Fujitsu ASYA07LCC Service Instruction

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FINISHING(1) Insulate between pipes.● For rear, right, and bottom piping, overlap the connection pipe heat insulation andindoor unit pipe heat insulation and bind them with vinyl tape so that there is no gap.● For left and left rear piping, butt the connection pipe heat insulation and indoor unitpipe heat insulation together and bind them with and vinyl tape so that there is no gap.● For left and left rear piping, wrap the area which accommodates the rear piping housingsection with cloth tape.● For left and left rear piping, bind the connection cord to the top of the pipe with vinyltape.● For left and left rear piping, bundle the piping and drain hose together by wrappingthem with cloth tape over the range within which they fit into the rear piping housingsection.(2) Temporarily fasten the connection cord along the connection pipe with vinyl tape. (Wrapto about 1/3 the width of the tape from the bottom of the pipe so that water does notenter.)(3) Fasten the connection pipe to the outside wall with saddles, etc.(4) Fill the gap between the outside wall pipe hole and the pipe with sealer so that rainwater and wind cannot blow in.(5) Fasten the drain hose to the outside wall, etc.Fig. 16Fig. 15Pipe(Saddle) (Outside wall cap)(Sealer putty)(Outdoors)PipeDrain hose Cloth tapeWrap with cloth tapeLeft pipingConnection cordPipe Drain hoseFor connection from the left rearConnection cordWall pipeConnectionpipeCheck the following:GOODLifted upSaddleWave End in waterOverlap the insulationBind the pipes together sothat there is no gap.Connection pipe(heat insulation)Vinyl tapeWallIndoor unit pipe(heat insullation)Drain hoseBAD BAD BADDrain hoseP/N 9314989018-01INDOOR UNITCUTTING THE HOLE IN THE WALL FOR THE CONNECTING PIPING(1) Cut a 65 mm diameter hole in the wall at the position shown in (Fig.5).(2) When cutting the wall hole at the inside of the installation frame, cutthe hole within the range of the left and right center marks 40 mmbelow the installation frame.When cutting the wall hole at the outside of the installation frame,cut the hole at least 10 mm below over.(3) Cut the hole so that the outside end is lower (5 to 10 mm) than theinside end.(4) Always align the center of the wall hole. If misaligned, water leakagewill occur.(5) Cut the wall pipe to match the wall thickness, stick it into the wall cap,fasten the cap with vinyl tape, and stick the pipe through the hole.(The connection pipe is supplied in the installation set.) (Fig. 5)(6) For left piping and right piping, cut the hole a little lower so that drainwater will flow freely. (Fig. 5)INSTALLING THE WALL HOOK BRACKET(1) Install the wall hook bracket so that it is correctly positioned horizon-tally and vertically. If the wall hook bracket is tiled, water will drip tothe floor.(2) Install the wall hook bracket so that it is strong enough to withstandthe weight of an adult.● Fasten the wall hook bracket to the wall with 6 or more screws throughthe holes near the outer edge of the bracket.● Check that there is no rattle at the wall hook bracket.FORMING THE DRAIN HOSE AND PIPEWARNINGIf the wall pipe is not used, the cord interconnectingthe indoor and outdoor units may touch metal andcause electric leakage.[Rear piping, Right piping, Bottom piping]● Install the indoor unit piping in the direction of the wall hole and bindthe drain hose and pipe together with vinyl tape. (Fig. 7)● Install the piping so that the drain hose is at the bottom.● Wrap the pipes of the indoor unit that are visible from the outsidewith decorative tape.[For Left rear piping, Left piping]Interchange the drain cap and the drain hose.Fig. 5LowerCenter markFasten withvinyl tape(Wall cap)(Wall pipe)(Inside)5 to 10mm lowWall (Outside)65 mm dia. holeFig. 6Fig. 7Drain capIndoor unitdrain hoseRemove the drain cap by pullingat the projection at the end ofthe cap with pliers, etc.Lower10 mmor over65 mm dia. holeFor left outlet piping, cut off thepiping outlet cutting groovewith a hacksaw.● For left piping and left rear piping, align the marks on the wall hookbracket and shape the connection pipe.● Bend the connection piping at the bend radius of 70 mm or more andinstall no more than 35 mm from the wall.● After passing the indoor piping and drain hose through the wall hole,hang the indoor unit on the hooks at the top and bottom of the wallhook bracket.[Installing the indoor unit]● Hang the indoor unit from the hooks at the top of the wall hook bracket.● Insert the spacer, etc. between the indoor unit and the wall hookbracket and separate the bottom of the indoor unit from the wall.Fig. 8After hooking the indoor unit to the top hook, hook the fittings of theindoor unit to the two bottom hooks while lowering the unit andpushing it against the wall.(1) Remove the cord clamp.(2) Bend the end of the connection cord as shown in the figure.(1) Match the terminal block numbers and connectioncord colors with those of the outdoor unit.Erroneous wiring may cause burning of the elec-tric parts.