Fujitsu AB*30LBAG series Service Instruction page 91

SPLIT TYPE AIR CONDITIONER
INSTALLATION INSTRUCTION
SHEET
(PART NO. 9374995011)
For authorized service personnel only.
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.
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 DANGER
Never touch electrical components immediately after the power supply has been turned off. Electrical shock may occur. After 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. turning off the power, always wait 5 minutes or more before touching electrical components.
This air conditioner uses new refrigerant HFC (R410A). 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
2
It is recommended the gauge with seals –0.1 to 5.3 MPa (–76 cmHg to 53 kgf/cm ) 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 con-
12.70 mm (1/2 in.)
ventional refrigerant, it is necessary to choose adequate materials.
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
19.05 mm (3/4 in.)
market.
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 room air conditioner piping and cords available standards parts. This
installation 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 Also, 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.
0 Use a clean gauge manifold and charging hose for R410A exclusively.
A 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.
• • • • • 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 PARTS
The following installation parts are furnished.
Use them as required.
Name and Shape Q'ty Application
Drain pipe
1
For outdoor unit drain
piping work (May not be
Drain cap supplied, depending on
the model.)
2
Insulation (seal) For filling in a gap at the
entrance of connection
1
cords
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
operation can not be guaranteed.
Maximum height
Diameter Pipe length
Model Type
(between indoor
and outdoor)
Liquid Gas MAX. MIN.
30,000 BTU/h class
50 m
36,000 BTU/h class
9.52 mm (3/8 in.) 15.88 mm (5/8 in.) 5 m 30 m
45,000 BTU/h class
70 m
54,000 BTU/h class
• • • • • 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).
9374995011_IM_front.p65 1
ELECTRICAL REQUIREMENT
• • • • • Electric wire size and breaker capacity:
2 2
Power supply cord (mm ) Connection cord (mm )
Model Type Breaker capacity (A)
MAX. MIN. MAX. MIN.
30,000 BTU/h class
4.0 3.5 2.5 1.5
36,000 BTU/h class
45,000 BTU/h class
6.0 5.3 3.5 2.5
54,000 BTU/h class
• • • • • Always use H07RN-F or equivalent to the connection cord.
• • • • • 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)
• • • • • Install the circuit breaker nearby the units.
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.
WARNING
1 Install the unit where it will not be tilted by more than 3˚. However, do not install the unit with it tilted towards the side
containing the compressor.
2 When installing the outdoor unit where it may exposed to strong wind, fasten it securely.
(1) Install the outdoor unit in a location which can withstand the weight of the unit and vibration, and which can install horizontally.
(2) Provide the indicated space to ensure good airflow.
(3) 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 airflow.)
(4) Do not install the unit near a source of heat, steam, or flammable gas.
(5) During heating operation, drain water flows from the outdoor unit.
Therefore, install the outdoor unit in a place where the drain water flow will not be obstructed. (Reverse cycle model only)
(6) Do not install the unit where strong wind blows or where it is very dusty.
(7) Do not install the unit where people pass.
(8) Install the outdoor unit in a place where it will be free from being dirty or getting wet by rain as much as possible.
(9) Install the unit where connection to the indoor unit is easy.
• 30,000 BTU/h class • 45,000 BTU/h class
• 36,000 BTU/h class • 54,000 BTU/h class
When there are obstacles at the back side.
Thickness
0.80 mm
0.80 mm
0.80 mm
1.00 mm
1.20 mm
When there are obstacles at the back and front sides.
AIR
When there are obstacles at the back, side(s), and top.
When there are obstacles at the back side with the installation of
more than one unit.
* If the space is larger than that is stated, the condition
will be the same as that there are no obstacles.
INSTALLATION PROCEDURE
1
OUTDOOR UNIT
INSTALLATION
30
1. OUTDOOR UNIT PROCESSING
30
(1) Outdoor unit to be fasten with bolts at the four places indicated by the
arrows without fail.
Drain cap
Bottom side
mounting place
650 mm
Drain pipe
4-ø 12 hole
mounting place
(2) Fix securely with bolts on a solid block. (Use 4 sets of commercially
available M10 bolt, nut and washer.)
