Fujitsu AOYR07LCC, Service Instruction

Page: 105 / 108

FINISHING
(1) Insulate between pipes.
●
For rear, right, and bottom piping, overlap the connection pipe heat insulation and
indoor 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 unit
pipe 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 housing
section with cloth tape.
●
For left and left rear piping, bind the connection cord to the top of the pipe with vinyl
tape.
●
For left and left rear piping, bundle the piping and drain hose together by wrapping
them with cloth tape over the range within which they fit into the rear piping housing
section.
(2) Temporarily fasten the connection cord along the connection pipe with vinyl tape. (Wrap
to about 1/3 the width of the tape from the bottom of the pipe so that water does not
enter.)
(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 rain
water and wind cannot blow in.
(5) Fasten the drain hose to the outside wall, etc.
Fig. 16
Fig. 15
Pipe
(Saddle) (Outside wall cap)
(Sealer putty)
(Outdoors)
Pipe
Drain hose
Cloth tape
Wrap with cloth tape
Left piping
Connection cord
Pipe
Drain hose
For connection from the left rear
Connection cord
Wall pipe
Connection
pipe
Check the following:
GOOD
Lifted up
Saddle
Wave End in water
Overlap the insulation
Bind the pipes together so
that there is no gap.
Connection pipe
(heat insulation)
Vinyl tape
Wall
Indoor unit pipe
(heat insullation)
Drain hose
BAD BAD BAD
Drain hose
1. Check if the piping connections are secure.
2. Check that the stems of 2-way valve and 3-way valve are closed
fully.
3. Connect the gauge manifold charge hose to the charging port
of the 3-way valve (side with the projection for pushing in the
valve 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 air
enters, then retighten the flare nut.
(When the flare nut is loosened the operating sound of the
vacuum pump changes and the reading of the compound
pressure gauge goes from minus to zero.)
OUTDOOR UNIT
OUTDOOR UNIT INSTALLATION
AIR PURGE
Always use a vacuum pump to purge the air.
Refrigerant for purging the air is not charged in the
outdoor unit at the factory.
Close the high pressure side valve of the gauge manifold fully and do
not operate it during the following work.
●
Set the unit on a strong stand, such as one made of concrete blocks
to 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 the
compound pressure gauge reads -0.1 MPa (-76 cmHg, -1 bar).
8. At the end of pump down, close the low pressure side gauge of
the gauge manifold fully and stop the vacuum pump.
9. Slowly loosen the valve stem of the 3-way valve. When the
compound pressure gauge reading reaches 0.1-0.2 MPa,
retighten the valve stem and disconnect the charge hose
from the 3-way valve charging port.
(If the stem of the 3-way valve is opened fully before the
charge hose is disconnected, it may be difficult to disconnect
the charge hose.)
10. Fully open the valve stems of the 2-way valve and 3-way valve
using 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 it
stops turning.)
11. Firmly tighten the 2-way valve and 3-way valve blank cap and
the charging port cap.
Fig. 11
CAUTION
(1) R e f r i g e r a n t m u s t n o t b e d i s c h a r g e d i n t o
atmosphere.
(2) After connecting the piping , check the joints for
gas 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 connection
cord colors with those of the indoor unit.
Erroneous wiring may cause burning of the electric
parts.
(2) Connect the connection cords firmly to the terminal
block. Imperfect installation may cause a fire.
(3) Always fasten the outside covering of the connec-
tion cord with the cord clamp. (If the insulator is
chafed, 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.
CAUTION
45mm
12mm
5mm
5mm
12mm
30mm
Fig. 13
Sheath
Cord clamp
Earth screw
Outdoor unit terminal block Indoor unit terminal block
Connection cord
Earth screw
Earth screw
Table 4
Tightening torque
Blank 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 while
the air conditioner is running, (Point the transmitter section of the remote control unit toward the air conditioner and press the test run button
with 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 simultaneously
flash 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?
WARNING
(1) Install the unit where it will not be tilted by more
than 5°.
(2) When installing the outdoor unit where it may ex-
posed to strong wind, fasten it securely.
Connection cord
Cord clamp
Control box
Fig. 14
Connection cord
Connection cord wiring
Run the connection cord to the rear of the outdoor unit within the
A
range of the arrows shown in the figure.
(The connector cover becomes difficult to install.)
Fig. 12
Additional charge
Refrigerant suitable for a piping length of 15 m is charged in the outdoor
unit at the factory.
When the piping is longer than 15 m, additional charging is necessary.
For the additional amount, see the table below.
Pipe length
Additional refrigerant
Table 5
15 m
None
20 m
100 g
Tapping screw
Rear hooks
Connector cover
Front hooks
CAUTION
(1) When adding refrigerant, add the refrigerant from
the charging port at the completion of work.
(2) The maximum length of the piping is 20 m. If
the units are further apart than this, correct
operation can not be guaranteed.
Between 15 m and 20 m, when using a connection pipe other than
that in the table, charge additional refrigerant with 20g/1 m as the
criteria.
Control box cover
Transmitter section
Test run button
Fig. 17
P/N 9315140012-02
Wall hook bracket
INDOOR UNIT
CUTTING 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 wall hook bracket, cut
the hole within the range of the left and right center marks 40 mm
below the wall hook bracket.
When cutting the wall hole at the outside of the wall hook bracket, 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 the
inside end.
(4) Always align the center of the wall hole. If misaligned, water leakage
will 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 drain
water will flow freely. (Fig. 5)
Fig. 5
Lower
Center mark
Fasten with
vinyl tape
(Wall cap)
(Wall pipe)
(Inside)
5 to 10
mm low
Wall (Outside)
65 mm dia. hole
Lower
10 mm
or over
65 mm dia. hole
(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 connection
cord 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 terminal
block. Imperfect installation may cause a fire.
