Fujitsu 9315342089 Installation Manual

SPLIT TYPE ROOM AIR CONDITIONER

INSTALLATION MANUAL

(PART NO. 9315342089)
• Connect all wiring tightly. Loose wiring may cause overheating at con-
IMPORTANT!
nection points and a possible fire hazard.
Please Read Before Starting
When Transporting
This air conditioning system meets strict safety and operating standards. Be careful when picking up and moving the indoor and outdoor units.
As the installer or service person, it is an important part of your job to Get a partner to help, and bend your knees when lifting to reduce strain
install or service the system so it operates safely and efficiently.
on your back. Sharp edges or thin aluminum fins on the air conditioner
can cut your fingers.
For safe installation and trouble-free operation, you must:
When Installing...
• Carefully read this instruction booklet before beginning.
• Follow each installation or repair step exactly as shown.
...In a Ceiling or Wall
• Observe all local, state, and national electrical codes.
Make sure the ceiling/wall is strong enough to hold the unit's weight. It
• Pay close attention to all danger, warning, and caution notices given in
may be necessary to construct a strong wood or metal frame to provide
this manual.
added support.
This symbol refers to a hazard or unsafe practice which
WARNING: ...In a Room
can result in severe personal injury or death.
Properly insulate any tubing run inside a room to prevent "sweating" that
can cause dripping and water damage to walls and floors.
This symbol refers to a hazard or unsafe practice which
CAUTION: can result in personal injury and the potential for product
or property damage. ...In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to provide a solid, level
• Hazel alerting symbols
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.
• Check carefully for leaks before starting the test run.
or maintenance service, including failure to follow the instructions in this
document.
NOTE:
SPECIAL PRECAUTIONS Depending on the system type, liquid and gas lines may be either nar-
row or wide. Therefore, to avoid confusion the refrigerant tubing for your
particular model is specified as either "small" or "large" rather than as
When Wiring
"liquid" or "gas".
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL
When Servicing
INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED
ELECTRICIAN SHOULD 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.
• Keep your fingers and clothing away from any moving parts.
or reconnected and checked.
• Highly dangerous electrical voltages are used in this system. Carefully • Clean up the site after you finish, remembering to check that no metal
scraps or bits of wiring have been left inside the unit being serviced.
refer to the wiring diagram and these instructions when wiring. Improper
• After installation, explain correct operation to the customer, using the
connections and inadequate grounding can cause accidental injury
or death. operating manual.
• Ground the unit following local electrical codes.
GENERAL STANDARD ACCESSORIES
This INSTALLATION MANUAL briefly outlines where
The following installation accessories are supplied. Use them as
and how to install the air conditioning system. Please
required.
read over the entire set of instructions for the indoor
Name and Shape Q'ty Name and Shape Q'ty
and outdoor units and make sure all accessory parts
listed are with the system before beginning.
Wall hook bracket Cloth tape
1. TYPE OF COPPER PIPE AND INSULATION MATERIAL
1
Copper tubing for connectin the outdoor unit to the indoor
unit and insulation material is available for purchase locally.
When you purchase them, please specify the following.
Tapping screw (big)
A. Deoxidized annealed copper pipe for refrigerant piping as: Remote
control
unit
Small pipe Large pipe
Outer diameter Thickness Outer diameter Thickness 1
0.031496 in 0.03937 in Tapping screw (small)
3/8"(9.52 mm) 5/8"(15.88 mm)
(0.8 mm) (1.0 mm)
Cut each pipe to the appropriate length +12" (30 cm)
Battery
to16" (40 cm) to dampen vibration between units.
B. Foamed polyethylene insulation for copper pipes as
Air cleaning filter
2
required to precise length of piping. Wall thickness
of the insulation should not be less than 5/16" (8 mm).
C. Use insulated copper wire for field wiring.
CAUTION
Remote control Air cleaning filter frame
unit holder
Check local electrical codes and regulations
before obtaining wire. Also, check any specified
instructions or limitations.
1
2. ADDITIONAL MATERIALS REQUIRED FOR INSTALLATION
Insulation (Drain hose)
A. Refrigeration (armored) tape
B. Insulated staples or clamps for connecting wire
(See your local electrical codes.)
C. Putty
D. Refrigeration lubricant
E. Clamps or saddles to secure refrigerant piping
The following items are necessary to install this air conditioner. (The
3. OPERATING RANGE items are not included with the air conditioner and must be purchased
separately.)
