En-5
4-1. PURGING PROCEDURES AND LEAK TEST
Fig.
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
3. FLARING WORK AND PIPE CONNECTION
3-1. FLARING WORK
Pipe diameter
(mm)
Nut
(mm)
A (mm)
Tightening torque
Clutch
type tool
for R40A
Clutch
type tool
for R22
Wing nut
type tool
for R22
N•m
kgf•cm
ø6.35 (/4”)
7
0 to 0.5
.0 to .5
.5 to 2.0
3.7 to 7.7 40 to 80
ø9.52 (3/8”)
22
34.3 to 4.2 350 to 420
ø2.7 (/2”)
26
2.0 to 2.5
49.0 to 56.4 500 to 575
ø5.88 (5/8”)
29
73.5 to 78.4 750 to 800
Tilted Uneven Burred
Good
No good
Burr
Copper pipe
Spare reamer
Pipe cutter
Smooth all
around
Even length
all around
Inside is shin-
ing without any
scratches.
Flare nut
Die
Copper pipe
Clutch type
Flaring tool
Wing nut type
3-2. PIPE CONNECTION
1) Apply a thin coat of refrigeration oil (G) to the flared ends of the pipes
and the pipe connections of the outdoor unit. Do not apply refrigeration
oil on screw threads. Excessive tightening torque will result in damage
on the screw.
2) Align the center of the pipe with that of the pipe connections of the out-
door unit, then hand tighten the flare nut 3 to 4 turns.
3) Tighten the flare nut with a torque wrench as specified in the table.
• Over-tightening may cause damage to the flare nut, resulting in refrig
-
erant leakage.
• Be sure to wrap insulation around the piping. Direct contact with the
bare piping may result in burns or frostbite.
3-3. INSULATION AND TAPING
) Cover piping joints with pipe cover.
2) For outdoor unit side, surely insulate every piping including valves.
3) Using piping tape (E), apply taping starting from the entry of outdoor
unit.
• Stop the end of piping tape (E) with tape (with adhesive agent at-
tached).
• When piping have to be arranged through above ceiling, closet or
where the temperature and humidity are high, wind additional commer-
cially sold insulation to prevent condensation.
4. PURGING PROCEDURES, LEAK TEST, AND TEST RUN
Copper
pipe
) Cut the copper pipe correctly with pipe cutter. (Fig. , 2)
2) Completely remove all burrs from the cut cross section of pipe. (Fig. 3)
• Aim the copper pipe downward while removing burrs to prevent
burrs from dropping in the pipe.
3) Remove flare nuts attached to indoor and outdoor units, then put them
on pipe having completed burr removal. (Not possible to put them on
after flaring work.)
4) Flaring work (Fig. 4, 5). Firmly hold copper pipe in the dimension
shown in the table. Select A mm from the table according to the tool
selected.
5) Check
• Compare the flared work with Fig. 6.
• If flare is noted to be defective, cut off the flared section and do flar
-
ing work again.
) Remove service port cap of stop valve on the side of the outdoor unit
gas pipe. (The stop valves are fully closed and covered in caps in their
initial state.)
2) Connect gauge manifold valve and vacuum pump to service port of
stop valve on the gas pipe side of the outdoor unit.
3) Run the vacuum pump. (Vacuumize for more than 5 minutes.)
4) Check the vacuum with gauge manifold valve, then close gauge mani-
fold valve, and stop the vacuum pump.
5) Leave as it is for one or two minutes. Make sure the pointer of gauge
manifold valve remains in the same position. Confirm that pressure
gauge shows -0.0 MPa [Gauge] (-760 mmHg).
6) Remove gauge manifold valve quickly from service port of stop valve.
7) Fully open all stop valves on the gas pipe and the liquid pipe. Operat-
ing without fully opening lowers the performance and this causes trou-
ble.
8) Refer to -2., and charge the prescribed amount of refrigerant if
needed. Be sure to charge slowly with liquid refrigerant. Otherwise,
composition of the refrigerant in the system may be changed and af-
fect performance of the air conditioner.
9) Tighten cap of service port to obtain the initial status.
0) Leak test
WARNING
When installing the unit, securely
connect the refrigerant pipes before
starting the compressor.
CAUTION
When there are the ports which are
not used, make sure their nuts are
tightened securely.
Service port cap
(Torque 3.7 to
7.7 N•m, 40 to
80 kgf•cm)
Stop valve
for GAS
Stop valve cap
(Torque 9.6 to
29.4 N•m, 200
to 300 kgf•cm)
Gauge manifold
valve (for R40A)
Compound pressure
gauge (for R40A)
–0.0MPa
(–760 mmHg)
Handle
Low
Handle High
Vacuum pump
(for R40A)
Charge hose
(for R40A)
*Close
*Open
Hexagonal wrench
*4 to 5 turns
Stop valve
for LIQUID
Pressure gauge
(for R40A)
Precautions when using
the control valve
When attaching the control valve to
the service port, valve core may de-
form or loosen if excess pressure is
applied. This may cause gas leak.
Service port
Charge hose
(for R40A)
Body
Close
Open
Control
valve
A
When attaching the control valve to
the service port, make sure that the
valve core is in closed position, and
then tighten part A. Do not tighten
part A or turn the body when valve
core is in open position.
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