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Schematic Drawing of VRV Installation

(9) Outdoor unit installation
(10) Air tightness test
(11) Vacuum drying
(12) Additional refrigerant charge

(1) Sleeve work

(2) Indoor unit

(6) Duct work (indoor)

(3) Piping support

(5) Drain piping work

(8) Control wiring work

(7) Insulation

(4) Refrigerant piping work

・ Flaring
・ Bending
・ Pipe expansion
・ Brazing

1. Work Flow by Process


<Key Points>


Determination of the work classification
Preparation of the installation drawing


Sleeve work ............................ Consider the downward gradient of the drain pipes. ························································ 2


Indoor unit installation ............. Confirm the model names to avoid any installation mistakes.·········································· 3


Piping support


Refrigerant piping work


Drain piping work

.................. Maintain a downward gradient of at least 1/100.······························································ 22


Duct work (indoor)

................ Ensure that a sufficient airflow is maintained. ································································· 26


Insulation work


Control wiring work ............... Use applicable two-core wires. ························································································ 30
(Do not use multi-core.)


Outdoor unit installation

........................ Use supports within the designated support intervals. ······················································ 5
......... Pay attention to the principles of dry, clean and tight.························································ 9

...................... Ensure that there are no gaps at the joints between insulation materials.·························· 27

........ Make considerations to prevent short-circuiting and maintain a workspace for servicing. 32

(10) Air tightness test

.................... Make a final confirmation that there is no pressure drop at 4 MPaG for 24 hours.··········· 34

(11) Vacuum drying

...................... Use a vacuum pump that can achieve an ultimate vacuum of –100.7 kPaG or lower. ······ 36

(12) Additional refrigerant charge ... Enter the additional refrigerant charge amount onto the outdoor unit and the log book.··· 39

The above order represents the general procedure. It may differ depending on the local conditions and actual circumstances.
*Please note that lengths without any units are all in millimeters (mm) throughout this document.

Caution: Points of caution at the job site

One point lesson: Expertise gained from onsite work

Case example: An actual example of onsite work


2. Work by Process and Key Points

(1) Sleeve work
Meeting with the


Determination of
the location and
sleeve diameter



~Working points~
¡ Determination of the placement of the through-holes
x Determine the placement so that the drain piping is at a downward gradient of at least 1/100.
x Consider the thickness of the insulation material when determining the sleeve diameters for
refrigerant piping and drain piping.




Insulation thickness: Liquid piping
Gas piping




Diameter of liquid piping
insulation material


Diameter of gas piping
insulation material

Upper cell: Sleeve diameter
Lower cell: (Calculated value)

Sleeve inner diameter


10 mm
10 mm

φB (gas piping diameter)




































φA (liquid piping diameter)


At least D/4 and 150 mm







Ì Note that the beam structure limits the allowable area for the placement of through-holes.

At least 3 x [(R1 + R2)/2]

Location into which the sleeve cannot be
inserted through the beam

At least D/2

z Cover both ends of the sleeves with masking tape to prevent any concrete from entering


be sure to check for any blemishes or dents. attach a sheet of paper to a visible spot on the packing that notes the installation location and the system number. At least 200 mm At least 1. –3– .500 mm Installation space for FXFQ Ì The space required for servicing and installation may differ depending on the model.500 mm At least 1. (5) Use a laser pointer or the like to transfer the suspension location from the floor to the ceiling slab. Upper packing material Unit suspension location gs ide Dra in sid e Center of the unit Base point line (4) Using the upper packing material. Before transporting the indoor unit.500 mm (1) Confirm the space required for servicing and installation. Be sure to conduct all work according to the accompanying installation manual. 1) Transporting (1) Determine the transporting route.500 mm The following explains the procedure in the event an insert is not contained within the package. be sure to try another location for the hole. (3) When receiving the products. 1F reception room AC1-1 2) Determination of installation location At least 1. mark the suspension locations on the floor based on the center of the unit. Do not remove the packing until it is to be installed. and use a drill to open up a pilot hole. (2) Transport the indoor units to the installation location in the original packing. z How to prevent the installation of the wrong indoor unit model or in the wrong location. At least 200 mm At least 1. using the base point lines drawn on the floor as a guide. Please confirm the details in the installation manual or the like. Pip in (3) Mark the center of the indoor unit with chalk lines. Ceiling Laser pointer Suspension location Ì If a pilot hole for the anchors leads to a steel beam.2. Work by Process and Key Points (2) Installation of indoor units 1) Work procedure 2) 3) Determination of installation location Transporting 4) Installation of suspension bolts Indoor unit installation ~Working points~ Installation procedures differ according to the indoor unit model. (2) Confirm the piping direction and air discharge direction.

place the nuts (2. first hook the main unit's suspention bracket onto the suspension bolts on opposing corners to suspend the indoor unit. locally procured parts) and washers (2. Washer plate (accessory) Insert Washer (accessory) Upper nut Suspension bracket Tighten (double-nut) [Secure the suspension bracket] Ì Check the installation manual for the installation height when attaching optional accessories. z If the suspension bolt length is 1. adversely affecting capacity. adjust the nut on the lower side to the installation height. use the attached washer plate to secure.(2)Installation of indoor units 3) Installation of suspension bolts (1) Determine the length of the suspension bolts according to the height of the installation.500 [Secure the washer] <Protected> „ Why protect it? Dust and the like can get on the filter and heat exchanger.5 m or longer. An example of steady brace installation 4) Indoor unit installation (1) Install the indoor unit level. Re-tighten the double nut after completing adjustment. (2) Before installing. (3) After installing the indoor unit. be sure to remove the protective plastic covering and the like from the indoor unit. –4– . accessories) on the suspension bolt (double-nut on the lower side of the bolt). remove the lower nut on the suspension bolt before doing so. attach a steady brace on the longitudinal side of the suspension pitch. Ì If you assume that the temperature and humidity in the ceiling space exceed 30°C and RH80%. And. z The suspension bolt size (M10 or W3/8) is compatible with all models. (2) When installing manually. (4) For the upper washer. if suspending the indoor unit with a device such as a lifter. Steady brace bolt z The height of the indoor unit can easily be adjusted by loosening the double nut.) ¡ How to protect the indoor unit <Left unprotected> At least 1. be sure to protect it with a plastic bag or the like. (3) After installing. (Use polyethylene foam or glass wool with a thickness of at least 10 mm. reinforce the insulation (thickness) of the indoor unit. Ì After all work is complete.

