).
Large
Nylon fastener For fixing the coupler heat
4
insulator
Small
4
Special nut A For installing indoor unit
(large flange) 4
Template
Special nut B For installing indoor unit
4
(small flange)
1. LOCATION OF CEILING SUSPENSION BOLTS
Installation For positioning the indoor
template 1 unit
30 mm
Auxiliary pipe assembly For connecting the piping
1
OPTIONAL PARTS
Thickness
The following options are available.
0.80 mm
• • • • • DRAIN PUMP UNIT: UTR-DPB241 (P/N 9034087001)
0.80 mm
INDOOR UNIT
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
3 Right piping
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 Flare nut
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
Ceiling panel
(4) Attach the connection pipe.
Connection pipe (Gas)
Connection pipe (Liquid)
Indoor unit
150 mm
or over
10 mm
or over
[For Half-Concealed Installation]
• • • • • Suspension-bolt pitch should be as shown in the figure.
40 mm Ceiling Opening: 1580 mm 40 mm
Ceiling panel
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)
1 Right rear piping
INDOOR UNIT
INDOOR UNIT (TOP VIEW)
Side cover B
(Left side)
Side cover A (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 Drain cap seal
Drain cap
Ceiling
Wall
Push cap all the way on
(as far as it will go).
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
(Space Required the unit. The M10 nut must be obtained locally.) Refer to the figure.
for Installation)
10 mm Bolt Strength 980 to 1470 N (100 to 150 kgf)
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.
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)
Connection pipe (Gas)
Indoor unit
Connection pipe (Liquid)
Coupler heat insulation (Small)
Holding spanner Nylon fastener (Large)
No gap
Body side
Indoor unit
Coupler heat
insulation
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-
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
product.
63 to 77 N·m (630 to 770 kgf·cm)
100 to 110 N·m (1000 to 1100 kgf·cm)
15/9/05, 11:41
[If using anchor bolts] 5. DRAIN PIPING
(1) Drill holes for anchor bolts at the locations at which you will set the
suspension bolts. Note that anchor bolts are M10 bolts (to be ob-
tained locally).
(2) Install the anchor bolts, then temporarily attach special nut "B" (in- Install the drain pipe in accordance with the instructions
cluded) and a locally-procured M10 nut to each of the bolts. in this installation instruction sheet and keep the area
warm enough to prevent condensation. Problems with the
piping may lead to water leaks.
Anchor-Bolt Strength 980 to 1470 N (100 to 150 kgf)
• • • • • 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
Ceiling
38 mm].
• • • • • During installation of the drain pipe, be careful to avoid applying
Special nut B
pressure to the drain port of the indoor unit.
(Included) • • • • • When the pipe is long, install supporters.
• • • • • Do not perform air bleeding.
M10 Nut
• • • • • Always heat insulate (8 mm or over thick) the indoor side of the drain
(Obtained locally)
M10 Anchor Bolt
pipe.
(Obtained locally)
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. Arrange the drain pipe
lower than this portion.
Lifted up
Ceiling
BAD
3 Right
piping
Wall
Supporter
(1) Install insulation for the drain pipe.
Ceiling panel
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
and the M10 nuts. Make sure that unit is secure and will not shift back
Indoor unit (drain port)
and forth.
[For Half-Concealed Installation]
When installing the indoor unit in a semi-concealed orientation, make sure
to reinforce the insulation of the unit on all sides. Drops of water may fall
Indoor unit
from the unit if it is not thoroughly insulated.
Glass wool insulate
No gap
(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
Ceiling panel
Indoor unit (rear view)
CAUTION
In order to check the drainage, be sure to use a level
during installation of the indoor unit. If the installation site
of the indoor unit is not level, water leakage may occur.
4
ELECTRICAL WIRING 1. CONNECTION DIAGRAMS
Power line
WARNING 3
2
1 Before starting work, check that power is not being
1
supplied to the indoor unit and outdoor unit.
2 Match the terminal board numbers and connection
Indoor unit
cord colors with those of the outdoor unit.
side terminal
Erroneous wiring may cause burning of the electric
parts.
2. CONNECTION CORD PREPARATION
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.) For earth
5 Always connect the ground wire.
3. INDOOR UNIT
HOW TO CONNECT WIRING TO THE
TERMINALS
Use care not to mistake the power supply cord and
A. For solid core wiring (or F-cable)
connection wires when installing.
(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.
(1) Remove the two tapping screws and pull the control box downward.
(2) Using a screwdriver, remove the terminal screw(s) on the terminal
board.
(3) Using pliers, bend the solid wire to form a loop suitable for the
terminal screw.
Indoor unit
(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 Tapping screw
terminal to each stripped wire end.
(4) Position the round terminal wire, and replace and tighten the (2) Remove the Cover A and install the Connection cord.
(3) Reattach Cover A. Then fasten the control box back into its original
terminal screw using a screwdriver.
position using the two tapping screws.
Round
A. Solid wire B. Strand wire
terminal
Loop
Insulation
Screw with
special washer
Screw with
Round terminal special washer (4) After wiring is complete, clamp the Connection cord with the Cord
clamp.
Terminal Round
Wire
board
terminal
Wire
Terminal block
3
CONNECTING THE PIPE
CAUTION
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 the
table. 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
Drain pipe remove the burrs.
(3) Insert the flare nut (always use the flare nut attached to the indoor
GOOD 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.
B
Wave Die
BAD
A
Pipe
End in water
Dimension A (mm)
Pipe outside diameter
Flare tool for R410A, clutch type
1.5 to 2 m
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
0 to 0.5
12.70 mm (1/2 in.)
15.88 mm (5/8 in.)
19.05 mm (3/4 in.)
Drain pipe
0
Pipe outside diameter Dimension B (mm)
Insulation for drain pipe -0.4
(To be obtained locally. Length 6.35 mm (1/4 in.) 9.1
should be at least 8 mm.)
9.52 mm (3/8 in.) 13.2
Drain pipe insulation (accessories)
12.70 mm (1/2 in.) 16.6
15.88 mm (5/8 in.) 19.7
19.05 mm (3/4 in.) 24.0
Drain pipe insulation
Drain pipe
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
10 mm or over
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
VT wire
diameter of Flare nut
6.35 mm (1/4 in.) 17 mm
9.52 mm (3/8 in.)
22 mm
Drain hose
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.
Control line
Control box
Outdoor unit
Connection cord
Terminal board
Earth screw
Cord clamp
Connection cord
To outdoor unit
Power supply cord
Connection cord
or connection cord
CAUTION
Cable clip
Control box
Control box
Cover A
- Continued on back -