Fujitsu AOU9RL2 Installation Manual

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Fujitsu AOU9RL2 Installation Manual | Manualzz
STANDARD ACCESSORIES
ELECTRICAL REQUIREMENT
The following installation accessories are supplied. Use them as
required.
Always make the air conditioner power supply a special branch circuit and
provide a special switch and receptacle. Do not extend the power cord.
Always select the size that corresponds to the capacity of the breaker to the size of the power cord.
SPLIT TYPE ROOM AIR CONDITIONER
INSTALLATION MANUAL
(PART No. 9332824001-03)
Q’ty
Drain pipe
CAUTION
1
1
9000 BTU/h 12000 BTU/h
When Transporting
For safe installation and trouble-free operation, you must:
Carefully read this instruction booklet before beginning.
Follow each installation or repair step exactly as shown.
Observe all local, state, and national electrical codes.
Pay close attention to all danger, warning, and caution notices given
in this manual.
CAUTION:
Name and Shape
 Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.
This air conditioning system meets strict safety and operating standards.
As the installer or service person, it is an important part of your job to
install or service the system so it operates safely and efficiently.
WARNING:
Q’ty
Installation Manual
(This manual)
English
IMPORTANT!
Please Read Before Starting




Name and Shape
This symbol refers to a hazard or unsafe practice which
can result in severe personal injury or death.
This symbol refers to a hazard or unsafe practice which
can result in personal injury and the potential for product or property damage.
Be careful when picking up and moving the indoor and outdoor units.
Get 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 cut your fingers.
Make sure the ceiling/wall is strong enough to hold the unit’s weight. It
may be necessary to construct a strong wood or metal frame to provide added support.
...In a Room
Properly insulate any tubing run inside a room to prevent “sweating”
that can cause dripping and water damage to walls and floors.
...In Moist or Uneven Locations
...In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a metal frame.
Provide a suitable air baffle.
Tool name
Install the outdoor unit on a raised platform that is higher than drifting
snow. Provide snow vents.
If Necessary, Get Help
In Case of Improper Installation
The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to follow the instructions in
this document.
MAXIMUM OVERCURRENT
PROTECTION (TIME DELAY FUSE OR HACR
TYPE CIRCUIT BREAKER)
15 A
20 A
Special tools for R410A
...In a Snowy Area (for Heat Pump-type Systems)
These instructions are all you need for most installation sites and maintenance conditions. If you require help for a special problem, contact our
sales/service outlet or your certified dealer for additional instructions.
15 A
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 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.
...In a Ceiling or Wall
Electrical
Safety / alert
13.5 A
This air conditioner uses new refrigerant HFC (R410A).
When Installing...
Use a raised concrete pad or concrete blocks to provide a solid, level
foundation for the outdoor unit. This prevents water damage and abnormal vibration.
 Hazard alerting symbols
MINIMUM CIRCUIT AMPACITY
Gauge manifold
When Connecting Refrigerant Tubing
 Keep all tubing runs as short as possible.
 Use the flare method for connecting tubing.
 Apply refrigerant lubricant to the matching surfaces of the flare and
union tubes before connecting them, then tighten the nut with a
torque wrench for a leak-free connection.
 Check carefully for leaks before starting the test run.
Charge hose
Vacuum pump
Gas leakage detector
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.
It is recommended the gauge with seals-0.1 to 5.3 MPa (30 in.Hg to 768 psi) for high pressure.
-0.1 to 3.8 MPa (30 in.Hg to 551 psi) for low pressure.
To increase pressure resistance, the hose material and base size were changed.
A conventional vacuum pump can be used by installing a vacuum pump adapter.
Special gas leakage detector for HFC refrigerant R410A.
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 particular model is specified as either “small” or “large” rather
than as “liquid” or “gas”.
When Wiring
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL
INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED
ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM.
When Servicing
 Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked.
 Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring.
Improper connections and inadequate grounding can cause accidental injury or death.
 Ground the unit following local electrical codes.
 Turn the power OFF at the main circuit breaker panel before opening the unit to check or repair electrical parts and wiring.
 Keep your fingers and clothing away from any moving parts.
 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.
 After installation, explain correct operation to the customer, using
the operating manual.
• Cancer and Reproductive Harm - www.P65Warnings.ca.gov.
1
OUTDOOR UNIT INSTALLATION
Copper pipes
It is necessary to use seamless copper pipes and it is desirable
Thicknesses of Annealed Copper Pipes
that the amount of residual oil is less than 40 mg/10 m (0.004 oz /
Thickness (mm(in.))
