Fujitsu ABYG 54 Series Installation Instruction Sheet

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Refrigerant

R410A

Ceiling Suspension Type

SPLIT TYPE AIR CONDITIONER

INSTALLATION INSTRUCTION

SHEET

(PART NO. 9360461094)

For authorized service personnel only.

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.

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

) 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

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.)

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

conventional refrigerant, it is necessary to choose adequate materials.

12.70 mm (1/2 in.)

Thicknesses of copper pipes used with R410A are as shown in the table. Never

15.88 mm (5/8 in.)

use copper pipes thinner than that in the table even when it is available on

the market.

19.05 mm (3/4 in.)

STANDARD PARTS

OUTDOOR UNIT ACCESSORIES

The following installation parts are furnished.

Name and Shape

Q'ty

Use them as required.

Drain pipe

For outdoor unit drain

INDOOR UNIT ACCESSORIES

piping work (May not be

Drain cap

supplied, depending on

Name and Shape

Q'ty

Application

the model.)

Remote

Use for air conditioner

control unit

operation

Insulation (seal)

For filling in a gap at the

entrance of connection

cords

Battery (penlight)

For remote control unit

OPTIONAL PARTS

The following options are available.

Remote

For mounting the remote

• • • • • DRAIN PUMP UNIT: UTR-DPB241 (P/N 9034087001)

control

control unit

unit holder

Tapping screw

For remote control unit

(ø3 × 12)

holder installation

Adhesive type 70 × 230

Drain hose insulation

VT wire

For fixing the drain hose

L 280 mm

Coupler heat insulator (large)

For indoor side pipe joint

(Gas pipe)

Coupler heat insulator (small)

For indoor side pipe joint

(Liquid pipe)

Large

Nylon fastener

For fixing the coupler heat

insulator

Small

Special nut A

For installing indoor unit

(large flange)

Special nut B

For installing indoor unit

(small flange)

Installation

For positioning the indoor

template

unit

Auxiliary pipe assembly

For connecting the piping

CONNECTION PIPE REQUIREMENT

CAUTION

The maximum lengths of this product are shown in the following table. If the units are further apart than this, correct operation

can not be guaranteed.

Diameter

Maximum height

Pipe length

Gas

(between indoor

Liquid

and outdoor)

36 Type

45, 54 Type

MAX.

MIN.

9.52 mm (3/8 in.)

15.88 mm (5/8 in.) 19.05 mm (3/4 in.)

50 m

5 m

30 m

• • • • • 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 120 °C. (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 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).

ELECTRICAL REQUIREMENT

• • • • • Electric wire size and breaker capacity:

Power supply cord (mm )

Connection cord (mm )

Breaker capacity (A)

MAX.

MIN.

MAX.

MIN.

4.0

2.5

1.0

• • • • • Always use H07RN-F or equivalent to the connection cord.

• • • • • Install all electrical works in accordance to the standard.

• • • • • Install the disconnect device with a contact gap of at least 3 mm 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

80 mm

in the figure. Also install the unit where the filter can be removed.

or over

Ceiling

INDOOR UNIT

Thickness

0.80 mm

Ceiling

0.80 mm

80 mm

150 mm

or over

1.00 mm

1.20 mm

10 mm

or over

OUTDOOR UNIT

Application

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.

(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.

• • • • • 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.

AIR

If the space is larger than that is stated, the condition

will be the same as that there are no obstacles.

INSTALLATION PROCEDURE

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 "B FRESH-AIR INTAKE".

Air filter

Intake grille

Tapping screw

INDOOR UNIT

Side cover A (Right side)

Side cover B (Right side)

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

Template

Drilling position for piping

Ceiling panel

1. LOCATION OF CEILING SUSPENSION BOLTS

INDOOR UNIT

30 mm

Suspension bolt pitch 1600 mm

30 mm

Dimensions

(Space Required

for Installation)

Ceiling panel

10 mm

150 mm

155 mm

or over

INDOOR UNIT (TOP VIEW)

300 mm

10 mm

or over

Suspension bolt should

extend outward 30 to 75 mm.

INDOOR UNIT

OUTDOOR UNIT

INSTALLATION

1. OUTDOOR UNIT PROCESSING

(1) Outdoor unit to be fasten with bolts at the four places indicated by the

arrows without fail.

Drain cap

Bottom side

mounting place

650 mm

Drain pipe

4-ø 12 hole

mounting place

(2) Fix securely with bolts on a solid block. (Use 4 sets of commercially

available M10 bolt, nut and washer.)