2. Therefore.2 ≥56 ≤1. Prevention of sagging due to their own weight 2.5 300~500 Pipe outer diameter (mm) Support interval (m) . the piping can expand or contract 10 mm for every 10 meters.5 ≥56 At least one spot per floor –5– 1500 ≤9. Ì Upon start and stop of the air conditioner.5 <Vertical pipes> Pipe inner diameter (mm) Support interval (m) ≤44 ≤1. While it may depend on the particular operation state.5 ≤1. Work by Process and Key Points (3) Piping support (Refrigerant and drain) 1) Work procedure 2) Installation of suspension bolts and supporting fixtures Determination of location ~The purpose of piping supports~ <Support of horizontal pipes> 1.5 300~500 Refrigerant piping Ø19.7 ≤2. ¡ Interval for drain piping support (in the case of polyvinyl-chloride pipes) <Horizontal pipes> Pipe inner diameter (mm) Support interval (m) ≤44 ≤1.1/Ø9.5 Horizontal pipe z Adjust based on the liquid piping size when the liquid and gas piping are suspended together. Prevention of spot overloading due to pipe expansion and contraction as a result of temperature differences <Support of vertical pipes> 1. Prevention of swaying and buckling due to their own weight 1) Determination of location ¡ Interval for refrigerant piping support Vertical pipe <Horizontal pipes> ≥12.45 ≤1. refrigerant pipes expand or contract due to temperature differences. be sure to adhere to the required support interval.0 1500 1500 1500 1500 1500 Indoor unit <Vertical pipes> Pipe outer diameter (mm) Support interval (m) Supporting fixture ≤44.

first secure the pipes directly with the supporting fixtures and then place the insulation materials on top of this. ¡ Horizontal piping support z Minimize the length of the suspension bolts z Consider the downward gradient when determining the length of the drain piping suspension bolts. place a hard pad (e. Suspension band with turnbuckle Suspension bolt supporting fixture (for shaped steel) Support of horizontal refrigerant piping Suspension bolt supporting fixture (for flat decks) ¡ Vertical piping support z Allow sufficient space for maintenance and insulation installation when determining the distance between the unit body surface and piping as well as the piping interval when many pipes are laid in parallel. x With regard to drain piping support. z When supporting the refrigerant piping. Anchor Leg for vertical band Vertical band Vertical piping support (example) Battledore bolt with washer T-shape leg Legs for vertical band Vertical band Brazing areas Special supporting fixtures for vertical piping –6– .. Suspension band with turnbuckle Polyvinyl pipe Ì Never provide additional piping support from the piping.g. polyvinyl-chloride pipe) between the supporting fixture and insulation material as shown in the photo to the right in order to prevent crushing of the insulation material from the weight of the piping.(3) Piping support 2) Installation of suspension bolts and supporting fixtures ~Working points~ x Attach refrigerant piping support on top of the insulation material.

Prevention of overload on the connecting area to the unit due to expansion 3. Prevention of overload on areas due to expansion 2. it is easier to support the branch piping branches if a different interval is used for each support. „ Support around the indoor unit Support point C A B A+B+C=300~500 „ Through-hole support Support point 300~500 300~500 –7– . Prevention of impact on waterproofing due to expansion „ Support of refrigerant piping branch and bend 300~500 300~500 ≤300 ≤300 Support points Support points 300~500 z As shown in the above illustration.(3) Piping support ¡ Spot support (refrigerant piping) ~Purposes~ 1.

(3) Piping support ¡ Spot support (drain piping) „ Bend support ≤300 ≤300 Support points „ Support around the indoor unit x The horizontal section of the drain piping after the first upward section x The piping connection with the drain hose accessory Drain hose accessory „ Through-hole support Support point 300~500 300~500 –8– .

Ì Do not use piping that has not been protected (covered). <Unprotected (uncovered) pipe ends> <Protected (covered) pipe ends> –9– . contaminants or dust enter into the refrigerant piping. Ì If water/moisture. Your utmost effort is required in preventing this from occurring. but use a table or the like when placing them. (2) Do not lay refrigerant pipes directly onto a floor surface. Work by Process and Key Points (4) Refrigerant piping work 1) Work procedure 2) Protection (covering) 3) Pipe processing Unit connection ~Working points~ x Adhere to the following three basic principles when conducting refrigerant piping work: [The 3 basic principles of refrigerant piping] Dry Clean Tight No water/moisture inside No dust/contaminants inside Do not let water/moisture in Do not let dust/contaminants in Dust/ contaminants Water/ moisture No leakage of refrigerant Leak 1) Protection (covering) Protection (covering) during storage and work involving refrigerant piping is the most important type of work in order to prevent water/moisture. not only will it prevent the air conditioner from operating normally but it will also cause a malfunction of the machine and significant inconvenience for the customer. ¡During storage (1) Make sure to protect (cover) both pipe ends. contaminants or dust from entering into the piping.2.

Site Outdoor Indoor Work period Protecting (covering) method 1 month or more Pinching Less than 1 month Pinching or taping Not considered Pinching or taping <Pinching> A method by which the ends of the copper tube are closed off and the gaps are brazed.' but taping can also be selected as an easy method depending on the site and time frame. (2) Be sure to protect (cover) the ends when pushing a pipe through a through-hole. – 10 – Wrap with tape again . <Unprotected (uncovered) pipe ends> <Protected (covered) pipe ends> [How to protect (cover)] The most reliable is the 'pinch method. Copper tube Brazing filler metal Braze <Taping> A method by which the ends of the copper tube are covered with vinyl tape Cut flat Pipe end Fold down Wrap the copper tube with tape.(4) Refrigerant piping work –Protection- ¡During work (1) Be sure to protect (cover) the ends even when leaving the pipes for a short period of time.