100 ft.). Do not use copper pipes having a collapsed, deformed or
Nominal diam- Outer diameter
R410A
[ref.] R22
discolored portion (especially on the interior surface). Otherwise,
eter (in.)
(mm)
the expansion value or capillary tube may become blocked with
0.80 (0.032)
0.80 (0.032)
1/4
6.35
contaminants.
0.80 (0.032)
0.80 (0.032)
3/8
9.52
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 Table. Never use copper pipes thinner than 0.8 mm (0.032 in.)
even when it is available on the market.
●
●
Connector cover removal
●
Hook
Remove the tapping screw.
Installing the connector cover
(1) After inserting the four hooks, then push upward.
(2) Tighten the tapping screw.
Tapping screw
WARNING
(1) Install the unit where it will not be tilted by more than 5°.
Hooks
(2) When installing the outdoor unit where it may exposed to
strong wind, fasten it securely.
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 rupture, 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 rupture, injury, etc.
SELECTING THE MOUNTING
POSITION
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 the 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.
CAUTION
When installing pipes shorter than 10 ft (3 m), sound of the outdoor unit will be transferred to the indoor unit, which
will cause large operating sound or some abnormal sound.
For authorized service personnel only.
WARNING
Install at a place that can withstand the weight of the
outdoor units and install positively so that the units will
not topple or fall.
WARNING
(1) For the room air conditioner to operate satisfactory, install it as outlined in this installation manual.
(2) Connect the indoor unit and outdoor unit with the air conditioner piping and cords available standards parts. This
installation manual describes the correct connections using the standard accessories and the parts specified in
this installation manual.
(3) Have installation work done by authorized service 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 use this equipment with air or any other unspecified refrigerant in the refrigerant lines.
Excess pressure can cause a rupture.
(7) During the pump-down operation, make sure that the compressor is turned off before you remove the refrigerant
piping. Do not remove the connection pipe while the compressor is in operation with 2 way or 3 way valve open.
This may cause abnormal pressure in the refrigeration cycle that leads to rupture and even injury.
(8) 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 2-way or 3-way valve
open. This may cause abnormal pressure in the refrigeration cycle that leads to rupture and even injury.
(1)
(2)
(3)
CAUTION
Do not install where there is the danger of combustible gas leakage.
Do not install near heat sources.
If children under 10 years old may approach the unit,
take preventive measures so that they cannot reach
the unit.
Connector cover
Always use the screws as shown above.
INSTALLATION DIAGRAM OF
OUTDOOR UNIT
INDOOR UNIT
Connection Cord
14AWG
4” (10 cm)
or over
[OUTDOOR UNIT]
24” (60 cm) or over
4” (10 cm) or over
10” (25 cm)
or over
8” (20 cm) or over
2” (5 cm) or over
• Do not directly install it on
the ground, otherwise it
will cause failure.
• To obtain better operation efficiency, when the outdoor unit
is installed, be sure to open
the front and left side.
Outdoor unit bottom
Drain hose
CAUTION
(1) When the outdoor temperature is 32 ° F (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).
CAUTION
(2) In the area with heavy snowfall, if the intake and outlet of outdoor unit is
blocked with snow, it might become difficult to get warm and it is likely to
because of the breakdown. Please construct a canopy and a pedestal or
place the unit on a high stand (local configured).
This installation manual describes how to install the outdoor unit only.
To install the indoor unit, refer to the installation manual 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 manual because it is used when the air conditioner is serviced or moved.
The maximum length of the piping is 66 ft (20 m). The maximum height difference of the piping is 49 ft (15 m),
if the units are further apart than these, correct operation can not be guaranteed.
17-7/8”(45.4 cm)
12-5/8”(32 cm)
●
●
●
●
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.
Installation instruction on the back.
2
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POWER
PUMP DOWN OPERATION (FORCED COOLING OPERATION)
To avoid discharging refrigerant into the atmosphere at the time of relocation or disposal, recover refrigerant by doing the cooling operation or
forced cooling operation according to the following procedure. (When the cooling operation cannot start in winter, and so on, start the forced
cooling operation.)
WARNING
(1)
(2)
(5)
(6)
The rated voltage of this product is 115 V AC 60 Hz.
Before turning on the power, check if the voltage is within the
115 V ± 10 % range.
Always use a special branch circuit and install a special disconnect switch to supply power to the room air conditioner.
Use a circuit breaker and disconnect switch matched to the
capacity of the air conditioner.
