Fujitsu ASYA24LCC Installation Manual

SPLIT TYPE ROOM AIR CONDITIONER

INSTALLATION MANUAL

(PART NO. 9315342010-01)
This air conditioner uses new refrigerant HFC (R410A).
The basic installation work procedures are the same as conventional refrigerant (R22) models.
However, pay careful attention to the following points:
(1) Since the working pressure is 1.6 times higher than that of conventional refrigerant (R22) models,
some of the piping and installation and service tools are special.(See the table below.)
Especially, when replacing a conventional refrigerant (R22) model with a new refrigerant R410A
model, always replace the conventional piping and flare nuts with the R410A piping and flare nuts.
(2) Models that use refrigerant R410A have a different charging port thread diameter to prevent
erroneous charging with conventional refrigerant (R22) and for safety. Therefore, check
beforehand.[The charging port thread diameter for R410A is 1/2 UNF 20 threads per inch.]
(3) Be more careful that foreign matter (oil, water, etc.) does not enter the piping than with refrigerant
(R22) models. Also, when storing the piping ,securely seal the opening by pinching ,taping, etc.
(4) When charging the refrigerant, take into account the slight change in the composition of the
gas and liquid phases, and always charge from the liquid phase side whose composition is
stable.
Special tools for R410A
Tool name Contents of change
Pressure is high and cannot be measured with a conventional gauge. To prevent erroneous
mixing of other refrigerants, the diameter of each port has been changed.
Gauge manifold
It is recommended the gauge with seals-0.1 to 5.3 MPa (-1 to 53 bar) for high pressure.
-0.1 to 3.8 MPa (-1 to 38 bar) for low pressure.
Charge hose To increase pressure resistance, the hose material and base size were changed.
Vacuum pump A conventional vacuum pump can be used by installing a vacuum pump adapter.
Gas leakage detector Special gas leakage detector for HFC refrigerant R410A.
Copper pipes
It is necessary to use seamless copper pipes and it is desirable CONNECTION PIPE REQUIREMENT
that the amount of residual oil is less than 40 mg/10m. Do not
use copper pipes having a collapsed, deformed or discolored Nominal Outer Maximum
Thickness
diameter diameter
portion (especially on the interior surface). Otherwise, the ex-
pansion value or capillary tube may become blocked with
0.8mm
1/4in 6.35mm
contaminants. 30m(99ft)
5/8in 15.88mm 1.0mm
As an air conditioner using R410A incurs pressure higher than
when using R22, it is necessary to choose adequate materials.
Thicknesses of copper pipes used with R410A are as shown in the table. Never use copper pipes thinner than that in the
table even when it is available on the market.
WARNING
(1) Do not use the existing (for R22) piping and flare nuts.
• If the existing materials are used, the pressure inside the refrigerant cycle will rise and cause breakage, injury,
etc.(Use the special R410A materials.)
(2) When installing and relocating the air conditioner, do not mix gases other than the specified refrigerant(R410A)
to enter the refrigerant cycle.
• If air or other gas enters the refrigerant cycle, the pressure inside the cycle will rise to an abnormally high value
and cause breakage, injury, etc.
CAUTION
When installing pipes shorter than 3m, sound of the outdoor unit will be transferred to the indoor unit, which will
cause large operating sound or some abnormal sound.
SELECTING THE MOUNTING INSTALLATION DIAGRAM OF
POSITION INDOOR AND OUTDOOR UNITS
[INDOOR UNIT]
Decide the mounting position with the customer as follows:
1. INDOOR UNIT 6 cm or over
(1) Install the indoor unit level on a strong wall which is not subject to 5 cm or over
vibration.
(2) The inlet and outlet ports should not be obstructed : the air should
be able to blow all over the room.
(3) Install the unit near an electric outlet or special branch circuit.
(4) Do not install the unit where it will be exposed to direct sunlight.
(5) Install the unit where connection to the outdoor unit is easy.
(6) Install the unit where the drain pipe can be easily installed.
(7) Take servicing, etc. into consideration and leave the spaces shown
150 cm or over
in the figure. Also install the unit where the filter can be removed.
230 cm or over
2. OUTDOOR UNIT
(1) 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 air flow.)
(2) Do not install the unit where a strong wind blows or where it is very
dusty. Remote
(3) Do not install the unit where people pass. control unit
(4) Take your neighbors into consideration so that they are not dis-
turbed by air blowing into their windows or by noise.
