Fujitsu ABU36RSLX Installation Instruction

Refrigerant
R410A Ceiling Suspension Type
SPLIT TYPE AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET
(PART NO. 9364488028)
For authorized service personnel only.
IMPORTANT!
Please Read Before Starting
This air conditioning system meets strict safety and operating standards. When Transporting
As the installer or service person, it is an important part of your job to
Be careful when picking up and moving the indoor and outdoor units. Get
install or service the system so it operates safely and efficiently.
a partner to help, and bend your knees when lifting to reduce strain on
your back. Sharp edges or thin aluminum fins on the air conditioner can
For safe installation and trouble-free operation, you must:
cut your fingers.
•
Carefully read this instruction booklet before beginning.
•
Follow each installation or repair step exactly as shown. When Installing...
• Observe all local, state, and national electrical codes.
...In a Ceiling or Wall
• Pay close attention to all danger, warning, and caution notices given in
Make sure the ceiling/wall is strong enough to hold the unit's weight. It
this manual.
may be necessary to construct a strong wood or metal frame to provide
This symbol refers to a hazard or unsafe practice which added support.
WARNING:
can result in severe personal injury or death.
...In a Room
This symbol refers to a hazard or unsafe practice which
Properly insulate any tubing run inside a room to prevent "sweating" that
CAUTION: can result in personal injury and the potential for can cause dripping and water damage to walls and floors.
product or property damage.
...In Moist or Uneven Locations
•
Hazel alerting symbols Use a raised concrete pad or concrete blocks to provide a solid, level
foundation for the outdoor unit. This prevents water damage and abnor-
mal vibration.
Electrical
...In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a metal frame.
Provide a suitable air baffle.
Safety / alert ...In a Snowy Area (for Heat Pump-type Systems)
Install the outdoor unit on a raised platform that is higher than drifting
snow. Provide snow vents.
If Necessary, Get Help
When Connecting Refrigerant Tubing
These instructions are all you need for most installation sites and mainte-
•
nance conditions. If you require help for a special problem, contact our Keep all tubing runs as short as possible.
•
sales/service outlet or your certified dealer for additional instructions. Use the flare method for connecting tubing.
• Apply refrigerant lubricant to the matching surfaces of the flare and
In Case of Improper Installation
union tubes before connecting them, then tighten the nut with a torque
The manufacturer shall in no way be responsible for improper installation
wrench for a leak-free connection.
or maintenance service, including failure to follow the instructions in this •
Check carefully for leaks before starting the test run.
document.
NOTE:
SPECIAL PRECAUTIONS Depending on the system type, liquid and gas lines may be either narrow
or wide. Therefore, to avoid confusion the refrigerant tubing for your
When Wiring particular model is specified as either "small" or "large" rather than as
"liquid" or "gas".
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR
DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD When Servicing
ATTEMPT TO WIRE THIS SYSTEM.
• Turn the power OFF at the main circuit breaker panel before opening
• Do not supply power to the unit until all wiring and tubing are completed the unit to check or repair electrical parts and wiring.
•
or reconnected and checked. Keep your fingers and clothing away from any moving parts.
• • Clean up the site after you finish, remembering to check that no metal
Highly dangerous electrical voltages are used in this system. Carefully
scraps or bits of wiring have been left inside the unit being serviced.
refer to the wiring diagram and these instructions when wiring. Improper
•
connections and inadequate grounding can cause accidental injury or After installation, explain correct operation to the customer, using the
operating manual.
death.
•
Ground the unit following local electrical codes.
• Connect all wiring tightly. Loose wiring may cause overheating at con-
nection points and a possible fire hazard.
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.) 0.80 mm (0.0315 in.)
expansion valve or capillary tube may become blocked with contaminants.
As an air conditioner using R410A incurs pressure higher than when using 9.52 mm (3/8 in.) 0.80 mm (0.0315 in.)
conventional refrigerant, it is necessary to choose adequate materials.
12.70 mm (1/2 in.) 0.80 mm (0.0315 in.)
Thicknesses of copper pipes used with R410A are as shown in the table. Never
15.88 mm (5/8 in.) 1.00 mm (0.0394 in.)
use copper pipes thinner than that in the table even when it is available on
the market.
GENERAL
This INSTALLATION INSTRUCTION SHEET briefly outlines where and how to install the air conditioning system. Please read over the entire set of instructions
for the indoor and outdoor units and make sure all accessory parts listed are with the system before beginning.
CONNECTION PIPE REQUIREMENT
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 248 °F. (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 (19/32 in.) or
thicker and if the expected humidity exceeds 80%, use heat insulation that is 20 mm (3/4 in.) 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 68 °F).
ELECTRICAL REQUIREMENT
• • • • • Electric wire size:
Connection cord (mm ) 2
MAX. MIN.
