Fujitsu AUY12FBAB Installation Instruction Sheet

Refrigerant
R410A
SPLIT TYPE AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET
(PART NO. 9359992097)
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 (R22) models.
However, pay careful attention to the following points:
(1) Since the working pressure is 1.6 times higher than that of conventional refrigerant (R22) models, some of the piping and
installation and service tools are special. (See the table below.)
Especially, when replacing a conventional refrigerant (R22) 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 con-
ventional refrigerant (R22) 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 (R22) 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
Table 1 Thicknesses of Annealed Copper Pipes
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
Nominal Outer diameter
collapsed, deformed or discolored portion (especially on the interior surface). R410A
diameter (inch) (mm)
Otherwise, the expansion valve or capillary tube may become blocked with
1/4 6.35
contaminants. 0.80
As an air conditioner using R410A incurs pressure higher than when using
3/8 9.52 0.80
R22, it is necessary to choose adequate materials.
1/2 12.70 0.80
Thicknesses of copper pipes used with R410A are as shown in Table 1. Never
use copper pipes thinner than 0.8 mm (Nominal diameter is 1/4 in., 3/8 in.,
1/2 in.), even when it is available on the market.
For authorized service personnel only.
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 air conditioner piping and cords available from our 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) Do not turn on the power until all installation work is complete.
• 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.
SELECTING THE MOUNTING POSITION
Especially, the installation place is very important for the split type air con- OUTDOOR UNIT
ditioner because it is very difficult to move from place after the first instal-
lation. WARNING
Decide the mounting position together with the customer as follows:
(1) Install the unit where it will not be tilted by more than
The discharge direction can be selected as shown below.
5˚.
Fig. 1
(2) When installing the outdoor unit where it may exposed
100 mm (4") or more 100 mm (4") or more 1,000 mm (39") or more
to strong wind, fasten it securely.
(1) If possible, do not install the unit where it will exposed to direct sun-
light. (If necessary, install a blind that does not interfere with the air
flow.)
(2) Install the outdoor unit in a place where it will be free from being dirty
or getting wet by rain as much as possible.
(3) Install the unit when connection to the indoor unit is easy.
(4 directions) (3 directions) (2 directions) (2 directions)
(4) Do not place animals and plants in the path of the warm air.
Piping position 100 mm (4") or more
(5) Take the air conditioner weight into account and select a place where
noise and vibration are small.
CAUTION (6) Select a place so that the warm air and noise from the air conditioner
do not disturb neighbors.
Since 2-way outlet as shown below causes performance
(7) Provide the space shown in Fig. 3 so that the air flow is not blocked.
problems, do not set it.
Also for efficient operation, leave open three of the four directions
front, rear, and both sides.
(8) During heating operation, drain water flows from the outdoor unit.
Therefore, install the outdoor unit in a place where the drain water
Pipe
Pipe
flow will not be obstructed. (Reverse cycle model only)
Fig. 3
INDOOR UNIT [12000 and 14000 BTU/h models]
(1) Install the indoor unit on a place having a sufficient strength so that it
10 cm (4")
withstands against the weight of the indoor unit.
or more
(2) The inlet and outlet ports should not be obstructed; the air should be
able to blow all over the room.
(3) Leave the space required to service the air conditioner. (Fig. 2)
(4) The ceiling rear height is 250 mm (9-3/8") or more.
10 cm (4")
60 cm (2') 60 cm (2')
(5) A place from where the air can be distributed evenly throughout the
or more
or more or more
room by the unit.
(6) A place from where drainage can be extracted outdoors easily.
Fig. 2
60 cm (2')
Strong and durable ceiling
or more
250 mm
(9-3/8")
or more
1,000 mm (39")
1,000 mm (39")
or more
or more
Obstruction
STANDARD PARTS
The following installation parts are furnished. Use them as required.