(5) Provide the space shown in the figure so that the air flow is not blocked.
Also for efficient operation, leave open three of the four directions
front, rear, and both sides.
[OUTDOOR UNIT]
60 cm or over
WARNING
Install at a place that can withstand the weight of the
indoor and outdoor units and install positively so that 10 cm or over
the units will not topple or fall.
30 cm or over
CAUTION
(1) Do not install where there is the danger of com-
bustible gas leakage.
• Do not directly install it on
(2) Do not install near heat sources.
the ground, otherwise it
(3) If children under 10 years old may approach the will cause failure.
5 cm or over
unit, take preventive measures so that they can-
not reach the unit. • To obtain better operation
efficiency, when the outdoor
(4) Install the indoor unit on the wall where the height
unit is installed, be sure to
open the front and left side.
from the floors more than 230 cm.
54 cm
[Indoor unit piping direction]
The piping can be connected in the 7 directions in the figure. When
the piping is connected in direction 2, 3, 4 or 5, cut along the
piping groove in the side of the front panel with a hacksaw.
CAUTION
(1) When the outdoor temperature is 0 °C or less, do not use the accessory
drain pipe and drain cap. If the drain pipe and drain cap are used, the
drain water in the pipe may freeze in extremety cold weather.(Reverse
cycle model only)
(Rear) (2) In the area with heavy snowfall, if the intake and outlet of outdoor unit
is blocked with snow, it might become difficult to get warm and it is
likely to cause of the breakdown. Please construct a canopy and a ped-
estal or place the unit on a high stand (local configured).
5 Left
outlet
7 Left rear
outlet
2 Right
1 Rear 6 Center
outlet 4 Left bottom
outlet
outlet
3 Bottom outlet
outlet
For authorized service personnel only.
WARNING
(1) For the room air conditioner to operate satisfactory, install it as outlined in this installation manual.
(2) Connect the indoor unit and outdoor unit with the air conditioner piping and cords available standards parts. This
installation manual describes the correct connections using the standard accessories and the parts specified in
this installation manual.
(3) Have installation work done by authorized service personnel only.
(4) Do not use an extension cord.
(5) Do not turn on the power until all installation work is complete.
G Be careful not to scratch the air conditioner when handling it.
G After installation, explain correct operation to the customer, using the operating manual.
G Let the customer keep this installation manual because it is used when the air conditioner is serviced or moved.
G The maximum length of the piping is 30 m. The maximum height difference of the piping is 20 m,
if the units are further apart than these, correct operation can not be guaranteed.
STANDARD ACCESSORIES
The following installation accessories are supplied. One set of following parts are necessary in istallation of this product.
Use them as required.
Name and Shape Q'ty Name and Shape Q'ty
Connection pipe assembly
Wall hook bracket Cloth tape
Connection cord
Wall pipe
1 1
Decorative tape
Vinyl tape
Wall cap
Tapping screw (big)
Remote
Saddle
control
8 Drain hose
unit
Tapping screws
1 Sealant
Tapping screw (small)
Maximum height
(between indoor and
length 2
outdoor)
ELECTRICAL REQUIREMENT
20m(66ft)
Battery
• Electric wire size and fuse capacity:
Air cleaning filter
2 MODEL
Power supply cord (mm
2
Remote control
Connection cord (mm
unit holder
Fuse capaclity (A)
Air cleaning filter frame
1 • Install the disconnect device with a contact gap of at
2
least 3 mm nearby the units. (Both indoor unit and out-
door unit)
• Always make the air conditioner power supply a spe-
cial branch circuit and provide a special breaker.
Drain pipe Insulation (Drain hose)
• Always use H07RN-F or equivalent as the power sup-
1 ply cord and the connection cord.
1
Wall hook bracket
5 cm or over
(Wall cap)
Remote
control unit
holder
Tapping
screw
(small)
10 cm or over
30 cm or
over
Outdoor
unit bottom
Drain hose
INDOOR UNIT
CUTTING THE HOLE IN THE WALL FOR THE CONNECTING PIPING
(1) Cut a 80 mm diameter hole in the wall at the position shown in the
figure.
(2) When cutting the wall hole at the inside of the wall hook bracket, cut
the hole to a point of intersection of center marks.
