Haier AU96NXTAAA User manual

Free Multi Air Conditioning System
Please read this manual carefully before installing and using the air conditioning unit.
No. : 0010576255
Outdoor Unit
Please keep this manual safe for future use.
Installation Manual
AU96NXTAAA

Unit components.........................................................................................................4
Safety precautions...................................................................................................5-6
Installation diagrams................................................................................................7-8
Trouble shooting ....................................................................................................9-10
Installation of the outdoor unit..............................................................................13-23
Cautions..................................................................................................................2-3
Installation instruction........................................................................................ 11-12
Contents
Installation note.........................................................................................................24
1

Disposal of old air conditioning units
Before disposing of an old air conditioning unit
that is no longer useable, please make sure it's
inoperative, power supply disconnected and safe.
It must be noted that all air conditioning systems
contain refrigerants, which require specialized
waste disposal in accordance with current
legislation. The valuable materials contained in
an air conditioning unit can be recycled. Contact
your local waste disposal centre for proper
disposal of an old unit and contact your local
authority or contractor if you have any questions.
Ensure good environmental awareness by
insisting on an appropriate, anti-pollution
method of disposal.
Disposal of the packaging of your new air
conditioning unit
All the packaging materials employed in the
package of your new air conditioning unit may
be disposed of without any danger to the
environment.
The cardboard box may be broken or cut into
smaller pieces and given to a waste paper
disposal service. The wrapping bag made of
polyethylene and the polyethylene foam pads
contain no fluorochloric hydrocarbon.
All these valuable materials may be taken to a
waste collecting centre and used again after
adequate recycling.
Consult your local authority for the name and
address of the waste materials collecting centres
and waste paper disposal services nearest to your
premises.
Safety Instructions and Warnings
Cautions
2
Before starting the air conditioning unit, read the
information given in the User's Guide carefully.
The User's Guide contains very important
information relating to the assembly, operation
and maintenance of the unit.
The manufacturer will accept no responsibility
for any damage that may arise due to non-
observation of the following instruction.
Damaged air conditioning units are not to be
put into operation. In case of doubt, consult your
supplier/installer.
Operating the air conditioning unit is to be
carried out in strict compliance with the relative
instructions set forth in the User's Guide.
Installation shall be carried out by professional
qualified installers, do not install the unit by
yourself.
For the purpose of safety, the air conditioning
units must be properly earthed in accordance
with the specification and current regulations.
Always remember to isolate the air conditioning
unit supply, before servicing.

All electrical repairs must be carried out by
qualified air conditioning electrician/contractors.
Inadequate repairs may result in a major source
of danger for the user of the air conditioning unit.
Do not damage any parts of the air
conditioning unit that carries refrigerant by
piercing or perforating the tubes with sharp or
pointed items, crushing or twisting any tubes, or
scraping the coatings off the surfaces. If the
refrigerant spurts out and gets into eyes, it may
result in serious eye injuries.
Do not obstruct or cover the ventilation grille
of the air conditioniong unit. Do not put fingers
or any other object into the inlet/outlet and swing
louvre.
Do not allow children to play with the air
conditioning unit. Under no circumstances should
children be allowed to sit on the outdoor unit.
Specifications
The refrigerating circuit is leak-proof.
The machine is designed to operate in ambient
temperatures as defined below.
1. Applicable ambient temperature range:
2. If the power supply cable is damaged, it must
be replaced by the contractor/installer or a
similar qualified person.
3. If the fuse on the PC board is damaged please
change with a suitable rated part.
4. The wiring method should be in line with the
current wiring legislation.
5.All cables shall comply with current regulation
requirements.
6. The isolator for the air conditioning unit
should be via a Two-pole switch. Suitable means
for isolation must be incorporated in the wiring.
Cautions
If the system operates out of this range for a
long time, the protection device will act and the
unit will alarm.
Cooling
Heating
Indoor Maximum:
Minimum: D.B / W.B
D.B / W.B
D.B
Outdoor Maximum:
Minimum: D.B
D.B
Indoor Maximum:
Minimum: D.B
Outdoor Maximum:
Minimum: D.B / W.B
D.B / W.B
3

Unit Components
1 Air outlet
2 Air inlet
3 Condensors
4 Service panel (Electrical control box inside)
5 Stop valves(Inside of unit)
6 Air inlet
7 Compressors (Inside of unit)
8 Rating lable
4
*
*
*
*
*
*
*
*

