Fujitsu CPYA080LLW Installation guide

Brand: Fujitsu

Model: CPYA080LLW

Category: Split-system air conditioners

Type: Installation guide

This manual is also suitable for

Installation manual

A CLASS ENERGY EFFICIENCY AIRCOOLED REVERSIBLE HEAT PUMPS WITH EC INVERTER AXIAL FANS,

INVERTER ROTARY COMPRESSOR, PLATE EXCHANGER AND HYDRONIC KIT

CP*A050LLW/CP*A060LLW/CP*A080LLW

PART No. 9377863553

1. GENERAL 4

1.1 DOCUMENT INFORMATION 4

1.2 ACCESSORIES 4

1.3 MACHINE IDENTIFICATION 5

1.4 INTENDED USE 5

1.5 GENERAL PRECAUTIONS 5

1.6 BASIC SAFETY RULES 6

1.7 RESIDUAL RISK 6

1.8 USER GUIDELINES 7

1.9 MACHINE DESCRIPTION 7

1.10 DIMENSIONS DRAWINGS 8

1.11 SAFETY DEVICE 9

1.12 DECOMMISSIONING AND DISPOSING 9

2. SHIPMENT 10

2.1 POSITION OF THE EQUIPMENT 10

2.2 EQUIPMENT 10

2.3 STORAGE 10

2.4 HANDLING 10

2.5 UNPACKING 11

2.6 ACCESS TO INTERNAL PARTS 11

2.7 RESTING ON THE GROUND 11

3. INSTALLATION 12

3.1 INSTALLATION LOCATION REQUIREMENTS 12

3.2 WORK FIELDS 12

3.3 UNIT POSITIONING AND FUNCTIONAL SPACES 12

4. WATER CONNECTIONS 15

4.1 CONNECTION DIAGRAM 15

4.2 POSITION OF CONNECTIONS 15

4.3 HYDRAULIC DATA 15

4.4 CONNECTION TO THE SYSTEM 16

4.5 SYSTEM FILL-UP 16

4.6 PIPING INSULATION 16

4.7 PROTRUSION LENGTH OF OUTDOOR TEMP THERMISTOR 16

5. ELECTRICAL CONNECTIONS 17

5.1 MACHINE CONNECTION 17

5.2 CONNECTIONS OF THE ACCESSORIES 17

5.3 WIRING METHOD 18

5.4 ELECTRICAL DATA 18

5.5 EXTERNAL INPUT AND OUTPUT 18

6. COMMISSIONING 19

6.1 PRELIMINARY INSPECTIONS 19

6.2 FIRST START-UP OR RESTART AFTER LONG INACTIVITY 19

6.3 SHUT-DOWN 19

6.4 FLOW RATE CALIBRATION 19

6.5 FLOW RATE BALANCE 19

7. CONTROL PANEL 20

7.1 USER INTERFACE 20

7.2 ALARMS 24

7.3 REMOTE CONTROL PANEL 25

7.4 AVP CONTROLLER 26

1. General

1.1 Document information

1.2 Accessories

1.3 Machine identification

1.4 Intended use

1.5 General precautions

1.6 Basic safety rules

1.7 Residual risk

1.8 User guidelines

1.9 Machine description

1.10 Dimensions drawings

1.11 Safety device

1.12 Decommissioning and disposing

Preliminary precautions

1.1 Document information

1.2 Accessories

model Item amount

CP*A050LLW Installation manual 1

D.O.C. 1

Energy label 1

CP*A060LLW Installation manual 1

D.O.C. 1

Energy label 1

EMI core 1

CP*A080LLW Installation manual 1

D.O.C. 1

Energy label 1

EMI core 1

Drain pipe 1

Drain cap 2

1.1.1 Symbols

• This publication contains the following symbols:

• This publication is an integral part of the equipment and therefore it should be kept with

care and should always go with the equipment also in case of its cession to another owner,

user or moving to another plant. If it is damaged or lost, request another copy from customer

service in the relevant area.

• The document is reserved by law and any kind of duplication or transmitting to a third party

without our explicit consent of the manufacturing company is forbidden.

• The manufacturer reserves the right to make changes to its models at any time without

prejudice to the basic features described in this manual.

• The manufacturing company excludes any contractual and extra-contractual liability

for damage caused to people, animals or objects, due to installation, regulation and

maintenance errors, to improper use or non-compliance with the rules reported in

the accompanying documents, in the signposting applied on the machine, in Safety

Regulations in force in the installation place as well as in the precautions suggested by

common sense.

• Inform all personnel involved in machine use about these instructions.

• The manual is divided into chapters as follows:

 General;

 Shipment;

 Installation;

 Water connections;

 Electrical connections:

 Commissioning;

 Control panel;

 Maintenance.

 Attached.

• The preliminary precautions must be read before performing any of the following operations.

This document uses the following definitions:

 Danger zones: any area inside and/or near the machine in which the presence of an

exposed person constitutes a risk to his/her own health and safety.

 Exposed person: any person who is entirely or partially in a danger zone.

 Operator/Maintenance Technician: the person/s assigned to operate, adjust, service, repair

or move the machine.

A Chapter

B Sequence of paragraphs

C Preliminary precautions

D Operations

Danger

Draws attention to actions that can cause serious injury if not performed

correctly.

