Fujitsu AOU24RLXFZ Inverter Air Conditioner User Guide

Fujitsu AOU24RLXFZ Inverter Air Conditioner

SPECIAL PRECAUTIONS

When Wiring

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM.

• 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 earthing (grounding) can cause
  accidental injury or death.
• Earth (Ground), the unit following local electrical codes.
• Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.

When Transporting

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.

When Installing…

• …In a Ceiling or Wall
  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
  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.
• …In an Area with High Winds
  Securely anchor the outdoor unit down with bolts and a metal frame. Provide a suitable air baffle.
• …In a Snowy Area (for Heat Pump-type Systems)
  Install the outdoor unit on a raised platform that is higher than the drifting snow. Provide snow vents.

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 opening the refrigerant valves.

NOTE: 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 Servicing

• 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.

WARNING

• Installation of this product must be done by experienced service technicians or professional installers only in accordance with this manual.
• Installation by a nonprofessional or improper installation of the product may cause serious accidents such as injury, water leakage, electric shock, or fire. 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 before the work is completed can cause serious accidents such as electric shock or fire.
• 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.
• Installation must be performed in accordance with regulations, codes, or standards for electrical wiring and equipment in each country, region, or installation place.
• Do not use this equipment with air or any other unspecified refrigerant in the refrigerant lines.
• Excess pressure can cause a rupture.
• 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 a 2-way or 3-way valve open. This may cause abnormal pressure in the refrigeration cycle that leads to rupture and even injury.
• 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.
• 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 an installation set.

SPECIAL TOOLS FOR R410A

Copper pipes

It is necessary to use seamless copper pipes, and the amount of residual oil should be 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 value or capillary tube may become blocked with contaminants. 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 Table1. Never use copper pipes thinner than 0.8 mm, even when they are available on the market.

CONNECTION PIPE REQUIREMENT

GENERAL SPECIFICATION

This INSTALLATION MANUAL briefly outlines where and how to install the air conditioning system. Please read over the entire set of instructions for the indoor and outdoor units and make sure all accessory parts listed are with the system before beginning.

1. TYPE OF COPPER PIPE AND INSULATION MATERIAL
   Copper tubing for connecting the outdoor unit to the indoor unit and insulation material are available for purchase locally. When you purchase them, please specify the following.
   • Deoxidized annealed copper pipe for refrigerant piping as: Cut each pipe to the appropriate length +12” (300 mm) to 15” (400 mm) to dampen vibration between units.
   • Foamed polyethylene insulation for copper pipes as required to the precise length of piping. Wall thickness of the insulation should not be less than 5/16” (8 mm).
   • Use insulated copper wire for field wiring.
2. ADDITIONAL MATERIALS REQUIRED FOR INSTALLATION
   1. Refrigeration (armored) tape
   2. Insulated staples or clamps for connecting wire (See your local electrical codes.)
   3. Putty
   4. Refrigeration lubricant
   5. Clamps or saddles to secure refrigerant piping
3. OPERATING RANGE

STANDARD ACCESSORIES

The following installation accessories are supplied. Use them as required.

The following items are necessary to install this air conditioner. (The items are not included with the air conditioner and must be purchased separately.)

ELECTRICAL REQUIREMENT

Always make the air conditioner power supply a special branch circuit and provide a special switch and receptacle. Do not extend the power cord.

SELECTING THE MOUNTING POSITION

Decide the mounting position with the customer as follows:

OUTDOOR UNIT

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 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.

INSTALLATION DIAGRAM OF OUTDOOR UNITS

[OUTDOOR UNIT]

• Do not directly install it on the ground, otherwise it will cause failure.
• obtain better operation efficiency, when the outdoor unit is installed, be sure to open the front and left side.

CAUTION: In areas with heavy snowfall, if the intake and outlet of the outdoor unit is blocked with snow, it is likely to cause a breakdown. Please construct a canopy and a pedestal or place the unit on a high stand (locally configured).

POWER

WARNING

• The rated voltage of this product is 208/230 V AC 60 Hz.
• Before turning on the power, check if the voltage is within the 208 V -10 % to 230 V +10% range.
• Always use a special branch circuit and install a special receptacle to supply power to the room air conditioner.
• Use a circuit breaker and a receptacle matched to the capacity of the air conditioner.
• Do not extend the power cord.
• 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 the electric company standards.

CAUTION

• The power source capacity must be the sum of the air conditioner’s 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 to check the voltage.

LIMITATION OF REFRIGERANT PIPING LENGTH

CAUTION: The total maximum pipe lengths and height difference of this product are shown in the table. If the units are further apart than this, correct operation cannot be guaranteed.

CUSTOMER GUIDANCE

Explain the following to the customer in accordance with the operating manual:

1. Starting and stopping method, operation switching, temperature adjustment, timer, air flow switching, and other remote controller operations.
2. Air filter removal and cleaning, and how to use the air louvers.
3. Give the operating and installation manuals to the customer.

OUTDOOR UNIT

OUTDOOR UNIT INSTALLATION

WARNING

• Install the unit where it will not be tilted by more than 3°. However, do not install the unit with it tilted towards the side containing the compressor.
• When installing the outdoor unit where it may be exposed to strong winds, fasten it securely.

1. The outdoor unit to be fastened with bolts at the four places indicated by the arrows without fail.
2. Fix securely with boltsona solid block. (Use 4 sets of commercially available M10 bolts and washers.)

CAUTION
Do not use the 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.

CONNECTING THE PIPE

CONNECTION PIPES

Outdoor unit

Valve cover removal.