ON
OFF
WARNING
CAUTION
WARNING
CAUTION
CAUTIONS FOR INSTALLATION
The system should be applied to places as
office, restaurant, residence and the like. The system should be installed by your
dealer or a professional installer. When you need some optional devices such as a
humidifier, electric heater, etc., be sure to use the
products which are recommended by us. These devices
should be attached by a
professional installer.
Application to inferior environment such as an
engineering shop, could cause equipment malfun-
ction and serious injury or death.
Installation by yourself is not encouraged
because it could cause such problems as
water leakage, electrical shock or fire accident
by some improper handing.
Installation by yourself is not encouraged because it could
cause such problems as water leakage, electrical shock or fire
accident by some improper handing.
Do not install nearby the place where may
have leakage of flammable gas. Depending on the place of installation, a
circuit breaker may be necessary.
Drain pipe should be arranged to provide a
positive draining.
If the gas leakes and gathers around, it may cause
the fire.
Unless the circuit breaker is installed, it could
cause elecrical shocks.
Where strong winds may prevail, the
system should be fixed securely to prevent
a collapse.
Install on the place where can endure
the weight of air conditioner. Make sure the system is grounded.
If the pipe is arranged improperly, furniture or the
likes may be damaged by leaked water.
Bodily injury could result by a collapse.
Bodily injury could result by a careless installation.
Grounding cable should never be connected to a gas
pipe, city water pipe, lightning conductor rod or
grounding cable of telephone. If the grounding cable
is not set properly, it could cause electric shocks.
CAUTIONS FOR OPERATION
You should refrain from exposing your body
directly to cool wind for a long time. Do not poke the air inlet or outlet with a
bar, etc.
When any abnormal condition (scorching smell or oth-
ers) is found, stop the operation immediately and turn
off the power switch. Then consult your dealer.
It could affect your physical condition or cause
some health problems. Since the internal fan is operating with a high
speed, it could cause an injury.
If you continue the operation without removing the
cause, it could result in a trouble, electric shock or fire.
The system should never be used for any
other purposes than intended such as for
preservation of food, flora and fauna, pre-
cision deices or work of art.
Do not handle switches with a wet hand.
Combustion apparatus should not be placed
allowing a direct exposure to wind of air con-
ditioner.
Incomplete combustion could occur on the apparatus.
It could cause electric shocks.
It could cause deterioration of food or other problems.
5
Safety precautions
WARNING Incorrect operations may result in death or serious injuries.
CAUTION Incorrect operations may result in damage to the air conditioning unit.
Symbols which appear frequently in the text have following meanings.
Strictly prohibited. Observe instructions faithfully. Provide a positive grounding.
The Safety Cautions should be at hand so that they can be checked at any time when needed. If the air conditioning unit
is transferred to a new user, this manual should be transferred to the new user.
Before starting to use the system, read carefully this"SAFETY PRECAUTIONS" to ensure a proper operation of the system.

Safety precautions
CAUTION
Do not wash the air conditioner with water.
Do not install the system where the air outlet
reaches directly the flora and fauna.
Make sure to use a fuse of proper electric
rating.
Do not operate the system while the
air outlet grill is removed.
It is strictly prohibited to place a container of
combustible gas or liquid near the air condi-
tioner or to spray it directly with the gas or liquid.
Neither stand on the air conditioner nor
place something on it.
Do not use the power switch to turn on or
off the system. Do not touch the air outlet section while
the swing louver is operating. Do not use such equipment as a water
heater, etc. around the indoor unit or the
wire controller.
ON
OFF
It could cause electric shocks. It will not be good for their health.
Use of steel or copper wire in place of a fuse is strictly
prohibited because it could result in a trouble or fire
accident.
There is a risk of injury.
It could cause a fire accident.
There are risks of falling or injury by collapsed object.
It could cause a fire or water leakage. There is a risk of injury.
If the system is operated at the vicinity of such equip-
ment which generates steam, condensed water may
drip during cooling operation or it could cause a fault
current or short-circuit.
When operating the system simultaneously
with a combustion apparatus, indoor air must
be ventilated frequently.
Check occasionally the support structure of
the unit for any damage after a use of long
period of time.
Insufficient ventilation could cause an
oxygen deficiency accident. If the structure is not repaired immediately, the
unit could topple down to causea personal injury.
When cleaning the system, stop the operation
and turn off the power switch. Do not put water containers on the unit
such as a flower vase, etc.
Cleaning should never be done while the internal
fans are running with high speed. If the structure is not repaired immediately, the
unit could topple down to cause apersonal injury.
WARNING
CAUTIONS FOR TRANSFER OR REPAIR
Modification of the system is strictly prohibited. When the system
needs a repair, consult your dealer. When the air conditioner is relocated, contact your dealer or a pro- fessional installer.
Improper practice of repair could cause water leakage, electric shock or fire. Improper practice of installation could cause water leakage, electric shock or fire.
Do not place any objects on or climb on
the unit.
Do not try to repair or reconstruct by yourself.
6