Bolt
Nut
Block
(3) Since the drain water flows out of the outdoor unit during heating
operation, install the drain pipe and connect it to a commercial 16 mm
hose. (Reverse cycle model only)
(4) When installing the drain pipe, plug all the holes other than the drain
pipe mounting hole in the bottom of the outdoor unit with putty so
there is no water leakage. (Reverse cycle model only)
CAUTION
When the outdoor temperature is 0 °C or less, do not use
the accessory drain pipe and drain cap. If the drain pipe
and drain cap are used, the drain water in the pipe may
freeze in extremely cold weather. (Reverse cycle model
only)
Drain pipe mounting hole
Base
Drain pipe
4. 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
gauge indicates –0.1 MPa (–76 cmHg).
(3) When –0.1 MPa (–76 cmHg) is reached, operate the vacuum pump
for at least 60 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: 6~7 N·m (60 to
70 kgf·cm)].
(6) Tighten the blank caps of the 2-way valve and 3-way valve to the
specified torque.
Tightening torque
AIR
6.35 mm (1/4 in.) 20 to 25 N·m (200 to 250 kgf·cm)
9.52 mm (3/8 in.) 20 to 25 N·m (200 to 250 kgf·cm)
Blank
12.70 mm (1/2 in.) 25 to 30 N·m (250 to 300 kgf·cm)
cap
15.88 mm (5/8 in.) 30 to 35 N·m (300 to 350 kgf·cm)
19.05 mm (3/4 in.) 35 to 40 N·m (350 to 400 kgf·cm)
10 to 12 N·m (100 to 120 kgf·cm)
Charging port cap
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
Gauge manifold
Use a clean gauge mani-
fold and charging hose
for R410A exclusively.
Lo Hi
AIR
Vacuum pump
Service hose
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 and gauge manifold and charg-
ing hose for R410A exclusively. Using the same vacuum
for different refrigerants may damage the vacuum pump
or the unit.
4/5/05, 10:01 AM
2
CONNECTING THE PIPE 2. BENDING PIPES
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,
CAUTION
making it difficult to bend or stretch them any more. Do not bend or
1 Do not use mineral oil on flared part. Prevent mineral
stretch the pipes more than three times.
oil from getting into the system as this would reduce
the lifetime of the units.
CAUTION
2 While welding the pipes, be sure to blow dry nitrogen
1 To prevent breaking of the pipe, avoid sharp bends.
gas through them. Bend the pipe with a radius of curvature of 150 mm or
over.
3 The maximum lengths of this product are shown in the
table. If the units are further apart than this, correct 2 If the pipe is bent repeatedly at the same place, it will
operation can not be guaranteed. break.
1. FLARING 3. CONNECTION PIPES
(1) Cut the connection pipe to the necessary length with a pipe cutter.
Outdoor unit
(2) Hold the pipe downward so that cuttings will not enter the pipe and
(1) Detach the caps and plugs from the pipes.
remove the burrs.
(3) Insert the flare nut (always use the flare nut attached to the indoor
CAUTION
and outdoor units respectively) onto the pipe and perform the flare
processing with a flare tool.
1 Be sure to apply the pipe against the port on the in-
Use the special R410A flare tool, or the conventional flare tool.
door unit and the outdoor unit correctly. If the centering
Check if [L] is flared uniformly is improper, the flare nut cannot be tightened smoothly.
and is not cracked or scratched.
If the flare nut is forced to turn, the threads will be
B
damaged.
Die
2 Do not remove the flare nut from the indoor unit pipe
A
until immediately before connecting the connection
Pipe pipe.
Dimension A (mm)
(2) Centering the pipe against port on the outdoor unit, turn the flare nut
Pipe outside diameter
Flare tool for R410A, clutch type with your hand.
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
0 to 0.5
12.70 mm (1/2 in.)
To prevent gas leakage, coat the flare
15.88 mm (5/8 in.) surface with alkylbenzene oil (HAB).
Do not use mineral oil.
19.05 mm (3/4 in.)