When cutting the wall hole at the outside of the wall hook bracket, cut
the hole at a point of 10mm below.
(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.)
(6) For left piping and right piping and center piping, cut the hole a little
lower so that drain water will flow freely.
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.
G Fasten the wall hook bracket to the wall with 6 or more screws through
the holes near the outer edge of the bracket.
G
Check that there is no rattle at the wall hook bracket.
Name
WARNING
If the wall pipe is not used, the cord interconnecting
the indoor and outdoor units may touch metal and
cause electric leakage.
FORMING THE DRAIN HOSE AND PIPE
[Rear piping, Right piping, Bottom piping]
G
Install the indoor unit piping in the direction of the wall hole and bind
the drain hose and pipe together with vinyl tape.
G
Install the piping so that the drain hose is at the bottom.
G
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.
CAUTION
(1) In order to align the drain hose and drain cap, be
sure to insert securely and vertically. Incline inser-
24,000 BTU class
tion will cause water leakage.
MAX. 4.0 (2) When inserting, be sure not to attach any material
2
)
besides water. If any other material is attached, it
MIN. 3.5
will cause deterioration and water leakage.
MAX. 2.5
2 )
(3) After removing drain hose, be sure not to forget
MIN. 1.5
mounting drain cap.
30
(4) Be sure to fix the drain hose with tape to the bottom
of piping.
(5) Prevent drain water frozen under low tempera-
ture environment.
When installing indoor unit's drain hose outdoors, necessary
measure for frost protection should be taken to prevent drain
water frozen.
• Under low temperature environment (when outdoor tem-
perature under 0 °C), after cooling operation is executed,
water in the drain hose could be frozen.
Once drain water is frozen, the drain hose will be blocked
and water leakage may be resulted for indoor unit.
CONNECTING THE PIPING
CONNECTION
(1) Install the outdoor unit wall cap (supplied with the optional installa-
tion 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.
FLARING
(1) Cut the connection pipe to the necessary length
Check if [L] is flared uniformly
and is not cracked or scratched.
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 at-
tached 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- Die
entional (for R22) flare tool.
When using the conventional flare tool, always
use an allowance adjustment gauge and secure
the A dimension shown in the table.
BENDING PIPES
(1) When bending the pipe, be careful not to crush it.
(2) To prevent breaking of the pipe, avoid sharp bends.
Bend the pipe with a radius of curvature of 150mm or over.
(3) If the copper pipe is bend the pipe or pulled to often, it will become stiff.
Do not bend the pipes more than three times at one place.
INDOOR UNIT WIRING
(1) Remove the cord clamp.
(2) Bend the end of the connection cord as shown in the figure.
Connection cord
Cord clamp
(There is a
terminal block
inside.)
Screw
Connection cord
HOW TO CONNECT WIRING TO THE TERMINALS
A. For solid core wiring (or F-cable)
(1) Cut the wire end with a wire cutter or wire-cutting pliers, then strip the insula-
tion to about 25 mm (1") to expose the solid wire.
(2) Using a screwdriver, remove the terminal screw(s) on the terminal board.
(3) Using pliers, bend the solid wire to form a loop suitable for the terminal screw.
(4) Shape the loop wire properly, place it on the terminal board and tighten se-
curely with the terminal screw using a screwdriver.
B. For strand wiring
(1) Cut the wire end with a wire cutter or wire-cutting pliers, then strip the insula-
tion to about 10 mm (3/8") to expose the strand wiring.
(2) Using a screwdriver, remove the terminal screw(s) on the terminal board.
(3) Using a round terminal fastener or pliers, securely clamp a round terminal to
each stripped wire end.
(4) Position the round terminal wire, and replace and tighten the terminal screw
using a screwdriver.
(1) Match the terminal block numbers and connection
cord colors with those of the outdoor 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.
G For left piping and left rear piping, align the marks on the wall hook
bracket and shape the connection pipe.
G Bend the connection piping at the bend radius of 100 mm or more
and install no more than 35 mm from the wall.
Centering marks
Wall hook bracket
G 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.
Lower Lower [Installing the indoor unit]
G Hang the indoor unit from the hooks at the top of the wall hook bracket.
G Insert the spacer, etc. between the indoor unit and the wall hook
bracket and separate the bottom of the indoor unit from the wall.
