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Fujitsu Luftkonditionering AOEG54KBTB

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En-1

WARNING

• Installation of this product must be done by experienced service technicians or

professional installers only in accordance with this manual. Installation by nonprofes-

sional or improper installation of the product may cause serious accidents such as

injury, water leakage, electric shock, or ﬁ re. If the product is installed in disregard of

the instructions in this manual, it will void the manufacturer’s warranty.

• To avoid getting an electric shock, never touch the electrical components soon

after the power supply has been turned oﬀ . After turning oﬀ the power, always wait

10 minutes or more before you touch the electrical components.

• Do not turn on the power until all work has been completed. Turning on the power be-

fore the work is completed can cause serious accidents such as electric shock or ﬁ re.

• If refrigerant leaks while work is being carried out, ventilate the area. If the refrigerant

comes in contact with a ﬂ ame, it produces a toxic gas.

• Installation must be performed in accordance with regulations, codes, or standards

for electrical wiring and equipment in each country, region, or the installation place.

• Do not use this equipment with air or any other unspeciﬁ ed refrigerant in the refriger-

ant lines. Excess pressure can cause a rupture.

• During installation, make sure that the refrigerant pipe is attached ﬁ rmly 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 refrigera-

tion cycle that leads to rupture and even injury.

• When installing or relocating the air conditioner, do not mix gases other than the

speciﬁ ed refrigerant (R32) 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.

• To connect the indoor unit and outdoor unit, use air conditioner piping and cables

available locally as standard parts. This manual describes proper connections using

such installation set.

• Do not modify power cable, use extension cable or branch wiring. Improper use may

cause electric shock or ﬁ re by poor connection, insuﬃ cient insulation or over current.

• Do not purge the air with refrigerants but use a vacuum pump to vacuum the installation.

• There is not extra refrigerant in the outdoor unit for air purging.

• Use a vacuum pump for R32 or R410A exclusively.

• Using the same vacuum pump for diﬀ erent refrigerants may damage the vacuum

pump or the unit.

• Use a clean gauge manifold and charging hose for R32 or R410A exclusively.

• Do not use means to accelerate the defrosting process or to clean, other than those

recommended by the manufacturer.

• The appliance shall be stored in a room without continuously operating ignition sources

(for example: open ﬂ ames, an operating gas appliance or an operating electric heater).

• Do not pierce or burn.

• Be aware that refrigerants may not contain an odour.

• 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 3-way

valve open.

This may cause abnormal pressure in the refrigeration cycle that leads to rupture and

even injury.

• This appliance is not intended for use by persons (including children) with reduced

physical, sensory or mental capabilities, or lack of experience and knowledge, unless

they have been given supervision or instruction concerning use of the appliance by a

person responsible for their safety. Children should be supervised to ensure that they

do not play with the appliance.

• If the power cable or the connection cable is damaged, it must be replaced by the

manufacturer, its service agent or similar qualiﬁ ed persons in order to avoid a safety

hazard.

• Keep any required ventilation openings clear of obstruction.

CAUTION

• For the air conditioner to work appropriately, install it as written in this manual.

• This product must be installed by qualiﬁ ed personnel with a capacity certiﬁ cation of

handling refrigerant ﬂ uids. Refer to regulation and laws in use on installation place.

• Install the product by following local codes and regulations in force at the place of

installation, and the instructions provided by the manufacturer.

• This product is part of a set constituting an air conditioner. The product must not be

installed alone or be installed with non-authorized device by the manufacturer.

• Always use a separate power supply line protected by a circuit breaker operating on

all wires with a distance between contact of 3 mm for this product.

• To protect the persons, ground (earth) the product correctly, and use the power cable

combined with an Earth Leakage Circuit Breaker (ELCB).

• This product is not explosion proof, and therefore should not be installed in explosive

atmosphere.

• This product contains no user-serviceable parts. Always consult experienced service

technicians for repairing.