Prohibited Draws attention to actions that impose a prohibition.

1.3 Machine identification

A Rating Label

The equipment can be identified from:

• Rating Label

 Affixed on the machine, it shows the technical and performance data of the equipment.

The loss of the label may compromise CE compliance. If it is lost or

deteriorated, request a duplicate from Technical Support.

Tampering with, removal and deterioration of the identification plates complicate any

installation, maintenance and spare part request.

1.4 Intended use

This equipment is intended to heat or cool water (eventually added with inhibited ethylene

glycol) which circulates in a closed circuit.

Hot or cold water produced by the machine shall be used for heating-cooling applications or

industrial process.

Any other use of the machine is forbidden.

Do not use flammable products near the machine.

Do not use substances that can form explosive mixtures close to the

machine.

Do not use the machine where there are problems of environmental

impact.

The unit will be damaged if the unit is left prolonged periods at pow-

er-off state with an outside temperature of 0°C or lower.

Do not install the unit at a location exposed to salty breeze or in hot

springs where a sulfidizing gas is generated.

1.5 General precautions

Please ask professional sales shop to install this unit.

Do not attempt to install this unit by yourself to avoid the accidents such as electric shock,

fire and leakage of water.

These units must comply with their intended use in line with their performance character-

istics.

Wear suitable and accident prevention clothing and equipment during installation and/or

maintenance. The manufacturer declines any liability for non-compliance with safety and

accident prevention regulations in force.

All unit installation, connection, start-up and shut-down operations must only be

implemented by qualified and authorised personnel.

Comply with the laws in force in the country where the machine is installed, concerning

the use and disposal of the packaging, the products used for cleaning and maintenance

and for the management when the unit life cycle is complete.

Any repairs or maintenance must be performed by the technical support of the manufac-

turer or by qualified personnel, in accordance with this publication.

Preferably use original spare parts when replacing components.

If the refrigerant should leak, ventilate the room. The liquid refrigerant produces toxic gas

when exposed to a flame.

In the case of a malfunction or spill of liquid or gas refrigerant, set the main switch to “off”

and close the shut-off valves. Promptly call technical support or professional personnel. Do

not intervene personally on the unit.

If the outside temperature may drop below zero, there is a freezing hazard and the system

must be drained or anti-freeze must be added.

Where the outdoor temperature is 0 °C or less, set up the outdoor unit in a high place,

and do not arrange the frame of installed stand under the drain port. Because the water

dropped from the drain port repeats freezing and accumulating, and may block the drain

port.

In the area with heavy snowfall, if the intake and outlet of unit is blocked with snow, it

might become difficult to get warm and it is likely to cause of the breakdown. Please con-

struct a canopy and a pedestal or baffle board.(local configured).

This unit contains fluorinated greenhouse gas covered by the Kyoto Protocol. Maintenance

and disposal must be carried out only by qualified personnel.

CP*A050-060LLW CP*A080LLW

• Based on CE Standard no. 842/2006 on certain fluorinated greenhouse gases, it is mandatory

to indicate the total amount of refrigerant in the installed system. This information is present in

the technical plate found in the outdoor unit.

• After finishing the installation, please check no defective points in the testing operation. Then,

kindly explain to the user about the directions and maintenance according to the operation

manual.

• For product modification, the product and its specification may show slight differences from

the description of this manual.

• Be sure to install the unit in steady place to hold the heavy weight. Lack of stability or

imperfect installation may cause injury due to the fall of the unit.

• Be sure to fix the power supply cord in connecting points of the terminal block correctly,

Imperfection of the connecting may cause overheating and a fire.

• Be sure to install the wiring lid in a straight line. Imperfect wiring works may cause

overheating, a fire or electric shock at the connecting point in the terminal block.

1.6 Basic safety rules

Using products that require electricity and water require some basic safety rules to be complied

with, such as:

It is prohibited to operate the unit before having disconnecting it from the power supply by

setting the main switch to "off".

It is prohibited to modify the safety devices or the settings without authorisation and

instructions from the manufacturer of the unit.

It is prohibited to pull, detach or twist the electrical cables coming from the unit, even if it is

disconnected from the power supply.

It is strictly prohibited to touch any moving parts, interpose between them or introduce

pointed objects through the grids.

It is prohibited to use gas and water pipes to earth the unit.

It is prohibited to touch the unit when barefoot or with wet or damp parts of the body.

It is prohibited to stand on the unit, sit down on it and/or lean any type of object against it.

It is prohibited to dispose of and leave the packaging material in the reach of children as it

can be a potential source of danger.

It is prohibited for children or unassisted disabled persons to use the unit.

It is prohibited to introduce R410A in the atmosphere: R410A is a fluorinated greenhouse

gas referred to in the Kyoto Protocol with a Global Warming Potential (GWP)= 2088.

1.7 Residual risk

Description

The description of the residual risk considers the following elements:

• the type of dangers those working around the machine are subject to;

• a description of main risks;

• who could be exposed to such risks;

• what are the main safety measures adopted to reduce the risk of injury.

The guidelines for the prevention of accidents reported below, with reference to the relative areas

of residual risk, must be integrated with all the general instructions of this chapter and with the

accident prevention regulations in force in the destination country of the system.