Cooling/Dry Mode
Name
Outdoor temperature About 14 to 115 °F
Connection pipe assembly
Indoor temperature About 64 to 90 °F
Connection cord
Indoor humidity About 80% or less
Wall pipe
Decorative tape
ADDITIONAL CHARGE
Vinyl tape
Refrigerant suitable for a piping length of 66 ft (20 m) is charged in
Wall cap
the outdoor unit at the factory.
When the piping is longer than 66 ft (20 m), additional charging is necessary. Saddle
For the additional amount, see the table below.
Drain hose
Tapping screws
Pipe length 99 ft (30 m) 131 ft (40 m) 165 ft (50 m)
Sealant
Additional
14.2 oz (400 g) 1 lb 12 oz (800 g) 2 lb 10 oz (1200 g)
refrigerant M10 bolt, nut
Between 66 ft (20 m) and 165 ft (50 m), when using a connection pipe
other than that in the table, charge additional refrigerant with 0.43 oz/ ELECTRICAL REQUIREMENT
ft (40g/1 m) as the criteria.
Always make the air conditioner power supply a special branch cir-
CAUTION cuit and provide a special switch and receptacle. Do not extend the
power cord.
(1) When adding refrigerant, add the refrigerant from
the charging port at the completion of work.
(2) The maximum length of the piping is 165 ft (50 CAUTION
m). If the units are further apart than this, cor-
MINIMUM CIRCUIT AMPACITY
rect operation can not be guaranteed.
MAXIMUM OVERCURRENT PROTECTION
(TIME DELAY FUSE OR HACR TYPE CIRCUIT BREAKER)
05M109_9315342089_En 1
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) mod-
els, some of the piping and installation and service tools are special.(See the table below.)
ENGLISH
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 conventional refrigerant(R22) and for safety. Therefore, check
beforehand.[The charging port thread diameter for R410A is 1/2 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 opening 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 (-1 to 53 bar) for high pressure.
-0.1 to 3.8 MPa (-1 to 38 bar) 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.
Special gas leakage detector for HFC refrigerant R410A.
Gas leakage detector
Copper pipes
It is necessary to use seamless copper pipes and it is desirable
CONNECTION PIPE REQUIREMENT
that the amount of residual oil is less than 40 mg/10m. Do not
use copper pipes having a collapsed, deformed or discolored
Nominal
portion (especially on the interior surface). Otherwise, the ex- diameter
pansion value or capillary tube may become blocked with con-
3/8in
taminants.
5/8in
As an air conditioner using R410A incurs pressure higher than
when using R22, it is necessary to choose adequate materials.
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 the market.
WARNING
(1) Do not use the existing (for R22) piping and flare nuts.
• If the existing materials are used, the pressure inside the refrigerant cycle will rise and cause breakage, injury,
etc.(Use the special R410A materials.)
(2) When installing and relocating the air conditioner, do not mix gases other than the specified refrigerant(R410A) to
enter the refrigerant cycle.
• If air or other gas enters the refrigerant cycle, the pressure inside the cycle will rise to an abnormally high value
and cause breakage, injury, etc.
CAUTION
When installing pipes shorter than 17ft (5m), sound of the outdoor unit will be transferred to the indoor unit, which
will cause large operating sound or some abnormal sound.
SELECTING THE MOUNTING INSTALLATION DIAGRAM OF
INDOOR AND OUTDOOR UNITS
POSITION
Decide the mounting position with the customer as follows: [INDOOR UNIT]
1. INDOOR UNIT
(1) Install the indoor unit level on a strong wall which is not subject
2"(5 cm) or over
to vibration.
(2) The inlet and outlet ports should not be obstructed : the air should
1
be able to blow all over the room.
(3) Install the unit near an electric outlet or special branch circuit.
(4) Do not install the unit where it will be exposed to direct sunlight.
(5) Install the unit where connection to the outdoor unit is easy.
(6) Install the unit where the drain pipe can be easily installed.
(7) Take servicing, etc. into consideration and leave the spaces shown
8
in the figure. Also install the unit where the filter can be removed.
60"(150 cm)
2. OUTDOOR UNIT
or over
(1) If possible, do not install the unit where it will be exposed to di-
rect sunlight. (If necessary, install a blind that does not interfere
2 with the air flow.)
