Fujitsu ABYG 36 Series Installation Instruction Sheet

Refrigerant
R410A Ceiling Suspension Type
SPLIT TYPE AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET
(PART NO. 9360461094)
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.)
STANDARD PARTS OUTDOOR UNIT ACCESSORIES
The following installation parts are furnished. Name and Shape Q'ty
Use them as required.
Drain pipe
1
For outdoor unit drain
INDOOR UNIT ACCESSORIES
piping work (May not be
Drain cap supplied, depending on
Name and Shape Q'ty Application
the model.)
2
Remote Use for air conditioner
control unit operation
Insulation (seal) For filling in a gap at the
1
entrance of connection
1
cords
Battery (penlight) For remote control unit
2
OPTIONAL PARTS
The following options are available.
Remote For mounting the remote
• • • • • DRAIN PUMP UNIT: UTR-DPB241 (P/N 9034087001)
control control unit
unit holder
1
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
Coupler heat insulator (large) For indoor side pipe joint
(Gas pipe)
2
Coupler heat insulator (small) For indoor side pipe joint
1 (Liquid pipe)
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
Auxiliary pipe assembly For connecting the piping
1
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.
Diameter
Maximum height
Pipe length
Gas (between indoor
Liquid
and outdoor)
36 Type 45, 54 Type MAX. MIN.
9.52 mm (3/8 in.) 15.88 mm (5/8 in.) 19.05 mm (3/4 in.) 50 m 5 m 30 m
• • • • • 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 and breaker capacity:
Power supply cord (mm ) 2 Connection cord (mm ) 2
Breaker capacity (A)
MAX. MIN. MAX. MIN.
4.0 2.5 2.5 1.0 20
• • • • • 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.
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
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
80 mm
in the figure. Also install the unit where the filter can be removed.
or over
Ceiling
INDOOR UNIT
Thickness
0.80 mm
0.80 mm
Ceiling
0.80 mm
80 mm 150 mm
or over or over
1.00 mm
1.20 mm
10 mm
or over
OUTDOOR UNIT
Application
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.
(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.
• • • • • When there are obstacles at the back side. • • • • • When there are obstacles at the back and front sides.
• • • • • 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.
AIR
If the space is larger than that is stated, the condition
*
will be the same as that there are no obstacles.
INSTALLATION PROCEDURE
1
PREPARING INDOOR UNIT
INSTALLATION
REMOVE THE INTAKE GRILLE AND SIDE COVER
(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
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
side). (Refer to "2 INDOOR UNIT INSTALLATION".)
(4) This air conditioner can be set up to intake fresh air. For information
about how to install for fresh-air intake, refer to "B FRESH-AIR INTAKE".
Air filter
Intake grille
Tapping screw
INDOOR UNIT
Side cover A (Right side)
Side cover B (Right side)
2
INDOOR UNIT INSTALLATION
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).
Drilling position for Suspension bolt
Ceiling
Wall
Template
Drilling position for piping
Ceiling panel
1. LOCATION OF CEILING SUSPENSION BOLTS
INDOOR UNIT 30 mm Suspension bolt pitch 1600 mm
30 mm
Dimensions
(Space Required
for Installation)
Ceiling panel
10 mm
150 mm
155 mm
or over
INDOOR UNIT (TOP VIEW) 300 mm
10 mm
or over
Suspension bolt should
extend outward 30 to 75 mm.
INDOOR UNIT
3
OUTDOOR UNIT
INSTALLATION
1. OUTDOOR UNIT PROCESSING
(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
AIR
(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
[For Half-Concealed Installation]
[If using anchor bolts]
• • • • • Suspension-bolt pitch should be as shown in the figure.
(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).
40 mm Ceiling Opening: 1580 mm 40 mm (2) Install the anchor bolts, then temporarily attach special nut "B" (in-
cluded) and a locally-procured M10 nut to each of the bolts.
Ceiling panel
Anchor-Bolt Strength
Ceiling Opening: 640 mm
15 mm
Ceiling panel
Ceiling
Suspension bolt should
extend outward 30 to 50 mm.
INDOOR UNIT
M10 Anchor Bolt
(Obtained locally)
2. SELECT PIPING DIRECTION
Select connection piping and drain piping directions. 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.
4 Left rear piping 2 Top piping
5 Left piping (Drain pipe only) (Connection pipe only)
(Drain pipe only)
1 Right rear piping
Ceiling
INDOOR UNIT (TOP VIEW)
Side cover B
(Left side) 3 Right
piping
Cut off the piping outlet cutting groove
with a hacksaw, etc.