(3) Always fasten the outside covering of the connec-
tion cord with the cord clamp. (If the insulator is
chafed, 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. 10
CAUTION
(3) Connect the end of the connection cord fully into the terminal block.
(4) Fasten the connection cord with a cord clamp.
INDOOR UNIT WIRING
Connection cord
40
m
m
12
m
m
50
m
m
12
m
m
5 m
m
5 m
m
Cord clamp
(There is a
terminal block
inside.)
Screw
Connection cord
Cord clamp
Tab
Screw
Square hole
Insert the tab into the square hole of the
indoor unit and fasten with a screw.
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 to
the floor.
(2) Install the wall hook bracket so that it is strong enough to withstand
the weight of an adult.
●
Fasten the wall hook bracket to the wall with 6 or more screws through
the holes near the outer edge of the bracket.
●
Check that there is no rattle at the wall hook bracket.
FORMING THE DRAIN HOSE AND PIPE
WARNING
If the wall pipe is not used, the cord interconnecting
the indoor and outdoor units may touch metal and
cause electric leakage.
[Rear piping, Right piping, Bottom piping]
● Install the indoor unit piping in the direction of the wall hole and bind
the 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 outside
with decorative tape.
[For Left rear piping, Left piping]
Interchange the drain cap and the drain hose.
Fig. 6
Fig. 7
Drain cap
Indoor unit
drain hose
Remove the drain cap by pulling
at the projection at the end of
the cap with pliers, etc.
For left outlet piping, cut off the
piping outlet cutting groove
with a hacksaw.
CAUTION
(1) In order to align the drain hose and drain cap, be
sure to insert securely and vertically. Incline
insertion will cause water leakage.
(2) When inserting, be sure not to attach any material
besides water. If any other material is attached, it
will cause deterioration and water leakage.
(3) After removing drain hose, be sure not to forget
mounting drain cap.
(4) Be sure to fix the drain hose with tape to the bottom
of piping.
CAUTION
Install the wall hook bracket horizontally and
perpendicularly.
Wall hook bracket
Center notch
Hook
Tapping screw
Wall hook bracket
String
Removal method of drain
hose
●
Remove the screw at the left of
drain hose and pull out drain
hose.
Installation method of
drain hose
●
Vertically insert the drain hose
toward the inside, so that the
d r a i n f i x t u r e ( b l u e ) c a n
accurately align with the screw
hole around the drain cock.
After inserting and before
replacing, please reinstall and
fix the removed screws.
Right piping
Bind with vinyl tape
Indoor unit drain hose (bottom)
Pipe (top)
Rear piping
Bottom piping
● Be sure to install around the drain hose connector.
●
As the screw is inside, be sure to use screwdriver treated with
magnet.
Screw Drain hose
Drain fixture
(blue)
Screw hole
Drain hose
Screw
Drain cock
Drain fixture (blue)
●
For left piping and left rear piping, align the marks on the wall hook
bracket and shape the connection pipe.
● Bend the connection piping at the bend radius of 70 mm or more and
install 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 wall
hook 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 hook
bracket and separate the bottom of the indoor unit from the wall.
Fig. 8
After hooking the indoor unit to the top hook, hook the fittings of the
indoor unit to the two bottom hooks while lowering the unit and
pushing it against the wall.
CONNECTION
(1) Install the outdoor unit wall cap (supplied with the optional installation set
or 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 hand
tight, tighten the nut to the specified tightening torque with a torque wrench.
(Table 2)
FLARING
(1) Cut the connection pipe to the necessary
length with a pipe cutter.
(2) Hold the pipe downward so that cuttings
will not enter the pipe and remove the
burrs.
(3) Insert the flare nut onto the pipe and flare
the pipe with a flaring tool.
Insert the flare nut (always use the flare nut
attached to the indoor and outdoor units
respectively) onto the pipe and perform the
flare 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, always
use an allowance adjustment gauge and secure
the A dimension shown in table 3 .
CONNECTING THE PIPING
Check if [L] is flared uniformly
and is not cracked or scratched.
Fig. 9
Die
A
Pipe
Connection pipe
(6.35 mm dia.)
Connection pipe
(9.52 mm dia.)
Align the marks. Bend (R70) with
a pipe bender
Top hooks
Indoor unit (Fitting) Bottom hooks
Wall hook
bracket
Indoor unit
Wall hook bracket
(Spacer)
Table 2 Flare nut tightening torque
Tighten with two wrenches.
Torque
wrench
Wrench (fixed)
Flare nut
Indoor unit pipe
Connection pipe
To prevent gas leakage, coat the flare
surface with refrigerator oil.
Table 3 Pipe outside diameter
Flare nut
6.35 mm dia.
9.52 mm dia.
Tightening torque
15.7 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 strength
Arm strength
A (mm)
Pipe outside
diameter
ø 6.35 mm (1/4”)
ø 9.52 mm (3/8”)
Flash tool for
R410A, clutch type
0 to 0.5
0 to 0.5
Conventional (R22) flare tool
Clutch type
1.0 to 1.5
1.0 to 1.5
Wing nut type
1.5 to 2.0
1.5 to 2.0
CAUTION
(1) Fasten a flare nut with a torque wrench as instructed in this manual. If
fastened too tight, the flare nut may be broken after a long period of time
and cause a leakage of refrigerant.
(2) During installation, make sure that the refrigerant pipe is attached firmly
before you run the compressor. Do not operate the compressor under the
condition of refrigerant piping not attached properly with 2-way or 3-way
valve open. This may cause abnormal pressure in the refrigeration cycle
that leads to breakage and even injury.