Gas line
Liquid line
3) Quattro combination
A1
B1
A2
B2
A1/A2 B1/B2
Model
Gas pipe
Liquid pipe
24000BTU
15.88mm
9.52mm
24000BTU
15.88mm
9.52mm
Indoor
unit
2) Trio combination
A1 B1
Model
Gas pipe
Liquid pipe
24000BTU
15.88mm
9.52mm
46000BTU
19.05mm
9.52mm
A1
B1
A2
A2
24000BTU
15.88mm
9.52mm
Indoor
unit
1) Duo combination
A1
B1
A1 B1
Model
Gas pipe
Liquid pipe
46000BTU
19.05mm
9.52mm
46000BTU
19.05mm
9.52mm
Indoor
unit
1. Combination instructions
Installation diagrams
7

FQG-B180(GAS)
L1
L2
L3
h H +
H -
A1
A2
B1
Descriptions Recommended
A1/A2 liquid pipe
A1/A2 Gas pipe
B1 Liquid pipe
mm
Item
The piping length information, please refer the following table.
Maximum
Unit
B1 Gas pipe
L1 (one way)
L2 (one way)
L3 (one way)
h
H +
H -
mm
mm
mm
m
m
m
m
m
m
Size of the liquid side connection pipe
Pipe length when the compressor connects with two indoor units
Drop between the two indoor units those in the same system
Drop between the outdoor unit and the indoor unit
*15
*5
*10
*10
/
/
/
/
Size of the gas side connection pipe
Size of the liquid side connection pipe
Size of the gas side connection pipe
Pipe length when the compressor connects with two indoor units
Pipe length when the compressor connects only one indoor unit
Drop between the outdoor unit and the indoor unit
9.52
9.52
15.88
19.05
*15
*30
*25
*5
*20
*30
*25
*50
FQG-B180(LIQUID)
2. Limitations on the piping work (Take a trio combination as an example)
Installation diagrams
8

Please check the following things about your air conditioner before making a servie call.
Unit fails to start
Trouble shooting
ON
OFF
Is the power source
switch adjust cut in? Is city supply power in normal?
Power
stoppage?
Isn't the signal receiving
section exposed to the
direct sunlight or strong
illumination?
Isn't the earth leakage
breaker in action?
It is dangerous. Turn off
the power supply switch
immediately and contact
the sales dealer.
Power supply switch is
not ON.
Cooling or heating is not sufficient
Is the thermostat adjust
as required? Isn't the air filter dirty?
Isn't any doors or windows
left open? Doesn't any obstacle exist at the air inlet or
outlet?
Cooling is not sufficient
Isn't sun-shine invading
direct? Isn't any unexpected heating load generated? Isn't the room much crowded?
Isn't the swing louver
horizontal?
(At HEATING mode)
If swing louver is horizontal,
the blow wind does not reach
floor.
The wind does not blow
during heating operation
Isn't it warming up?
When the air conditioner does not operate properly after you have checked the above mentioned
items or when the following phenomenon is observed, stop the operation of the air conditioner
and contact your sales dealer.
9
The fuse or breaker often shuts down.
Water drops off during cooling operation.
There is a irregularity in operation or abnormal sound is audible.
When the CHECK lamp (red) flickers, an irregularity has occurred in the air conditioner.
Note:
This unit has a function of automatic restart system after recovering power stoppage. Please contact the sales
dealer if it is not required.