OUTDOOR UNIT ACCESSORIES
INDOOR UNIT ACCESSORIES
Name and Shape Q'ty Application
Drain pipe
Coupler heat insulation For indoor side pipe joint
2
Drain cap
Special nut A (large flange) For installing indoor unit
4
GRILLE ACCESSORIES
Special nut B (small flange) For installing indoor unit
4
Bolt
Template For ceiling hole cutting
Washer
1
Remote control unit Use for air conditioner Spring washer
operation
1
Blower cover insulation
Battery (penlight) For remote control unit
2
Remote control unit holder For mounting the remote
control unit
1
Tapping screw (ø3 × 12)
For remote control unit
holder installation
2
Thickness (mm)
[ref.] R22
0.80
0.80
0.80
[18000 BTU/h model]
4
30 cm (1')
or more
Do not use the existing (for R22) piping and flare nuts.
30 cm (1') 30 cm (1')
Air • If the existing materials are used, the pressure inside the
or more
or more
refrigerant cycle will rise and cause breakage, injury, etc.
60 cm (2')
or more (Use the special R410A materials.)
(1) Do not use mineral oil on flared part.
60 cm (2')
Prevent mineral oil from getting into the system as this
or more
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 ta-
ble 2. If the units are further apart than this, correct
operation can not be guaranteed.
1. FLARING
CONNECTION PIPE REQUIREMENT
(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.
Table 2
(3) Insert the flare nut (always use the flare nut attached to the indoor
14000 and 18000
and outdoor units respectively) onto the pipe and perform the flare
MODEL 12000 BTU/h model
BTU/h models
processing with a flare tool.
Small 6.35 mm (1/4 in.) 6.35 mm (1/4 in.) Use the special R410A flare tool, or the conventional (for R22) flare
Diameter
Large 9.52 mm (3/8 in.) 12.70 mm (1/2 in.) tool.
When using the conventional flare tool, always use an allowance ad-
Maximum length
20 m (66 ft) 20 m (66 ft) justment gauge and secure the A dimension shown in table 4.
Maximum Height Fig. 11
8 m (26 ft) 8 m (26 ft)
(between indoor and outdoor)
• 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. L
Use heat insulation with heat resistance above 120 °C. (Re-
verse cycle model only)
In addition, if the humidity level at the installation location
of the refrigerant piping is expected to exceed 70%, install
Pipe outside
heat insulation around the refrigerant piping. If the ex-
diameter
pected humidity level is 70-80%, use heat insulation that
is 15 mm or thicker and if the expected humidity exceeds
6.35 mm (1/4 in.)
80%, use heat insulation that is 20 mm or thicker. 9.52 mm (3/8 in.)
If heat insulation is used that is not as thick as specified,
12.70 mm (1/2 in.)
condensation may form on the surface of the insulation.
In addition, use heat insulation with heat conductivity of 2. Bending pipes
0.045 W/(m·K) or less (at 20 °C).
The pipes are snapped by your hands. Be careful not to collapse them.
Fig. 12
ELECTRICAL REQUIREMENT
• Electric wire size and fuse capacity:
Table 3
12000 and 14000
MODEL
18000 BTU/h model
BTU/h models
MAX.
Power supply cord 3.0 3.0
(mm 2 ) MIN. 2.0 2.5
Connection cord MAX. 2.5 2.5
Do not bend the pipes in an angle more than 90°.
(mm 2 )
MIN. 1.5 1.5 When pipes are repeatedly bent or stretched, the material will harden,
Fuse capacity (A) 15 20 making it difficult to bend or stretch them any more. Do not bend or stretch
the pipes more than three times.
• Always use H07RN-F or equivalent to the connection cord.
• Install the circuit breaker nearby the units. (Both indoor unit and out-
door unit)
INSTALLATION PROCEDURE
Install the air conditioner as follows:
Name and Shape Q'ty Application
1
INDOOR UNIT INSTALLATION
1
For outdoor unit drain piping
work
[Heat & Cool model
12000 and 14000 1. Position the ceiling hole and hanging bolts as
2 (Reverse cycle) only]
BTU/h models
shown in Fig. 4.
18000 BTU/h model 1
Fig. 4
( 650 mm) (Grille measurement)
( 650 mm (25-15/32")
Name and Shape Q'ty Application (Hanging bolt position)
400 mm (15-3/4")
For mounting grille
4
For mounting grille
4
For mounting grille
4
For discharged air
2
66 mm (2-19/32")
2. Hanging preparations
Firmly fasten the hanging bolts as shown in Fig. 5 or by another method.