(3)
(4)
Do not extend the power cable.
Perform wiring work in accordance with standards so that the
air conditioner can be operated safely and positively.
Install a leakage circuit breaker in accordance with the related
laws and regulations and electric company standards.
(7)
(1) Do the air purging of the charge hose by connecting the charging hose of gauge manifold to the charging port of 3 way valve and opening
the low-pressure valve slightly.
(2) Close the valve stem of 2 way valve completely.
(3) Start the cooling operation or following forced cooling operation.
Keep on pressing the MANUAL AUTO button of the indoor unit for more than 10 seconds.
The operation indicator lamp and timer indicator lamp will begin to flash simultaneously during test run.
(The forced cooling operation cannot start if the MANUAL AUTO button is not kept on pressing for more than 10 seconds.)
(4) Close the valve stem of 3 way valve when the reading on the compound pressure gage becomes 0.05~0 MPa (7.25~0 psi).
(5) Stop the operation.
• Press the START/STOP button of the remote control unit to stop the operation.
• Press the MANUAL AUTO button when stopping the operation from indoor unit side.
(It is not necessary to press on keeping for more than 10 seconds.)
CAUTION
(1)
The power source capacity must be the sum of the air conditioner current and the current of other electrical appliances. When the current contracted capacity is insufficient, change the contracted capacity.
When the voltage is low and the air conditioner is difficult to start, contact the power company the voltage raised.
(2)
OUTDOOR UNIT WIRING
(1)
(2)
(3)
(4)
CAUTION
During the pump-down operation, make sure that the compressor is turned off before you remove the refrigerant piping.
Do not remove the connection pipe while the compressor is in operation with 2 way or 3 way valve open. This may cause abnormal pressure in the refrigeration cycle that leads to rupture and even injury.
Remove the screws, then remove the control box cover.
Fasten the Inter-unit wire harness and power supply to the conduit holder using the lock nut.
Connect inter-unit wire harness and power supply to the terminal.
Use the screws to install the control box cover.
WARNING
OPERATING RANGE
NOTE:
•
Be sure to comply with local codes while running the wire from the
indoor unit to the outdoor unit (size of wire and wiring method, etc.).
Connector trade size for this unit is 1/2”(12.7 mm). The connector can be bought at a hard ware store. Refer to “How
to connect wiring to the terminals“ for instructions on connecting depending on the wire type you are using.
The fuse located in the outdoor unit provides power supply
protection and may blow when power is applied if the system
has been in correctly wired.
Every wire must be connected firmly.
•
No wire should be allowed to touch refrigerant tubing, the compressor
or any moving part.
Loose wiring may cause the terminal to overheat or result in unit malfunction. A fire hazard may also exist. Therefore, be sure all wiring is
tightly connected.
G
N
Control line
L
3
3
2
2
1
1
DISCONNECT
SWITCH (FIELD SUPPLY)
1 2
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 (for R22) flare tool.
When using the conventional flare tool, always
use an allowance adjustment gauge and secure
the A dimension shown in table 2 .
Outdoor unit terminal block
3 4
1 2
3 L N
G
Earth
(Ground) screw
Connection cable
G
G
BENDING PIPES
Check if [L] is flared uniformly
and is not cracked or scratched.
CAUTION
(1) Match the terminal block numbers and connection cord (3) Always fasten the outside covering of the connection
cord with the cord clamp. (If the insulator is chafed,
colors with those of the indoor unit.
electric leakage may occur.)
Erroneous wiring may cause burning of the electric
(4) Securely earth the power cord.
parts.
(2) Connect the connection cords firmly to the terminal block. (5) Do not use the earth screw for an external connector.
Only use for interconnection between two units.
Imperfect installation may cause a fire.
Flare nut
Torque
wrench
Connection pipe
To prevent gas leakage, coat the flare
surface with refrigerator oil.
Table 1 Flare nut tightening torque
Tightening torque [N • m (lbt • ft)]
Flare nut
1/4” (6.35 mm) dia.
16 to 18 (11.8 to 13.3)
3/8” (9.52 mm) dia.
32 to 42 (23.6 to 31.0)
Table 2 Pipe outside diameter
Pipe outside
diameter
Die
A
Pipe
(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 2-13/16° (70mm) 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.
Power supply cable
Wrench (fixed)
Indoor unit pipe
(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 onto the pipe and flare
the pipe with a flaring tool.
Power supply
Inter-unit wire
hamess
(Inter Unit)
Power line
Earth
(Ground) screw
Tighten with two wrenches.