Trouble shooting
The followings are not malfunction
Shuru
Shuru
When the air conditioner is started, when the compressor starts or
stops during operation or when the air conditioner is stopped, it
sometimes sounds "shuru shuru" or "gobo gobo". It is the flowing
sound of the refrigerant, and it is not a trouble.
Water flowing
sound is heard.
This is caused by heat expansion or contraction of plastics.Cracking sound is heard.
It smells. Air which blows out from the indoor unit sometimes smells.
The smell results from residents of tobacco smoke or cosmetics
stuck inside of unit.
When the air conditioner is used at restaurant etc. where dense
edible oil fume is always exists, white fog sometimes blows out
of air outlet during operation.
In this case consult sales dealer for cleaning the heat exchanger.
During operation,
white fog comes
out of indoor unit.
Unit does
not start Wait for
three
minutes
It is switched into the FAN mode
during cooling. To prevent frost from being accumulated on the indoor unit heat exchanger, it is sometimes automatically switched to the FAN mode
but it will soon return to the cooling mode.
Even if the operation switch is turned on, cooling, dehumidifying
or heating is not operable for three minutes after the conditioner is
stopped. Because the protecting circuit is activated.
(During this time air conditioner operates in fan
mode.)
The air conditioner can not be
restarted soon after it stops.
Air does not blow or the fan
speed can not be changed during
dehumidifying
During operation, operation mode
has changed over automatically.
Water or steam generates from
the outdoor unit during heating.
When it is excessively cooled during dehumidifying, the blower
automatically repeats reducing and lowering the fan speed.
Isn't the AUTO mode selected?
In the case of AUTO mode, operation mode is changed automati-
cally from cooling to heating or vise-versa according to the room
temperature.
This results when frost accumulated on the outdoor unit is removed
(during defrosting operation).
10

Installation Instruction
Meanings of Warning and Cautions:
Installation work must be carried out by professional qualified people, do not install the unit by
yourself. Incorrect installation will cause water leakage, electric shock and potentially fire.
Install the unit as per the Manual. Incorrect installation will cause water leakage, electric shock or
fire risk.
unit falling down may occur.
causing injuries.
When installing the unit, take in consideration storms, & high winds Incorrect installation may cause
the unit to fall down.
All electric work should be carried out by experienced personnel as per current regulations and this
Manual. Incorrect installation or undersized electric cable may cause electric shock or fire risk.


In the case of a refrigerant leakage during unit installation, keep the room well ventilated.
Check the unit upon installation. Be sure there is no leakage. Refrigerant will induce a poisonous
gas subject to heat.
Isolate power supply before touching terminal block.
All units shall be earthed. The earth must not not be connected to a gas pipe, water pipe, or
telephone line. Poor earthing could cause electric shock.
Be sure to install a circuit breaker to avoid electric shock.
Arrange water drainage according to this Manual. Cover pipe with insulation materials to prevent
condensation occuring. Improper installation of water drainage will cause water leakage.
To maintain good picture or reduce noise, keep the unit at least 1 m from T.V. radio, when installing
the indoor and outdoor unit, connecting wire and power supply. (If the radio wave is relatively
strong, 1 m is not enough to reduce interference).
Do not install the unit in following places:
(a) Oil mist or oil gas exists, such as kitchen, or, plastic parts may age, or water leakage.
(b) Where there is corrosive gas. Copper tube and welded part may be damaged due to corrosion,
causing leakage.
(c) Where there is strong radiation. This will affect the unit's control system, causing malfunction of
the unit
(d) Where flammable gas, dirt, and volatile matter (thinner, gasoline) exist, These items will cause a
fire risk.
WARNING!
CAUTION!
WARNING Incorrect operations may result in death or serious injuries.
CAUTION Incorrect operations may result in damage to the air conditioning unit.
CAUTIONS: To ensure proper installation, read "Cautions" carefully before working.
After installation, start the unit correctly and ensure that you show the
customer how to operate and maintain the unit.
Be sure to use specified accessories and parts. Otherwise, water leakage, electric shock, fire risk or
Mounting position must be strong enough to hold the unit. Or, the unit will potentially fall down
All circuits must be earthed. Ensure that no external forces will affect the terminal block and electric
cable. Poor wiring and installation may cause fire risk.
Arrange wire connection between connecting the indoor and outdoor power supply correctly. Fix
terminal cover firmly to avoid overheating, electric shock or even fire risk.
Do not fail to show your customer how to operate the unit.
11

