Fujitsu Halcyon HFI Systems User manual

1 2

Quick Installation Guide

for Halcyon HFI Systems

Checklist

AOU48RLXFZ Outdoor Condensing Unit

Separation Tube Assemblies

– when using more than one branch box

Branch boxes

– primary used for 1-3 indoor units

– secondary used when installing more than 3 units

Correctly sized line sets (both lines insulated separately)

2 to 8 Indoor units Halcyon HFI type (RLF)

Pipe, wire, fittings, and mounting hardware

R410a adaptor(s) Part# K9R410A55

Nitrogen & regulator to purge lines

Vacuum pump, micron gauge and torque wrench

Normal tools for mini-split installation

• This is a quick installation guide not intended to

replace the actual installation manual. For

complete instructions follow the installation manual

that is included with each piece of equipment.

• Don’t take shortcuts and Don’t follow any “rule

of thumb”

• Always follow Local, State & Federal codes during

installation

• Don’t connect power to the equipment until you are

ready to start and test.

• Adhere to all safety and installation warnings on

the installation instructions for this equipment.

• Long piping can limit capacity. Please refer to the

Design & Technical Manual for details.

Things to Note

Use this Quick Installation Guide to install Halcyon HFI Systems. Use the Installation Manual

provided in the box only where this Guide asks you to refer to it for more information.

To download the newest full Installation Manual, go to http://portal.fujitsugeneral.com.

This is an Installation Guide and is not a replacement for proper system design. Please

refer to the Design & Technical Manual for complete design limitations and capacity tables.

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Branch Boxes Unit Placement

Branch Boxes: Special Precautions

When installing

Branch Boxes:

• Always install and tighten required flare adapters

BEFORE installing or attaching Branch Box to the

wall or ceiling especially in a confined space.

• Always tighten any flare caps on unused circuits.

• If you use pre-flared refrigerant pipes: Remember

to remove the rubber end plug before attaching!

- Unless line set flares are R410a rated, cut

them off and re-flare using R410a rated

flare nuts.

12” Clearance

8 in.

2 in.

20 in.

40 in.

60 in.*

For 16 additional

placement options,

please refer to the

installation manual

Above pad and

anticipated snow depth

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 branch boxes or outdoor unit until

refrigerant charging is completed.

• 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.

• Connect all wiring tightly. Loose wiring may cause

overheating at connection points and a possible fire hazard.

40 in. to 60 in.*

12 in.

20 in.

* 60 inches or more

above when installed in

a confined space.

• Knock out holes are provided for wiring (Fig. A)

• Knock out holes are provided 2 each in the same

size in front, lateral, and rear sides (Fig. B)

Knock Out Holes Fig. A Fig. B

6Basic Wiring Overview

Refer to installation manual for complete wiring and design criteria.

39,000 Btu Minimum connected capacity

62,000 Btu Maximum connected capacity

Outdoor Unit Electrical Requirements.

40A Breaker 8AWG 2+Ground

*Caution:

When installing this system in high humidity

locations, install using ground fault equipment

breakers (often referred to in other countries

as an ELCB earth leakage current breaker) to

reduce the risk of leaking current which may

result in electric shock or potential fire. We

suggest installing GFEB breakers or follow

local electrical code. This system uses an

inverter, which means that when used with a

ground fault breaker you must use breakers

that can handle higher harmonics such as a

(GFEB) Ground Fault Equipment Breaker

(30 mA or greater) in order to prevent

malfunctioning of ground fault device.

1 - Communication wires [Outdoor unit to Primary (Branch Box) B.B.]

2 - Communication wires [Primary B.B. to Secondary B.B.]

3 - Central remote controller wires [Central remote controller to B.B.]

4 - Power supply and Communication wires [B.B. to indoor units]

5 - Power supply [Outdoor unit]

6 - Power supply [Branch Box]

7 - Remote control wires [Indoor units to Remote Controller]

Branch Box 3

Secondary

Circuit Breaker

(over current)

Earth Leakage

Breaker*

Indoor Units

Power

Supply

Branch Box 2

Secondary

Circuit Breaker

(over current)

Earth Leakage

Breaker*

Power

Supply

Branch Box 1

Primary

Circuit Breaker

(over current)

Earth

Leakage

Breaker*

Power

Supply Central Remote

Control

Outdoor Unit

Circuit Breaker

(over current)

Earth

Leakage

Breaker*

Power

Supply

WARNING!