80 mm hole
10 mm or
over
80 mm hole
Indoor unit
Fasten with
vinyl tape
Wall hook bracket
(Wall pipe)
(Wall cap)
(Inside) Wall (Outside)
FRONT PANEL REMOVAL AND INSTALLATION
Wall hook bracket
THE INTAKE GRILLE REMOVAL
(1) Open the intake grille.
(2) Pull down the knob.
Leveling method (3) Lift the intake grille upward, until the axle at the top of the in-
take grille is removed.
Hang weight
from here.
Tapping screw
THE INTAKE GRILLE INSTALLATION
(size: large; quantity: 8)
(1) The fixing axle of the intake grille is installed on the Panel.
(2) Lay down the intake grille.
Wall hook
bracket THE FRONT PANEL REMOVAL
String
Weight
(1) Remove intake grille (Reference the intake grille removal.)
(2) Remove six screws.
CAUTION
(3) The thumb is hung on the lower part as shown in the figure,
Install the wall hook bracket horizontally and and it pulls to the front, pushing [-] mark , and bottom hooks
(two position) is removed from wall hook bracket.
perpendicularly.
(4) The front panel is pulled to the front, raising the upper surface,
and a front panel is removed.
THE FRONT PANEL INSTALLATION
(1) Firstly, fit the lower part of the front panel, and insert top and
bottom hooks. (Three top sides)
(2) Six screws is attached.
(3) The intake grille is attached.
Bind with vinyl tape
Right piping
Pipe (top)
Rear piping
Bottom Indoor unit drain hose
piping (bottom)
Install the front panel and INTAKE GRILLE securely. If installation is imperfect, the front panel or INTAKE GRILLE may
For left outlet piping, cut off the
piping outlet cutting groove
fall off and cause injury.
with a hacksaw.
REMOTE CONTROL UNIT INSTALLATION
Remove the drain cap by pulling
Indoor unit
at the projection at the end of
drain hose
Drain cap the cap with pliers, etc.
CAUTION
(1) Check that the indoor unit correctly receives the signal
from the remote control unit, then install the remote
Insert the drain hose and drain cap into the drain port, mak-
ing sure that it comes in contact with the back of the drain control unit holder.
port, and then mount it. If the drain hose is not connected
(2) Select the remote control unit holder selection site by
properly, leaking will occur.
paying careful attention to the following:
• Attach the Insulation (Drain hose) to the drain hose.
Avoid places in direct sunlight.
Select a place that will not be affected by the heat from
a stove, etc.
Insulation (Drain hose)
Drain hose
CUSTOMER GUIDANCE
Tighten with two wrenches.
Explain the following to the customer in accordance with the operating manual:
(1) Starting and stopping method, operation switching, temperat-ure adjustment, timer, air flow switching, and other remote control unit operations.
Wrench (fixed)
(2) Air filter removal and cleaning, and how to use the air louvers.
(3) Give the operating and installation manuals to the customer.
Flare nut
Torque
wrench
To prevent gas leakage, coat the flare PUMP DOWN OPERATION (FORCED COOLING OPERATION)
Connection pipe
Indoor unit pipe surface with refrigerator oil.
Flare nut tightening torque and L dimension To avoid discharging refrigerant into the atmosphere at the time of relocation or disposal, recover refrigerant by doing the cooling operation or
forced cooling operation according to the following procedure. (When the cooling operation cannot start in winter, and so on, start the forced
Flare nut Tightening torque L dimension
cooling operation.)
16 to 18 N•m
(1) Do the air purging of the charge hose by connecting the charging hose of gauge manifold to the charging port of 3 way valve and opening the
6.35 mm dia. 1.4 to 1.7mm
(160 to 180 kgf•cm)
low-pressure valve slightly.
63 to 75 N•m 2.2 to 2.4mm
15.88 mm dia. (2) Close the valve stem of 2 way valve completely.
(630 to 750 kgf•cm)
(3) Start the cooling operation or following forced cooling operation.
Pipe outside diameter
When using the remote control unit
A (mm) Press the TEST RUN button after starting the cooling operation by the remote control unit.
Pipe outside
Conventional (R22) flare tool The operation indicator lamp and timer indicator lamp will begin to flash simultaneously during test run.
diameter Flash tool for
R410A, clutch type When using the MANUAL AUTO button of the indoor unit (The remote control unit is lost, and so on.)
