Education Material
Tools & Measuring Instrument
Basic Handling Work
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MPa Gauge
MPaGauge
GAUGE MANIFOLD
Lo Va p o r
R410A
Hi L iq u id
T AS CO J APAN
7 312
KI HIO
MP C LA
ACAHz 50 1 50/50
ON
E ES T Hi T
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15 6 60
300 750 300 150 ACV MAX 5V 750V DC7 LOOK + METE
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INTRODUCTION Air conditioners are now necessities of life, the functions and performance of which have been changing and growing more sophisticated almost daily. In order to make the full use of the functions and performance of the air conditioners and operate them with efficiency, to say nothing of proper selection of models, the installation work of the air conditioners serves as a key factor in providing comfortable environments for customers. For proper installation, it is important to learn expert knowledge and proper basic work and to use proper tools.
This book is summarized for you to learn the proper basic work. So, it is hoped that you make the most effective use of this book and put it to work on improvement in the quality of installation work.
Basic Knowledge
Basic Work Remember your srcinal intention.
Let’s learn properly.
The more haste, the less speed.
Four Basic Hints
Attentiveness to details
Strength creditability
Safety-first
1
CONTENTS Details of work Basic work
Page Installation work
Test run
Relocation
Service
Flaring
P3 - P8
Bending
P9 - P10
Rigid PVC pipe connection
P11
Wire connection
P12 - P13
How to use gauge manifold
P14 - P17
How to use control valve
P18
Pressure measurement
P19
Vacuum drying
P20 - P21
Airtight test (Gas leak)
P22 - P23
Gas leak test
P24 - P25
Refrigerant charging
P26 - P27
Pump down
P28
How to use measuring instruments
Multiple meter
P29 - P31
Clamp meter
P32 - P34
Megger
P35 - P36
Temperature measurement P37 Frequency measurement
P38 - P40
2
1. Flaring
On air conditioners, the refrigerant piping serves to connect the indoor and outdoor units, through which refrigerant gas passes.“Flaring connection” and “Brazing” are available to the connection of the machine and piping. The refrigerant piping is of primary importance in the installation work, thus requiring exert skill and knowledge.
● Refrigerant pipe connections become places which
Three Principles of Refrigerant Piping
refrigerant gas may leak, or moisture or dust may enter, it is important to accomplish the refrigerant piping work with
No air or moisture enters the inside of piping.
DRY
the three principles of refrigerant piping in mind.
CLEAN TIGHT
No dust or swarf enters the inside of piping.
No refrigerant leaks.
● The wall thickness of refrigerant piping partially varies with the type of refrigerant. ● Pipe sizes used for flaring (in the case of round copper pipes) (Unit: mm)
Nominal size1
Popular size
Outside dia
1/4 pipe 3/8 pipe 1/2 pipe
2-bu-pipe 3-bu-pipe 4-bu-pipe
6.4 9.5 12.7
5/8 pipe 3/4 pipe
5-bu-pipe 6-bu-pipe
15.9 19.1
For R22 Class-1 piping 0.80 0.80 0.80
Wall thickness For R407C Class-1 piping 0.80 0.80 0.80
1.00 1.00
1.00 1.00
For 410A Class-2 piping 0.80 0.80 0.80 1.00
1-1 Relationship between structure of flared section and flared seal face Cross section of flare nut 45°-46° Copper pipe
C B A
Seal face A Cross section of union pipe
43 °-4 6
Nominal Outside dia. of pipe size 1/4 3/8 1/2 5/8 3/4
6.4 9.5 12.7 15.9 19.1
°
Dimension A +0-0.4 For R22·R407C For R410A Class-1 piping Class-2 piping 9.0 9.1 13.0 13.2 16.2 16.6 19.4 19.7 23.7 24.0
Dimension Dimension B C 9.2 13.5 16.0 19.0 24.0
6.5 9.7 12.9 16.1 19.13
Daikin standard (Unit: mm) Width of flare nut For R22 For R407C For R410A Class-1 piping Class-1 piping Class-2 piping 17 17 17 22 22 22 24 24 26 27 27 29 36 36 36
● Basically, if the seal face A makes in absolute contact with the copper pipe, no gas leaks will occur.
3
1-2 Flaring tools Name & Shape Pipe cutter
Used to cut copper pipes.