Installation Instruction
The Free Multi air conditioning system adopts the " SAME MODE " control method, that is to say,
all the indoor units those connected to the same outdoor unit can only work in the same mode, it
can not realize the synchronously cooling and heating operation.
To protect the compressors, the system must be in " Stand-By " mode before running to warm up
the crankcases by the crankcase heaters at least 12 hours.
Item to the checked Improper installation may cause Check
Is the indoor unit firmly installed? Unit might fall down, vibrate or produce
excessive noise.
Has there been a gas leakage check performed? This may lead to gas shortage.
Is the unit properly insulated? Dew or water droplets may occur.
Is the water drainage smooth? Dew or water droplets may occur.
Does the power supply meet that stipulated on Problems may occur.
the nameplate?
Is the wiring and piping correctly arranged? Problems may occur.
Is the unit safely earthed? There might be a danger of electric shock.
Is the cable size correct? Problems may occur.
Are there any obstacles in the way of the air inlet This may cause poor cooling.
and outlet grille, of the indoor and outdoor units?
Has the correct amount of refrigerant charging It is hard to control refrigerant charging amount.
been used for the piping length?
Pay special care to the following and check after installation
Avoid such places where:
(a) Oil mist or oil gas exists, such as kitchen, or plastic parts may age, or a water leakage
may occur.
(b) Where there is corrosive gas. Copper tube and welded parts may be damaged due to corrsion,
causing leakage.
(c) Where there is strong radiation. This will affect the unit's control system causing malfunction
of the unit.
(d) Where flamable gas, dirt, and volatile matter(thinner, gasoline) exist, these items will cause fire
risk.
Refer to paper pattern when installing the unit.
WARNING!
CAUTION!


12

Warning
Selection of installation site
It should be installed at places where it is firm enough to withstand the weight of the air conditioner to
prevent falling.
Typhoon and earthquake prevention. It should be installed according to specific requirements.
Inasppropriate installation may lead to accidents.
Note: Obstacles should be 2000mm off the top of the out-
door unit. Obstacles nearby should be 400mm lower
than the top of the unit.
1. Handing
As there is no protective package for the outdoor unit,so
the following points merit attention:
(1) When forklift is used, insert the fork into the holes in
the base plate.
(2) When crane is used, lift the unit with 4 pieces of steel
rope with diameter above 6 mm.
(3) Put protective materials between the cable and the
unit to prevent deformation and damage of the surface.
2.Mounting
(1) The distance between two connections
must not beless than 20mm.
(1)During installation, connect the outdoor unit and align
the mounting surface(See the figure on the right).Mount
the electric distribution device on the external side of
the unit in accordance to the installation instructions for
electric distribution device.
(2)To ensure good performance of the machine and facili-
tate installation and maintenance, adequate space must
be reserved (See figure on the right).
Installtion space
Installation of the outdoor unit
Blow out
Absorb in Absorb in
Absorb in
Working, repair surface
A vertical view of the outdoor unit
Over 300mm
Over 20mm
Over
20mm Over 20mm Over 20mm
Over
1000mm
(front side)
Wire rope
Protection cushion
Base panel
Wire rope
M12 foot screw bolt
4 screws each unit
13

Refer to the following figure for the distance between the
foundation bolts.
(2)When the refrigerant pipe is connected from the bottom of
the unit,the unit should be raised at least 500mm(see the
figure below)
(3)In snowy regions,snow-proof facilities should be used(see
the figure below).
(Poor snow-proof facilities may lead to damge.To avoid
inconveniences,the unit should be raised and snow-proof
covers should be installed at the air inlet and outlet.)
(4)During installation,anti-vibration rubber pads should be
used between the machine and the bracket.
3. Rrefrigerant piping
a. The joints of the refrigerant pipes are inside of the unit. Please take off the access hole cover
in front of the unit.
b. Install the removed flare nuts to the pipes to be connected, then flare the pipes.
c. The refrigerant pipes can be connected from the front or bottom of the outdoor unit. See Fig. 1
Refrigerant tube
Above 500mm
(1) Outline of piping
Snow-proof cover
on air outlet side
Snow-proof cover
on air inlet side
Branch pipe(FQG-B180(GAS))
Gas pipes
Liquid pipe Liquid pipe
3-way Stop valves(inside of unit)
Flared connections
Welding connections
Warning
During installation, if refrigerant leakage occurs, a ventilation measures must be taken.
After installation, please make sure that there is no refrigerant leakage.
It may produce hazardous gas when refrigerant meets fire.
Installation of the outdoor unit
Brand pipe
FQG-B180(LIQUID)
Through hole(15x20)
1100
790
14

