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Airtight test procedure
1. Nitrogen gas pressurization
(1) After pressurizing to the design pressure (4.15 MPa [602 psi]) using nitrogen gas, allow it to
stand for about one day. If the pressure does not drop, airtightness is good.
However, if the pressure drops, since the leaking point is unknown, the following bubble test
may also be performed.
(2) After the pressurization described above, spray the flare connection parts, brazed parts, and
other parts that may leak with a bubbling agent (Kyuboflex, etc.) and visually check for bubbles.
(3) After the airtight test, wipe off the bubbling agent.
2. Pressurization using refrigeration gas and nitrogen gas
(1) After first pressurizing with R410A liquid refrigerant to a gas pressure of approximately 0.2
MPa [29 psi], pressurize to the design pressure of 4.15 MPa [602 psi] using nitrogen gas.
However, do not pressurize at one time. Stop during pressurization and check that the pres-
sure does not drop.
(2) Check for gas leaks by checking the flare connection parts, brazed parts, and other parts
which may leak using an R410A compatible electric leak detector.
(3) This test may be used together the with bubble type gas leak test.
•
Front pipe routing
1
Connecting elbow (ID ø25.4 mm [1 in], OD ø25.4 mm [1 in]) <Included with outdoor unit>
2
Connecting pipe (ID ø15.88 mm [5/8 in], OD ø9.52 mm [3/8 in]) <Included with outdoor unit>
3
Connecting pipe (ID ø15.88 mm [5/8 in], OD ø12.7 mm [1/2 in]) <Included with outdoor unit>
4
Connecting pipe (ID ø25.4 mm [1 in], OD ø19.05 mm [3/4 in]) <Included with outdoor unit>
5
Connecting pipe (ID ø25.4 mm [1 in], OD ø22.2 mm [7/8 in]) <Included with outdoor unit>
6
Connecting pipe (ID ø9.52 mm [3/8 in], OD ø9.52 mm [3/8 in]) <Included with outdoor unit>
7
Connecting pipe (ID ø15.88 mm [5/8 in], OD ø15.88 mm [5/8 in]) <Included with outdoor unit>
•
Bottom pipe routing
2
Connecting pipe (ID ø15.88 mm [5/8 in], OD ø9.52 mm [3/8 in]) <Included with outdoor unit>
3
Connecting pipe (ID ø15.88 mm [5/8 in], OD ø12.7 mm [1/2 in]) <Included with outdoor unit>
*1 P72, P96: Expand the liquid pipe (ID ø9.52 mm [3/8 in]) and connect directly to
the valve. <field supply required>
4
Connecting pipe (ID ø25.4 mm [1 in], OD ø19.05 mm [3/4 in]) <Included with outdoor unit>
5
Connecting pipe (ID ø25.4 mm [1 in], OD ø22.2 mm [7/8 in]) <Included with outdoor unit>
•
After evacuation and refrigerant charging, ensure that the handle is fully open.
If operating with the valve closed, abnormal pressure will be imparted to the
high- or low-pressure side of the refrigerant circuit, giving damage to the com-
pressor, four-way valve, etc.
•
Determine the amount of additional refrigerant charge by using the formula,
and charge refrigerant additionally through the service port after completing
piping connection work.
•
After completing work, tighten the service port and cap securely so as not to
generate any gas leakage. (Refer to the table on the below for appropriate
tightening torque.)
Restriction
• If a flammable gas or air (oxygen) is used as the pressurization
gas, it may catch fire or explode.
• Do not use a refrigerant other than that indicated on the unit.
• Sealing with gas from a cylinder will cause the composition of
the refrigerant in the cylinder to change.
• Use a pressure gauge, charging hose, and other parts especially
designed for use with R410A.
• An electric leak detector for R22 cannot detect leaks of R410A.
• Do not use a haloid torch. (Leaks cannot be detected.)
Caution:
Only use refrigerant R410A.
- The use of other refrigerant such as R22 or R407C, which contains chlorine, will deteriorate the refrigerating machine oil or cause the compressor to malfunction.
10.3. Airtight test, evacuation, and refrigerant charging
1
Airtight test
Perform with the valve of the outdoor unit closed, and pressurize the connection piping and the indoor unit from the service port provided on the valve of the outdoor unit.
(Always pressurize from both the liquid pipe and the gas pipe service ports.)
[Fig. 10.3.1]
D
C
C
B
B
E
F
G
H
I
J
A
LO
HI
[Fig. 10.2.3]
A
B
A
Example of closure materials (field-supplied)
B
Fill the gap at the site
Make sure to seal-off the openings for the
pipe and wire retrieval with closure mate-
rials (field-supplied) to keep small animals
and rainwater from entering through the
openings to avoid causing damage to the
device.
Appropriate tightening torque:
Outer diameter of
copper pipe (mm [in])
ø9.52 [3/8]
ø12.7 [1/2]
ø15.88 [5/8]
ø19.05 [3/4]
ø25.4 [1]
Shaft
(N·m/kg·cm)
6/60
9/90
15/150
30/300
30/300
Size of hexagonal
wrench (mm)
4
4
6
6
10
Cap
(N·m/kg·cm)
15/150
20/200
25/250
25/250
25/250
Service port
(N·m/kg·cm)
12/120
Caution:
•
Keep the valve closed until refrigerant charging to the pipes to be added
on site has been completed. Opening the valve before charging the re-
frigerant may cause damage to the unit.
•
Do not use a leak detection additive.
A
Nitrogen gas
B
To indoor unit
C
System analyzer
D
Lo knob
E
Hi knob
F
Valve
G
Liquid pipe
H
Gas pipe
I
Outdoor unit
J
Service port
Observe the following restrictions when conducting an air tightness test to prevent
negative effects on the refrigerating machine oil. Also, with nonazeotropic refriger-
ant (R410A), gas leakage causes the composition to change and affects perform-
ance. Therefore, perform the airtightness test cautiously.
Caution:
Make sure to seal-off the openings for the pipe and wire retrieval.
•
Small animals and rainwater entering through the openings may cause
damage to the device.