FLARING
Inter-unit wire
harness
Indoor unit terminal block
15 to 75 °F (-10 to 24 °C)
(1) Install the outdoor unit wall cap (supplied with the optional installation set
or procured at the site) to the wall 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.
(Table 1)
Control box cover
POWER SUPPLY
Single phase, 115 V
G
15 to 115 °F (-10 to 46 °C)
CONNECTION
Outdoor unit
Earthing
(Grounding) Terminal
line
G
HEAT mode
CONNECTING THE PIPING
Lock nut
Connect wires to the matching numbers of terminals.
Indoor unit
Terminal
Outdoor temperature
COOL/DRY mode
1/4” (6.35 mm)
3/8” (9.52 mm)
Flare tool for
R410A, clutch type
A [in (mm)]
Conventional (R22) flare tool
Clutch type
Wing nut type
0 to 1/32 (0 to 0.5) 1/32 to 2/32 (0.5 to 1.5) 2/32 to 3/32 (1.5 to 2.0)
0 to 1/32 (0 to 0.5) 1/32 to 2/32 (0.5 to 1.5) 2/32 to 3/32 (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 2-way or 3-way
valve open. This may cause abnormal pressure in the refrigeration cycle
that leads to rupture and even injury.
3
AIR PURGE
Always use a vacuum pump to purge the air.
Refrigerant for purging the air is not charged in the
outdoor unit at the factory.
Close the high pressure side valve of the gauge manifold fully and do
not operate it during the following work.
1.
Check if the piping connections are secure.
2.
Check that the stems of 2-way valve and 3-way valve are closed fully.
3.
Connect the gauge manifold charge hose to the charging port of the
3-way valve (side with the projection for pushing in the valve core).
4.
CAUTION
(1)
Refrigerant must not be discharged into atmosphere.
(2)
After connecting the piping , check the joints for gas
leakage with gas leak detector.
10. Fully open the valve stems of the 2-way valve and 3-way valve using a hexagon
wrench. (After the valve stem begins to turn, turn it with a torque of less than
2.9 N • m (30 kgf • cm) until it stops turning.)
11. Firmly tighten the 2-way valve and 3-way valve blank cap and the charging port cap.
Open the low pressure side valve of the gauge manifold fully.
Gauge manifold
Compound pressure gauge
Pressure gauge
-0.1 MPa
5.
Operate the vacuum pump and start pump down.
6.
Slowly loosen the flare nut of the 3-way valve and check if air enters, then
retighten the flare nut.
(When the flare nut is loosened the operating sound of the vacuum
pump changes and the reading of the compound pressure gauge goes
from minus to zero.)
3-way valve
2-way valve
(30 in.Hg )
Flare nut
Low pressure
side valve
Valve stem
7.
Pump down the system for at least 15 minutes, then check if the compound
pressure gauge reads -0.1 MPa (30 in.Hg ).
Blank cap
High
pressure
side valve
(closed)
Charge
hose
Charge hose
Charging port
8.
At the end of pump down, close the low pressure side gauge of the gauge
manifold fully and stop the vacuum pump.
9.
Slowly loosen the valve stem of the 3-way valve. When the compound pressure gauge reading reaches 0.1-0.2 MPa (14.5~28.9 psi), retighten the valve
stem and disconnect the charge hose from the 3-way valve charging port.
(If the stem of the 3-way valve is opened fully before the charge hose
is disconnected, it may be difficult to disconnect the charge hose.)
Charging port cap
Tightening torque [N • m (lbt • ft)]
Blank cap
20 to 25 (14.8 to 18.4)
Charging port cap
10 to 12 (7.4 to 8.8)
Additional charge
Refrigerant suitable for a piping length of 49 ft (15 m) is charged in the
outdoor unit at the factory.
When the piping is longer than 49 ft (15 m), additional charging is necessary.
For the additional amount, see the table below.
Pipe length
Additional refrigerant
49 ft (15 m)
None
66 ft (20 m)
Rate
+3.5 oz (+100 g) 0.2 oz/ft (20 g/m)
Vacuum pump
CAUTION
(1)
(2)
When adding refrigerant, add the refrigerant from the
charging port at the completion of work.
The maximum length of the piping is 66 ft (20 m). If
the units are further apart than this, correct operation
can not be guaranteed.
Between 49 ft (15 m) and 66 ft (20 m), when using a connection pipe other than that
in the table, charge additional refrigerant with 0.2 oz/ft (20 g/m) as the criteria.
4
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