Clutch type Wing nut type
Keep on pressing the MANUAL AUTO button of the indoor unit for more than 10 seconds.
ø 6.35 mm (1/4") 0 to 0.5 1.0 to 1.5 1.5 to 2.0
(The forced cooling operation cannot start if the MANUAL AUTO button is not kept on pressing for more than 10 seconds.)
A ø 15.88 mm (5/8") 0 to 0.5 1.0 to 1.5 1.5 to 2.0
(4) Close the valve stem of 3 way valve when the reading on the compound pressure gage becomes 0.05~0 MPa (0.5~0 kg/cm
Pipe (5) Stop the operation.
CAUTION
• Press the START/STOP button of the remote control unit to stop the operation.
(1) Fasten a flare nut with a torque wrench as instructed in this manual. If
• Press the MANUAL AUTO button when stopping the operation from indoor unit side.
fastened too tight, the flare nut may be broken after a long period of time
(It is not necessary to press on keeping for more than 10 seconds.)
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 During the pump-down operation, make sure that the compressor is turned off before you remove the refrigerant piping.
that leads to breakage and even injury.
Do not remove the connection pipe while the compressor is in operation with 2 way or 3 way valve open. This may cause abnormal pressure
in the refrigeration cycle that leads to breakage and even injury.
(3) Connect the end of the connection cord fully into the terminal block.
(4) Fasten the connection cord with a cord clamp.
POWER
1 2 3 4 Cord clamp (1) The rated voltage of this product is 230 V AC 50 Hz.
Tab (2) Before turning on the power, check if the voltage is within the
220 V -10 % to 240 V +10 % range.
(3) Always use a special branch circuit and install a special recepta-
Screw cle to supply power to the room air conditioner.
Square hole
(4) Use a circuit breaker and receptacle matched to the capacity of
Insert the tab into the square hole of the
the air conditioner.
indoor unit and fasten with a screw.
Round
A. Solid wire B. Strand wire
terminal
(1) The power source capacity must be the sum of the air conditioner current and the current of other electrical appliances. When the
Loop
current contracted capacity is insufficient, change the contracted capacity.
(2) When the voltage is low and the air conditioner is difficult to start, contact the power company the voltage raised.
Insulation
Screw with
Screw with
special washer
special washer
Round Install heat insulation around both the gas and liquid pipes. Failure to do so may cause water leaks.
terminal
Use heat insulation with heat resistance above 120 °C. (Reverse cycle model only)
Terminal
Round
Wire In addition, if the humidity level at the installation location of the refrigerant piping is expected to exceed 70%, install heat insulation
board
terminal
around the refrigerant piping. If the expected humidity level is 70-80%, use heat insulation that is 15 mm or thicker and if the
Wire
expected humidity exceeds 80%, use heat insulation that is 20 mm or thicker.
Terminal block If heat insulation is used that is not as thick as specified, condensation may form on the surface of the insulation.
In addition, use heat insulation with heat conductivity of 0.045 W/(m·K) or less (at 20 °C).
CAUTION
(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.
Alignment marks
Wall hook
bracket
Small piping
Connection piping Large piping
Top hooks
Wall hook
Indoor unit
bracket
(Spacer) (Fitting) Bottom hooks
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.
Intake grille
Intake grille
Mounting shaft
Bearing
Front panel Knob
Front panel
Screws (6 position)
Front panel
Wall hook bracket
Push
[-] mark
Push
Top holes (two sides)
Top hook (center)
Top hole (center) Front panel
Top hooks
Indoor unit
(two sides)
CAUTION
1. REMOTE CONTROL UNIT HOLDER INSTALLATION
CAUTION
• Install the remote control unit with a distance of 7 m between the re-
mote control unit and the photocell as the criteria. However, when
installing the remote control unit, check that it operates positively.
• Install the remote control unit holder to a wall, pillar, etc. with the
tapping screw.
Remote control unit holder fixing Remote control unit mounting
1 Set
Remote control
unit holder
2 Push
Tapping
screw
Remote
(small)
control unit
2 ).
CAUTION
WARNING
(5) Do not extend the power cord.
(6) Perform wiring work in accordance with standards so that the
air conditioner can be operated safely and positively.
(7) Install a leakage circuit breaker in accordance with the related
laws and regulations and electric company standards.
CAUTION
CAUTION
Installation instruction on the back.