(2) Do not install the unit where a strong wind blows or where it is
very dusty.
(3) Do not install the unit where people pass.
(4) Take your neighbors into consideration so that they are not dis-
turbed by air blowing into their windows or by noise.
(5) Provide the space shown in the figure so that the air flow is not blocked.
Also for efficient operation, leave open three of the four direc-
2
tions front, rear, and both sides.
[OUTDOOR UNIT]
WARNING
Install at a place that can withstand the weight of the
indoor and outdoor units and install positively so that
2
the units will not topple or fall.
4"(10 cm) or over
CAUTION
(1) Do not install where there is the danger of com-
24"(60 cm) or over
bustible gas leakage.
1
(2) Do not install near heat sources.
(3) If children under 10 years old may approach the
unit, take preventive measures so that they can-
• Do not directly install it on
the ground, otherwise it
not reach the unit.
will cause failure.
(4) Install the indoor unit on the wall where the height
from the floors more than 240 cm.
Q'ty
1
1 [Indoor unit piping direction]
The piping can be connected in the 7 directions in the figure. When
1
the piping is connected in direction 2, 3, 4 or 5, cut along the
1
piping groove in the side of the front panel with a hacksaw.
1
1
1 set
1
1 set
(Rear) In the area with heavy snowfall, if the intake and outlet of outdoor unit is
blocked with snow it is likely to cause of the breakdown. Please con-
1
struct a canopy and a pedestal or place the unit on a high stand (local
configured).
4 set
5 Left
outlet
7 Left rear
outlet
2 Right
1 Rear 6 Center
outlet 4 Left bottom
outlet
outlet
3 Bottom outlet outlet
22 A
30 A
INDOOR UNIT
5 cm or over
CUTTING THE HOLE IN THE WALL FOR THE CONNECTING PIPING
(1) Cut a 3-1/8"(80 mm) diameter hole in the wall at the position shown in
the figure.
(2) When cutting the wall hole at the inside of the wall hook bracket, cut
the hole to a point of intersection of center marks.
When cutting the wall hole at the outside of the wall hook bracket, cut
the hole at a point of 10mm below.
(3) Cut the hole so that the outside end is lower (3/16" to 3/8" (5 to 10
mm)) than the inside end.
(4) Always align the center of the wall hole. If misaligned, water leakage
will occur.
(5) Cut the wall pipe to match the wall thickness, stick it into the wall cap,
fasten the cap with vinyl tape, and stick the pipe through the hole. (The
connection pipe is supplied in the installation set.)
(6) For left piping and right piping, cut the hole a little lower so that drain
water will flow freely.
INSTALLING THE WALL HOOK BRACKET
(1) Install the wall hook bracket so that it is correctly positioned horizon-
tally and vertically. If the wall hook bracket is tiled, water will drip to the
floor.
(2) Install the wall hook bracket so that it is strong enough to withstand
the weight of an adult.
G
Fasten the wall hook bracket to the wall with 6 or more screws through
the holes near the outer edge of the bracket.
G Check that there is no rattle at the wall hook bracket.
WARNING
If the wall pipe is not used, the cord interconnecting
the indoor and outdoor units may touch metal and
cause electric leakage.
FORMING THE DRAIN HOSE AND PIPE
[Rear piping, Right piping, Bottom piping]
G
Install the indoor unit piping in the direction of the wall hole and bind
the drain hose and pipe together with vinyl tape.
G
Install the piping so that the drain hose is at the bottom.
G Wrap the pipes of the indoor unit that are visible from the outside with
Maximum height
Outer Maximum
Thickness decorative tape.
(between indoor and
diameter length
outdoor)
[For Left rear piping, Left piping]
9.52mm 0.8mm Interchange the drain cap and the drain hose.
50m(165ft) 30m(99ft)
15.88mm 1.0mm
CAUTION
(1) In order to align the drain hose and drain cap, be
sure to insert securely and vertically. Incline inser-
tion will cause water leakage.
(2) When inserting, be sure not to attach any mate-
rial besides water. If any other material is attached,
it will cause deterioration and water leakage.
(3) After removing drain hose, be sure not to forget
mounting drain cap.
(4) Be sure to fix the drain hose with tape to the bottom
of piping.
(5) Prevent drain water frozen under low temperature
environment.
When installing indoor unit's drain hose outdoors, necessary
measure for frost protection should be taken to prevent drain
water frozen.