Fig. 5
Hole-in anchor
Concrete Insert
Hole-in plug
Hanging bolt
M10
Fig. 6
60 mm (2-3/8")
Drain pipe (I. D. ø32 mm)
46 mm (1-27/32")
86 mm (3-3/8")
600 mm ( 23-5/8")
(Ceiling opening measurement)
CONNECTING THE PIPING When bending the pipe, do not Fig. 13
Pipe
bend it as is. The pipe will be
collapsed. In this case, cut the Heat insulating
pipe
heat insulating pipe with a
sharp cutter as shown in Fig.
WARNING
Cutter
13, and bend it after exposing
the pipe. After bending the pipe
as you want, be sure to put the
heat insulating pipe back on the
Cut line
pipe, and secure it with tape.
CAUTION
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
(1) Indoor unit side
Fig. 14
Indoor unit
CAUTION
Check if [L] is flared uniformly (1) Be sure to apply the pipe against the port on the in-
and is not cracked or scratched.
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.
Die
A (2) Do not remove the flare nut from the indoor unit pipe
unit immediately before connecting the connection
Pipe
pipe.
Table 4 Pipe outside diameter When the flare nut is tightened properly by your hand, hold the body side
coupling with a separate spanner, then tighten with a torque wrench. (Fig.
A (mm)
15)
Flare tool for Conventional (R22) flare tool
Fig. 15
R410A, clutch type Clutch type Wing nut type
0 to 0.5 1.0 to 1.5 1.5 to 2.0
Tighten with two wrenches.
0 to 0.5 1.0 to 1.5 1.5 to 2.0
0 to 0.5 1.0 to 1.5 2.0 to 2.5
Wrench (fixed)
Flare nut
Torque wrench
Indoor unit
To prevent gas leakage,
pipe
Connection pipe
coat the flare surface with
alkylbenzene oil (HAB).
Do not use mineral oil.
Extend the pipe
by unwinding it.
2
3. Body installation INSTALLING DRAIN PIPE
(1) Install special nut A, then special nut B onto the hanging bolt. (Fig. 7)
(2) Raise the body and mount its hooks onto the hanging bolt between
Note: Install the drain pipe.
the special nuts. (Fig. 7)
• Install the drain pipe with downward gradient (1/50 to 1/100) and so
(3) Turn special nut B to adjust the height of the body. (Fig. 7)
there are no rises or traps in the pipe.
(4) Leveling
• Use general hard polyvinyl chloride pipe (VP25) [outside diameter 32
Using a level, or vinyl hose filled with water, fine adjust so that the
mm (1-1/4")] and connect it with adhesive (polyvinyl chloride) so that
body is level.
there is no leakage.
• When the pipe is long, install supporters.
WARNING
• Do not perform air bleeding.
• Always heat insulate the indoor side of the drain pipe.
Perform final tightening by tightening the double nut firmly.
• When desiring a high drain pipe height, raise it up to 400 mm (15") or
less from the ceiling within a range of 150 mm (6") from the body. A
rise dimension over this range will cause leakage.
Fig. 7
Fig. 9
Special nut A
After installing the
Hook
body, tighten the nuts.
Special nut B
30 mm
Hanging bolt
or more
Air bleeding
15 mm (19/32")
Ceiling
Fig. 8
Vinyl hose
Table 5 Flare nut tightening torque Fig. 16
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)
Outdoor unit
12.70 mm (1/2 in.) dia. 50 to 62 N · m (500 to 620 kgf · cm)
Service hose
Do not remove the cap from the connection pipe before connecting with valve core
the pipe.
CAUTION
Be sure to connect the large pipe after connecting the small
pipe completely.
Fig. 17
(2) Outdoor unit side
Tighten the flare nut of the connection pipe at the outdoor unit valve [12000 and 14000 BTU/h models]
connector. The tightening method is the same as that as at the indoor
side.
Small pipe
Large pipe
[18000 BTU/h model]
5
VACUUM PROCESS
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 for R410A exclusively. Using the
same vacuum pump for different refrigerants may dam-
age the vacuum pump or the unit.
1. 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 15 minutes.