Normal use Flaring dies (Flaring tool) ● Main tool used for flaring. ● Two types of tools are available, for R22 (also
available to R407C) and for R410A. ● Any tools for new standard are compatible with both
R22 and R410A.
Reamer
Used to remove burr/flash from the cut edges of copper pipe.
File
Used to smooth out the cut edges of copper pipe.
Torque wrench
Used to torque pipes to a specific degree.
Refrigerating machine oil ● Apply this oil to the inside and outside of flared
section. ● Use oil applicable to new refrigerant (HFC) units as
well.
4
Used in confined places
1-3 Flaring procedure (Practical flaring skill training manual) Parts & Tools
Copper pipe/Flare nut/Flaring tool (of Rigid make)/Reamer/Pipe cutter/File
Working steps
Vital points
1) Cut the copper pipe. If a left hand slides, the pipe cutter blade has been fed too much.
2) Deburr the end face of the pipe (if the end face is poor in the shape).
Reasons
1. Use the pipe cutter in left-hand rotation (counterclockwise). 2. Make the pipe cutter one rotation and then slowly feed.
Unnecessary to change hands when feeding the pipe cutter. The engagement of the cutter blade becomes tight, thus requiring exert a force on the rotation of the cutter. The copper pipe will be deformed.
1. Smooth out the end face. 2. Put the copper pipe in a downward direction. 3. Do not blow the copper pipe.
Poor shape of the flared section will result in gas leaks. Swarf will enter the pipe. Spit or swarf will enter the pipe.
File
3) Deburr the cut edge of the pipe.
1. Put the copper pipe in a downward direction. 2. Do not blow the copper pipe.
Swarf will enter the pipe.
3. Do not flaw the inside of the copper pipe.
Gas leaks will result.
Spit or swarf will enter the pipe.
Reamer
4) Deburr the end face of the pipe.
1. Conduct the Step 2) again.
[Finished surface after deburring] Slant Excessive Insufficient deburring finish deburring
File Slant
5) Deburr the cut edge of the
1. Conduct the Step 3) again.
pipe.
Reamer
5
Tapered Cracked Flawed
To make flaring more secure.
Working steps
Vital points
Reasons
6) Clean the inside of the copper pipe.
1. Remove swarf completely from the inside of the copper pipe. (Put the copper pipe in a downward direction to remove swarf.) (Use a cotton swab or cloth to remove swarf.)
Metal parts used in the compressor will burn out. If swarf bites the flared section, gas leaks will result.
7) Put the flare nut onto the copper pipe.
1. Before flaring, be sure to put the flare nut onto the pipe.
After flaring, the flare nut cannot go onto the copper pipe.
8) Pinch the copper pipe in the flaring dies.
1. Make sure the inside of the flaring dies is clean. 2. Protrude the copper pipe from the flaring dies by a specified dimension.
Dimensions from the dies face to the front edge of copper pipe
45°
Flaring dies
9) Align the main unit of punch.
A
Copper pipe size A n io s n e im D
Rigid Corp. make
φ 6.4
φ 9.5
φ 12.7
φ 15.9
0.5mm
e ip p
Note) For flaring of R410A with the use of conventional
re p p o C
flaring tools, be sure to use a copper pipe gauge or the like for the adjustment of the protrusion dimension and set the Dimension A to 1.0 to 1.5 mm. The Dimension A is involved with the flaring size.
1. Set a position marked with an arrow on the main unit of the punch to a given position on the flaring dies side. 2. Firmly tighten the side screw of the main unit of the punch. A
The Dimension A is a specified dimension.
The copper pipe will come out during flaring process. The finish dimension of flaring will vary.
10) Conduct flaring.
1. Conduct flaring slowly and positively until you feel a click and the pipe goes into a freewheeling
No perfect flaring will be accomplished.
condition. 11) Remove the flaring dies.
1. Rotate the handle part counterclockwise and pull it up to its uppermost position.
The pipe- expanded section (cone section) will be flawed.
If the handle is not pulled up to the uppermost position, the flaring punch will hit the pipeexpanded section (strobilus) to flaw it.
6
1-4 Points to connect pipes 1) Check the flared section.
4) Align the flared face with the shaft center. Check the inside and outside surfaces for any flaw or dust.
Surface flaws
Cracks
Align the flared face in a straight line with the shaft center of the union and screw in while making four or
2) Check the union part.
five turns by hand. 5) Torque the flare nut to a specified degree until you hear it click.