Residual risk near the machine

• Electrocution, if the electrical connection and earthing of the machine are not carried out

correctly.

• Cuts or abrasions due to the presence of sharp edges.

• Suction of substances in the installation site and subsequent dispersion in the environment.

• Projection of any object that may fall on the fans blades.

• Leakage of water (in case of a fault).

• Formation of condensation water and ice in the area in front of the machine during the

heating operation of the heat pump machines.

• Micro-climate alteration (during operation).

• Noise emission (during operation). The sound pressure levels of the individual units are shown

in this manual.

• Oils leaks (due to a fault).

• Refrigerant gas leak (due to a fault).

Refrigerant gas is a greenhouse gas effect substance. Vapours are heavier than air and they

can cause suffocation by reducing oxygen available for breathing. Rapid evaporation of the

liquid can cause freezing.

Measures to be adopted if refrigerant gas leaks

• Product type:

 R410A

First aid measures

• General information:

 do not administer anything to an unconscious person.

• Inhalation:

 move outdoors.

 use oxygen or artificial respiration if needed.

 do not administer adrenaline or similar drugs.

• Contact with eyes:

 rinse thoroughly with plenty of water for at least 15 minutes and consult a doctor.

• Contact with skin:

 wash immediately with plenty of water

 immediately remove all contaminated clothing

Measures in the event of accidental spillage

• Personal precautions:

 Move all personnel to safe areas.

 Provide adequate ventilation.

 Use personal protective equipment.

• Environmental precautions:

 Intercept the emission.

• Cleaning methods:

 Use absorbent products.

Operations with removed panels

Some of the operations and/or tests described below require the removal of the panels to access

inside the unit.

There may be hot surfaces (piping, compressor, etc.) or cold (compressor, intake separator, etc.),

sharp edges (coils fins) or moving parts (fans) even with the machine stationary.

The power supply must be disconnected before removing any panel.

Operations that require the panels to be opened must only be carried out by qualified

personnel wearing personal protective equipment.

1.8 User guidelines

• Keep this manual in a place accessible to the operator.

• Take note of the unit identification data so as to provide them to the service centre when

required (see the "Machine identification" paragraph).

• It is recommended to keep track of the operations carried out on the unit, so as to facilitate any

troubleshooting.

• Request the installer to be trained on:

 switching on/shut-down;

 shutting down for long periods;

 maintenance;

 what to do/not to do in case of a fault.

In case of a fault or malfunction:

 immediately disable the unit without resetting the alarm;

 verify the type of alarm to notify the service centre;

 contact an authorised service centre;

 request original spare parts.

1.9 Machine description

1.11.1 Features

Structure

Self-supporting galvanised steel frame further protected with polyester powder painting.

Panels are easily removable to facilitate the inspection and maintenance of the internal

components of the unit.

Coil protection metallic guards and stainless steel bolts

Compressor

DC Inverter Rotary, internal overheat protection and crankcase heater, if needed, mounted on

shock absorbers.

It is installed in a compartment separate from the air flow to reduce noise.

The crankcase heater is always powered when the units is in stand-by.

Inspection is possible through the front panel of the unit.

EC Inverter fans

Axial fans with low rpm and special wing profile directly coupled to high efficiency DC Brushless

motors with external rotor, propelled by INVERTER.

They are statically and dynamically balanced and complete with safety protection grid placed on

the air outlet.

Condenser

Made up of a finned coil with copper pipes and aluminium fins.

With moisture drain pan.

Evaporator

In AISI 304 stainless steel braze welded plates type, insulated with closed cell foam.

An antifreeze heater is always installed.

Electrical board

It includes: main switch with door lock device, fuses, filter for harmonic current, compressor

contact, external air sensor for climatic adjustment, DHW sensor, and external three-way valve

management.

Microprocessor

For the automatic control of the following functions: water temperature regulation, antifreeze

protection, compressor timing, alarm reset, alarm management and operating LEDs, cumulative

alarm contact for remote signalling, local or remote commutation of the cooling / heating cycle,

high and low pressure control.

The unit includes serial interface.

Control logic of the Inverter Scroll compressor

It adjusts using Inverter the power supplied by the compressor as a function of the system

thermal load, the condensing pressure and the outdoor air temperature.

The control system, thanks to Inverter technology, monitors and adapts rapidly the performances

of the Inverter compressor, the pump and the fans in order to guarantee the best operating

conditions for the unit.

Thanks to the Inverter logic, units are able to operate even with low water content in the system,

thus making the use of the inertial tank superfluous.

Refrigerant circuit

The circuit, in copper tubing, includes: dryer filter, electronic expansion valves, liquid receiver,

4-ways reversing valve; pressure transducer; shut-off valves; silencer; electro valve; capillary tube;

regulation expansion valve.

Water circuit

It includes: evaporator; temperature sensor; antifreeze sensor; circulator with high efficiency DC

Brushless motor; flow switch; water gauges in suction line; expansion vessel; manual air vent;

water drain; security valve.