Ì When processing the cut surface. X Y X≅Y Ì The size of the flare will become larger in proportion to Dimension A to the right. Remove burrs from the inner portion of the pipe.(4) Refrigerant piping work –Flaring- 2) Pipe processing ¡Flaring…This is one method of connecting refrigerant piping of a diameter of 15. face it down to prevent any swarf from falling into the pipe. – 11 – A . Ì Make sure that the burrs are completely removed.9 mm or smaller to an air conditioner. x Feed the blade of the pipe cutter bit by bit into the pipe with each rotation. as not removing the burrs sufficiently can result in a refrigerant gas leak at the flare. x Ensure that the size of the flare is within the prescribed range. <Tools> Reamer Pipe cutter File Flaring tool Scraper <Work procedure> (1) Pipe cutting x Use a pipe cutter with left rotation. (2) Processing of the cut surface x x x x Remove burrs from the tip of the cut surface with a file. Use the file again in order to remove burrs from the tip. Ì Excessive feeding of the blade can disfigure the pipe so special care is required. using a reamer or scraper. z Note that an appropriate size for the flare is virtually the same as that of the union. Note that Dimension A differs according to the flaring tool manufacturer. Burrs Facing down Facing down (3) Flaring x Insert a flare nut into the pipe before flaring. Use the reamer or scraper again in order to remove burrs from the inner portion of the pipe.

X From the right Y From the left (2) Insert the pipe into the bender. Align the center line (middle) of that pipe with the mark on the pipe. Following is a description of the work procedure with a lever-type bender: <Tools> Lever-type bender <Work procedure> „ The bending dimensions depend on whether they are taken from the left or right end. (4) Use the handle to bend the pipe to the desired angle. End of the handle Handle 0 (3) Align the mark on the pipe with the 'R' or 'L' on the handle by adjusting the pipe. Appropriate bend End of the handle Handle R (2) Insert the copper tube into the bender x Align the end of the handle with the '0' mark on the clamping lever. Clamping lever X Ì Bend the pipe slowly to prevent pleating or deformation of the inner curve of the pipe. 0 0 45 (3) Insert the same size of pipe into the bender slot so that the pipe becomes parallel to the clamping lever. Deformation due to pleating Deformation due to damage „ If the handle does not have the 'L' mark (1) Mark the finished dimension from the left end. L R 45 0 Pipe Mark 90 (4) Move the handle to bend the pipe to the desired angle. Ì Do not bend beyond 90°. lever-type and ratchet-type benders. x Align the end of the handle with the '0' mark on the clamping lever.(4) Refrigerant piping work –Bending- ¡Bending…Some of the tools used to bend refrigerant pipes are electric-type. 90 Clamping lever Y – 12 – Mark Same size of pipe . (1) Measure the finished dimensions from the right or left end of the pipe. hydraulic-type.

(3) Insert the other pipe fully into the tip portion of the head. close the lever and expand the pipe. – 13 – . inserting the other pipe in question inside and brazing the connection. (2) Slightly expand the tip of the head. Ì Note that excessive deburring can thin the walls of the pipe and cause vertical (lengthwise) cracking when expanding.(4) Refrigerant piping work –Pipe expansion - ¡Pipe expansion…Two pipes can be connected by expanding the end of the refrigerant pipe. (4) This may leave vertical scratches on the inner surface of the pipe so rotate the pipe to remove them. <Tools> Expander <Work procedure> (1) Remove the burrs on the cut surface with a reamer or scraper.

Ì Be sure to wear all the necessary protective gear (e. „ For nitrogen replacement Tapered nozzle Nitrogen cylinder Nitrogen gas regulator – 14 – Pressure hose Valve .5 Φ12. as fire is being used. If too small.5 1. <Tools> „ For brazing Welding torch Oxygen regulator Acetylene regulator (with flashback arrester) Welding kit Twin hose z In order to ensure safety when lighting the flame. it makes preheating and heating difficult. leather gloves). Use a nozzle that suits the outer diameter of the pipe to be brazed.6 #400 Φ44. be sure to have all work conducted by a certified individual. Ì For solder.7~1.2 1. Ì Don't use a cutting torch. a combustion flame of flammable gas (e.9 Φ19.1 1. be sure to use an acetylene regulator with a flashback arrester. eye protectors. The following is an explanation of the work procedure when using acetylene: Ì If certification is required in your country. use a phosphor copper metal (silver composition: 0%).3 #225 Φ25. propane) and oxygen is used.2 #200 Φ22.5 #315 Φ38.g.4 #250 Φ31.1 Ì If the nozzle is too large...8 #450~500 Φ6. [Standards for selecting the outer diameter of the pipe to be brazed and nozzle diameter (French standards)] Outer diameter Nozzle diameter (mm) Nozzle number 1.4 1. acetylene. brazing takes too long.4 Φ9.(4) Refrigerant piping work – Brazing- ¡Brazing…Brazing refers to the use of a metal with a lower melting temperature than that of the base metal as well as the alloy of these metals as solder in order to joint the two base metals without melting them.7 Φ15. To heat the solder.g. Ì Always have handy fire prevention equipment such as a fire extinguisher.8 1.

Nitrogen replacement „ Purpose A voluminous oxide film develops on the inner surface of the pipe during brazing. Procedure 2. Be sure to note that use of a lesser purity nitrogen may likely result in oxide film formation. This work is referred to as nitrogen replacement. z Use of the tapered nozzle results in efficient replacement.02 (MPaG) or so. Make sure that the pressure is not excessively high. The film can clog. hampering normal operation. capillary tube and compressor's oil pump inlet. . it may cause the brazing filler metal (solder) not to reach completely around the pipe or pinholes to develop in it. The effects of nitrogen replacement No nitrogen replacement The inner surface of the pipe has blackened due to the oxide film. – 15 – Nitrogen replacement The inner surface of the piping is clean. (2) Adjust the nitrogen gas pressure to 0.99% is recommended. (1) Set up the required tools as shown below: Taping N2 Pressure hose N2 Nitrogen gas regulator Taping Tapered nozzle Valve Nitrogen cylinder z It is even more effective to open up a small hole in the tape to release the nitrogen after covering the end of the pipe with tape or the like. In order to prevent this from occurring. among other parts.(4) Refrigerant piping work – Brazing- <Work procedure> Procedure 1. Ì Use of nitrogen with a purity of at least 99. Ì If the nitrogen pressure is too high. Confirmation of an appropriate gap between the pipe and joint z An appropriate gap is when the pipe can be inserted into the joint and held upside down without falling. the solenoid valve. it is necessary to replace the air within the pipe with nitrogen.