Do not turn on power to system or branch boxes before

completing full evacuation and refrigerant charging!

Piping Restrictions

Refrigerant Pipe Sizes

Liquid Adaptor Gas

Branch

Box

Indoor

Unit

7,000 BTU

1/4”

1/2” to 3/8”

adaptors

included

(3 of each)

3/8”9,000 BTU

12,000 BTU

18,000 BTU 1/4” 1/2”

24,000 BTU 1/4”

1/2” to 5/8”

adaptors

included

(3 of each)

5/8”

Outdoor Unit Branch Box

Separation Tube

Assembly Kit

Liquid pipe 3/8 inch

Gas pipe 5/8 inch

Branch Box

Flare connections

=Flare connections

Liquid pipe 1/4 inch

Gas pipe 3/8”, 1/2”, or 5/8”

based on indoor unit size*

=*Branch box outlets are all 1/2” on gas pipe connections.

1/2” to 3/8” adaptors and 1/2” to 5/8” adaptors included (3 of each).

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10aPipe Length

Pipe Limitation Limitations

Allowable

pipe length

(actual pipe

length)

Total Pipe Length Up to 377 ft.

Between outdoor unit and the farthest indoor unit Up to 230 ft.

Between outdoor unit and branch boxes Up to 180 ft.

Between branch boxes and indoor unit Total Up to 197 ft.

Ea. Unit 10 ft. to 49 ft.

Between outdoor unit and the first separation tube 16 ft. or more

Between outdoor unit and branch box (no separation tube) 16 ft. or more

Between outdoor unit and branch box (if separation tube used) 17 ft. or more

Vertical Positioning:

Tubes must stand straight up

or down. They CANNOT be

tilted or angled more than 10%

off perfectly vertical.

Horizontal Positioning:

Tubes must lay flat horizontal

They CANNOT be tilted or angled

more than 10% off Flat and Level

in either direction.

Separation Tube Assembly

Pipe Limitation Limitations

Allowable

height

difference

Between outdoor unit and indoor unit Up to 98 ft.

Between outdoor unit and branch box Up to 98 ft.

Between branch box and branch box Up to 49 ft.

Between indoor unit and indoor unit Up to 49 ft.

MINIMUM Allowable Pipe Lengths MAXIMUM Allowable Pipe Lengths

Note: Pipe lengths must include fitting losses.

10bElevation

Maximum allowable height difference

Height = Elevation, not pipe length

16 Ft. Min. - if no separation tube

16 Ft. Min. 10 Feet Min. 180 Feet Max. 49 Feet Max.

230 Feet maximum to furthest indoor unit

377 Feet maximum connected pipe

98 Feet 49 Feet

98 Feet

49 Feet

Branch box to

branch box 49 Feet

Max to highest

branch box

From a branch box to its

highest indoor unit

From the lowest indoor unit

to the highest indoor unit

Max to highest

indoor unit

Outdoor unit can be above or

below evaporators

All indoor equipment must be

installed witihin the same 49 feet

of elevation from each other

1 Ft. Min.

197 Ft. Max Combined

12 13

11 Flaring

Insulation

Pipe Size Torque

• Cut pipe with a sharp tube cutter

• Deburr & clean out shavings

• Flare with quality tool

• Set depth properly for good flange

• Make sure nut pulls easily over flange not scraping threads.

Too big and it will leak.

• Place a thin film of correct refrigerant oil on male bevel.

• Hand tighten keeping line straight.

• Tighten correctly using a torque wrench according to the,

“Tightening torque” chart.

Pipe outside

diameter

in.(mm)

Dimension A

in. (mm)

Flare tool for

R410A, clutch type

Dimension B

in. (mm)

1/4 (6.35)

0 to 0.0197

(0 to 0.5)

23/64 (9.1)

3/8 (9.52) 33/64 (13.2)

1/2 (12.7) 21/32 (16.6)

5/8 (15.88) 25/32 (19.7)

Check if (L) is flared uniformly

and is not cracked or scratched.