(2) Connect the connection cords firmly to the terminalblock. Imperfect installation may cause a fire.(3) Always fasten the outside covering of the connec-tion cord with the cord clamp. (If the insulator ischafed, electric leakage may occur.)(4) Securely earth the power cord plug.(5) Do not use the earth screw for an external connector.Only use for interconnection between two units.Fig. 10CAUTION(3) Connect the end of the connection cord fully into the terminal block.(4) Fasten the connection cord with a cord clamp.INDOOR UNIT WIRINGConnection cord40 mm12 mm50 mm 12 mm5 mm5 mmRight bottom ofindoor unitCord clamp(There is aterminal blockinside.)ScrewConnection cordCord clampTabScrew Square holeInsert the tab into the square hole of theindoor unit and fasten with a screw.1. Check if the piping connections are secure.2. Check that the stems of 2-way valve and 3-way valve are closedfully.3. Connect the gauge manifold charge hose to the charging portof the 3-way valve (side with the projection for pushing in thevalve core).4. Open the low pressure side valve of the gauge manifold fully.5. Operate the vacuum pump and start pump down.6. Slowly loosen the flare nut of the 3-way valve and check if airenters, then retighten the flare nut.(When the flare nut is loosened the operating sound of thevacuum pump changes and the reading of the compoundpressure gauge goes from minus to zero.)OUTDOOR UNITOUTDOOR UNIT INSTALLATIONAIR PURGEAlways use a vacuum pump to purge the air.Refrigerant for purging the air is not charged in theoutdoor unit at the factory.Close the high pressure side valve of the gauge manifold fully and donot operate it during the following work.● Set the unit on a strong stand, such as one made of concrete blocksto minimize shock and vibration.● Do not set the unit directly on the ground because it will cause trou-ble.Connector cover removal● Remove the tapping screws.Installing the connector cover(1) After inserting the two front hooks, then insert the rear hook.(2) Tighten the tapping screws.7. Pump down the system for at least 15 minutes, then check if thecompound pressure gauge reads -0.1 MPa (-76 cmHg, -1 bar).8. At the end of pump down, close the low pressure side gauge ofthe gauge manifold fully and stop the vacuum pump.9. Slowly loosen the valve stem of the 3-way valve. When thecompound pressure gauge reading reaches 0.1-0.2 MPa,retighten the valve stem and disconnect the charge hosefrom the 3-way valve charging port.(If the stem of the 3-way valve is opened fully before thecharge hose is disconnected, it may be difficult to disconnectthe charge hose.)10. Fully open the valve stems of the 2-way valve and 3-way valveusing a hexagon wrench. (After the valve stem begins to turn,turn it with a torque of less than 2.9 N • m (30 kgf • cm) until itstops turning.)11. Firmly tighten the 2-way valve and 3-way valve blank cap andthe charging port cap.Fig. 11CAUTION(1) Refrigerant must not be discharged intoatmosphere.(2) After connecting the piping , check the joints forgas leakage with gas leak detector.OUTDOOR UNIT WIRING(1) Remove the outdoor unit connector cover.(2) Bend the end of the cord as shown in the figure.(3) Connect the end of the connection cord fully into the terminal block.(4) Fasten the sheath with a cord clamp.(5) Install the connector cover.(1) Match the terminal block numbers and connectioncord colors with those of the indoor unit.Erroneous wiring may cause burning of the electricparts.(2) Connect the connection cords firmly to the terminalblock. Imperfect installation may cause a fire.(3) Always fasten the outside covering of the connec-tion cord with the cord clamp. (If the insulator ischafed, electric leakage may occur.)(4) Securely earth the power cord plug.(5) Do not use the earth screw for an external connector.Only use for interconnection between two units.CAUTION45mm 12mm5mm5mm12mm30mmFig. 13SheathCord clampEarth screwOutdoor unit terminal blockIndoor unit terminal blockConnection cordEarth screw Earth screwTable 4Tightening torqueBlank cap 19.6 to 24.5 N • m (200 to 250 kgf • cm)Charging port cap 12.3 to 15.7 N • m (125 to 160 kgf • cm)TEST RUNNING● Perform test operation and check items 1 and 2 below.● For the test operation method, refer to the operating manual.● The outdoor unit, may not operate, depending on the room temperature. In this case, press the test run button on the remote control unit whilethe air conditioner is running, (Point the transmitter section of the remote control unit toward the air conditioner and press the test run buttonwith the tip of a ball-point pen, etc.)● To end test operation, press the remote control unit START/STOP button.(When the air conditioner is run by pressing the test run button, the OPERATION indicator lamp and TIMER indicator lamp will simultaneouslyflash slowly.)1. INDOOR UNIT(1) Is operation of each button on the remote control unit normal?(2) Does each lamp light normally?(3) Do the air flow-direction louver operate normally?