000°C) Carburizing flame Flame core (Roughly a 5 cm carburizing flame) x Change the flame intensity according to the size of the base metal. – 16 – Roughly 5 cm 80–85° . Preheating <The five key points for preheating> Point 1: Heat both base metals evenly. Point 4: Flame angle (heat control) x Make the flame angle 80 to 85°. 640~780°C (where the base metals change color from reddish black to red) Too early to apply the brazing filler metal (base metal temperature of 500 to 600°C) Appropriate timing for application of solder material (base metal temperature of 640 to 780°C) Point 3: Torch flame adjustment and flame intensity adjustment x Conduct brazing with a reducing flame. (The inner and outer pipes and the circumference) Inner pipe A A B 780°C 780°C 600°C 400°C 780°C 780°C 780°C 600°C Broad heating range Appropriate heating range Inner pipe B Outer pipe Outer pipe A and B Same temperature A and B Large temperature difference Uniform temperature around the circumference Non-uniform temperature around the circumference Point 2: Heat until an appropriate temperature for applying the brazing filler metal (solder).(4) Refrigerant piping work – Brazing- Procedure 3. Outer flame Too late to apply the brazing filler metal (base metal temperature of 800 to 1.

(4) Refrigerant piping work – Brazing- Point 5: Visual confirmation x Distance from the carburizing flame tip x Flame location x Flame direction Carburizing flame Carburizing flame Roughly 5 mm 2~3mm Distance from the carburizing flame tip Flame location Flame loss 2~3 mm Flame direction Procedure 4. Brazing filler metal application <Five key points when applying the brazing filler metal> Point 1: Confirm the range of brazing filler metal application (spread range) Overlap – 17 – Not overlapping results in a gas leak .

Brazing filler metal Brazing filler metal Roughly 90° – 18 – .(4) Refrigerant piping work – Brazing- Point 2: Confirm the volume of the brazing filler metal flow (differs according to the base metal heating range) Appropriate heating range Excessively broad heating range Excessively narrow heating range Excessive flow of brazing filler metal Lack of flow of brazing filler metal Point 3: Melt the brazing filler metal from the rod tip (melt it gradually. gently applying it upon the base metal) Hanging brazing filler metal Point 4: The angle of flame and brazing filler metal x Increase the flame angle slightly compared to preheating During brazing 80~85° During preheating x Make the angle between the brazing filler metal and flame roughly 90°.

it is relatively difficult to spread it and can result in a refrigerant leak. if the pipe is facing up. location of flame on the pipe and flame direction) 2~3 mm Distance from the carburizing flame tip 1~2 mm Location of flame on the pipe Flame direction Final confirmation (Move the flame up/down and left/right at a right angle to the pipe) Facing sideways Facing down Facing up Relatively difficult Relatively easy z It is relatively easy to apply the brazing filler metal when the pipe is facing down or sideways. – 19 – . Procedure 5. make efforts to enable brazing with the pipe facing down or sideways. But. Therefore. Cooling x Cool the brazed location with a moist cloth or the like to enable work afterward and prevent burns. (Final confirmation of the distance from the carburizing flame tip. z Do not turn off the nitrogen until the pipe is completely cooled down.(4) Refrigerant piping work – Brazing- Point 5: Confirm visually. If the nitrogen gas is stopped before the pipe has sufficiently been cooled down. it will result in the development of an oxide film on the inner surface of the pipe.

At least 1. – 20 – . Arrow view Perpendicular <Horizontal pipe> <Vertical pipe> 2. resulting in abnormal noise or preventing normal operation. Be sure to install it horizontally. Install the REFNET header horizontally. Install the REFNET joint horizontally or perpendicularly.000 At least 500 At least 500 <Top view> ¡ Example of refrigerant branch pipe installation <Installed at a 90° angle> <Installed horizontally> „ Installing the REFNET joint while it is leaning at an angle can cause refrigerant drift.(4) Refrigerant piping work – Refrigerant branch pipe (REFNET joint) – ¡ Refrigerant branch pipe (REFNET joint) <Installation standards> 1. Example of liquid-side header installation Example of gas-side header installation Ceiling Ceiling Supporting fixture (locally procured) Horizontal Horizontal Mount (locally procured) z Create at least 500 mm of a straight pipe section before and after branches when connecting refrigerant branch pipe to the field pipe. Horizontal A A. <Reason> Bending the pipe too close to the branch can lead to complaints about abnormal noise.

Φ 6.> Torque wrench Refrigerant oil <Work procedure> (1) Apply refrigerant oil (ethereal oil.1 9720~11860 z When tightening with a spanner (monkey wrench) because a torque wrench is unavailable: x When tightening a flare nut with a spanner.5 Φ 12. From that point. (2) Turn the flare nut 3 or 4 times to the machine union side by hand.(4) Refrigerant piping work – Flare connection – 3) Unit connection ¡Flare connection <Tools. ester oil) to the inner surface of the flare. 200 mm Approx. etc.4 Tightening angle (rough standard) 60°~90° Recommended length of tool being used Approx.1 25°~35° Approx. Tightening torque standards for flare nuts Pipe outer diameter Tightening torque (N•cm) Φ 6. (3) Tighten to the prescribed torque value using the torque wrench Ì Tighten. tighten only with an angle shown in the table below. 300 mm Φ 19.7 4950~6030 Φ 15. Please try again. Ì Note that tightening the flare nut with a spanner longer than the recommended tool length shown in the table below can result in excessive tightening. 250 mm Approx. Ì If the flare nut cannot be turned by hand. 450 mm Pipe outer diameter Tool length z Marking the flare nut with a magic marker or the like after it has been tightened prevents the worker from forgetting to tighten the flare nut.4 1420~1720 Φ 9.9 60°~90° 30°~60° 30°~60° Approx. Marking – 21 – .7 Φ 15. as tightening excessively can cause gas leakage due to flare nut cracking and the like. Where the refrigerant oil is applied Ì Be sure to use the flare nuts that come with the unit. there may be a shaft misalignment of the flare and union. there comes a point where the tightening torque increases rapidly. Ì Be careful. using a technique that employs both the torque wrench and (spanner) monkey wrench. 150 mm Φ 9.9 6180~7540 Φ 19.5 3270~3990 Φ 12.