Die

Pipe

Flare nut (lbf)

Tightening torque

1/4 - 16 to 18

3/8 - 32 to 42

1/2 - 49 to 61

5/8 - 63 to 75

Flare nut (N·m)

Tightening torque

6.35 - 142 to 159

9.52 - 283 to 372

12.70 - 434 to 540

15.88 - 558 to 664

Blank Cap Flare Nut

Torque Wrench

Holding

Wrench

Torque

Wrench

All refrigerant pipes and connections

MUST BE INSULATED SEPARATELY

Gas Pipe

Connection Cable

Finishing Tape

Liquid Pipe

Heat Insulation

Gas Pipe

Liquid Pipe

Heat Insulation

Coupler Heat

Insulation (large)

Butting Surfaces

Coupler Heat Insulation (small)

Insulation (long)

Adhesive Tape

(field supplied)

Adhesive Tape

(field supplied)

Adhesive Tape

(field supplied)

15a15b

14 Refrigerant Pipe - Example Layout

Equivalent

Pipe Length

To reduce the number of calculated feet always use smooth 6in. radius bends.

Note - Separation tubes

are installed in a Flat -

Horizontal or Vertical

position only!

For more information

refer to the installation

manual.

Primary

Secondary 1

Secondary 2

An onsite bend of less than 6 in. radius is

calculated at .35 Equivalent Feet.

Halcyon HFI system requires any bends tighter than a

6 in. radius to be counted as extra feet of pipe.

• Count the number of bends that have a less than 6 in.

radius ______(#)

• Multiply the number of bends by 0.35 = (Equivalent

Length)

• Add the Equivalent length to the actual feet of installed

line set = the calculated length.

3.5 feet added to actual length makes the

equivalent pipe length you must calculate.

Example: (Your pipe sizes are 5/8 and 3/8)

A System with 5 bends each less than 6 in radius

between the outdoor unit and the 1st branch box.

5/8 - Multiply no. of bends 5X 0.35 = 1.75(ft)

3/8 - Multiply no. of bends 5X 0.35 = 1.75(ft)

Now add those 2 together to equal= 3.5 (ft)

When brazing:

Refer to the installation manual when using elbows or

hard pipe for pipe length calculation.

16a16b

Branch Box

Layout

Branch Box Installation

• Factory Insulated Branch Boxes do not need a

condensate drain line or a drain pan.

• Incorrect installation will void warranty and may cause

electrical short in board.

• Suction line should always be on the top or side never

on the bottom in relation to the discharge line.

Electrical box is never on the bottom.

4 factory supplied hanger brackets allow for flexible

positioning.

Outlet

Side

Inlet

Side

VERTICAL

Vertical Wall Mount

• Can be hung from the ceiling or on the wall by

changing the location of hanger.

• Control box can be attached to the either side in

HORIZONTAL position only.

• Branch boxes do not have a weatherproof enclosure.

• Cannot be mounted outside or in a space

above 80% relative humidity.

• May be installed in a storage space that is inside the

insulated envelope of the building.

Outlet

Side

Inlet

Side

CAUTION

• Do not hang from the ceiling when

performing a vertical installation.

• Secure the accessory hangers to the branch box

with the screws provided.

• Use 3/8 threaded rods with hexagonal nuts and

washers (field supplied) as shown on the figure.

• Make sure branch box is level before fastening the

nuts. (The unit’s slope must be within ±5° from

level.)

Branch box is marked with engraved letters indicating each

corresponding indoor unit (UNIT A, UNIT B and UNIT C).

UNIT A: Refrigerant pipe connection port for UNIT A

UNIT B: Refrigerant pipe connection port for UNIT B

UNIT C: Refrigerant pipe connection port for UNIT C

CAUTION

Label all the refrigerant piping

(liquid pipe, gas pipe) specifying

to which indoor units they will

be connected.

Threaded Rod

Washers Nuts

Hanger brackets ship

with branch box

18 19

Leak Test Evacuate

& Charge

Refrigerant Charge

YOU

MUST!

YOU

MUST!

Never apply power to a Fujitsu HFI system

until leak testing, repair, evacuation & the

refrigerant has been added to the system!

IMPORTANT NOTE:

R410a must be added to ALL Halcyon HFI Systems!

Charge is based on length of the liquid/small line side of the system’s pipes

- Total length in feet of liquid ⅜ (small) pipes from outdoor unit to Branch Boxes

- Total length of feet of liquid ¼ pipes from Branch Boxes to all indoor units

- Then add charge based on table below.

