17
General Installation Guidelines
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GENERAL INSTALLATION GUIDELINES
Piping Preparation
• Do not allow the refrigerant to leak during brazing; if the refrigerant combusts, it generates a toxic gas which can cause physical injury or death.
• Do not braze in an enclosed location, and always test for gas leaks before/after brazing. Gas leaks can cause physical injury or death.
• After brazing, check for refrigerant gas leaks. Refrigerant gas leaks can cause physical injury or death.
3. Flaring the pipe end.
• Use the proper size flaring tool to finish flared connections as
shown.
• ALWAYS create a 45° flare when working with R410A. See Warn-
ing on this page.
Creating a Flare Fitting
One of the main causes of refrigerant leaks is defective flared
connections. Create flared connections using the procedure at right (Fig
-
ure 19).
1. Cut the pipe to length.
• Measure the distance between the indoor unit and the outdoor unit.
• Cut the pipes a little longer than measured distance.
• Cut the cable 4.9 ft longer than the pipe length.
2A. Remove the burrs.
• Completely remove all burrs from pipe ends.
• When removing burrs, point the end of the copper pipe down to
avoid introducing foreign materials in the pipe.
2B. Slide the flare nut onto the copper tube.
4. Carefully inspect the flared pipe end.
• Compare the geometry with the figure to the right and dimensions
as detailed in Figure 18.
• If the flare is defective, cut it off and re-do procedure.
• If flare looks good, blow clean the pipe with dry nitrogen.
90°
2
45°
2
A
R=0.4~0.8
Figure 18: Dimensions of the Flare
Pipe
“A”
Thickness
Vapor (in. O.D.) Liquid (in. O.D.) Vapor (in.)
Liquid (in.)
Vapor (in.) Liquid (in.)
1/2
1/4
1/8
1/16
1/8
1/8
5/8
3/8
1/8
1/16
1/16
1/8
Table 3: Flared Connection Dimensions
Piping Preparation
1. Do not use kinked pipe caused by excessive bending in one specif-
ic area on its length.
2. Braze the pipes to the service valve pipe stub of the outdoor unit.
When selecting flare fittings, always use a 45° fitting rated for use with
high pressure refrigerant R410A. Failure to do so may result in refrig
-
erant leaks which in turn could result in personal injuries or death from
oxygen depletion. Selected fittings must also comply with local, state, or
federal standards.
Figure 19: Creating a Flare Fitting
Single Zone Pipe Connections
Copper
tube
90°
Slanted Uneven Rough
Pipe
Reamer
Point
down
Flare nut
Copper
tube
Bar
Copper pipe
Clamp handle
Red arrow
Cone
Yoke
Handle
Bar
"A"
Slanted
Inside is shiny with no scratches
Smooth
Even length
Damaged
surface
Cracked Uneven
thickness
Incorrect Flares
1.
2A.
2B.
3.
4.