Example of drain trap installation Indoor unit FXMQ Indoor unit FXMQ H H: At least 50 mm H Cleanout Attach a cleanout to allow for cleaning Drain trap – 22 – . ¡ Reverse gradient of the drain piping In some cases it is difficult to ensure the required drain piping gradient within the ceiling spaces when other piping and equipment crowd the area. Work by Process and Key Points (5) Drain piping work 1) Work procedure Indoor unit installation 2) Indoor unit side drain piping 3) Collective drain piping Drain flow test ~Working points~ x Ensure a downward gradient of the drain piping of at least 1/100.2. the drain trap requires a cleanout for cleaning. Most of such problems can be averted by prior consultation with the installers handling the other equipment. Ì Indoor units in which the drain piping connection becomes a negative pressure require a drain trap (see below) for each unit. Indoor unit Downward gradient of at least 1/100 (1 cm/1 m) Ì Do not connect drain pipes to the building's sanitary sewer pipes or waste pipes as it may cause an odor problem. so always check the installation manual before installing. 1/100 gradient 1) Indoor unit side drain piping Ì The installation procedures for drain piping at the indoor unit side differ by the model. In addition. x Keep the drain piping as short as possible in order to prevent air pockets.

The flexible type prevents any undue stress on the drain pan. Indoor unit Hose band Attached drain hose Insulation material (piping section) Drain pain Insulation material (band section) (3) Install the drain branch piping up to the main drain pipe. Allows for adjustment of the angle Main drain pipe Example of installation ¡ If the main drain pipe has already been installed and the required gradient for the drain branch piping cannot be achieved. maximize the drain-up height. Ì Do not bend the drain hose in the middle so as to prevent any excessive force on it. z Refer to the illustration below for connection from the indoor unit to the main pipe.) Drain branch piping Main drain piping Drain-up height – 23 – . Ì Be sure to use the drain hose that comes with the unit. It complicates removal of the drain hose from the machine during maintenance and the like. Bending can lead to a water leak. (2) Tighten the indoor unit's drain connection and drain hose with the attached hose band. (Confirm the drain-up height with the installation manual as it differs depending on the model. Ì Do not attach the indoor unit's drain connection and drain hose (accessory) with adhesive.(5) Drain piping work <Work procedure> (1) Connect the attached drain hose (flexible type) to the indoor unit's drain outlet.

– 24 – . Cleanout Drain branch piping Vent piping Vertical drain piping Main drain piping Example of drain piping installation 3) Drain flow test (1) Conduct a drain flow test before insulation work.(5) Drain piping work 2) Collective drain piping z An example of a connection from the main drain pipe to a vertical pipe It is ideal to use a Y joint. z Attach a cleanout (cap) at the top of the main drain pipe for water flow tests. (2) Use the cleanout on the main drain pipe for the water flow test. z Minimize the number of indoor units per group as few as possible in order to prevent the drain piping from becoming too long. a T joint can also be used. use of colored adhesive prevents workers from forgetting to replace the plug. Y joint T joint Connection to vertical pipe with a Y joint Connection to vertical pipe using a T joint z Maximize the size of the main drain pipe as much as possible. z In the case of polyvinyl piping. If it is not locally available.

440 PVC63 56 2. (2) The relationship between the inner diameter of the vertical drain pipe and allowable drainage volume when using collective piping (in the case of an air vent) PVC Inner piping diameter (Reference value: mm) Allowable flow rate [L/hr] PVC25 19 220 PVC32 27 410 PVC40 34 730 PVC50 44 1.(5) Drain piping work (Reference) Inner diameters of the main drain piping and vertical drain piping x Calculate the drainage volume based on the number of indoor units connected to the main drain pipe. (1) The relationship between the inner diameter of the main drain pipe and allowable drainage volume when using collective piping (in the case of an air vent) PVC Inner piping diameter Allowable flow rate [L/hr] Comments (Reference value: mm) Gradient=1/50 Gradient=1/100 PVC25 19 39 27 Not suitable for the main drain PVC32 27 70 50 piping due to the limited allowable flow rate PVC40 34 125 88 PVC50 44 247 175 PVC63 56 473 334 Suitable for the main drain piping Note: Calculated assuming that the water ratio within the piping is 10%. in the event of 3 units with 2 HP and 2 units with 3 HP: 6 L/hr × 2 HP × 3 units + 6 L/hr × 3 HP × 2 units = 72 L/hr. The pipe after collection should have an inner diameter of at least 34 mm. Vertical pipes within collective piping should have an inner diameter of at least 34 mm.710 PVC90 79 8. Round off the allowable flow rate to the nearest whole number. – 25 – .280 Comments Not suitable for vertical drain piping in the case of collective piping Can be used for vertical drain piping in the case of collective piping Note: Round off the allowable flow rate to the nearest 10. The inner diameter of the piping can be determined using the following method: x 6 liters per hour per 1 HP is a rough measure for drainage volume from the indoor units.760 PVC75 66 5. For example.

Ì Be sure to insulate the discharge duct. – 26 – . Ì Consider the positioning of the suction and discharge grilles so as to prevent short-circuiting. Work by Process and Key Points (6) Duct work (indoor) Work procedure Indoor unit installation Air inlet/outlet installation Duct connection ~Noise and vibration considerations~ x Be sure to use canvas joints between the indoor unit and suction ducts as well as the indoor unit and discharge ducts. Suspension bolt Canvas duct Canvas duct Indoor unit x Select suction and discharge grilles in consideration of the airflow rate so as to prevent any air distribution noise (wind roar). Ì Check the static pressure so the prescribed discharge air flow rate is being produced. This is because they are useful in preventing reverberations when the product's vibrations and operating noise travel through the building and ducts. Ì Use canvas ducts with a metal framework on the inlet side.2. Ì Make it so the air filter is easy to remove when necessary.

Ì Be sure to insulate connections (brazed. [Materials] For the insulation. Gap in the insulation joint Damaged insulation material – 27 – . Ì Be careful not to use damaged insulation material. so ensure that any maintenance and repair on the insulation joints and the like is done properly. use materials that can sufficiently withstand the temperature of the piping.) after they have passed air tightness tests. Ì Polyethylene foam insulation material cannot be used in some areas (Hong Kong) due to the fire codes. please use insulation with a thickness of 20 mm or more. Therefore. Ì Be sure to insulate both the gas and liquid piping individually. Work by Process and Key Points (7) Insulation work Refrigerant piping work Insulation work (other than the connections) Air tightness test Insulation work (the connections) Drain piping work Insulation work (other than the connections) Drain flow test Insulation work (the connections) Work procedure ~Working points~ Insulation work does not allow for checks/tests. confirm this in advance. Insulate both the gas and liquid piping together Liquid piping Gas piping Insulation material Insulate only the gas piping Liquid piping Insulation material Gas piping Insulate the gas and liquid piping individually Gas piping Liquid piping Insulation material Insulation material Ì Be careful not to leave any gaps in the insulation joints.2. etc. flared. <Refrigerant piping> x Heat-pump type…Heat resistant polyethylene foam (that can withstand temperatures over 120°C) x Cooling-only type…Polyethylene foam (that can withstand temperatures over 100°C) <Drain piping> x Polyethylene foam (heat resistant temperature: –70 ~ 80°C) Ì If you assume that the temperature and humidity around the refrigerant pipe might exceed 30°C and RH80%.