(4) Is the drain normal?2. OUTDOOR UNIT(1) Is there any abnormal noise and vibration during operation?(2) Will noise, wind, or drain water from the unit disturb the neighbors?(3) Is there any gas leakage?CAUTION● In order to align the drain hose and drain cap, besure to insert securely and vertically. ncline insertionwill cause water leakage.● When inserting, be sure not to attach any materialbesides water. If any other material is attached, itwill cause deterioration and water leakage.● After removing drain hose, be sure not to forgetmounting drain cap.● Be sure to fix the drain hose with tape to the bottomof piping.CAUTIONInstall the wall hook bracket horizontally andperpendicularly.Wall hook bracket Center notchHookTapping screwWall hook bracket StringRemoval method of drainhose● Remove the screw at the left ofdrain hose and pull out drainhose.Installation method ofdrain hose● Vertically insert the drain hosetoward the inside, so that thed r a i n f i x t u r e ( b l u e ) c a naccurately align with the screwhole around the drain cock.After inserting and beforereplacing, please reinstall andfix the removed screws.Right piping Bind with vinyl tapeIndoor unit drain hose (bottom)Pipe (top)Rear pipingBottom pipingCONNECTION(1) Install the outdoor unit wall cap (supplied with the optional installation setor procured at the site) to the wall pipe.(2) Connect the outdoor unit and indoor unit piping.(3) After matching the center of the flare surface and tightening the nut handtight, tighten the nut to the specified tightening torque with a torque wrench.(Table 2)FLARING(1) Cut the connection pipe to the necessarylength with a pipe cutter.(2) Hold the pipe downward so that cuttingswill not enter the pipe and remove theburrs.(3) Insert the flare nut onto the pipe and flarethe pipe with a flaring tool.Insert the flare nut (always use the flare nutattached to the indoor and outdoor unitsrespectively) onto the pipe and perform theflare processing with a flare tool.Use the special R410A flare tool, or the conv-entional (for R22) flare tool.When using the conventional flare tool, alwaysuse an allowance adjustment gauge and securethe A dimension shown in table 3 .CONNECTING THE PIPINGCheck if [L] is flared uniformlyand is not cracked or scratched.Fig. 9DieAPipeWARNING(1) Install the unit where it will not be tilted by morethan 5°.(2) When installing the outdoor unit where it may ex-posed to strong wind, fasten it securely.Connector cordCord clampControl boxFig. 14Connector cordConnection cord wiringRun the connection cord to the rear of the outdoor unit within the Arange of the arrows shown in the figure.(The connector cover becomes difficult to install.)Connection pipe(6.35 mm dia.)Connection pipe(9.52 mm dia.)Align the marks.Bend (R70) witha pipe benderTop hooksIndoor unit (Fitting) Bottom hooksWall hookbracketIndoor unitWall hook bracket(Spacer)Table 2 Flare nut tightening torqueTighten with two wrenches.TorquewrenchWrench (fixed)Flare nutIndoor unit pipe Connection pipe To prevent gas leakage, coat the flaresurface with refrigerator oil.Table 3 Pipe outside diameterFlare nut6.35 mm dia.9.52 mm dia.Tightening torque15.7 to 17.6 N • m(160 to 180 kgf • cm)29.4 to 41.1 N • m(300 to 420 kgf • cm)Tightening torque standard(using a 20 cm wrench)Wrist strengthArm strengthA (mm)Pipe outsidediameterø 6.35 mm (1/4”)ø 9.52 mm (3/8”)Flash tool forR410A, clutch type0 to 0.50 to 0.5Conventional (R22) flare toolClutch type1.0 to 1.51.0 to 1.5Wing nut type1.5 to 2.01.5 to 2.0CAUTION(1) Fasten a flare nut with a torque wrench as instructed in this manual. Iffastened too tight, the flare nut may be broken after a long period of timeand cause a leakage of refrigerant.(2) During installation, make sure that the refrigerant pipe is attached firmlybefore you run the compressor. Do not operate the compressor under thecondition of refrigerant piping not attached properly with 2-way or 3-wayvalve open. This may cause abnormal pressure in the refrigeration cyclethat leads to breakage and even injury.● Be sure to install around the drain hose connector.● As the screw is inside, be sure to use screwdriver treated withmagnet.Screw Drain hoseDrain fixture(blue)Screw holeDrain hoseScrewDrain cockDrain fixture (blue)Fig. 12Additional chargeRefrigerant suitable for a piping length of 15 m is charged in the outdoorunit at the factory.When the piping is longer than 15 m, additional charging is necessary.For the additional amount, see the table below.Pipe lengthAdditional refrigerantTable 515 mNone20 m100 gTapping screwRear hooksConnector coverFront hooksCAUTION(1) When adding refrigerant, add the refrigerant fromthe charging port at the completion of work.(2) The maximum length of the piping is 20 m. Ifthe units are further apart than this, correctoperation can not be guaranteed.Between 15 m and 20 m, when using a connection pipe other thanthat in the table, charge additional refrigerant with 20g/1 m as thecriteria.Control box coverTransmitter sectionTest run buttonFig. 17

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