General Assist Technical Reference
Fujitsu R32 Product Launch Training
KU, KM and CM wall-mounted systems
Product features, R32 safety principles, installation tooling and flare-less joint procedures
Purpose: This article summarises the dealer and installer training presentation used to introduce Fujitsu General's R32 KU, KM and CM wall-mounted systems. It explains the original product range, environmental benefits, safety considerations and installation practices presented at launch.
Important historical reference: The source presentation is dated August 2013. Standards, legislation, refrigerant classifications, licensing arrangements, safe-work guidance and product installation requirements may have changed. Always use the current product installation manual, current Australian Standards, applicable WHS/OHS requirements and current ARC licensing guidance before carrying out work.
1. New product line overview
| Series | Positioning | Original capacity range shown |
|---|---|---|
| KU Series | Designer range, reverse cycle | 2.5, 3.5 and 5.0 kW classes |
| KM Series | Standard reverse-cycle range | 2.5, 3.5, 5.0, 6.0 and 7.1 kW classes |
| CM Series | Cooling-only range | 2.1, 2.5, 3.5, 5.0 and 7.1 kW classes |
The three ranges introduced a more unified, simple appearance intended to complement modern interiors. The original release schedule showed production commencing progressively from August to October 2013 across the listed capacity classes.
Model identification: The presentation includes launch-era model numbers such as ASTG09KUCA, ASTG12KUCA, ASTG09KMCA, ASTG12KMCA and ASTG07CMCA. Confirm the exact model and installation manual before applying any procedure in this article.
2. Efficiency and key product features
Efficiency improvements presented at launch
- Cooling energy ratings increased across the new range, with the 2.1 kW cooling-only model shown at up to 5.5 stars.
- The presentation stated that R32 could improve equipment energy efficiency by approximately 10% and reduce refrigerant charge volume by approximately 15% compared with R410A.
- Efficiency improvements were supported by high-efficiency DC fan motors, a DC rotary compressor, larger heat exchangers and a high-density multi-path heat exchanger.
| Feature | Function described in the training |
|---|---|
| Human Sensor | Detects movement and adjusts operation when the room is unoccupied to reduce energy use. |
| Power Diffuser | KM-series airflow diffuser automatically changes to suit cooling or heating operation. |
| Built-in Demand Response | Demand-control PCB supports energy-provider demand-response functions when connected to suitable field-supplied equipment. |
| 7-day programmable timer | Weekly, program and sleep timers were provided through the wireless controller. |
| Quiet operation | Indoor sound level was shown as low as 21 dB(A) on applicable models and operating conditions. |
| Powerful operation | Temporarily increases output and airflow for rapid cooling or heating. |
| Economy operation | Allows the control temperature to shift to reduce maximum energy consumption. |
| 10°C Heat operation | Maintains a low background heating setpoint to help prevent an unoccupied room becoming excessively cold. |
3. R32 refrigerant and safety principles
R32 is difluoromethane, an HFC refrigerant that is also used as a component of refrigerant blends including R410A and R407C. The 2013 presentation referred to pure R32 as an A2 flammable refrigerant. Current documentation commonly uses updated flammability classifications, so technicians must use current product and regulatory information.
| Launch-training value | Value presented |
|---|---|
| Global warming potential | 675 kg CO₂ equivalent per kilogram of refrigerant |
| Flammable concentration range | Approximately 14–30% by volume |
| Minimum ignition energy | Approximately 30–100 mJ |
| Flame propagation speed | Approximately 0.19 km/h |
Conditions required for ignition
The training explained that combustion requires all three of the following conditions to occur at the same time:
- Refrigerant concentration within its flammable range.
- A continuing supply of oxygen.
- An ignition source with sufficient energy.
Product design controls
- Construction designed to minimise refrigerant stagnation.
- Electrical components designed to make ignition less likely.
- Chassis and cover design intended to reduce flame propagation.
Combustion by-product: Burning fluorinated refrigerants can generate toxic hydrogen fluoride. The presentation requires dry nitrogen to be used during brazing. Refrigerant must be fully recovered and the system made safe before hot work begins.
4. Installation, labelling and work-area controls
Licensing and standards referenced in the presentation
- Technicians were instructed to hold the applicable ARC refrigerant-handling licence.
- The presentation referenced AS/NZS 60335.2.40, AS/NZS 1677.1 and AS/NZS 1677.2.
- Electrical installation was to comply with AS/NZS 3000, including an adjacent isolator where required.
- Local WHS or OHS requirements were to be confirmed for the state or territory where the work was performed.
Use current requirements: The standards and editions cited above are those shown in the 2013 training. Do not assume that the cited editions or specific requirements remain current.
Service exclusion zone
When servicing equipment containing flammable refrigerant, the training required a temporary controlled work area with suitable flammable-gas and restricted-entry signage. Ignition sources must be identified and controlled, and appropriate ventilation and PPE must be provided.
