Fujitsu VRF Installation Manual

The Fujitsu VRF (Variable Refrigerant Flow) system is an advanced multi-zone HVAC solution designed for commercial and large residential applications. This system features intelligent zoning capabilities, energy-efficient inverter technology, flexible piping configurations, centralized control systems, and advanced refrigerant management. Below are key sections covering safety protocols, system components, installation procedures, commissioning, operation, and maintenance guidelines.

System Overview

Key components: Outdoor unit with inverter compressor, Multiple indoor units (ceiling cassette, wall-mounted, ducted), Refrigerant piping network, Branch controllers, Central control system, Power supply units.

Safety Precautions

Follow all safety protocols during installation and maintenance.

1. Electrical Safety: Disconnect all power sources before working on electrical components.
2. Refrigerant Handling: Use proper PPE and follow EPA guidelines for refrigerant management.
3. Lifting Procedures: Use appropriate lifting equipment for heavy components.
4. Working at Height: Follow fall protection protocols when installing ceiling units.
5. Fire Safety: Keep work area clear of flammable materials.

WARNING! Only qualified HVAC technicians should install and service this equipment. Failure to follow safety procedures may result in serious injury or equipment damage.

Pre-Installation Requirements

Complete site assessment and preparation before installation.

1. Site Survey: Verify structural integrity, access routes, and space requirements.
2. Load Calculation: Perform heat load calculation for proper system sizing.
3. Permit Acquisition: Obtain all necessary building and mechanical permits.
4. Material Preparation: Ensure all components, tools, and materials are available.
5. Safety Equipment: Verify all required safety equipment is on site.

CAUTION! Improper site preparation may lead to system performance issues and void warranty.

Technical Specifications

• System Type: Variable Refrigerant Flow Multi-Zone
• Refrigerant: R410A
• Capacity Range: 8HP to 48HP outdoor units
• Maximum Indoor Units: Up to 64 units per system
• Piping Length: Maximum 165m total equivalent length
• Height Difference: Up to 90m between outdoor and indoor units
• Power Supply: 208-230V, 3-phase, 60Hz
• Operating Temperature: -13°F to 122°F (-25°C to 50°C)
• Communication: RS-485 network protocol
• Control Options: Central controller, wall controllers, BMS integration

Installation Procedures

Follow systematic installation sequence for optimal performance.

1. Outdoor Unit Placement: Install on stable, level surface with adequate clearance.
2. Indoor Unit Mounting: Secure units according to manufacturer specifications.
3. Piping Installation: Route refrigerant lines with proper slope and support.
4. Electrical Wiring: Connect power and communication cables following electrical codes.
5. Drainage System: Install condensate drains with proper slope and traps.
6. Insulation: Apply thermal insulation to all refrigerant and drain pipes.

Note: Maintain minimum clearances as specified in technical data sheets.

Piping and Refrigerant Management

Proper piping installation is critical for system performance and longevity.

1. Pipe Sizing: Use correct diameter pipes based on system capacity and length.
2. Brazing Procedures: Use nitrogen purge during brazing to prevent oxidation.
3. Pressure Testing: Conduct strength and leak tests according to standards.
4. Vacuum Dehydration: Achieve vacuum level below 500 microns.
5. Refrigerant Charging: Charge with correct amount of R410A refrigerant.
6. Leak Checking: Verify all connections are leak-free before operation.

Tip: Always use torque wrenches for flare nut connections to prevent leaks.

Electrical Connections

Follow electrical codes and manufacturer specifications for all connections.

1. Power Wiring: Use correct wire gauge and type for electrical loads.
2. Grounding: Ensure proper grounding of all components.
3. Communication Wiring: Use shielded twisted pair cables for control networks.
4. Circuit Protection: Install appropriate circuit breakers and disconnects.
5. Control Wiring: Connect controllers and sensors according to wiring diagrams.

WARNING! All electrical work must be performed by qualified electricians following local codes.

Commissioning and Testing

Complete system commissioning before handing over to customer.

1. System Start-up: Power up system following proper sequence.
2. Function Testing: Verify operation of all indoor and outdoor units.
3. Performance Verification: Check cooling/heating capacity and temperature control.
4. Control System Check: Test all control functions and settings.
5. Documentation: Complete commissioning reports and provide to customer.

CAUTION! Do not operate system without proper refrigerant charge and electrical verification.

Control System Setup

Configure control system for optimal operation and user convenience.

Central Controller: Group control, scheduling, temperature settings, system monitoring.

Basic Settings: System mode selection, temperature setpoints, fan speed control. Advanced Settings: Group zoning, scheduling programs, setback temperatures, maintenance alerts. Network Configuration: BMS integration, remote monitoring setup, alarm notifications.

Maintenance Guidelines

Regular maintenance ensures optimal performance and extends system life.

1. Filter Cleaning: Clean or replace air filters every 3-6 months.
2. Coil Cleaning: Clean evaporator and condenser coils annually.
3. Drain System: Clear condensate drains and check traps regularly.
4. Electrical Inspection: Check connections and components during seasonal maintenance.
5. Refrigerant Check: Monitor system pressures and check for leaks.

CAUTION! Only qualified technicians should perform refrigerant-related maintenance.

Troubleshooting

Reset Procedure: Power cycle system and check control settings.

Technical Support: Contact Fujitsu technical support at 1-800- Fujitsu or visit www.fujitsugeneral.com