(2) Piping size
Apply refrigerant oil
Torque spanner
spanner
Piping joing
Flare nut
Medium size seal pad 11
Clip
Gas pipe
Liquid pipe
Insulator
(For liquid pipe)
Insulator
(For gas pipe)
(Cover the piping joint with seal pad.)
R0.4 ~ 0.8
A
Pipe
size Tighten
torque A(mm) Flare shape
9.52
(
3
/ 8 ") 3270~3990N.cm
(333~407kgf.cm)
6180~7540N.cm
(630~770kgf.cm)
15.88
(
5
/ 8 ")
19.05
(
3
/ 4 ")
9720~11860N.cm
(990~1210kgf.cm)
12.0~12.4
18.6~19.0
22.9~23.3
90 0.5
45
2
Table 1
Fig. 2
(3). Piping connection
Cover joint of gas piping and insulator with seal.
Check piping joints for gas leakage. Insulate piping as shown in Fig. below.
Use torque specified in Table 1. (Too much force may damage the flare nut, causing gas leakage).
Apply refrigerant oil at both inside and outside of flare nut. Tighten by hand 3-4 turns then tighten as specified.

For the size of the flare nut, please refer to Table 1.
The Outdoor unit is precharged with R22 refrigerant.

Refer to Fig.2, when connecting and removing piping from unit.
Be careful not to let foreign matters, such as sand enter the pipe.

Bend pipe, with as large as possible radius so as not to crush pipe. When connecting pipe, hold the pipe
central an then screw nut on by hand, refer to Fig.

Installation of the outdoor unit
Base plate
Tube to the right
Tube to the back
Access hole cover
M4
M6
Tube fixing
panel
Tube to the left Tube to the left Tube to the right
15
FQG-B180
Gas pipe
Inlet pipe
Outlet pie
19.05x1.0mm
19.05mm
15.88mm
AU96NXTAAA Liquid pipe 9.52x0.8mm
Gas pipe 15.88x1.0mm
9.52x0.8mm
19.05x1.0mm
24000BTU/h
Indoor unit Liquid pipe 9.52x0.8mm
46000BTU/h
Indoor unit Liquid pipe
Gas pipe

During welding of the distribution pipe
1. In case of brazing weld of joint, nitrogen must be filled in the pipe to prevent oxidization.
2. The refrigerant pipe should be newly-made and clean. During installation, do not let water and other
substance into the pipe.
3. Use two spanners to tighten the connecting nut. One spanner will make loose connection.
outdoor unit
Diag2. Outdoor unit is above the indoor unit
Accumulator (set 1 per 6 meters)
indoor unit
Installation of the outdoor unit
(5) It should installation the liquid check-ring and accumulator according to the outdoor unit and
indoor unit position.(see the attached diagram)
16
indoor unit
outdoor unit
Diag1.outdoor unit below the indoor unit.
Liuid check-ring
(4)Installation of the brand pipe (FQG-B180(GAS))
CAUTION!
Please do not bend the connecting pipe at the welding
place. If this kind of bending must be taken, please leave
at least an 150mm straight pipe(See Fig.).
Horizontal
Ground
Vertical
Ground GroundGroundGround
Connecting
pipe Straight pipe
(Over 150mm)
Fig.

Installation of the outdoor unit
17
Tightly
closed
Welding joint
Field tube
installation Field tube
installation
To the unit
To the unit
(Gas side)three-way valve
(Gas side )access hole
Detailed diagram of the
three-way valve
To the gauge
distributor
(Liquid side)access hole
Three-way valve fully closed
liquid side
6.4
6.4
Copper pipe
Relief valve
Nitrogen bottle
VL VH Gauge distributor
High-pressure
gauge
Low-pressure
gauge
Three-way valve fully
closed(gas side)
Tightly
closed
Indoor unit
Indoor Outdoor
Access hole
Copper
pipe
Welding joint Tightly
closed
Tightly
closed Access hole
Outdoor unit
(Liquid side)three-way valve
Matters needing attention
Never use oxygen, flamable and any poisonous gases for the leakage testing.
Leakage testing must be done after the connection of the refrigerant pipes according to the following
diagram.
Close all the gas and liquid valves.To prevent nitrogen gas from invading the outdoor circulating
system,close the valve tightly before pressure increase, (Both the gas and liquid valves must be
tightly closed).
Every cooling system must be charged slowly from the gas and liquid valves.
It must be charged from the gas and liquid valves.
Leakage testing