• When installing pipes shorter than 3 m, sound of the outdoor unit will be transferred

to the indoor unit, which will cause large operating sound or some abnormal sound.

• When moving or relocating the air conditioner, consult experienced service techni-

cians for disconnection and reinstallation of the product.

• Do not touch the ﬁ ns of the heat exchanger. Touching the heat exchanger ﬁ ns could

result in damage to the ﬁ ns or personal injury such as skin rupture.

• An indoor unit error (error code: 2-3) occurs if an indoor unit for R410A is connected to

the refrigerant system in a concurrent multiple connection environment. In that case,

note the indoor model name that experiences the error, and contact our service centre.

AIR CONDITIONER

OUTDOOR UNIT

INSTALLATION MANUAL

PART No. 9379069960-03

1. SAFETY PRECAUTIONS

• Be sure to read this manual thoroughly before installation.

• The warnings and precautions indicated in this manual contain important information

pertaining to your safety. Be sure to observe them.

• Hand this manual, together with the operation manual, to the customer. Request the

customer to keep them on hand for future use, such as for relocating or repairing the

unit.

WARNING

Indicates a potentially or imminently hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that may result in

minor or moderate injury or damage to property.

[Original instructions] For authorized service personnel only.

Contents

1. SAFETY PRECAUTIONS ............................................................................1

2. PRODUCT SPECIFICATION ....................................................................... 3

2.1. Installation tools ....................................................................................3

2.2. Accessories ..........................................................................................4

2.3. Pipe requirements ................................................................................4

2.4. Electrical requirements .........................................................................5

2.5. Additional charge amount .....................................................................5

2.6. General information .............................................................................. 6

3. INSTALLATION WORK ...............................................................................6

3.1. Installation dimensions .........................................................................7

3.2. Transporting the unit ............................................................................. 7

3.3. Mounting the unit ..................................................................................8

3.4. Drain installation ................................................................................... 8

3.5. Pipe installation ....................................................................................8

3.6. Sealing test ......................................................................................... 10

3.7. Vacuum process ................................................................................. 10

3.8. Additional charging ............................................................................. 11

3.9. Electrical wiring ................................................................................... 11

4. TEST RUN .................................................................................................14

4.1. Pre-test run check items ..................................................................... 14

4.2. Test operation method ........................................................................14

4.3. Checklist ............................................................................................. 14

5. FINISHING.................................................................................................15

5.1. Installing insulation .............................................................................15

5.2. Filling with putty ..................................................................................15

6. HOW TO OPERATE DISPLAY UNIT .........................................................15

6.1. Display unit position ............................................................................15

6.2. Description of display and buttons ......................................................15

7. FIELD SETTING ........................................................................................ 16

7.1. Field setting buttons ...........................................................................16

7.2. Function settings ................................................................................16

8. EXTERNAL INPUT AND OUTPUT ............................................................17

8.1. External input ......................................................................................17

8.2. External output ...................................................................................18

9. PUMP DOWN ............................................................................................18

9.1. Preparation for pump down ................................................................19

9.2. Pump down procedure .......................................................................19

10. ERROR CODES ........................................................................................19

10.1. Error display mode ...........................................................................19

10.2. Error code check table ......................................................................20

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En-2

2-7. Checks to the refrigeration equipment

• Where electrical components are being changed, they shall be ﬁ t for the purpose

and to the correct speciﬁ cation.

• At all times the manufacturer’s maintenance and service guidelines shall be followed.

• If in doubt consult the manufacturer’s technical department for assistance.

• The following checks shall be applied to installations using ﬂ ammable refrigerants.

- The charge size is in accordance with the room size within which the refrigerant

containing parts are installed.

- The ventilation machinery and outlets are operating adequately and are not

obstructed.

- If an indirect refrigerating circuit is being used, the secondary circuit shall be

checked for the presence of refrigerant.

- Marking to the equipment continues to be visible and legible. Markings and signs

that are illegible shall be corrected.