• Under low temperature environment (when outdoor tempera-
ture under 32 °F), after cooling operation is executed, water in
the drain hose could be frozen.
Once drain water is frozen, the drain hose will be blocked
and water leakage may be resulted for indoor unit.
ELECTRICAL WIRING (INDOOR UNIT)
HOW TO THE INSTALL THE INTER-UNIT WIRE HARNESS
1. Remove the screws, then remove the conduit holder.
2. Fasten the inter-unit wire harness to the conduit holder using the lock nut.
Wall hook bracket
IMPORTANT: Refer to figure of inlet-unit wire length about the length of
2-1/2"(6 cm)
inter-unit wire harness.
or over
3. Use the screws to install the conduit holder with which Inter-unit wire har-
ness is included.
2"(5 cm) 4. Remove the screws, then remove the cord clamp.
or over
5. Connect inter-unit wire harness to the terminal.
Refer to the wiring diagram.
6. Use the screws to install the cord clamp.
95"(240 cm)
(Wall cap)
or over
Remote
Connection cord
control unit
holder
Cord clamp
Remote
Tapping
control unit
screw(small)
4"(10 cm) or over
24"(60 cm) or over
Screw
10"
(25 cm)
or over
HOW TO CONNECT WIRING TO THE TERMINALS
A. For solid core wiring (or F-cable)
2"(5 cm) or over
(1) Cut the wire end with a wire cutter or wire-cutting pliers, then strip
the insulation to about 15/16" (25 mm) to expose the solid wire.
• To obtain better operation
(2) Using a screwdriver, remove the terminal screw(s) on the terminal
efficiency, when the outdoor
board.
unit is installed, be sure to
open the front and left side. (3) Using pliers, bend the solid wire to form a loop suitable for the termi-
nal screw.
(4) Shape the loop wire properly, place it on the terminal board and
tighten securely with the terminal screw using a screwdriver.
B. For strand wiring
(1) Cut the wire end with a wire cutter or wire-cutting pliers, then strip
the insulation to about 3/8" (10 mm) to expose the strand wiring.
(2) Using a screwdriver, remove the terminal screw(s) on the terminal
board.
(3) Using a round terminal fastener or pliers, securely clamp a round
CAUTION
terminal to each stripped wire end.
(4) Position the round terminal wire, and replace and tighten the termi-
nal screw using a screwdriver.
(1) Match the terminal block numbers and connection
cord colors with those of the outdoor unit.
Erroneous wiring may cause burning of the electric
parts.
(2) Connect the connection cords firmly to the terminal
block. Imperfect installation may cause a fire.
2006.1.12, 13:48
G For left piping and left rear piping, align the marks on the wall
hook bracket and shape the connection pipe.
G Bend the connection piping at the bend radius of 4"(100 mm) or
Centering marks more and install no more than 1-3/8"(35 mm) from the wall.
Wall hook bracket
G
After passing the indoor piping and drain hose through the wall
hole, hang the indoor unit on the hooks at the top and bottom of
the wall hook bracket.
Lower
Lower [Installing the indoor unit]
G Hang the indoor unit from the hooks at the top of the wall hook
bracket.
G Insert the spacer, etc. between the indoor unit and the wall hook
3-1/8"(80 mm) 3/8" (10 mm)
hole bracket and separate the bottom of the indoor unit from the wall.
or over
3-1/8"(80 mm)
Fasten with
hole
vinyl tape Indoor unit
3/16" to 3/8"(5 to 10 mm)
(Wall pipe)
(Wall cap)
Wall hook bracket
(Inside) Wall (Outside)
Wall hook bracket
Leveling method
CONNECTING THE PIPING
Hang weight
from here.
Tapping screw
(size: large; quantity: 8)
CONNECTION
(1) Install the outdoor unit wall cap (supplied with the optional
installation set or procured at the site) to the wall pipe.
Wall hook
bracket (2) Connect the outdoor unit and indoor unit piping.
String
Weight
(3) After matching the center of the flare surface and tightening
the nut hand tight, tighten the nut to the specified tightening
CAUTION
torque with a torque wrench.
Install the wall hook bracket horizontally and perpen-
FLARING
dicularly.
(1) Cut the connection pipe to the
necessary length with a pipe cut-
ter.
(2) Hold the pipe downward so that
cuttings will not enter the pipe
and remove the burrs.
