Fujitsu 9374318117 Installation Instructions

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SPLIT TYPE AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET

(PART NO. 9374318117)

For authorized service personnel only.

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 instal-

lation 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 con-

ventional 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

) for high pressure.

–0.1 to 3.8 MPa (–76 cmHg to 38 kgf/cm

) 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

It is necessary to use seamless copper pipes and it is desirable that the amount

Table 1 Thicknesses of Annealed Copper Pipes

of residual oil is less than 40 mg/10 m. Do not use copper pipes having a

collapsed, deformed or discolored portion (especially on the interior surface).

Otherwise, the expansion valve or capillary tube may become blocked with

Nominal

Outer diameter

contaminants.

diameter (inch)

(mm)

As an air conditioner using R410A incurs pressure higher than when using

1/4

6.35

R22, it is necessary to choose adequate materials.

3/8

9.52

Thicknesses of copper pipes used with R410A are as shown in Table 1. Never

1/2

12.70

use copper pipes thinner than 0.8 mm (Nominal diameter is 1/4 in., 3/8 in. 1/2

in.), 1.0 mm (Nominal diameter is 5/8 in.) even when it is available on the market.

5/8

15.88

For authorized service personnel only.

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 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 standards parts. This installa-

tion 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 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.

(10) Use a clean gauge manifold and charging hose for R410A exclusively.

(11) 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.

CAUTION

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.

• • • • • 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.

STANDARD ACCESSORIES

CONNECTION PIPE REQUIREMENT

The following accessories are supplied with the outdoor unit. Use them as

required.

Install heat insulation around both the gas and liquid pipes.

Name and Shape

Q'ty

Application

Failure to do so may cause water leaks.

Use heat insulation with heat resistance above 120 °C. (Re-

Drain pipe

For outdoor unit drain piping

verse cycle model only)

work

In addition, if the humidity level at the installation location

[Heat & Cool model

(Reverse cycle) only]

of the refrigerant piping is expected to exceed 70%, install

Drain cap

heat insulation around the refrigerant piping. If the ex-

pected humidity level is 70-80%, use heat insulation that

is 15 mm or thicker and if the expected humidity exceeds

Adapter assy

For use when connecting

80%, use heat insulation that is 20 mm or thicker.

12.7 mm / 9.52 mm

model 12,000 BTU/h

If heat insulation is used that is not as thick as specified,

(1/2" / 3/8")

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.

MODEL

Diameter

Maximum length

Maximum Height

(between indoor and outdoor)

• • • • • Use pipe with water-resistant heat insulation.

• • • • • Use pipe that can withstand a pressure of 4,150 kPa.

ELECTRICAL REQUIREMENT

• • • • • Electric wire size and fuse capacity:

Power supply cord (mm

Connection cord (mm

Fuse capacity (A)

• • • • • 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.

• • • • • Always use H07RN-F or equivalent as the power supply cord and the

connection cord.

Thickness (mm)

R410A

0.80

1.00

SELECTING THE MOUNTING POSITION

WARNING

Install at a place that can withstand the weight of the indoor and outdoor units and install positively so that the units will not

topple or fall.

CAUTION

(1) Do not install where there is the danger of combustible gas leakage.

(2) Do not install near heat sources.

(3) If children under 10 years old may approach the unit, take preventive measures so that they cannot reach the unit.

Decide the mounting position with the customer as follows:

(1) 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

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 disturbed

by air blowing into their windows or by noise.

(5) Provide the space shown in figure so that the air flow is not blocked.

Also for efficient operation, leave open three of the four directions

front, rear, and both sides.

•

When selecting the installation location of the indoor unit, consult the

customer and refer to the installation instruction sheet included with

the indoor unit.

INSTALLATION PROCEDURE

CAUTION

OUTDOOR UNIT INSTALLATION

1. OUTDOOR UNIT PROCESSING

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.

• 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 a commercial 16 mm

hose. (Heat & Cool model (Reverse cycle) only)

• When installing the drain pipe, plug all the holes (• hole at one place)

Table 2

other than the drain pipe mounting hole in the bottom of the outdoor

14000 BTU/h

12000 BTU/h

unit with putty so there is no water leakage. (Heat & Cool model (Re-

model

verse cycle) only)

Small

6.35 mm (1/4 in.) 6.35 mm (1/4 in.)

Large

12.70 mm (1/2 in.) 9.52 mm (3/8 in.)

CAUTION

25 m (82 ft)

Installation in cold regions. Do not use the accessory drain

pipe and drain cap.

15 m (49 ft)

(If the drain pipe and drain cap are used, the drain water in

the pipe may freeze in extremely cold weather.)

Air flow

Bottom

Drain

cap

Table 3

3.0

MAX.

)

MIN.

2.0

603 mm

MAX.

2.5

)

MIN.