- Refrigeration pipe or components are installed in a position where they are unlikely

to be exposed to any substance which may corrode refrigerant containing compo-

nents, unless the components are constructed of materials which are inherently

resistant to being corroded or are suitably protected against being so corroded.

2-8. Checks to electrical devices

• Repair and maintenance to electrical components shall include initial safety checks

and component inspection procedures.

• If a fault exists that could compromise safety, then no electrical supply shall be

connected to the circuit until it is satisfactorily dealt with.

• If the fault cannot be corrected immediately but it is necessary to continue opera-

tion, an adequate temporary solution shall be used.

• This shall be reported to the owner of the equipment so all parties are advised.

• Initial safety checks shall include.

- That capacitors are discharged: this shall be done in a safe manner to avoid

possibility of sparking.

- That there no live electrical components and wiring are exposed while charging,

recovering or purging the system.

- That there is continuity of earth bonding.

3. Repairs to sealed components

• During repairs to sealed components, all electrical supplies shall be disconnected

from the equipment being worked upon prior to any removal of sealed covers, etc.

• If it is absolutely necessary to have an electrical supply to equipment during servic-

ing, then a permanently operating form of leak detection shall be located at the

most critical point to warn of a potentially hazardous situation.

• Particular attention shall be paid to the following to ensure that by working on

electrical components, the casing is not altered in such a way that the level of

protection is aﬀ ected.

• This shall include damage to cables, excessive number of connections, terminals

not made to original speciﬁ cation, damage to seals, incorrect ﬁ tting of glands, etc.

• Ensure that apparatus is mounted securely.

• Ensure that seals or sealing materials have not degraded such that they no longer

serve the purpose of preventing the ingress of ﬂ ammable atmospheres.

• Replacement parts shall be in accordance with the manufacturer’s speciﬁ cations.

NOTES: The use of silicon sealant may inhibit the eﬀ ectiveness of some types of

leak detection equipment.

Intrinsically safe components do not have to be isolated prior to working

on them.

4. Repair to intrinsically safe components

• Do not apply any permanent inductive or capacitance loads to the circuit without

ensuring that this will not exceed the permissible voltage and current permitted for

the equipment in use.

• Intrinsically safe components are the only types that can be worked on while live in

the presence of a ﬂ ammable atmosphere.

• The test apparatus shall be at the correct rating.

• Replace components only with parts speciﬁ ed by the manufacturer.

• Other parts may result in the ignition of refrigerant in the atmosphere from a leak.

5. Cabling

• Check that cabling will not be subject to wear, corrosion, excessive pressure, vibra-

tion, sharp edges or any other adverse environmental eﬀ ects.

• The check shall also take into account the eﬀ ects of aging or continual vibration

from sources such as compressors or fans.

6. Detection of ﬂ ammable refrigerants

• Under no circumstances shall potential sources of ignition be used in the searching

for or detection of refrigerant leaks.

• A halide torch (or any other detector using a naked ﬂ ame) shall not be used.

7. Leak detection methods

• Electronic leak detectors shall be used to detect ﬂ ammable refrigerants, but the

sensitivity may not be adequate, or may need re-calibration. (Detection equipment

shall be calibrated in a refrigerant-free area.)

• Ensure that the detector is not a potential source of ignition and is suitable for the

refrigerant used.

• Leak detection equipment shall be set at a percentage of the LFL of the refrigerant

and shall be calibrated to the refrigerant employed and the appropriate percentage

of gas (25 % maximum) is conﬁ rmed.

• Leak detection ﬂ uids are suitable for use with most refrigerants but the use of

detergents containing chlorine shall be avoided as the chlorine may react with the

refrigerant and corrode the copper pipe-work.

• If a leak is suspected, all naked ﬂ ames shall be removed/extinguished.

• If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall

be recovered from the system, or isolated (by means of shut oﬀ valves) in a part of

the system remote from the leak.