1.10 Dimensions drawings

Dimensions CP*A050-060LLW

Schema elettrico CP*A080LLW

621

330

830

373

320

892

1160

128

127

Ø12

1120

400

1180

Pitch of bolts for installation

28kg 33kg

111,3 111,3897,4

13,5

28kg 33kg

Pitch of bolts

for installation

OUT

Cables entry

130

290

625

627

105

320

105

274

354

800

Ø12

1010

127

1050

685

1058

Cables entry

Pitch of bolts for installation

15kg

20kg

15kg

20kg

Pitch of bolts

for installation

OUT

Manometer

1.11 Safety device

Model CP*A050LLW CP*A060LLW CP*A080LLW

Circuit protection

Main fuse current (next to main power supply terminals) 250V 1,25A-T

Auxiliary fuse current (next to main power supply terminals) 250V 1,25A-T

Main fuse current (next to ODU power supply terminals) 250V 20A 250V 25A 250V 25A

Fuse current (ODU fiche)

250V 15A

250V 3,15A 250V 3,15A250V 10A

250V 3,15A

Fan protection Thermal protection

Intervention 100°C

+/-10°C - motor stop

Rearmament 95°C

+/-10°C - motor on

Intervention 150°C +/-15°C

- motor stop

Rearmament 120°C

+/-15°C - motor on

Compressor protection

Motor thermal protection

Intervention 108°C - motor stop

Rearmament 80°C - motor on

Delivery thermal protection

Intervention 110°C - motor stop

Rearmament after 7 minutes - motor on

High pressure protection

Heat exchanger thermal protection

Intervention 67°C - compressor stop

Rearmament 63°C - compressor on

Pressure sensor

Intervention 4,2MPa - compressor stop

Rearmament 3,0MPa - compressor on

Low pressure (cooling only) Pressure sensor

Intervention 0,12MPa - compressor stop

Rearmament 0,15MPa - compressor on

1.12 Decommissioning and disposing

This product falls within the field of application of Directive 2012/19/EU on the management of

waste electric and electronic equipment (WEEE).

These types of products may contain substances that are potentially harmful to human

health and the environment and cannot be disposed of as household waste.

When the machine needs to be replaced or dismantled it must be disposed of according to local

regulations on sorted waste, otherwise you must contact your local dealer for information on free

pick-up.

2. Shipment

Preliminary precautions

• Complaints must be made within 8 days from receipt, late claims will not be valid.

• The unit must be moved only by qualified personnel, properly equipped and with

equipment suitable to the weight and dimensions of the device, provided below. If using

a forklift, insert the forks into the relative openings of the base. Avoid dangerous situations

if using a hoist to lift the unit. When using chains and ropes, make sure they are in good

conditions, of proper capacity and approved in compliance with safety regulations in force

in the place of installation.

• In all lifting operations be sure to have firmly anchored the unit to avoid tippings or

accidental falls.

• During the discharge and positioning of the unit, pay attention to not make abrupt

manoeuvres.

• Only remove the packaging when set in the place of installation.

• Do not dispose of the parts of the packaging in the environment or leave them within reach

of children as they are potential sources of danger; dispose of the packaging according to

regulations in force in the country.

• Move the unit with utmost care in order to not damage it.

• During lifting and moving operations, move away from the concerning area.

2.1 Position of the equipment

2.2 Equipment

2.3 Storage

2.4 Handling

2.5 Unpacking

2.6 Access to internal parts

2.7 Resting on the ground

2.4 Handling

It is prohibited to use the pipes or other components of the machine as lifting points.

5˚

During moving it is forbidden to pass the maximum inclination consented as indicated in

the figure.

2.4.1 Lifting with forks

• Insert the forks from the side;

2.1 Position of the equipment

A,B Pocket for accessories

Keep the documentation in a dry place to prevent deterioration, for at least 10 years for

future reference.

Any accessories that are not factory-fitted are supplied in separate packages, with a

relevant instruction sheet.

2.2 Equipment

Mounting positions of accessories

Ⓐ

Installation manual / D.O.C. / Energy label

Ⓑ

EMI core / Drain pipe / Drain cap

For details of accessories, see 1.2 Accessories

2.3 Storage

The room temperature in which the units are stored must be between -20 / +50°C.

2.5 Unpacking

Before positioning the unit in the right installation place, remove the protective packing.

• Cut and remove the strapping which block the cardboard packing.

• Remove the cardboard paying attention to not scratch the panels of the unit.

• Remove the protection sack.

• Remove the polystyrene parts, basement and cover.

The machine is supplied without shock absorbers. Install any shock absorbers before

resting the machine definitely on the ground.

Only remove the packaging when set in the place of installation.

Due to the different nature of packing materials (wood, nylon, polystyrene,

cardboard, etc.), it is advisable to store them separately and to deliver them to

companies specialized in waste disposal and recycling in order to safeguard the

environment.

2.6 Access to internal parts

CP*A050-060LLW CP*A080LLW

To access the electrical board:

• Disassemble the indicated panels.

• Before opening the electrical board, make sure to remove the voltage.

• Open the electrical board doors with the dedicated screwdriver.

• In reassembling the cover panels, make sure to mount the toothed washer screws to grant

earth continuity. As rule at least two screws per removable panel.

2.7 Resting on the ground

The unit must be positioned on a surface perfectly horizontal and able to withstand its

weight.

Install the unit where it will not be tilted more than 5°.

Positioning must be performed slowly and so that all support points are touching the floor.