Bolt

Nut

Block

AIR

(3) Since the drain water flows out of the outdoor unit during heating

operation, install the drain pipe and connect it to a commercial 16 mm

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)

CAUTION

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

Base

Drain pipe

[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

Ceiling Opening: 1580 mm

40 mm

(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

15 mm

Ceiling panel

Ceiling

Suspension bolt should

extend outward 30 to 50 mm.

INDOOR UNIT

M10 Anchor Bolt

(Obtained locally)

2. SELECT PIPING DIRECTION

Select connection piping and drain piping directions.

4. INSTALLING THE INDOOR UNIT

(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

Ceiling

INDOOR UNIT (TOP VIEW)

Side cover B

(Left side)

3 Right

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

[For Half-Concealed Installation]

(as far as it will go).

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

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.

CONNECTING THE PIPE

2. BENDING PIPES

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,

CAUTION

making it difficult to bend or stretch them any more. Do not bend or

1 Do not use mineral oil on flared part. Prevent mineral

stretch the pipes more than three times.

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

1 To prevent breaking of the pipe, avoid sharp bends.

gas through them.

Bend the pipe with a radius of curvature of 150 mm or

over.

3 The maximum lengths of this product are shown in the

table. If the units are further apart than this, correct

2 If the pipe is bent repeatedly at the same place, it will

operation can not be guaranteed.

break.

1. FLARING

3. CONNECTION PIPES

(1) Cut the connection pipe to the necessary length with a pipe cutter.

Indoor unit

(2) Hold the pipe downward so that cuttings will not enter the pipe and

(1) Detach the caps and plugs from the pipes.

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.

1 Be sure to apply the pipe against the port on the in-

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

door unit correctly. If the centering is improper, the flare

Check if [L] is flared uniformly

nut cannot be tightened smoothly. If the flare nut is

and is not cracked or scratched.

forced to turn, the threads will be damaged.

2 Do not remove the flare nut from the indoor unit pipe

Die

until immediately before connecting the connection

pipe.

Pipe

(2) Centering the pipe against port on the indoor unit, turn the flare nut

Dimension A (mm)

with your hand.

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.)

(3) Remove the filter guide.

19.05 mm (3/4 in.)

Indoor unit

Pipe outside diameter

Dimension B

(mm)

-0.4

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

(4) Attach the connection pipe.

flaring with R410A flare tools) to achieve the specified flaring. Use a thick-

ness gauge to measure the dimension A.

Indoor unit

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

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

piping may lead to water leaks.

980 to 1470 N (100 to 150 kgf)

• • • • • 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].

• • • • • 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 or over thick) the indoor side of the drain

(Obtained locally)

pipe.

Drain pipe

GOOD

Arrange the drain pipe

lower than this portion.

Lifted up

Wave

BAD

End in water

Wall

Supporter

1.5 to 2 m

(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.)

Drain pipe insulation (accessories)

Indoor unit (drain port)

Drain pipe insulation

Indoor unit

Drain pipe

Glass wool insulate

No gap

10 mm or over

(10 to 20 mm 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

• For 2 Top piping and 3 Right piping connections, use the Auxiliary

pipe (Gas pipe) provided.

2 Top piping

Connection pipe (Gas)

CAUTION

Indoor unit (rear)

Connection pipe (Gas)

Auxiliary pipe (Gas pipe)

3 Right piping

(5) When the flare nut is tightened properly by your hand, use a torque

wrench to finally tighten it.

Holding spanner

CAUTION

Body side

Torque wrench

CAUTION

Hold the torque wrench at its grip, keeping it in the right

angle with the pipe, in order to tighten the flare nut

correctly.

To prevent gas leakage, coat the flare

Flare nut

Tightening torque

surface with alkylbenzene oil (HAB).

6.35 mm (1/4 in.) dia.

14 to 18 N·m (140 to 180 kgf·cm)

Do not use mineral oil.

9.52 mm (3/8 in.) dia.

33 to 42 N·m (330 to 420 kgf·cm)

12.70 mm (1/2 in.) dia.

50 to 62 N·m (500 to 620 kgf·cm)

15.88 mm (5/8 in.) dia.

63 to 77 N·m (630 to 770 kgf·cm)

Filter guide

19.05 mm (3/4 in.) dia.

100 to 110 N·m (1000 to 1100 kgf·cm)

Outdoor unit

Tighten the flare nut of the connection pipe at the outdoor unit valve con-

nector. The tightening method is the same as that as at the indoor side.

3-way valve

(Liquid)

Flare nut

Connection pipe

Connection pipe (Gas)

(Liquid)

Connection pipe (Liquid)

3-way valve

(Gas)

Flare nut

Connection pipe

(Gas)

- Continued on back -