(3) Tighten the flare nut of the connection pipe at the outdoor unit valve
connector.
0
Pipe outside diameter Dimension B (mm)
-0.4
6.35 mm (1/4 in.) 9.1
3-way valve
9.52 mm (3/8 in.) 13.2 (Liquid)
12.70 mm (1/2 in.) 16.6
15.88 mm (5/8 in.) 19.7
Flare nut
19.05 mm (3/4 in.) 24.0
Connection pipe
(Liquid)
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.
3-way valve
(Gas)
Flare nut
Width across flats Pipe outside Width across flats
Connection pipe
diameter of Flare nut
(Gas)
6.35 mm (1/4 in.) 17 mm
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
3
5. ADDITIONAL CHARGE POWER
• 30,000 BTU/h class
• 36,000 BTU/h class
Refrigerant suitable for a piping length of 15 m is charged in the outdoor WARNING
unit at the factory.
1 The rated voltage of this product is 230 V a.c. 50 Hz.
When the piping is longer than 15 m, additional charging is necessary.
For the additional amount, see the table below.
2 Before turning on, verify that the voltage is within the
198 V to 264 V range.
Pipe length
15 m 20 m 30 m 45 m 50 m g/m
Model type
3 Always use a special branch circuit and install a spe-
30,000 BTU/h class
cial receptacle to supply power to the air conditioner.
None 200 g 600 g 1000 g 1400 g 40 g/m
36,000 BTU/h class
4 Use a special branch circuit breaker and receptacle
matched to the capacity of the air conditioner.
• 45,000 BTU/h class
(Install in accordance with standard.)
• 54,000 BTU/h class
Refrigerant suitable for a piping length of 20 m is charged in the outdoor
5 Perform wiring work in accordance with standards
unit at the factory.
so that the air conditioner can be operated safely and
When the piping is longer than 20 m, additional charging is necessary.
positively.
For the additional amount, see the table below.
6 Install a leakage special branch circuit breaker in
Pipe length
accordance with the related laws and regulations
20 m 30 m 40 m 50 m 60 m 70 m g/m
Model type and electric company standards.
45,000 BTU/h class
None 400 g 800 g 1200 g 1600 g 2000 g 40 g/m 7 The circuit breaker is installed in the permanent wir-
54,000 BTU/h class
ing. Always use a circuit that can trip all the poles of
the wiring and has an isolation distance of at least
CAUTION
3 mm between the contacts of each pole.
1 When moving and installing the air conditioner, do not
mix gas other than the specified refrigerant R410A
CAUTION
inside the refrigerant cycle.
1 The power source capacity must be the sum of the air
2 When charging the refrigerant R410A, always use conditioner current and the current of other electrical
an electronic balance for refrigerant charging (to appliances. When the current contracted capacity is
measure the refrigerant by weight). insufficient, change the contracted capacity.
2 When the voltage is low and the air conditioner is
3 When charging the refrigerant,
difficult to start, contact the power company the
take into account the slight change Gas
voltage raised.
in the composition of the gas and
R410A
liquid phases, and always charge
from the liquid phase side whose
composition is stable. Liquid
4 Add refrigerant from the charging valve after the
completion of the work.
5 If the units are further apart than the maximum pipe
length, correct operation can not be guaranteed.
6. GAS LEAKAGE INSPECTION
CAUTION
1 After connecting the piping, check the all joints for gas
leakage with gas leak detector.
2 When inspecting gas leakage, always use the vacuum
pump for pressure. Do not use nitrogen gas.
(4) When the flare nut is tightened properly by your hand, use a torque
wrench to finally tighten it.
°
.
Holding spanner
Body side
Torque wrench
CAUTION
Hold the torque wrench at its grip, keeping it in the right
angle with the pipe, in order to tighten the flare nut
correctly.
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)
12.70 mm (1/2 in.) dia. 50 to 62 N·m (500 to 620 kgf·cm)
15.88 mm (5/8 in.) dia. 63 to 77 N·m (630 to 770 kgf·cm)
19.05 mm (3/4 in.) dia. 100 to 110 N·m (1000 to 1100 kgf·cm)
(Continued to the next page)