Fujitsu AOY30LMAW4 Installation Instruction Sheet

SPLIT TYPE ROOM AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET
(PART NO. 9374872015)
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.
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.
Thicknesses of Annealed Copper Pipes (R410A)
Copper pipes
It is necessary to use seamless copper pipes and it is desirable that the amount of
Pipe outside diameter
residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed,
6.35 mm (1/4 in.)
deformed or discolored portion (especially on the interior 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.
15.88 mm (5/8 in.)
Thicknesses of copper pipes used with R410A are as shown in the table. Never
use copper pipes thinner than that in the table even when it is available on 19.05 mm (3/4 in.)
the market.
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.
WARNING
1 For the room 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 room 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 room air conditioner is serviced or moved.
STANDARD PARTS
The following installation parts are furnished. Use them as required.
Name and Shape Q'ty Use Name and Shape Q'ty
Drain pipe For outdoor unit drain piping Adapter assy For use when connecting
work 12.7 mm / 9.52 mm models 7–12 to outdoor port A
1 2
[Heat & Cool model (Reverse or B
cycle) only]
Drain cap Adapter assy For use when connecting
2 6.35 mm / 9.52 mm model 24
1
Putty For sealing
1 Adapter assy For use when connecting
12.7 mm / 15.88 mm model 24
1
SYSTEM LAYOUT
Layout example for the indoor units and outdoor unit
Power cord
Power source
220-240 V ~ 50 Hz
Circuit breaker
Connection cord
OUTDOOR UNIT
Refrigerant pipe
1. CONNECTABLE INDOOR UNIT CAPACITY TYPE
CAUTION
• The total capacity of the indoor units connected must be between 27,000 and 49,000 BTU. (Refer to the Table.)
Ex. Maximum connection of four indoor units: 22,000+9,000+9,000+9,000=49,000
• If the total capacity of the connected indoor units exceeds 49,000 BTU, an error will be displayed and the units will not operate.
(For information on error displays, refer to the installation instruction sheets included with the indoor units.)
• To install an indoor unit, refer to the installation instruction sheet included with the indoor unit.
• At least three indoor units must be connected to the outdoor unit.
Outdoor port Connectable model name
D 7 – 12
C 7 – 12 *1 When connecting models 7–12 to the outdoor unit, the included adapter is necessary. (For more
information, refer to "2-4 HOW TO USE ADAPTER".)
B 7 – 12 *1 /14 – 18
*2 When connecting model 24 to the outdoor unit, connect only two other indoor units to the outdoor unit.
7 – 12 *1 /14 – 22 (Max indoor unit capacity connection: 24,000 + 12,000 + 12,000 BTU)
A In addition, the included adapter is necessary to connect the indoor unit to the outdoor unit. (For more
24 *2
information, refer to "2-4 HOW TO USE ADAPTER".)
Thickness
0.80 mm
0.80 mm
0.80 mm
1.00 mm
1.20 mm
SELECTING THE MOUNTING POSITION
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.
Decide the mounting position with the customer as follows:
(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.
Use
• 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.
2. LIMITATION OF REFRIGERANT PIPING LENGTH
CAUTION
The total maximum pipe lengths and height difference of
UNIT D
this product are shown in the table.
d 7-12 If the units are further apart than this, correct operation
cannot be guaranteed.
Total max. length (a+b+c+d) 70 m (230 ft)
Max. length for each indoor unit
UNIT C
25 m (82 ft)
(A, B, C, or D)
c 7-12
Max. height difference (H) 10 m (33 ft)
Min. length for each indoor unit
H 5 m (16 ft)
(A, B, C, or D)
*3 If the total piping length is 51 m or longer, additional refrigerant charg-
ing is necessary. (For more information, refer to "2-6 ADDITIONAL
CHARGE".)
H
UNIT B
3. SELECTING PIPE SIZES
b
7-18
The diameters of the connection pipes differ according to the capacity of
the indoor unit.
Refer to the following table for the proper diameters of the connection
pipes between the indoor and outdoor units.
Gas pipe size Liquid pipe size
Capacity of
H
indoor unit (thickness) [mm] (thickness) [mm]
UNIT A
7 – 12 ø9.52 (0.8) ø6.35 (0.8)
a 7-24
14 – 22 ø12.7 (0.8) ø6.35 (0.8)
INDOOR UNITS 24 ø15.88 (1.0) ø9.52 (0.8)
CAUTION
Operation cannot be guaranteed if the correct combina-
tion of pipes, valves, etc., is not used to connect the in-
door and outdoor units.