Oxygen free nitrogen (OFN) shall then be purged through the system both before

and during the brazing process.

Precautions for using R32 refrigerant

The basic installation work procedures are the same as conventional refrigerant (R410A,

R22) models.

However, pay careful attention to the following points:

WARNING

• Since the working pressure is 1.6 times higher than that of refrigerant R22 models,

some of the piping and installation and service tools are special. (Refer to

“2.1. Instal-

lation tools”.)

Especially, when replacing a refrigerant R22 model with a new refrigerant R32 model,

always replace the conventional piping and ﬂ are nuts with the R32 and R410A piping

and ﬂ are nuts on the outdoor unit side.

For R32 and R410A, the same ﬂ are nut on the outdoor unit side and pipe can be

used.

• Models that use refrigerant R32 and R410A have a diﬀ erent charging port thread

diameter to prevent erroneous charging with refrigerant R22 and for safety. There-

fore, check beforehand. [The charging port thread diameter for R32 and R410A is 1/2

inch.]

• Be more careful than R22 so that foreign matter (oil, water, etc.) does not enter the

piping.

Also, when storing the piping, securely seal the opening by pinching, taping, etc.

(Handling of R32 is similar to R410A.)

CAUTION

1. Installation (Space)

• That the installation of pipe-work shall be kept to a minimum.

• That pipe-work shall be protected from physical damage.

• That compliance with national gas regulations shall be observed.

• That mechanical connections shall be accessible for maintenance purposes.

• In cases that require mechanical ventilation, ventilation openings shall be kept

clear of obstruction.

• When disposing of the product is used, be based on national regulations, properly

processed.

2. Servicing

2-1. Service personnel

• Any person who is involved with working on or breaking into a refrigerant circuit

should hold a current valid certiﬁ cate from an industry-accredited assessment

authority, which authorizes their competence to handle refrigerants safely in ac-

cordance with an industry recognised assessment speciﬁ cation.

• Servicing shall only be performed as recommended by the equipment manufac-

turer. Maintenance and repair requiring the assistance of other skilled personnel

shall be carried out under the supervision of the person competent in the use of

ﬂ ammable refrigerants.

• Servicing shall be performed only as recommended by the manufacturer.

2-2. Work

• Prior to beginning work on systems containing ﬂ ammable refrigerants, safety

checks are necessary to ensure that the risk of ignition is minimised. For repair to

the refrigerating system, the precautions in 2-2 to 2-8 shall be complied with prior

to conducting work on the system.

• Work shall be undertaken under a controlled procedure so as to minimize the risk

of a ﬂ ammable gas or vapour being present while the work is being performed.

• All maintenance staﬀ and others working in the local area shall be instructed on the

nature of work being carried out.

• Work in conﬁ ned spaces shall be avoided.

• The area around the workspace shall be sectioned oﬀ .

• Ensure that the conditions within the area have been made safe by control of ﬂ am-

mable material.

2-3. Checking for presence of refrigerant

• The area shall be checked with an appropriate refrigerant detector prior to and dur-

ing work, to ensure the technician is aware of potentially ﬂ ammable atmospheres.

• Ensure that the leak detection equipment being used is suitable for use with ﬂ am-

mable refrigerants, i.e. non sparking, adequately sealed or intrinsically safe.

2-4. Presence of ﬁ re extinguisher

• If any hot work is to be conducted on the refrigeration equipment or any associated

parts, appropriate ﬁ re extinguishing equipment shall be available at hand.

• Have a dry powder or CO2 ﬁ re extinguisher adjacent to the charging area.

2-5. No ignition sources

• No person carrying out work in relation to a refrigeration system which involves

exposing any pipe work that contains or has contained ﬂ ammable refrigerant shall

use any sources of ignition in such a manner that it may lead to the risk of ﬁ re or

explosion.

• All possible ignition sources, including cigarette smoking, should be kept suﬃ cient-

ly far away from the site of installation, repairing, removing and disposal, during

which ﬂ ammable refrigerant can possibly be released to the surrounding space.