[FOR 4 Left rear piping, 5 Left piping]
Ceiling panel
• • • • • Transfer the Drain cap and Drain cap seal.
Drain cap seal
Drain cap
Indoor unit
Drain pan
Drain cap seal
Drain cap (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
and forth.
Push cap all the way on
[For Half-Concealed Installation]
(as far as it will go).
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
3. DRILLING THE HOLES AND ATTACHING THE
from the unit if it is not thoroughly insulated.
SUSPENSION BOLTS
(1) Drill ø25 mm holes at the suspension-bolt locations.
(2) Install the bolts, then temporarily attach Special nuts A and B and a
normal M10 nut to each bolt. (The two special nuts are provided with
the unit. The M10 nut must be obtained locally.) Refer to the figure.
Bolt Strength 980 to 1470 N (100 to 150 kgf)
Ceiling panel
Special nut A (Included)
10 to 15 mm
Special nut B (Included)
M10 Nut (Obtained locally)
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
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.
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.
Indoor 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
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 correctly. If the centering is improper, the flare
Check if [L] is flared uniformly
nut cannot be tightened smoothly. If the flare nut is
and is not cracked or scratched.
forced to turn, the threads will be damaged.
B
2 Do not remove the flare nut from the indoor unit pipe
Die
until immediately before connecting the connection
A
pipe.
Pipe
(2) Centering the pipe against port on the indoor unit, turn the flare nut
Dimension A (mm)
with your hand.
Pipe outside diameter
Flare tool for R410A, clutch type
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
12.70 mm (1/2 in.) 0 to 0.5
15.88 mm (5/8 in.)
(3) Remove the filter guide.
19.05 mm (3/4 in.)
Indoor unit
0
Pipe outside diameter Dimension B (mm)
-0.4
6.35 mm (1/4 in.) 9.1
9.52 mm (3/8 in.) 13.2
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 (4) Attach the connection pipe.
flaring with R410A flare tools) to achieve the specified flaring. Use a thick-
ness gauge to measure the dimension A.
Indoor unit
Width across flats Pipe outside Width across flats
diameter of Flare nut
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
5. DRAIN PIPING
CAUTION
Install the drain pipe in accordance with the instructions
in this installation instruction sheet and keep the area
warm enough to prevent condensation. Problems with the
piping may lead to water leaks.
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
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)
pipe.
Drain pipe
GOOD
Arrange the drain pipe
lower than this portion.
Lifted up
Wave
BAD BAD
End in water
Wall
Supporter
1.5 to 2 m
(1) Install insulation for the drain pipe.
Cut the included insulation material to an appropriate size and adhere
it to the pipe.
Wall
Drain pipe
INDOOR UNIT
Insulation for drain pipe
(To be obtained locally. Length
should be at least 8 mm.)
Drain pipe insulation (accessories)
Indoor unit (drain port)
Drain pipe insulation
Indoor unit
Drain pipe
Glass wool insulate
No gap 10 mm or over
(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.
VT wire
INDOOR UNIT
(Top view)
Drain hose
Wall
Ceiling panel
Indoor unit (rear view)
CAUTION
• For 2 Top piping and 3 Right piping connections, use the Auxiliary
pipe (Gas pipe) provided.
° 2 Top piping
.
Connection pipe (Gas)
CAUTION
Indoor unit (rear)
Connection pipe (Gas)
Auxiliary pipe (Gas pipe)
3 Right piping
(5) When the flare nut is tightened properly by your hand, use a torque
wrench to finally tighten it.
Holding spanner
CAUTION
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.
To prevent gas leakage, coat the flare Flare nut Tightening torque
surface with alkylbenzene oil (HAB).
6.35 mm (1/4 in.) dia. 14 to 18 N·m (140 to 180 kgf·cm)
Do not use mineral oil.
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)
Filter guide 19.05 mm (3/4 in.) dia. 100 to 110 N·m (1000 to 1100 kgf·cm)
Outdoor unit
Tighten the flare nut of the connection pipe at the outdoor unit valve con-
nector. The tightening method is the same as that as at the indoor side.
3-way valve
(Liquid)
Flare nut
Connection pipe
Connection pipe (Gas) (Liquid)
Connection pipe (Liquid)
3-way valve
(Gas)
Flare nut
Connection pipe
(Gas)
- Continued on back -