2
CONNECTING THE PIPE
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
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 flare tool.
Check if [L] is flared uniformly
and is not cracked or scratched.
Die
A
Pipe
Dimension A (mm)
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.)
19.05 mm (3/4 in.)
Pipe outside diameter Dimension B
AIR
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
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
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
INSTALLATION PROCEDURE
4. HEAT INSULATION AROUND CONNECTION
PIPES REQUIREMENTS
1
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. (Re-
1. OUTDOOR UNIT PROCESSING
verse cycle model only)
(1) Outdoor unit to be fasten with bolts at the four places indicated by the
*3 In addition, if the humidity level at the installation location
arrows without fail.
of the refrigerant piping is expected to exceed 70%, install
heat insulation around the refrigerant piping. If the ex-
Bottom side
pected 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).
Connect the connection pipes according to "2 CONNECTING THE PIP-
ING" in this installation instruction sheet.
5. ELECTRICAL REQUIREMENT
Drain pipe
mounting place
• Electric wire size and fuse capacity:
(2) Fix securely with bolts on a solid block. (Use 4 sets of commercially
MAX. 4.0
available M10 bolt, nut and washer.)
Power supply cord (mm 2 )
MIN. 3.5
MAX. 2.5
Connection cord (mm 2 )
MIN. 1.5
OUTDOOR UNIT 25
Fuse capacity (A)
INDOOR UNIT 10
• Install the disconnect device with a contact gap of at least 3 mm nearby
the units.
• Always make the air conditioner power supply a special branch circuit
and provide a special breaker.
(3) Since the drain water flows out of the outdoor unit during heating
• Always use H07RN-F or equivalent as the power supply cord and the
operation, install the drain pipe and connect it to a commercial 16 mm
connection cord.
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)
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
2. BENDING PIPES (3) Attach the connection pipe.
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
over.
2 If the pipe is bent repeatedly at the same place, it will
break.
3. CONNECTION PIPES
Outdoor unit
2-way valve
(1) Detach the caps and plugs from the pipes.
(Liquid)
3-way valve (Gas)
CAUTION
1 Be sure to apply the pipe against the port on the in-
door unit and outdoor 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 dam-
B
aged.
(4) When the flare nut is tightened properly by your hand, use a torque
wrench to finally tighten it.
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
Body side
with your hand.
To prevent gas leakage, coat the flare
surface with alkylbenzene oil (HAB).
Do not use mineral oil.
0
(mm)
-0.4
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
6.35 mm (1/4 in.) dia.
9.52 mm (3/8 in.) dia.
12.70 mm (1/2 in.) dia.
15.88 mm (5/8 in.) dia.
19.05 mm (3/4 in.) dia.
Outdoor unit connection cord and pipe connection
preparations:
Remove outdoor unit valve cover.
OUTDOOR UNIT
INSTALLATION
* After removing the screws,
remove valve cover.
Drain cap
mounting place
Valve cover
650 mm
4-ø 12 hole
Bolt
Nut
Block
CAUTION
Base
Drain pipe
4. HOW TO USE ADAPTER (Connection ports of
outdoor unit)
• When using the ADAPTER, be careful not to overtighten the nut, or the
smaller pipe may be damaged.
• Apply a coat of refrigeration oil to the threaded connection port of the
outdoor unit where the flare nut comes in.
• Use appropriate wrenches to avoid damaging the connection thread by
overtightening the flare nut.
• Apply wrenches on both of flare nut (local part), and ADAPTER to tighten
them.
Adapter tightening torque
Adapter type Tightening torque
ø12.7 mm / ø9.52 mm
50 to 62 [N·m] (500 to 620 kgf·cm)
Flare nut
ø6.35 mm / ø9.52 mm 14 to 18 [N·m] (140 to 180 kgf·cm)
ø12.7 mm / ø15.88 mm
50 to 62 [N·m] (500 to 620 kgf·cm)
Connection pipe
(Liquid)
Frare nut
Connection pipe
(Gas)
Holding spanner
Torque wrench
CAUTION
Tightening torque
14 to 18 N·m (140 to 180 kgf·cm)
33 to 42 N·m (330 to 420 kgf·cm)
50 to 62 N·m (500 to 620 kgf·cm)
63 to 77 N·m (630 to 770 kgf·cm)
100 to 110 N·m (1000 to 1100 kgf·cm)
- Continued on back -