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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 fl are nut onto the pipe and fl are the
pipe with a fl aring tool.
Insert the flare nut (always use the flare nut
a t t a c h e d t o t h e i n d o o r a n d o u t d o o r u n i t s
respectively) onto the pipe and perform the fl are
processing with a fl are tool.
U s e t h e s p e c i a l R 4 1 0 A f l a r e t o o l , o r t h e
conventional (for R22) fl are tool.
When using the conventional fl are tool, always use
an allowance adjustment gauge and secure the A
dimension shown in table 2.
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 70 mm 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.
Holding spanner
Body side
90°
Torque wrench
Table 1
Flare nut tightening torque
Flare nut
6.35 mm dia.
15.88 mm dia.
Table 2
Pipe outside diameter
Pipe outside
Flare tool for
diameter
R410A, clutch type
ø 6.35 mm (1/4")
0 to 0.5
ø 15.88 mm (5/8")
0 to 0.5
Fasten a fl are nut with a torque wrench as instructed in this manual. If fastened too
tight, the fl are nut may be broken after a long period of time and cause a leakage of
refrigerant.
5.6. 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.
Refrigerant must not be discharged into atmosphere.
After connecting the piping , check the joints for gas leakage with gas leak detector.
(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 fl are nut of the 3-way valve and check if air enters, then retighten
the fl are nut.
(When the fl are nut is loosened the operating sound of the vacuum pump changes
and the reading of the compound pressure gauge goes from minus to zero.)
(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 disconnect-
ed, it may be diffi cult 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.
Check if [L] is fl ared uniformly and
is not cracked or scratched.
Die
A
Pipe
To prevent gas leakage, coat the fl are
surface with refrigerator oil.
Diameter (mm) x Torque (N • m)
17 x 16 ~ 18
26 x 63 ~ 75
A (mm)
Conventional (R22) Flaring tool
Clutch type
Wing nut type
1.0 to 1.5
1.5 to 2.0
1.0 to 1.5
1.5 to 2.0
CAUTION
CAUTION
-
2
way valve
3-way valve
Flare nut
Charging port
Charging port cap
Blank cap (2-way valve)
Blank cap (3-way valve)
Charging port cap
5.7. TEST RUN
Perform test operation and check items 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 controller while the air conditioner is running,
(Point the transmitter section of the remote controller 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 controller 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 fl ash slowly.)
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?
5.8. CUSTOMER GUIDANCE
Explain the followings to the customer in accordance with the operating manual:
(1) Starting and stopping method, operation switching, temperature adjustment, timer,
airfl ow switching, and other remote controller operations.
(2) Air fi lter removal and cleaning, and how to use the airfl ow direction louvers.
(3) Give the operating and installation manuals to the customer.
6. PUMP DOWN
6.1. Pump down
PUMP DOWN OPERATION (FORCED COOLING OPERATION)
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 cooling operation.).
(1) Do the air purging of the charge hose by connecting the charging hose of gauge mani-
fold to the charging port of 3-way valve and opening the low-pressure valve slightly.
(2) Close the valve stem of 2-way valve completely.
(3) Start the cooling operation or following forced cooling operation. Keep on pressing the
MANUAL AUTO button of the indoor unit for more than 10 seconds. The operation in-
dicator lamp and timer indicator lamp will begin to flash simultaneously during test run.
(The forced cooling operation cannot start if the MANUAL AUTO button is not kept on
pressing for more than 10 seconds.)
(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
(5) Stop the operation.
• Press the START/STOP button of the remote control unit to stop the operation.
• Press the MANUAL AUTO button when stopping the operation from indoor unit side. (It
is not necessary to press on keeping for more than 10 seconds.)
Gauge manifold
Compound pressure gauge
Pressure gauge
-0.1 MPa
(-76 cmHg
-1 bar)
Low pressure
side valve
Valve stem
Charge
hose
Blank cap
Charge hose
Vacuum pump
Tightening torque
20.0 to 25.0 N • m (200 to 250 kgf • cm)
28.0 to 32.0 N • m (280 to 320 kgf • cm)
12.5 to 16.0 N • m (125 to 160 kgf • cm)
Transmitter section
TEST RUN button
2
).
High
pressure
side valve
(closed)
En-4
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