• Remove the one mounting screw.
• Remove the valve cover by sliding upward.

1. Detach the caps and plugs from the pipes.
2. Centering the pipe against the port on the outdoor unit, turn the flare nut with your hand.
3. Tighten the flare nut of the connection pipe at the outdoor unit valve connector.
4. When the flare nut is tightened properly by your hand, use a torque wrench to finally tighten it.

Flare nut tightening torque

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 gauge indicates -0.1 MPa (-76 cmHg).
3. When -0.1 MPa (-76 cmHg) is reached, operate the vacuum pump for at least 60 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: 6~7 N·m (60 to 70 kgf·cm)].
6. Tighten the blank caps of the 2-way valve and 3-way valve to the specified torque.

CAUTION

• Do not purge the air with refrigerants, but use a vacuum pump to vacuum the installation! There is no extra refrigerant in the outdoor unit for air purging!
• Use a vacuum pump and gauge manifold and charging hose for R410A exclusively. Using the same vacuum for different refrigerants may damage the vacuum pump or the unit.

ADDITIONAL CHARGE

Refrigerant suitable for a piping length of 66ft(20m) is charged in the outdoor unit at the factory. When the piping is longer than 66ft(20m), additional charging is necessary. For the additional amount, see the table below.

CAUTION

• When moving and installing the air conditioner, do not mix gas other than the specified refrigerant R410A inside the refrigerant cycle.
• When charging the refrigerant R410A, always use an electronic balance for refrigerant charging (to measure the refrigerant by weight).
• 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.
• Add refrigerant from the charging valve after the completion of the work.
• If the units are further apart than the maximum pipe length, correct operation cannot be guaranteed.

GAS LEAKAGE INSPECTION

CAUTION

• After connecting the piping, check all joints for gas leakage with a gas leak detector.
• When inspecting gas leakage, always use the vacuum pump for pressure. Do not use nitrogen gas.

ELECTRICAL WIRING (OUTDOOR UNIT)

1. Service cover removal
   • Remove the two mounting screws.
   • Remove the service cover by pushing downwards.
2. Fasten the power supply cord and the connection cord to the conduit holder using the lock nut. (open the knockout holes if necessary)
3. Connect the power supply cord and the connection cord to the terminal.
4. Fasten the power supply cord and connection cord with the cord clamp.

Keep the earth wire longer than the other wires.

NOTE:
Factory-installed protective inline fuses for indoor units’ conductors are installed on the Power Supply PCB.

WARNING: Disconnect switch for overcurrent protection given in the table below is to be installed between the indoor unit and the outdoor unit.
Disconnect switch: 20A

CAUTION

• 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.).
• 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.
• Connect wires to the matching numbers of terminals.

WARNING

• Use ring terminals and tighten the terminal screws to the specified torques; otherwise, abnormal overheating may be produced and possibly cause heavy damage inside the unit.
• Match the terminal block numbers and connection cord colors with those of the outdoor unit. Erroneous wiring may cause burning of the electrical parts.
• Connect the connection cords firmly to the terminal block. An imperfect installation may cause a fire.
• Always fasten the outside covering of the connection cord with the cord clamp. (If the insulator is chafed, electric leakage may occur.)
• Securely earth the power cord plug.
• Do not use the earth screw for an external connector. Only use for the interconnection between two units.

HOW TO CONNECT THE WIRE TO THE TERMINALS

1. Use ring terminals with insulating sleeves, as shown in the figure below, to connect to the terminal block.
2. Securely clamp the ring terminals to the wires using an appropriate tool to prevent the wires from coming loose.
3. Use the specified wires, connect them securely, and fasten them so that no stress is placed on the terminals.
4. Use an appropriate screwdriver to tighten the terminal screws. Do not use a screwdriver that is too small; otherwise, the screw heads may be damaged, preventing the screws from being properly tightened.
5. Do not tighten the terminal screws too much; otherwise, the screws may break.
6. See the table below for the terminal screw tightening torques.

PUMP DOWN OPERATION (FORCED 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.)

1. Do the air purging of the charge hose by connecting the charging hose of the gauge manifold to the charging port of the 3-way valve (large) and opening the low-pressure valve slightly.
2. Close the valve stem of the 3-way valve (small) completely.
3.  Start the cooling operation or following forced cooling operation.
   When using the remote controller
   Press the TEST RUN button after starting the cooling operation with the remote controller. The operation indicator lamp and timer indicator lamp will begin to flash simultaneously during test run. When using the MANUAL AUTO button of the indoor unit (The remote controller is lost, and so on) keep pressing the MANUAL AUTO button of the indoor unit for more than 10 seconds. (The forced cooling operation cannot start if the MANUAL AUTO button is not kept pressed for more than 10 seconds.)
4. Close the valve stem of the 3-way valve (large) when the reading on the compound pressure gauge becomes 0.05~0 MPa (0.5~0 kg/cm2).
5. Stop the operation.
   • Press the START/STOP button of the remote controller to stop the operation.
   • Press the MANUAL AUTO button when stopping the operation from the indoor unit side.
     (It is not necessary to press on for more than 10 seconds.)

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 3-way valve open. This may cause abnormal pressure in the refrigeration cycle that leads to breakage and even injury.

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 248 °F (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 9/16” (15 mm) or thicker, and if the expected humidity exceeds 80%, use heat insulation that is 13/16” (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 a heat conductivity of 0.045 W/(m·K) or less [at 68 °F (20 °C)].

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Fujitsu AOU24RLXFZ Inverter Air Conditioner-FAQs