Insulating reinforcement tape (5t × 50w) Insulation material Supporting fixture Suspension band with turnbuckle Polyvinyl tube Example of a polyvinyl tube being used ¡ Reinforcement of the insulation material cuts z Insulation material shrinks with time.(7) Insulation work ¡ Indoor unit flares x Use the following guide to conduct insulation work properly up to the base of the refrigerant piping on the indoor units. (2) Securely fasten both ends of the joint insulation material with the clamp material (accessory). z Always face the joint of the insulation material upward. ¡ Supporting fixture insulation z When supporting the horizontal piping. At support spots. Flare insulation work guide Wind from the base of the machine to the upper portion of the flare nut connection Piping insulation material Joint insulation material (accessory) (machine side) Face the joint upward Piping insulation material (locally procured) Flare nut connection Attach to the base Clamp material (accessory) Tighten the section that overlaps with the piping insulation material Sealer (accessory) (only gas piping side) Gas piping Liquid piping (1) Wind the joint insulation material (accessory) around the flares on both the liquid and gas piping. so it is recommended that the insulation material cuts be reinforced with tape with insulation material after applying a special adhesive. either reinforce the insulation material using tape with insulating properties or provide support with a hard-type wide polyvinyl tube to spread the weight. (3) Wind sealer over the joint insulation material only for flares on the gas piping side. z Be careful not to wind any adhesive tape used for a temporary hold too tightly. Ì Be sure to always conduct the above work after the air tightness test. the weight of the piping tends to crush the insulation at the support spots and cause condensation. – 28 – .

(7) Insulation work ¡ When inserting the insulation material into a gap z In consideration of possible shrinking of the insulation material in the future. z Consider where to cut the insulation material so that its reinforcement after bending can be conducted at a straight pipe portion. L L+200 L + Approx. 200 mm of insulation material ¡ Reinforcement of insulation material at bends z Try to minimize the number of cuts in the insulation material (one cut is ideal). Special adhesive Reinforcement tape with insulation material – 29 – . The work that follows is the same as the above-mentioned (3). insert insulation material that is 200 mm longer than the gap into the gap.

In the case of a thick type 2 wires cannot be inserted into the terminal block Ì 2.25 mm2.2. Never use multi-core wiring (more than 2 cores). it can lead to communication problems. transmission may become unstable due to the drop in voltage. resulting in transmission errors. ¡ Thick type When using daisy-chain wiring. Moreover. Work by Process and Key Points (8) Control wiring work ~Working points~ x Prepare a system diagram and check your work to prevent miswiring. Use wires of a thickness between 0. 2 wires cannot be inserted into the indoor terminal block. it predisposes the wiring to noise effects. <When using multi-core cables (more than 2 cores)> ¡ Signal interference occurs. be sure to ground one end. when using a shielded wire. Ì 1. <When using wires of other sizes> ¡ Thin type When wiring over an extended distance. – 30 – . [When using multi-core cables: Example of the VRV series] Indoor RC Indoor Normal condition (when sending) 4-core cable (stray capacitance between cables) RC Interference condition (when sending) ¡ The same thing that happens when using multi-core cables will occur when many single-core wires are inserted into the conduit. [Compatible wiring types] Use the following 2-wire sheathed vinyl cords or cables: x Vinyl cabtyre cord (round type) VCTF JIS C3306 x Vinyl cabtyre cord (flat-round type) VCTFK JIS C3306 x 600V vinyl-insulated vinyl cabtyre cable VCT JIS C3312 x 600V vinyl-insulated vinyl sheathed cabtyre cable (round type) VVR JIS C3342 x Vinyl-insulated vinyl sheathed control cable CVV JIS C3401 x Instrumentation cable with braided screen (shielded wire) MVVS JIS C3102 Conductor Insulation Sheath <Example> Cross-section of a VCTF Ì If shielded wires are not properly grounded on one end. Therefore.75 mm2 and 1.

) [Good example] [Poor example] Remote control PCB Remote control PCB Start/Stop (6-core wire) Start/Stop Ì 5. – 31 – . leading to malfunctions.(8) Control wiring work Ì 3. Use the same type of wires for power wiring within the same system. Keep the control wiring and power wiring separate <If the power wire and signal wire are laid parallel> ¡ Due to the influence of the electrostatic and electromagnetic coupling. Indoor unit RC Indoor unit RC Ì 4. ¡ When laying the signal wiring parallel to the power wiring. Never wire with bound control wiring <If control wires are bound> ¡ Strong and weak currents may mix together.000 mm More than 100A At least 1. a disturbing wave that interferes with the signal wiring is induced. <If different types of wires are used for power wiring within the same system> ¡ Mixing the wire types can lead to communication problems. (It affects the wire withstanding voltage among other things. Never bind communication wires over an extended distance. so it is recommended not to use multi-core wires. predisposing the wires to interference.500 mm Ì 6. it is recommended to separate them with a distance shown in the table below: Power supply capacity for power wiring 220V or more Separation distance between power wiring and control wiring for Daikin air conditioners Less than 10A 50A Separation distance between power wiring for other equipment and control wiring for Daikin air conditioners At least 300 mm At least 50 mm At least 500 mm 100A At least 1. <If communication wires are bound> ¡ The insulation distance between wires shortens.

nuts and washers) The optimum length of the foundation bolts from the surface of the foundation is 20 mm 20 ・ ・ ・ ・ Make considerations for the drain outlet Pay attention to the floor strength and waterproofing when installing outdoor units on the roof. nuts and washers (Use four sets of M12-type foundation bolts. Required for any machine of at least 8 HP Required for any machine of at least 8 HP Middle of the machine Middle of the machine – 32 – .14P RXYQ16P. A (Foundation bolt hole) Model RXYQ5P RXYQ8P RXYQ10P RXYQ12P. use of small concrete blocks at the four bottom corners of the outdoor unit as a foundation is not possible.5 631 722~737 B A mm 635 B mm 497 930 792 1240 1102 At least 67 Foundation drawing for outdoor unit For anything 8 HP or above. attach it to the whole bearing face of the foundation The height of the foundation should be at least 150 mm from the floor Secure the unit to the foundation using the foundation bolts. However.18P At least 765 4-15×22.2. this is possible with the 5 HP models. Work by Process and Key Points (9) Outdoor unit installation Work procedure Foundation preparation Outdoor unit installation ¡ Precautions when preparing foundations for outdoor units ・ ・ ・ Support the unit with a foundation that is at least 66 mm wide When attaching the rubber cushion.