Calculate the refrigerant charge as follow:

• Multiply ⅜ calculated pipe length from outdoor unit

to branch boxes by .624 oz per ft.

• Multiply calculated ¼ pipe length Branch Boxes to

all Indoor Units by .224 oz per foot

Example: 78 ft calculated ⅜ pipe & 110 feet of calculated ¼pipe

• ⅜@78ft X .624oz = 48.672oz divide oz by 16 to get 3.042lbs

• ¼@110ft X .224 oz = 24.64 oz = divide by 16 to get 1.54lbs

• Now Add ⅜ @ 48.672oz + ¼@ 24.64oz = 73.31oz – 4.58 lbs of R410a

Pipe Diameter Location Additional Refrig.

3/8” Outdoor to Branch Box 0.624 oz./ft. or 58g/meter

1/4” Branch Box to Indoor Unit 0.224 oz./ft. or 21g/meter

(Total length of 3/8” liquid line × 0.624 oz./ft. or 58g/meter ) + (Total length of 1/4” liquid line × 0.224 oz./ft. or 21g/meter )

(a+b+c+d+e) × 0.624 oz./ft. or 58g/meter + (f+g+h+i+j+k+l+m) × 0.224 oz./ft. or 21g/meter = additional refrigerant

Never apply power to a Fujitsu

HFI system until leak testing and

evacuation and system

refrigerant has been added!

• After completing nitrogen purge and

leak test slowly remove nitrogen

from the system

• Connect vacuum pump and

micron gauge

• Using industry standard “Best Practices”

evacuate system to 500 microns and

make sure it holds for 60 minutes.

• While evacuating calculate system charge

requirements.

• After connecting all refrigerant pipes connect

gauge hose and a regulated nitrogen tank to one connection of the

outdoor unit’s port and purge entire system with nitrogen through

the indoor units and back out the other port.

• Pressurize the entire piping system with nitrogen to 600PSI and

leak test every fitting carefully with soap bubbles!

• Perform a 24 hour standing pressure test with nitrogen to assure a

leak free system

• Keep service valves on the outdoor unit closed until system is

evacuated and refrigerant is added.

• It is highly recommended that you replace the oil in the vacuum

pump before it is used.

21aElectrical Requirement - Outdoor Unit

Electrical Requirement - Branch Boxes

Secondary 2

Secondary 1

Primary

Communication Cable

3+Ground

Disconnect

Electrical Panel

Power Line

2+Ground

Communication Lines

Voltage Rating 1 Ø 208/230V (60Hz)

Operating Range 187 - 264V

Dedicated 208/230 40A

breaker for outdoor unit.

Cable Cable Size Remarks

Power Supply Cable 8 AWG 2 cable + Ground, 1 Ø 208/230V

Connection Cable 14 AWG 3 cable + Ground, 1 Ø 208/230V

Breaker Capacity (A)

HVACR Breaker* 40

Secondary 2

Secondary 1

Primary

Junction

Box

Disconnect

Electrical Panel

Power Line

2+Ground Power Line

2+Ground

Connection Cable 3 wire and a ground (4 wires)

Voltage Rating 1 Ø 208/230V (60Hz)

Operating Range 187 - 264V

Dedicated 208/230 15A

breaker for branch box.

Cable Cable Size Remarks

Power Supply Cable 14 AWG 2 cable + Ground, 1 Ø 208/230V

Connection Cable 14 AWG 3 cable + Ground, 1 Ø 208/230V

Breaker Capacity (A)

HVACR Breaker* 15

* When installing this system in high humidity locations, install using ground fault equipment breakers (often referred to in other countries as an ELCB earth leakage

current breaker) to reduce the risk of leaking current which may result in electric shock or potential fire. We suggest installing GFEB breakers or follow local

electrical code. This system uses an inverter, which means that when used with a ground fault breaker you must use breakers that can handle higher harmonics

such as a (GFEB) Ground Fault Equipment Breaker (30 mA or greater) in order to prevent malfunctioning of ground fault device.

* When installing this system in high humidity locations, install using ground fault equipment breakers (often referred to in other countries as an ELCB earth leakage

current breaker) to reduce the risk of leaking current which may result in electric shock or potential fire. We suggest installing GFEB breakers or follow local

electrical code. This system uses an inverter, which means that when used with a ground fault breaker you must use breakers that can handle higher harmonics