Install the unit in a location that can withstand its weight, and where it will not topple or

fall.

3. Installation

Installation location requirements

Work fields

Unit positioning and functional spaces

3.1

3.2

3.3

Preliminary precautions

• The location of the hydraulic, cooling and electric systems should be determined by the

system designer and must consider both the purely technical requirements as well as any

applicable local legislation and specific authorisations.

• Comply with the technical clearances to guarantee proper access when performing

maintenance on the machine.

• The whole area of compliance should be prohibited, except for the operators and

maintenance personnel of the machine.

• The units must not be installed in the presence of flammable or explosive gases, in very

humid environments (laundries, greenhouses, etc.) or in places where there are other

machines that generate a strong source of heat.

• Install the unit on a solid base that can support the weight; the unit, if installed

incompletely or on a non- adequate base, may harm people or damage objects if it

detaches from its base.

3.1 Installation location requirements

The installation place must be chosen according to that specified in standard EN 378-1 and the

requirements of standard EN 378-3. In any case, the installation site must consider the risks

associated with an accidental leak of refrigerant gas contained in the direct expansion units. Do

not install the unit near flammable materials or others that could cause a fire. Provide specific fire-

fighting measures.

3.2 Work fields

Operating ranges are indicative, in proximity of operation limits units may partialize their heating

or cooling capacity.

Check the actual capacity by using the capacity tables or the selection software.

Operating mode: cooling

Standard operation

Ta Ambient air temperature (°C)

To Outlet water temperature (°C)

Operating mode: heating

Standard operation

Ta Ambient air temperature (°C)

To Outlet water temperature (°C)

3.3 Unit positioning and functional spaces

The unit should be positioned far from any obstacle.

AIR

ABCDE

mm mm mm mm mm

Min 100 Min 300 Min 300 Min 300 Min 600

When there are obstacles behind and in front of the machine.

AIR

mm mm

Min 300 Min 600

When there are obstacles behind, on one side and over the machine.

CDEF

mm mm mm mm

Min 100 Min 300 Min 300 Min 300

When there are obstacles behind and in front with several units.

AIR

GH I

mm mm mm

Min 250 Min 1000 Min 300

Installation, in addition to the indicated spaces, must enable access to the authorised personnel

for maintenance operations and must take into account the safety distances from any other equip-

ment installed near the machine.

It is prohibited to place the unit under a roof, canopy or any covering in general.

The heat pump units allow ice and condensation to form that pours on to the floor in front

of the unit. Collect and drain the condensation and defrost water to prevent the floor from

becoming slippery.

It is prohibited to place the unit inside basement windows.

AIR

3.3.1 Noise

During operation, the unit generates noise.

Avoid installation in reverberant environments.

Avoid placing the machine with the side of the coil in the direction where the noise level is

more critical.

STD

(ISO 3744)

Model

CP*A050LLW CP*A060LLW CP*A080LLW

dB(A) dB(A) dB(A)

63 61 69.5 59.5

125 56.5 65 57

250 47.5 53.5 56

500 48 54.5 53.5

1000 46 52 51.5

2000 39.5 45 45

4000 37 40 45

8000 38 34.5 36

To t.

63 69 69

dB(A)

The sound level values, intended as sound power, in accordance with ISO 3744, in dB(A), have

been measured in free field conditions at 1 m distance from the unit with water temperature of

35°C.

3.3.2 Windy areas (Resting on the ground)

The wind can affect the operating conditions. Minimise the effects by:

• Placing the unit with the long side parallel to the direction of the main winds.

Avoid placing it with the coil perpendicular to the direction of the main wind.

3.3.3 Resting on the ground

D Rigid rubber band

H Slab of 10-15 cm

• Place the unit on a perfectly level support surface.

• Interpose a hard rubber band between the base of the machine and the support surface.

Verify that the support surface withstands the weight of the unit.

Provide a support slab that is proportional with the unit if resting on unstable ground.

The slab must be horizontal and able to withstand approximately 200% of the operating

weight of the machine.

In case of need it is advisable the use of rubber shock absorbers.

Lay the machine on the ground with screws and plugs appropriate to the support/

basement type.

• Provide the indicated space to ensure good airflow.

• 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 airflow.)

• During heating operation, drain water flows from the outdoor unit. Therefore, install the out-

door unit in a place where the drain water flow will not be obstructed.

• Do not install the unit where people pass.

• Install the unit in a place where it will be free from being dirty or getting wet by rain as much

as possible.

4. Water

connections

Preliminary precautions

• Selection and installation of the system components are assigned to the installer who must

operate according to the regulations of good technical practice and governing law.

• Make sure that the pipes do not contain stones, sand, rust, slag or other foreign objects that

could damage the system.

• It is mandatory to install a suitable filter for the impurities in the unit inlet water.

• It is mandatory to mount a flow switch for fluids which shall be dimensioned and adjusted

according to plant features.

• It is mandatory to install air vent valves at the highest points of the pipes.

• The water content of the system must prevent imbalance in the operation of the refrigerant

circuits.

• The installation of water disconnecting switches is advised to avoid vibration transmission

to the plant.

• Check the pressure drops of the equipment, system and of any accessories mounted.