(9) Outdoor unit installation ¡ Securing space for servicing/maintenance It is important to make considerations for space for servicing/maintenance. PCs.5 Radios.5m At least Indoor unit Branching switch. etc. overcurrent circuit breaker Cooling/ heating changeover RC 1m st a m le ast 1. Discharge duct For short-circuiting prevention Measures for obstacles above Installing under eaves ¡ Considerations when installing inverter air conditioners Be sure to secure enough space for servicing/maintenance according to the instructions in the installation manual. mmH2O is necessary. – 33 – . Not enough space for servicing/maintenance! (Impossible to remove the compressor. stereos and the like in consideration of the installation of the air conditioner and power wiring. overcurrent circuit breaker 1. Ì Note that replacement of the compressor may become difficult depending on the piping route. Ì Note that it may be necessary to install discharge ducts in cases as shown in the illustrations below: <When installing under eaves> <If there are horizontal obstacles above> x N ≥ M when L ≥ 1 m. When selecting a location for installation. slightly larger. At leas t1 m Indoor unit RC At least 1m Branching switch. maintain sufficient distances from radios. stereos. a discharge duct with Note that Dimension K refers to the dimensions duct resistance of less than 8 necessary when installing a single unit.5 At At le 1. x K ≥ M when L < 1 m. x No special measures are required if L ≥ 3 m.) Foundation ¡ Prevention of short-circuiting Short-circuiting can occur if the outdoor unit is not installed in a location with good ventilation. PCs.5m At least m At least 1. Refer to 'Standards for installing Dimension K for single unit upward-discharging outdoor units' when installation requires being installing on each floor. x If L < 3 m. Ì Inverter air conditioners may induce noise from other electronic equipment.

) z Step 1: Pressurize at 0.5 MPaG for approx. though it may differ depending the respective piping length. Operate the vacuum pump until the pressure reaches below –100. x The air tightness test pressure is the design pressure for air conditioners.0 If no pressure drop.0 Step2 1.5 Step1 Pressure MPaG 0 3 minutes 24 hours 5 minutes Time Ì Never pressurize at a pressure above 4. – 34 – PASS .0 MPaG.5 1. 3. 3 minutes Allows for detection of large leaks z Step 2: Pressurize at 1.2. Work by Process and Key Points (10) Air tightness tests Work procedure 1) Completion of refrigerant piping work 2) 3) Nitrogen pressurization Evacuation Check for drop in pressure Pass 4) Leak check ~Working points~ x Be sure to evacuate the piping before the air tightness test.5 2. a short time does not allow for detection of smaller leaks. 1) Evacuation of refrigerant piping <Work procedure> • Connect the gauge manifold to the service ports on the liquid and gas piping. Be sure to pressurize for 24 hours in Step 3.7kPaG (–755mmHg). Operate the vacuum pump for about 30 minutes. 2) Nitrogen pressurization <Work procedure> (1) Pressurize the liquid and gas piping for each refrigerant circuit according to the following steps: (Be sure to use nitrogen gas.0 MPaG for roughly 24 hours Allows for detection of smaller leaks Ì Even pressurized at 4. Example of the air tightness test [Time chart] Step3 4. 5 minutes z Step 3: Pressurize at 4.0 MPaG.3 MPaG for approx.0 0. x Be sure to always use nitrogen gas for the air tightness test.

If a pressure drop has been detected. the correction would be 0.00MPaG Ambient temperature 25°C 24 hours later 3. z It is rare to conduct an air tightness test on everything from the outdoor unit to indoor unit at the same time. z The work can be conducted efficiently if the pressurization assembly is prepared beforehand. search for the leak site by applying soapy water to the surface of the piping connections (flares. check from the indoor unit to the vertical pipe within each shaft. it takes a lot of time to check where the leak is. it has passed the test.2 and 0. (3) Check all piping from the indoor unit to the vertical piping to the outdoor unit. brazed spots) and charge the hose connections. An efficient method to check is on a block-by-block basis in accordance with the work schedule.95MPaG 20°C In this case.(10) Air tightness tests 3) Check for pressure drop ¡ If there is no pressure drop.01 MPaG (Example) Pressurization Pressure used for pressurization 4. z After conducting the air tightness test. Any differences in ambient temperature between during pressurization and during check for pressure drops will necessitate correction because pressure changes by roughly 0.01 MPaG per 1˚C. 4) Leak check x If a drop in pressure has been detected. – 35 – . (3) (1) Shaft (2) <Air tightness tests by the block> (1) For each floor. leaving the pressure between 0.05 MPaG so you can determine there has been no pressure drop (indicating a PASS). (2) Check the above (1) and the vertical piping within each shaft. Correction value: (Temperature during pressurization – Temperature during check) x 0.3 MPaG in the piping allows for the prevention of contamination in the piping.