(3) Insert the flare nut onto the pipe
and flare the pipe with a flaring
tool.
Bind with vinyl tape Insert the flare nut (always use the
Right piping
flare nut attached to the indoor and
Pipe (top)
outdoor units respectively) onto the
Rear piping
pipe and perform the flare process-
Bottom Indoor unit drain hose
ing with a flare tool.
(bottom)
piping
Use the special R410A flare tool,
For left outlet piping, cut off the or the conv-entional (for R22) flare
piping outlet cutting groove tool.
with a hacksaw.
When using the conventional flare
tool, always use an allowance ad-
justment gauge and secure the A di-
Remove the drain cap by pulling
mension shown in the table.
Indoor unit
at the projection at the end of
drain hose
Drain cap the cap with pliers, etc.
BENDING PIPES
CAUTION CAUTION (1) When bending the pipe, be careful not to crush it.
(2) To prevent breaking of the pipe, avoid sharp bends.
Insert the drain hose and drain cap into the drain port, mak- Bend the pipe with a radius of curvature of 6" (150 mm) or
ing sure that it comes in contact with the back of the drain over.
port, and then mount it. If the drain hose is not connected (3) If the copper pipe is bend the pipe or pulled to often, it will
become stiff.
properly, leaking will occur.
Do not bend the pipes more than three times at one place.
• Attach the Insulation (Drain hose) to the drain hose.
Insulation (Drain hose)
Drain hose
The method of adjusting inter-unit wire harness
To connect inter-unit wire harness to the terminal correctly, please
refer to the figure to adjust the length of the part of Inter-unit Wire
harness ahead from conduit holder.
lock nut
CONDUIT HOLDER
SCREW CONDUIT
CONNECTOR
1 2 3 4 Cord clamp
Tab
Screw Square hole
Insert the tab into the square hole of the
Connection cord
indoor unit and fasten with a screw.
Fig. 14
Round
A. Solid wire B. Strand wire
terminal
Loop
Insulation
Screw with
Screw with
special washer
special washer
Round
terminal
Round
Terminal terminal
Wire
board
Wire
Terminal block
CAUTION
(3) Always fasten the outside covering of the connection
cord with the cord clamp. (If the insulator is chafed,
electric leakage may occur.)
(4) Always connect the ground wire.
(5) Do not use the earth screw for an external connector.
Only use for interconnection between two units.
Alignment marks
Wall hook
bracket
Small piping
Connection piping Large piping
Top hooks
(Spacer)
Wall hook
bracket
Indoor unit
(Fitting) Bottom hooks
After hooking the indoor unit to the top hook, hook the fittings of the indoor
unit to the two bottom hooks while lowering the unit and pushing it against
the wall.
Tighten with two wrenches.
Wrench (fixed)
Flare nut
Torque
wrench
To prevent gas leakage, coat the flare
Indoor unit pipe Connection pipe surface with refrigerator oil.
Flare nut tightening torque and L dimension
Check if [L] is flared uniformly
and is not cracked or scratched.
Flare nut
Tightening torque L dimension
21.70 to 30.38 ft•lbs
3/8" (9.52 mm) dia. 1.8 to 2.0mm
(300 to 420 kgf•cm)
46.5 to 55.3 ft•lbs
5/8" (15.88 mm) dia. 2.2 to 2.4mm
(630 to 750 kgf•cm)
Pipe outside diameter
A (mm)
Die Pipe outside
Conventional (R22) flare tool
Flash tool for
diameter
A R410A, clutch type
Clutch type Wing nut type
ø 9.52 mm (3/8") 0 to 0.5 1.0 to 1.5 1.5 to 2.0
Pipe
ø 15.88 mm (5/8") 0 to 0.5 1.0 to 1.5 1.5 to 2.0
CAUTION
(1) Fasten a flare nut with a torque wrench as instructed in this manual. If
fastened too tight, the flare nut may be broken after a long period of time
and cause a leakage of refrigerant.
(2) During installation, make sure that the refrigerant pipe is attached firmly
before you run the compressor. Do not operate the compressor under the
condition of refrigerant piping not attached properly with 3-way valve open.
This may cause abnormal pressure in the refrigeration cycle that leads to
breakage and even injury.
14AWG
(1:1)
EARTH WIRE
CONDUIT HOLDER
CONDUIT CONNECTOR