Marking and labelling
- Label the system as required for flammable refrigerant.
- The presentation instructed installers to apply a class label at every two metres of visible, uncovered refrigerant pipework, including visible pipework in a roof space.
- Confirm the current installation manual and current labelling requirements before installation.
Transport and cylinder storage
The training referred installers to the Australian Dangerous Goods requirements, AS 4332 and the AIRAH Flammable Refrigerants Safety Guide for cylinder transport, handling and storage. The slides reproduce historical minor-storage information, including references to 500 L aggregate water capacity and 11 L or 22 L cylinder-storage table entries.
Do not use the launch presentation as a current storage limit: Cylinder-storage thresholds depend on the gas class, cylinder water capacity, location, aggregate quantity and current legislation. Confirm the current requirements with the relevant regulator, current standard and refrigerant supplier.
5. R32-compatible tooling
| Tool or equipment | Launch-training guidance |
|---|---|
| Vacuum pump | Must be suitable for the refrigerant and include a non-return valve to prevent contamination following a power failure. |
| Recovery unit | Must be suitable for flammable refrigerant. The training prohibited units using carbon-brush series motors. |
| Electronic leak detector | Must be compatible and approved for R32 or the applicable flammable refrigerant. |
| Gauge manifold and hoses | The presentation indicated suitable R410A-type equipment could be used where its pressure rating and compatibility were confirmed. |
| Torque wrench, flare tool, cutter and bender | Shown as generally common with R410A installation tooling. |
| Service refrigerant cylinder | Dedicated cylinder clearly marked for R32. |
| Recovery cylinder | Dedicated compatible cylinder. Do not mix refrigerants during recovery. |
| Flare-less joint removal tool | Special tool required to remove the single-use indoor connection joint. |
Evacuation and recovery
- Evacuate to at least 500 microns, measured with a digital vacuum gauge.
- The training specified confirming 500 microns with the vacuum pump isolated or switched off.
- Pressure-test the completed pipework with dry nitrogen before evacuation.
- To reduce switch-contact arcing during recovery, the presentation instructed technicians to isolate the recovery unit at the general-purpose outlet using a suitable extension lead arrangement.
6. Refrigerant conversion and retrofitting
Do not retrofit refrigerants: Use only the refrigerant for which the air conditioner was designed. An R32-designed system must be charged only with R32. Do not convert an R410A or other system to R32 unless the manufacturer has expressly designed and approved that system for the conversion.
7. Flare-less indoor connection method
The launch-era KU, KM and CM systems used a non-reusable mechanical joint at the indoor connection. The presentation stated that this arrangement was used to reduce leakage risk and satisfy the indoor-joint requirements applied to flammable-refrigerant systems at the time.
| Step | Procedure | Acceptance criteria |
|---|---|---|
| 1 | Mark the insertion depth on the connecting pipe. | 22 mm for 6.35 mm (1/4 in) pipe; 23 mm for 9.52 mm (3/8 in) pipe. |
| 2 | Remove the seal from the tightening nut. | Joint is clean, undamaged and ready for insertion. |
| 3 | Insert the connecting pipe until it contacts the internal joint. | Insertion mark remains correctly positioned. |
| 4 | Hand-tighten the nut to temporarily retain the pipe. | Pipe remains fully inserted and square to the joint. |
| 5 | Hold the joint body and tighten with a calibrated torque wrench. | 16–18 N·m for 6.35 mm; 32–42 N·m for 9.52 mm. |
| 6 | Check the pipe insertion mark. | Mark is no more than 1 mm from the tightening nut. |
| 7 | Pressure-test with dry nitrogen and evacuate the system. | No leakage and stable vacuum of at least 500 microns in accordance with the applicable manual. |
Single-use joint: The flare-less joint assembly cannot be reused after it has been fully tightened or removed. Replace it with a new assembly and repeat the full installation, pressure-test and evacuation procedure.
Joint removal sequence
- Split and remove the protective guard as shown in the applicable service instructions.
- Loosen the tightening nut while supporting the joint body.
- Fit the correct removal tool for the pipe size and rotate it counter-clockwise.
- Remove and dispose of the used flare-less joint assembly.
- Remove the reusable tool and install a new joint assembly.
8. Technical support and source limitations
The original presentation directed dealers and installers to Fujitsu General Technical Support on 1300 364 484 for product, installation, service or warranty enquiries.
Before starting work:
- Confirm the complete indoor and outdoor model numbers.
- Obtain the current installation and service manuals for those exact models.
- Confirm the refrigerant type and factory charge from the rating plate.
- Complete a task-specific risk assessment and establish the required controlled work area.
- Verify that all tools, detectors, pumps, recovery equipment and cylinders are approved for the refrigerant.
- Apply current legislation, standards and manufacturer instructions where they differ from this historical training summary.