4.1 Connection diagram

4.2 Position of connections

4.3 Hydraulic data

4.4 Connection to the system

4.5 System fill-up

4.6 Piping insulation

4.7 Protrusion length of outdoor temp thermistor

4.1 Connection diagram

1 UNIT

ANT Anti-vibration joint (recommended)

FTR Mesh filter (mandatory)

RI Shut-off ball valve

RIC Automatic water filling valve

SFA Automatic air vent

4.3 Hydraulic data

4.3.1 Water volume

Machine electronic control, to protect the electrical motor, limits hourly start up of the

compressor.

This operation creates oscillations of the water temperature in the draw-off point, affecting plant

efficiency.

For a proper operation it is necessary the water content complies with the following table:

Water flow

Evaporator

Model

CP*050LLW CP*060LLW CP*080LLW

Pmin l/s 0.19 0.22 0.30

Pmax l/s 0.37 0.44 0.60

V L 15 18 25

Pmin = Evaporator minimum capacity

Pmax = Evaporator maximum capacity

V = Water volume (l)

If the water volume in the circuit (V) does not reach what is indicated, installing a new inertial

storage tanks shall be required.

The machine is equipped with expansion vessel which consents a plant maximum water content

as shown below.

Plant pre-load 1bar

Water volume

max plant

Model

CP*050LLW CP*060LLW CP*080LLW

L 128 128 128

In the event that the plant water content is higher, it is necessary to include an additional external

expansion vessel as a supplement.

Some of the components in the diagram may already be included in the unit with the

hydronic kit. Those not present must be provided by the installer.

Connection pipes must have a suitable diameter and be supported so as not to impose

their weight on the unit.

4.2 Position of connections

The position of the water connections and the inlet and outlet direction is indicated by the labels

on the connections.

OUT

Unit

4.3.2 Protection against freezing

If you do not wish to drain the system during periods when the machine is not used, the water

may freeze, or if the system must operate with temperatures less than 5°C, ethylene glycol must

be mixed with the water.

Adding glycol changes the physical characteristics of the water and the performance of the ma-

chine.

The table indicates the multiplicative factors to calculate the performance change based on the

percentage of glycol used.

% G 0 10 20 30 40 50

Tc 0 -4.5 -9.5 -15.5 -21.5 -32.5

CQ 1 0.975 0.953 0.931 0.914 0.882

CP 1 1.01 0.995 0.99 0.985 0.975

CG 1 1.01 1.04 1.08 1.14 1.20

CP 1 1.05 1.13 1.21 1.26 1.32

% G = Glycol percentage

Tc = Water freezing temperature (°C)

CQ = Cooling capacity correction factor

CP = Electrical power absorbed correction factor

CG = Correction factor of mixing flow

Cp = Pressure drops correction factor

4.4 Connection to the system

Position of hydraulic fittings

IN OUT

CP*A050-60LLW / CP*A080LLW

In these models the connections are placed outside the unit and on the rear side.

• Remove the protection caps from the connections.

• Connect the pipes to the connections.

Tightening torque

15 to 30 Nm (150 to 350 kgfcm)

A safety valve on the water circuit provided as standard will permit, in case of

plant serious abnormalities (i.e. fire), to discharge the system avoiding possible

explosions.

During the hydraulic connection operations, never operate with free

flames near or inside the unit.

Provide shut-off valves and anti-vibration joints on the connection pipes.

• Make sure to provide a proper drain for the pressure relief valve to avoid any water coming into

contact with electrical parts.

• Air vents must be provided at all high points of the system. The vents should be located at

points which are easily accessible for servicing. An automatic air purge is provided inside the

unit. Check that this air purge valve is not tightened too much so that automatic release of air

in the water circuit remains possible .

• Take care that the components installed in the field piping can withstand the water pressure.

For threaded connections:

• Fasten by holding a part in order to tighten the other part.

• To guarantee the seal is recommended to use suitable seals (fibre seals, o-rings), teflon tape or

hemp, and sealing paste.

4.5 System fill-up

Before performing any operation, make sure the main switch is off.

Make sure that the drain valves are closed and the air vent valves are

open.

• Open the shut-off valves of the water system.

• Start filling.

• When starts the water outflow from the air vents, close the latter and pressure water to a

plant estimated value (max. 1 - 1,5 bar). Keep in mind that the calibration of the safety

valves is 3 bar.

• When the water pressure is stable (read the manometer installed on the machine side), close

the load valve and verify the tightness of all joints.

It is advisable to periodically check the pressure in the water circuits to prevent

malfunctions.

The water circuits must always be topped-up with the pumps off.

4.6 Piping insulation

The complete water circuit, inclusive all piping, must be insulated to prevent condensation during

cooling operation and reduction of the cooling and heating capacity.

If the temperature is higher than 30°C and the humidity is higher than RH 80%,then the thickness

of the sealing materials should be at least 20 mm in order to avoid condensation on the surface of

the sealing.

Be sure to insulate the pipes in order to prevent the water being frozen.

4.7 Protrusion length of outdoor temp thermistor

Confirm that the protrusion length of outdoor temp thermistor is 15mm.

If it is not 15mm, adjust the length to 15mm.

The illustration below is an image of CP*A050-060LLW.