(One with at least 40 L/min. 1. Reasons: Refrigerant oils differ between R410A and R22. the lower the boiling point becomes. At 1 atmospheric pressure (101. vacuum drying cannot be conducted unless the pressure is lowered below −100. gauge manifold. 2. Absolute pressure kPa mmHg Gauge pressure kPaG mmHgG Gauge pressure kPaG (mmHg) ℃ Necessary degree of vacuum Absolute pressure kPa (mmHg) Water boiling point Outdoor temperature range Evaporating point Temperature (˚C) ¡ Selection of the vacuum pump Note the following two points when selecting a vacuum pump. is recommended. the boiling point (evaporation temperature) for water is 100°C. Select one that allows for relatively high discharge volume. be sure to check with a vacuum gauge that the pressure reaches a level below −100.7 kPaG.g. charge hose).2°C. which will result in the development of impurities and the clogging of the refrigerant circuit. the moisture (liquid) in the piping is changed to vapor (gas) and expelled out of the piping in order to dry the inside of the piping. the closer the pressure within the piping comes to reaching a vacuum state as a result of using the vacuum pump. <Example> If the outdoor air temperature is 7. Work by Process and Key Points (11) Vacuum drying Work procedure After passing air tightness test Vacuum drying Vacuum test ~What is vacuum drying?~ Using a vacuum pump.. when conducting vacuum drying.3 kPaG (−752mmHg). Select one that allows for pressure to be brought below –100.3 kPa or 760 mmHg). – 36 – . the water will evaporate.2.) z Before conducting the vacuum drying work. Using different tools will result in refrigerant oils being mixed between the two. 'selection and maintenance of the vacuum pump' is important.7 kPaG (−755 mmHG). Once the boiling point falls below the outdoor temperature. Therefore. However. Ì Use special tools for R410A (e.

7 kPaG or −755 mmHg. [Normal vacuum drying time chart] +0.7 kPaG -101.7 kPaG or −755 mmHg even after vacuuming for 2 hours.(11) Vacuum drying <Work procedure> There are two methods of vacuum drying depending on the onsite conditions so selectively use them. z If the gauge indicator rises.3 kPaG Vacuum drying (2 hours) – 37 – Vacuum state (1 hour) Additional refrigerant charge (Refer to the following chapter.) . 1) Normal vacuum drying…This is the common method. x If the pressure does not fall below −100. (2) Vacuum test Leave the system in a vacuum state below −100.7 kPaG or −755 mmHg even after vacuuming for 3 hours. (1) Vacuum drying (1st time) x Connect a gauge manifold to the service ports of the liquid and gas piping and operate the vacuum pump for at least 2 hours. There are various types of functioning components in an indoor unit and evacuating only from one (liquid or gas) piping may result in a break in the vacuum state.05 MPaG Pressurized side Atmospheric pressure 0 MPaG -26. check for the leak site.) x If the pressure does not fall below −100.7 kPaG or −755 mmHg for at least 1 hour and confirm that the gauge indicator does not rise. there may either be moisture or a leak in the circuit.7 kPaG Vacuumed side -53.0 kPaG -93.3 kPaG -80. (The pressure must be below −100. Ì Conduct evacuation from both the liquid and gas piping.3 kPaG -100. Vacuum for 1 more hour to confirm this. there may be moisture remaining or a leak in the circuit.

7 kPaG -101. Determinations: The pressure must reach at least −100.0 kPaG -93.(11) Vacuum drying 2) Special vacuum drying Special vacuum drying is conducted when there is a risk of moisture within the piping.) x If the pressure does not fall below −100. x If the pressure does not fall below −100.7 kPaG or −755 mmHg for at least 1 hour and confirm that the gauge indicator does not rise.7 kPaG or −755 mmHg. Ì Be sure to use nitrogen gas when conducting vacuum break. [Special vacuum drying time chart] +0. (2) Vacuum break (1st time) Pressurize with nitrogen to 0. there may be moisture remaining or a leak in the circuit.3 kPaG -100. so breaking the vacuum state with it increases the effectiveness of the vacuum drying.7 kPaG or −755 mmHg.3 kPaG -80. Vacuum for 1 more hour to confirm this.7 kPaG or −755 mmHg even after vacuuming for 3 hours. If it does not even after 2 hours of operation. For example. (The pressure must be below −100. (1) Vacuum drying (1st time) x Connect a gauge manifold to the service ports of the liquid and gas piping and operate the vacuum pump for at least 2 hours.7 kPaG -100. (4) Vacuum test Leave the system in a vacuum state below −100.) (3) Vacuum drying (2nd time) Operate the vacuum pump for at least 1 hour. If the gauge indicator rises.3 kPaG Vacuum drying (2 hours) Additional refrigerant charge Vacuum break Vacuum state (1 hour) Vacuum drying (1 hour) – 38 – . repeat steps (2) (vacuum break) and (3) (vacuum drying).05 MPaG. (The nitrogen gas is a dry nitrogen. check for a leak site.05 MPaG Pressurized side Atmospheric pressure 0 MPaG -26.7 kPaG Vacuumed side -53. there may either be moisture or a leak in the line. x When work has been done during the rainy season and there is a risk of condensation within the piping x When the work has taken a long time and there is a risk of condensation within the piping x When there is a risk that rain has entered into the piping during work The special vacuum drying incorporates at least one vacuum break process using nitrogen gas during the normal vacuum drying process.7 kPaG or −755 mmHg even after vacuuming for 2 hours.

Ì Refer to the 'Service Precautions' label on the outdoor unit's electrical box cover for the procedures regarding additional refrigerant charge operation. If the refrigerant cannot be charged due to pressure equalization.) Ì Use a digital scale to measure. open Valve A and charge the calculated additional refrigerant from the cylinder via the liquid side stop valve service port using pressure difference. (6) Turn the additional refrigerant charge operation to ON using the setting mode while leaving the air conditioner OFF. Work by Process and Key Points (12) Additional refrigerant charge Work procedure After completion of vacuum drying Calculation of additional refrigerant charge amount based on piping length Additional refrigerant charge <Work procedure> (1) Calculation of the additional refrigerant charge amount x Accurately assess the length of the refrigerant piping to calculate the amount of additional refrigerant charge. (5) Completely open up the gas and liquid side stop valves. Ì Be sure to charge refrigerant from the refrigerant charge port. push the confirmation button (BS1) on the PCB (A1P) to stop the operation. leave the air conditioner OFF. Ì Be sure to charge the refrigerant in a liquid state.) Liquid side stop valve Refrigerant charge port Outdoor unit Gauge manifold Valve A Valve B Refrigerant cylinder with siphon Gauge Cylinder Indoor unit Gas side stop valve (2) After completing the vacuum drying. (Cylinders with siphons allow for charging of liquid refrigerant in a standing position.) Ì Be sure to enter the calculated additional refrigerant charge amount on the 'additional refrigerant charge instruction label' on the outdoor unit. (3) Close Valve A and then open Valve B. refer to the equipment design materials for the respective models. (4) Turn on the outdoor and indoor unit power supplies. (7) Once the required volume of refrigerant has been charged.2. (For calculating the formula. (The data will be needed for maintenance. – 39 – .

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