1.5

Drain pipe mounting hole

Bottom plate

Drain pipe

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

30 cm

gauge indicates –0.1 MPa (–76 cmHg).

or over

(3) When –0.1 MPa (–76 cmHg) is reached, operate the vacuum pump

for at least 15 minutes.

(4) Disconnect the service hoses and fit the cap to the charging valve to

the specified torque.

(5) Remove the blank caps, and fully open the spindles of the 2-way and

3-way valves with a hexagon wrench (Torque : 6 to 7 N · m (60 to 70

30 cm

kgf · cm).

Air

or over

(6) Tighten the blank caps of the 2-way valve and 3-way valve to the

specified torque.

60 cm

or over

Table 6

Tightening torque

Blank cap (2-way valve)

20 to 25 N · m (200 to 250 kgf · cm)

60 cm

Blank cap

12.70 mm (1/2 in.)

25 to 30 N · m (250 to 300 kgf · cm)

or over

(3-way valve)

15.88 mm (5/8 in.)

30 to 35 N · m (300 to 350 kgf · cm)

Charging port cap

10 to 12 N · m (100 to 120 kgf · cm)

Connecting pipe

Blank cap

Hexagon wrench

Outdoor unit

Use a 4 mm

hexagon wrench.

3-way valve

Service hose

with valve core

Charging port

Cap

CAUTION

Use a clean gauge mani-

fold and charging hose

for R410A exclusively.

Gauge manifold

Vacuum pump

Service hose

CONNECTING THE PIPING

2. OUTDOOR UNIT CONNECTION CORD AND

PIPE CONNECTION PREPARATIONS

Remove outdoor unit valve cover.

WARNING

Do not use the existing 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.)

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 ta-

ble 2. 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.

Valve cover

Use the special R410A flare tool, or the conventional flare tool.

When using the conventional flare tool, always use an allowance ad-

justment gauge and secure the A dimension shown in table 4.

Remove outdoor unit terminal cover.

Check if [L] is flared uniformly

and is not cracked or scratched.

* After removing the screws,

remove terminal cover.

Die

Terminal cover

Table 4 Pipe outside diameter

A (mm)

Pipe outside diameter

Flare tool for R410A, clutch type

6.35 mm (1/4 in.)

0 to 0.5

9.52 mm (3/8 in.)

0 to 0.5

12.70 mm (1/2 in.)

0 to 0.5

15.88 mm (5/8 in.)

0 to 0.5

2. BENDING PIPES

(1) When bending the pipe, be careful not to crush it.

(2) To prevent breaking of the pipe, avoid sharp bends. Bend the pipe

with a radius of curvature of 150 mm or over.

(3) If the copper pipe is bend the pipe or pulled to often, it will become

stiff. Do not bend the pipes more than three times at one place.

2. ADDITIONAL CHARGE

Refrigerant suitable for a piping length of 10 m is charged in the outdoor

unit at the factory.

When the piping is longer than 10 m, additional charging is necessary.

For the additional amount, see the table below.

Table 7

g/m

Pipe length

10 m

15 m

20 m

25 m

Additional

(oz/ft)

refrigerant

(33 ft)

(49 ft)

(66 ft)

(82 ft)

Heat &

Cool

12,000 BTU/h

100 g

200 g

300 g

20 g/m

model

14,000 BTU/h

None

(3-17/ 32 oz)

(7-1/16 oz)

(10-19/32 oz)

(7/32 oz/ft)

(Reverse

class

cycle)

CAUTION

(1) When moving and installing the air conditioner, do not

mix gas other than the specified refrigerant (R410A)

inside the refrigerant cycle.

(2) When charging the refrigerant R410A, always use an

electronic balance for refrigerant charging (to meas-

ure the refrigerant by weight).

(3) When charging the refrigerant, take

into account the slight change in the

Gas

composition of the gas and liquid

R410A

phases, and always charge from the

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

length, correct operation can not be guaranteed.

3. GAS LEAKAGE INSPECTION

CAUTION

After connecting the piping, check the joints for gas leak-

age with gas leak detector.

3. CONNECTION

(1) Install the outdoor unit wall cap (supplied with the optional installation

set or procured at the site) to the wall hole pipe.

(2) Connect the outdoor unit and indoor unit piping.

(3) After matching the center of the flare surface and tightening the nut

hand tight, tighten the nut to the specified tightening torque with a

torque wrench.

Tighten with two wrenches.

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.

Table 5 Flare nut tightening torque

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)

50 to 62 N · m (500 to 620 kgf · cm)

12.70 mm (1/2 in.) dia.

63 to 77 N · m (630 to 770 kgf · cm)

15.88 mm (5/8 in.) dia.

Do not remove the cap from the connection pipe before connecting

the pipe.

4. HOW TO USE ADAPTER (Connection ports of

12,000 BTU/h model 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

Pipe

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)

ø12.7 / ø9.52 (1/2" / 3/8")

ADAPTER

- Continued on back -