1.0
2.5
• • • • • Install all electrical works in accordance to the standard.
• • • • • Install the disconnect device with a contact gap of at least 3 mm (1/8") 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 in the
figure. Also install the unit where the filter can be removed.
Ceiling
80 mm (3-1/8")
or over
INDOOR UNIT
Ceiling
80 mm (3-1/8") 150 mm (6")
or over or over
10 mm (3/8")
or over
Floor
STANDARD PARTS OPTIONAL PARTS
The following installation parts are furnished. The following options are available.
Use them as required. • • • • • DRAIN PUMP UNIT: UTR-DPB241 (P/N 9034087001)
• • • • • WIRED REMOTE CONTROLLER UNIT: UTB-UUB (P/N 9075887004)
INDOOR UNIT ACCESSORIES
Name and Shape Q'ty Application
Remote Use for air conditioner
control unit operation
1
Battery (penlight) For remote control unit
2
Remote For mounting the remote
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
Thickness
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
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 "= 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
Ceiling panel Template
Drilling position for piping
INDOOR UNIT
1. LOCATION OF CEILING SUSPENSION BOLTS
30 mm (1-3/16") Suspension bolt pitch 1600 mm (63")
30 mm (1-3/16")
Dimensions
Ceiling panel
(Space Required
150 mm (6")
for Installation)
or over
10 mm (3/8")
155 mm (6-3/32")
10 mm (3/8")
INDOOR UNIT (TOP VIEW) 300 mm (12")
or over
Suspension bolt should
Floor extend outward 30 to 75 mm.
INDOOR UNIT
(1-3/16" to 2-31/32")
3
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
Pipe outside diameter
Flare tool for R410A, clutch type
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
0 to 0.5 mm (0 to 0.0197 in.)
12.70 mm (1/2 in.)
15.88 mm (5/8 in.)
Pipe outside diameter Dimension B
6.35 mm (1/4 in.) 9.1 mm (0.3583 in.)
9.52 mm (3/8 in.) 13.2 mm (0.5197 in.)
12.70 mm (1/2 in.) 16.6 mm (0.6536 in.)
15.88 mm (5/8 in.) 19.7 mm (0.7756 in.)
When using conventional flare tools to flare R410A pipes, the dimension
A should be approximately 0.5 mm (1/32 in.) more than indicated in the
table (for flaring with R410A flare tools) to achieve the specified flaring.
Use a thickness 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 (0.6693 in.)
9.52 mm (3/8 in.) 22 mm (0.8661 in.)
12.70 mm (1/2 in.) 26 mm (1.0236 in.)
15.88 mm (5/8 in.) 29 mm (1.1417 in.)
[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 (1-9/16") Ceiling Opening: 1580 mm (62") 40 mm (1-9/16")
(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 (25-3/16")
15 mm (19/32")
Ceiling panel
Ceiling
Suspension bolt should
extend outward 30 to 50 mm.
INDOOR UNIT
(1-3/16" to 1-31/32")
M10 Anchor Bolt
(Obtained locally)
2. SELECT PIPING DIRECTION
4. INSTALLING THE INDOOR UNIT
Select connection piping and drain piping directions.
(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
INDOOR UNIT (TOP VIEW)
Side cover B
3 Right
(Left side)
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
(as far as it will go). [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
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
(13/32" to 19/32")
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.
• 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
Connection pipe (Gas)
(6") or 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
Body side
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.
B
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.
Flare nut
To prevent gas leakage, coat the flare
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.
0 15.88 mm (5/8 in.) dia.
-0.4
Indoor unit
Filter guide
(4) Attach the connection pipe.
Connection pipe (Gas)
Connection pipe (Liquid)
Indoor unit
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
980 to 1470 N (100 to 150 kgf) piping may lead to water leaks.
• • • • • 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 (1-1/2")].
• • • • • 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 (5/16") or over thick) the indoor side of the
(Obtained locally)
drain pipe.
Drain pipe
GOOD
Arrange the drain pipe
lower than this portion.
Lifted up
Ceiling
Wave
BAD BAD
End in water
Wall
Supporter
1.5 to 2 m
(5 to 6.5 ft)
(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 (5/16").)
Drain pipe insulation (accessories)
Indoor unit (drain port)
Drain pipe insulation
Indoor unit Drain pipe
Glass wool insulate (10 to 20 mm
10 mm (3/8") or over
No gap
(3/8" to 3/4") 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
2 Top piping
Connection pipe (Gas)
Indoor unit (rear)
Auxiliary pipe (Gas pipe)
Holding spanner
Torque wrench
CAUTION
Tightening torque
16 to 18 N·m (160 to 180 kgf·cm)
30 to 42 N·m (300 to 420 kgf·cm)
49 to 61 N·m (490 to 610 kgf·cm)
63 to 75 N·m (630 to 750 kgf·cm)
- Continued on back -