• Prior to work taking place, the area around the equipment is to be surveyed to

make sure that there are no ﬂ ammable hazards or ignition risks. “No Smoking”

signs shall be displayed.

2-6. Ventilated area

• Ensure that the area is in the open or that it is adequately ventilated before break-

ing into the system or conducting any hot work.

• A degree of ventilation shall continue during the period that the work is carried out.

• The ventilation should safely disperse any released refrigerant and preferably

expel it externally into the atmosphere.

En-3

CAUTION

8. Removal and evacuation

• When breaking into the refrigerant circuit to make repairs – or for any other

purpose –conventional procedures shall be used.

However, it is important that best practice is followed since ﬂ ammability is a

consideration.

The following procedure shall be adhered to:

• remove refrigerant

• purge the circuit with inert gas

• evacuate

• purge again with inert gas

• open the circuit by cutting or brazing

• The refrigerant charge shall be recovered into the correct recovery cylinders.

• The system shall be “ﬂ ushed” with OFN to render the unit safe.

• This process may need to be repeated several times.

• Compressed air or oxygen shall not be used for this task.

• Flushing shall be achieved by breaking the vacuum in the system with OFN and

continuing to ﬁ ll until the working pressure is achieved, then venting to atmosphere,

and ﬁ nally pulling down to a vacuum.

• This process shall be repeated until no refrigerant is within the system.

• When the ﬁ nal OFN charge is used, the system shall be vented down to atmo-

spheric pressure to enable work to take place.

• This operation is absolutely vital if brazing operations on the pipe work are to take

place.

• Ensure that the outlet for the vacuum pump is not close to any ignition sources and

there is ventilation available.

9. Charging procedures

• In addition to conventional charging procedures, the following requirements shall

be followed.

- Ensure that contamination of diﬀ erent refrigerants does not occur when using

charging equipment.

- Hoses or lines shall be as short as possible to minimize the amount of refriger-

ant contained in them.

- Cylinders shall be kept upright.

- Ensure that the refrigeration system is earthed prior to charging the system with

refrigerant.

- Label the system when charging is complete (if not already).

- Extreme care shall be taken not to overﬁ ll the refrigeration system.

• Prior to recharging the system it shall be pressure tested with OFN.

• The system shall be leak tested on completion of charging but prior to commis-

sioning.

• A follow up leak test shall be carried out prior to leaving the site.

10. Decommissioning

• Before carrying out this procedure, it is essential that the technician is completely

familiar with the equipment and all its details.

• It is recommended good practice that all refrigerants are recovered safely.

• Prior to the task being carried out, an oil and refrigerant sample shall be taken in

case analysis is required prior to re-use of reclaimed refrigerant.

• It is essential that electrical power is available before the task is commenced.

a) Become familiar with the equipment and its operation.

b) Isolate system electrically.

c) Before attempting the procedure ensure that:

• mechanical handling equipment is available, if required, for handling refrig-

erant cylinders;

• all personal protective equipment is available and being used correctly;

• the recovery process is supervised at all times by a competent person;

• recovery equipment and cylinders conform to the appropriate standards.

d) Pump down refrigerant system, if possible.

e) If a vacuum is not possible, make a manifold so that refrigerant can be re-

moved from various parts of the system.

f) Make sure that cylinder is situated on the scales before recovery takes place.

g) Start the recovery machine and operate in accordance with manufacturer’s

instructions.

h) Do not overﬁ ll cylinders. (No more than 80 % volume liquid charge).

i) Do not exceed the maximum working pressure of the cylinder, even temporarily.

j) When the cylinders have been ﬁ lled correctly and the process completed, make

sure that the cylinders and the equipment are removed from site promptly and

all isolation valves on the equipment are closed oﬀ .

k) Recovered refrigerant shall not be charged into another refrigeration system

unless it has been cleaned and checked.