2. Additional charge
(4) Disconnect the service hoses and fit the cap to the charging valve to
the specified torque.
Refrigerant suitable for a piping length of 7.5 m is charged in the outdoor
(5) Remove the blank caps, and fully open the spindles of the 2-way and
unit at the factory.
3-way valves with a hexagon wrench (Torque : 6 to 7 N · m (60 to 70
When the piping is longer than 7.5 m, additional charging is necessary.
kgf · cm).
For the additional amount, see the table below.
(6) Tighten the blank caps of the 2-way valve and 3-way valve to the
specified torque.
Table 6
Additional
refrigerant
Tightening torque
12000 and 14000 BTU/h
Blank cap (2-way valve) models
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 cap
18000 BTU/h model
(3-way valve)
12.70 mm (1/2 in.) 25 to 30 N · m (250 to 300 kgf · cm)
Charging port cap
10 to 12 N · m (100 to 120 kgf · cm)
3
OUTDOOR UNIT
INSTALLATION
• Set the unit on a strong stand, such as one made of concrete blocks to
minimize shock and vibration.
• Do not set the unit directly on the ground because it will cause trouble.
• Since the drain water flows out of the outdoor unit during heating op-
eration, install the drain pipe and connect it to an commercial 16 mm
hose. (Heat & Cool model (Reverse cycle) only)
• When installing the drain pipe, plug all the holes (• hole at one place or
two places) other than the drain pipe mounting hole in the bottom of the
outdoor unit with putty so there is no water leakage. (Fig. 10) (Heat &
Cool model (Reverse cycle) only)
CAUTION
Installation in cold regions. Do not use the accessory drain
Supporter
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.)
Rise
Trap
Fig. 10
1.5 to 2.0 m (5 to 6.5 ft)
150 mm (6") or less
[12000 and 14000 BTU/h models]
Max. 400 mm (15") Air flow
Bottom
Drain cap
504 mm (21-1/4")
Drain pipe mounting hole
Bottom plate
Drain pipe
[18000 BTU/h model]
Air flow
Bottom
Drain cap
603 mm (23-23/32")
Drain pipe mounting hole
Bottom plate
Drain pipe
CAUTION
Connecting pipe
(1) When moving and installing the air conditioner, do not
mix gas other than the specified refrigerant (R410A)
Blank cap
inside the refrigerant cycle.
Hexagon wrench
(2) When charging the refrigerant R410A, always use an
Use a 4 mm
electronic balance for refrigerant charging (to meas-
hexagon wrench.
3-way valve
ure the refrigerant by weight).
Charging port
(3) When charging the refrigerant, take
into account the slight change in the Gas
composition of the gas and liquid
phases, and always charge from the
Cap
liquid phase side whose composi-
tion is stable. Liquid
(4) Add refrigerant from the charging valve after the com-
pletion of the work.
(5) If the units are further apart than the maximum pipe
Gauge manifold length, correct operation can not be guaranteed.
CAUTION
t
Use a clean gauge mani-
fold and charging hose
3. GAS LEAKAGE INSPECTION
for R410A exclusively.
Vacuum pump
CAUTION
After connecting the piping, check the joints for gas leak-
age with gas leak detector.
Service hose
CAUTION
Use a clean gauge mani-
fold and charging hose
for R410A exclusively. 6
INSTALLING THE COUPLER
HEAT INSULATION
Gauge manifold
After checking for gas leaks, insulate by wrapping insulation around the
LO HI
two parts (large and small) of the indoor unit coupling, using the coupler
heat insulation.
Vacuum pump
Fig. 18
Coupler heat insulation
Service hose
Body
Be sure to overlap the
insulation
CAUTION
Must fit tightly against body without any gap.
Table 7
No gap
Pipe length 7.5 m 10 m 15 m 20 m g/m
Coupler heat insulation
(25 ft) (33 ft) (49 ft) (66 ft) (oz/ft)
10 g/m
25 g 75 g 125 g
None
(0.9 oz) (2.6 oz) (4.4 oz) (0.35 oz/3.3 ft)
50 g 150 g 250 g 20 g/m
None
(1.8 oz) (5.3 oz) (8.8 oz) (0.71 oz/3.3 ft)
- Continued on back -
R410A