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3. FLARING WORK AND PIPE CONNECTION
3-1. FLARING WORK
) 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 inch (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 sec-
tion and do flaring work again.
Pipe diameter
B
[inch (mm)]
[inch (mm)]
Clutch type tool for R40A
/4 (ø6.35)
2/32 (7)
3/8 (ø9.52)
7/8 (22)
/2 (ø2.7)
-/32 (26)
5/8 (ø5.88)
-5/32 (29)
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.
2) Align the center of the pipe with that of the pipe connections of the outdoor
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 refrigerant
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
1) 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 attached).
• When piping have to be arranged through above ceiling, closet or where the
temperature and humidity are high, wind additional commercially sold insula-
tion to prevent condensation.
4. PURGING PROCEDURES, LEAK TEST, AND TEST RUN
4-1. PURGING PROCEDURES AND LEAK TEST
1) 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 15 minutes.)
4) Check the vacuum with gauge manifold valve, then close gauge manifold 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 -14.7 psi
[Gauge] (-0.0 MPa).
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. Operating without
fully opening lowers the performance and this causes trouble.
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 affect performance of the air conditioner.
9) Tighten cap of service port to obtain the initial status.
0) L eak test
En-5
Flaring tool
Clutch type
Wing nut type
A [inch (mm)]
Clutch type tool for R22
0 to 0.02
0.04 to 0.06
(0 to 0.5)
(.0 to .5)
No good
Good
Copper
pipe
Tilted Uneven Burred
Fig.
Copper pipe
Die
Flare nut
B
Fig. 4
Wing nut type tool for R22
ft-Ib
0 to 3
0.06 to 0.08
(.5 to 2.0)
25 to 30
36 to 42
0.08 to .0
(2.0 to 2.5)
54 to 58
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.
Compound pressure
gauge (for R40A)
-4.7 psi
(-0.0 MPa)
Pressure gauge
(for R40A)
Handle Low
Handle High
Charge hose
Gauge manifold
(for R40A)
valve
(for R40A)
Vacuum pump
(for R40A)
Close
Cap
Pull the handle toward you
and rotate /4 turn in a counter
clockwise direction to open.
Copper pipe
Burr
Spare reamer
Pipe cutter
Fig. 2
Fig. 3
Inside is shin-
ing without any
Smooth all
scratches.
around
Even length
all around
Fig. 5
Fig. 6
Tightening torque
N•m
kgf•cm
3.7 to 7.7
40 to 80
34.3 to 4.2
350 to 420
49.0 to 56.4
500 to 575
73.5 to 78.4
750 to 800
*4 to 5 turns
*Close
*Open
Hexagonal
wrench
Stop valve cap
(Torque 5 to
22 ft-lb, 9.6 to
Service port cap
29.4 N•m, 200
(Torque 0 to 3 ft-lb,
to 300 kgf•cm)
3.7 to 7.7 N•m, 40
to 80 kgf•cm)
Open
Push in the handle and rotate the
cap back to its original position.
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