11. Labelling

• Equipment shall be labelled stating that it has been de-commissioned and emptied

of refrigerant.

• The label shall be dated and signed.

• Ensure that there are labels on the equipment stating the equipment contains ﬂ am-

mable refrigerant.

12. Recovery

• When removing refrigerant from a system, either for servicing or decommissioning,

it is recommended good practice that all refrigerants are removed safely.

• When transferring refrigerant into cylinders, ensure that only appropriate refrigerant

recovery cylinders are employed.

• Ensure that the correct number of cylinders for holding the total system charge are

available.

• All cylinders to be used are designated for the recovered refrigerant and labelled

for that refrigerant (i.e. special cylinders for the recovery of refrigerant).

• Cylinders shall be complete with pressure relief valve and associated shut-oﬀ

valves in good working order.

• Empty recovery cylinders are evacuated and, if possible, cooled before recovery

occurs.

• The recovery equipment shall be in good working order with a set of instructions

concerning the equipment that is at hand and shall be suitable for the recovery of

ﬂ ammable refrigerants.

• In addition, a set of calibrated weighing scales shall be available and in good work-

ing order.

• Hoses shall be complete with leak-free disconnect couplings and in good condition.

• Before using the recovery machine, check that it is in satisfactory working order,

has been properly maintained and that any associated electrical components are

sealed to prevent ignition in the event of a refrigerant release.

Consult manufacturer if in doubt.

• The recovered refrigerant shall be returned to the refrigerant supplier in the correct

recovery cylinder, and the relevant Waste Transfer Note arranged.

• Do not mix refrigerants in recovery units and especially not in cylinders.

• If compressors or compressor oils are to be removed, ensure that they have been

evacuated to an acceptable level to make certain that ﬂ ammable refrigerant does

not remain within the lubricant.

• The evacuation process shall be carried out prior to returning the compressor to

the suppliers.

• Only electric heating to the compressor body shall be employed to accelerate this

process.

• When oil is drained from a system, it shall be carried out safely.

Explanation of symbols displayed on the indoor unit or outdoor unit.

WARNING

This symbol shows that this equipment uses a ﬂ ammable

refrigerant. If the refrigerant is leaked, together with an

external ignition source, there is a possibility of ignition.

CAUTION This symbol shows that the Operation Manual should be

read carefully.

CAUTION

This symbol shows that a service personnel should be

handling this equipment with reference to the Installation

Manual.

CAUTION This symbol shows that there is information included in the

Operation Manual and/or Installation Manual.

2. PRODUCT SPECIFICATION

2.1. Installation tools

WARNING

• To install a unit that uses R32 refrigerant, use dedicated tools and piping materials that

have been manufactured speciﬁ cally for R32(R410A) use. Because the pressure of

R32 refrigerant is approximately 1.6 times higher than R22, failure to use dedicated

piping material or improper installation can cause rupture or injury. Furthermore, it can

cause serious accidents such as water leakage, electric shock, or ﬁ re.

• Do not use a vacuum pump or refrigerant recovery tools with a series motor, since it

may ignite.

Tool name Contents of change

Gauge manifold Pressure is high and cannot be measured with a conventional

(R22) gauge. To prevent erroneous mixing of other refriger-

ants, the diameter of each port has been changed.

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. (R32/R410A)

Vacuum pump A conventional vacuum pump can be used by installing a

vacuum pump adapter.

(Use of a vacuum pump with a series motor is prohibited.)

Gas leakage detector Special gas leakage detector for HFC refrigerant R32/R410A.

 Copper pipes

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, deformed or

discolored portion (especially on the interior surface). Otherwise, the expansion valve or

capillary tube may become blocked with contaminants.

As an air conditioner using R32(R410A) incurs pressure higher than when using conven-

tional refrigerant, it is necessary to choose adequate materials.

Produktspecifikationer

Varumärke:	Fujitsu
Kategori:	Luftkonditionering
Modell:	AOEG54KBTB

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