Tightly
closed
Installation of the outdoor unit
To the unit
To the unit
(Gas side)three-way valve
(Gas side )access hole
Detailed diagram of the
three-way valve
To the gauge
distributor
(Liquid side)access hole
Three-way valve fully closed
liquid side
6.4Copper pipe
Vacuum pump
Gauge distributor
High-pressure
gauge
Low-pressure
gauge
Three-way valve fully
closed(gas side)
Welding joint
Tightly
closed
Indoor unit
Indoor Outdoor
Access hole
Welding joint Tightly
closed
Tightly
closed Access hole
Outdoor unit
(Liquid side)three-way valve
Field tube
installation Field tube installation
P
18
Step 1:Charge for more than 3 minutes under 0.3MPa(3.0kgf/cm2)
Step 2:Charge for more than 3 minutes under 1.5MPa(15kgf/cm2)
-----------Serious leakage may be found.
Step 3:Charge for more than 24 hours under 3.0MPa(3.0kgf/cm2)
----------Small leakage may be found.
Check for pressure decrease
Without pressure decrease-Pass
With pressure decrease-Check for leaage.
There will be a 0.01MPa(0.1kgf/cm2) pressure change for every 1 C ambient temperature
change during the 24-hour pressure charge.It should be corrected during the test.
In the case of pressure decrease during steps 1 to 3 ,check the joints with the ear,hand or
soapsuds for leakage.Repair it by welding or tighten the connecting nut up.
Use vacuum pump to evacuate the air. Never use the refrigerant for the evacuation.
Drain off the nitrogen gas after the leak test and then connect the vacuum pump as shown in
the figure below.
The vacuum pumping must be done from both the liquid and gas inlets.
Check for leakage
Vacuum Pumping

Installation of the outdoor unit
Use a vacuum pump with high degree of vacuum(below-755mmHg) and large volume
displacement (above 40L/min)
The pumping time depends on the length of the connecting pipe.Generally,it takes about 2-3
hours.Make sure that the Y-shaped valves on both the gas and liquid sides are closed before
pumping.
If the vacuum can no reach-755mmHg within 2 hours, continue pumping for another 1 hour.
If the vacuum can no reach-755mmHg after more than 2 hour's pumping,close the valves VL
and VH on the gauge distributor and stop pumping.One hour later, check the vacuum again. If
the vacuum has changed,it means there is a leakage. Repair it.
After the above steps, replace the vacuum pump with the refrigerant pump and refill refrigerant.
Refill refrigerant
When the outdoor valve is shut,fill the refrigerant from the access hole at the gas and liquid
sides.
If the required filling is impossible,open all the gas and liquid valves,then slightly shut the gas
valve, run the compressor and fill the refrigerant from the access hole at the gas side.
Now adjust the gas valve to control the refrigerant flow,which will be gasified during absorption
by the system.
If there is insufficient refrigerant in the system caused by leaks,refill it after the remaining
refrigerant is recollected.
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Open all valves
Open all the valves of the outdoor unit.
Heat isolation of the pipes
Separate isolation should be made for the liquid and gas pipes.
Materials used for the pipe isolation at the gas side must withstand above 120 C temperature.
After finished vacuum the system, change the vacuum to the refrigerant pump, charging the
refrigerant.
Calculation of the the refrigerant charge
Note: when the unit shipping out of the factory, charge the refrigerant not including the
construction procedure charged parts.
The calculation of the refrigerant charging:
When the total length of connection pipe (Liquid line:L) is less than 10 meters in one system,
there is no need to charge additional refrigerant;
If the total lenght (L)>10 meters, we need to recharge the 65g refrigerant per additional meter.
That is: the quantity of refrigerant charging of one system
(The outdoor unit has two separeted systems)=(L-10)*65(g)
Refrigerant charge