Outdoor temp thermistor

15 mm

5. Electrical

connections

Preliminary precautions

• Make sure that the characteristics of the mains are adequate for the consumption indicated

on the electrical board plate and the wiring diagram, considering also any other units in

parallel operation.

• Make sure that the power supply voltage corresponds to the nominal value +/- 5% with a

maximum imbalance between the phases of 2%.

• Use cables with double insulation for the electrical connections.

• The use of an omnipolar general-purpose circuit breaker adequately sized to protect the

power supply line is mandatory.

• It is mandatory to set up an effective earthing.

• It is prohibited to use gas and water pipes to earth the unit.

• The manufacturer is not liable for any damage caused if the earthing is missing or failure to

comply with that indicated in the wiring diagrams.

5.1 Machine connection

5.2 Connections of the accessories

5.3 Wiring method

5.4 Electrical data

5.5 External input and output

5.1 Machine connection

E Electrical wiring inlet

5.2 Connections of the accessories

5.2.1 External consents

If you wish to enable or disable the unit remotely, connect the external consent to the contacts

listed in the wiring diagram.

Avoid placing the control cables in the same duct as the power cables. Always use a

suitable shielded cable.

The connection cables must have a minimum cross section of 1.5 mm².

5.2.2 Noise Filter connection.

In CP*A060LLW and CP*A080LLW the noise filter shall be mounted (supplied with the machine).

The filter shall be installed near electrical power connections inside the electrical panel.

For the power supply connection, follow the attached wiring diagrams.

CP*A050-060-080LLW

The equipment is equipped with holes with cable glands for the power wiring inlet.

• The equipment incorporates earth connections with a sole functional purpose.

• Insert the cables from the outside, guiding them towards the electrical board.

Avoid direct contact with non-insulated copper pipes and with the compressor.

It is forbidden to enter the device with electrical cables in positions not specifically required

in this booklet.

• Before inserting the power supply cable to the outlet, be sure to check a proper voltage.

• Be sure to use an exclusive power source with a circuit breaker.

• Install the outlet within the length of power supply cord.

• Do not use power supply cord extended or connected halfway.

To set up the electrical connections:

• Place the main switch upstream the unit (electrical plant) on 0 (off).

• Open the electrical board.

• Make the connections as shown in the wiring diagram.

• Use the hole for the main power cable and the hole for the cables of other external

connections.

• Hold power wirings and external connection with cable ties present along the wiring path.

• After completing the electrical connections lock the cables with the cable glands and close the

doors of the electrical board.

Before connecting the remote ON-OFF switch, remove the jumper from

the relative clamps.

5.3 Wiring method

CP*A050-060LLW

Cable clamp

Power supply

cable

Cable preparation

(Unit : mm)

Power supply cable

EMI core

* for only

CP*A060LLW

Power supply

terminal

Cable clamp

120 60 10

CP*A080LLW

1050

(Unit : mm)

Power supply

terminal

Power supply

cable

Cable clamp

Cable preparation

Power supply cable

EMI core

side view

front view

*Processing of Rubber cap for all model

When passing the power cable, make cut of 10mm horizontally and vertically in the centre of the

rubber cap.

The illustlation below is an image of CP*A080LLW.

When passing the power cable, make a cut of 10mm

horizontally and vertically in the centre of the rubber cap.

Additional cable clamp (bottom)

Top view

5.4 Electrical data

Model CP*A050LLW CP*A060LLW CP*A080LLW

Power voltage V 220-240

Power supply

Voltage V 230

Frequency Hz 50

Maximum current

Heating A 14 19 20

Main fuse ( )

Current

A202525

Blocked rotor current Heating/cooling A Not applicable (lower than operating current)

Electrical connections Power wirings mm2 3,5-4,0

Electrical wirings

Power supply N° 3

Wiring type H05RN-F

5.5 External input and output

Using the external input and output allows you to use the functions listed in the following table.

Terminal number Input or Output Function

1,2 Input Capacity requirement

3,4 Input Offset of the set temperature

5,6 Output Auxiliary heater ON/OFF

7,8 Output Error occurrence output on IF side

9,10 Output DHW 3-way valve ON/OFF

11,12 Input External thermostat ON/OFF

13,14 Input DHW ON/OFF

15,16 Input External cooling/heating instruction

External input and output terminal

6. Commissioning

6.1 Preliminary inspections

6.2 First start-up or restart after long inactivity

6.3 Shut-down

6.4 Flow rate calibration

6.5 Flow rate balance

Preliminary precautions

6.1 Preliminary inspections

6.1.1 Electrical

• Verify the voltage on L1, L2 or L1, L2, L3 terminals is that indicated on the unit plate

(tolerance allowed) ±5% verifiable with a tester. If voltage changes occur frequently, please

contact our technical department to choose suitable protections.

• Check the connecting cables connected securely.

• Check pipe connection sections thermally insulated.

• Check the earthing lines connected securely.

6.1.2 Hydraulic

• Make sure that the water circuit has been previously cleaned: it is recommended to wash

the water circuit via by-passing the unit and then check the cleanliness of the system filter.

• The machines are shipped with open vents and drains, which must be closed during

installation when filling the water circuit. Labels indicate their positions.

• Make sure that the hydraulic system has been bled, thereby eliminating any residual air. The

operation must be performed by loading gradually and opening the venting devices set up by

the installer in the upper part of the system.

• If you are using glycol water you can move the antifreeze set-point. The value must be equal to

the value of the freezing temperature of the fluid plus 6K.

• Check no hot water socket above the regular socket.

• Check the equipment and main pipe connection sections free of circulating water leaks.

6.1.3 Cooling

• Check that there is no refrigerant leak, possibly using a leak detector.

6.2 First start-up or restart after long inactivity

6.2.1 Start-up

Activate the machine according to that described in the relative command section.

6.2.1.1 Checks during operation

• Check that the machine does not generate abnormal noise or excessive vibrations.

• Verify that the machine operates within the optimum working range.

• A few minutes after the compressors are started, during the summer mode cycle, make sure

that the condensing temperature is 18±4K higher than the air temperature entering the

condenser and that the average evaporating temperature is approximately 5K lower than the

water temperature leaving the utility exchanger.

• Verify that the overheating temperature of the refrigerant is between 5 and 7K. To verify:

 Measure the temperature with a contact thermometer placed on the intake pipe of the

condenser.

• Verify that the subcooling temperature of the refrigerant is between 4 and 8K. To verify:

 Measure the temperature with a contact thermometer placed on the outlet pipe from the

condenser.

• The initial start up of the chiller must be carried out by the Technical Support.

• Make sure that all safety conditions have been complied with.

• Make sure that the unit has been adequately fixed to the support surface.

• Make sure that you have complied with the clearance area.

• Make sure that the water connections have been implemented according to the instruction

manual.

• Make sure that the hydraulic system is filled and vented.

• Make sure that the shut-off valves of the water circuit are open.

• Make sure that the electrical connections have been implemented correctly and that all

terminals are tightened.

• Make sure that the earthing has been implemented correctly.

• Make sure that the all the electrical connections have been tightened correctly.

6.3 Shut-down

6.3.1 Temporary shut-down

Disable the machine according to that described in the relative command section.

Avoid to remove voltage using the switch on board or the main switch of the plant.

Voltage loss do not allow the antifreeze heater operation with the consequent risk of

freezing.

The antifreeze protection function is only active if the unit is in “STAND-BY” mode. In case of

operation, the unit controls pump start-up.

To safeguard the system and the units, we recommend installing an electrical heater on the

connection pipes, or to fully empty the system.

6.3.2 shutting down for long periods;

Not using the unit for a long period of time requires the following operations to be performed:

• Disable the unit in any mode of operation it may be, from the control panel.

• Set the remote switch to “OFF” (if present) after having turned off the unit.

• Disable the internal terminal units by setting the switch of each unit to “off”.

• Set the main switch of the system to ‘’off’’.

• Close the water valves.

If, during the period of inactivity the temperature drops below zero, the system must be

fully empties or topped up with antifreeze liquid.

6.4 Flow rate calibration

Once the pump has started, verify that the fluid flow rate of the utilities is within the expected

values for the unit.

To verify:

• Verify the temperature difference between fluid utilities inlet and outlet when the unit works at

full capacity.

• The difference in water temperature between input and output must be between 4° and 6°C:

 If lower than 4°C, the water flow is too high: slightly close the shut-off valve placed on the

pump delivery, plant side, coming out of the machine.

 If higher than 8°C, verify the pressure drops on water circuit.

6.5 Flow rate balance

When there are multiple units in parallel, the ΔT of the water produced by the machines turned on

must be checked.

It may occur that the units closer to the pump produce a ΔT<5°C (high flow rate), while the units

farther away may produce a ΔT>5°C (flow rate lower than nominal values).

To correct the potential flow rate offset, the shut off valves on the inlet and outlet of each machine

must be operated on.

Slightly close the valve on the units with high flow rate and make sure the shut off valves on the

units with lower flor rate are fully open.

7. Control Panel

7.1 User interface

7.2 Alarms

7.3 Remote control panel

7.4 AVP controller

7.1 User interface

7.1.1 Control panel

The control panel enables all machine functions to be performed, to display its operation and any

alarms which may trigger.

7.1.1 Display

From the display of the control panel it is possible to see the sizes of the values set and machine

operation may be displayed through the LEDs.

Values

A space of four digits can be seen on the display, from which you may read the numerical values

and letters corresponding to the entries of the menu and to the alarms triggered.

Alarm LED

The ALARM LED indicates that an alarm has triggered.

On: triggered alarm.

Flashing: resettable alarm.

Heating LED

The HEATING LED indicates that the unit is operating in Heat Pump mode.

On: heat pump operation.

Flashing: remote heat pump operation.

Cooling LED

The COOLING LED indicates that the unit is operating in cooling only mode.

On: cooling only operation.

Flashing: remote cooling mode only.

Stand-by LED

The STAND-BY LED indicates that the unit is in Stand-By mode.

On: the unit is in Stand-By.

Flashing: the unit has been remotely placed in Stand-By.

Defrosting LED

DEFROSTING LED indicates that the unit operates in defrosting mode.

Economy LED

The ECONOMY LED means that the economy function is on.

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Fujitsu CPYA080LLW Installation guide

Brand: Fujitsu

Model: CPYA080LLW

Category: Split-system air conditioners

Type: Installation guide

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Fujitsu CPYA080LLW Installation guide

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