Check the seal face of the union for any flaw or dust.
Torque wrench
Spanner
3) Apply oil to the inside and outside surfaces of the flared section.
Union joint Flare nut
Copper pipe
Pipe size
Torque N · m (kg · cm)
φ 6.4
14 - 17 ( 145 - 175)
φ 9.5
33 - 40 ( 335 - 405)
φ12.7
50 - 60 ( 505 - 615)
φ15.9
62 - 75 ( 630 - 770)
φ19.1
97 - 119 ( 990 - 1210)
Apply oil here (in order to lessen the friction with the nut).
Note) Use a torque wrench to securely tighten the flare nut. If the flare nut is tightened excessively
Flare nut
Apply oil here (in order to improve close contact of the seal face).
Apply refrigerating machine oil to the inside and outside surfaces of the flared section.
(1) The flare nut will crack, resulting in refrigerant gas leaks. (2) The flared section will be crushed to cause cracks, thus resulting in refrigerant gas leaks. (3) The seal face of the union will be dented to cause deterioration in close contact with the copper pipe, thus resulting in refrigerant gas leaks.
Dent
Seal face
Cross section of union
Seal face
Cross section of union
If no torque wrench is available ● If no torque wrench is available, take the following method as a guideline. And, after the completion of the work,
check to be sure that there is no gas leak. ● While tightening the flare nut with the use of a spanner, there is a position at which the tightening torque shows
a sharp increase. Tighten the flare nut further from this position by angles listed in Table below. Pipe size
Tightening angle (guideline) Recommendable length of tool arm
φ 6.4
60°- 90°
Approx. 150 mm
φ 9.5
60°- 90°
Approx. 200 mm
φ12.7
30°- 60°
Approx. 250 mm
φ15.9
30°- 60°
Approx. 300 mm
φ19.1
20°- 35°
Approx. 450 mm
7
Note) If an adjustable wrench is used, the arm length of the wrench shall conform with that listed in Table left. Using an adjustable wrench with excessively long arm will result in too much tightening of the flare nut.
1-5 Points to prevent gas leaks from flared section (summary) Items
Causes
Countermeasures(cautionsinconductingwork)
Burr produced by cutting the pipe
Be sure to remove burr or flash from the cut surface of the pipe.
1) Flaws on flared surface Faulty pipe cutter
Replace the tooth of the pipe cutter at regular intervals.
Faulty flaring tool
Clean so as not to deposit flaws or dust on the cone part of the flaring tool.
2) Flaws on union
Flaws on union seal face
Handle with care to cause no flaws.
3) Dust on seal face
Dust deposited on the seal face
Clean the seal face (of union or flared section), before tightening the flare nut.
Oil applied to the inside and outside 4) Refrigerating oil on seal face surfaces of the flared section
Apply a slight coating of refrigerating machine oil to the seal face of flare and union, thus accomplishing closer contact.
5) Tightening torque
Use a proper tool (∗torque wrench). Excessive tightening will crack the flare nut.
Excessive or insufficient torque
∗If using a torque wrench still causes gas leaks, there must be defective places. In this case, conduct flaring work again.
1-6 Causes of gas leaks from flared section Cutting of copper pipe
Deformation of copper pipe
Deformation of flared section
Excessive
Uneven flared thickness
Incomplete
Flaws on the inside surface of flared section
Dust/flaws on flaring dies
Flaws on the outside surface of flared section
Dust/flaws on cone part of punch
Flaws on the inside surface of flared section
Chamfering/ Deburring
Flaring
Flaring tool
Faulty protrusion dimension
Faulty flared dimension
of pipe head from flaring dies
Gas leaks
Excessive tightening of flare nut
Cracks of flare nut (Refer to information on the preceding page.)
Tightening torque
Insufficient tightening of flare nut
Torsion of piping
Pipe connection
Insufficient contact with seal face
Residual stress
Failure to apply oil to flared section
Poor close contact effect of seal face Flaws on union surface
Engagement of dust with seal face
Dust on seal face
If any gas leak occurs, be sure to avoid the following hazardous conditions. 1. Malfunction of air conditioner due to operation with gas run out 2. If leak gas is exposed to open flame (e.g. fan heater or stove), toxic gas will be generated, thus resulting in a accident leading to injury or death. 3. Danger of suffocation in a confined room (e.g. VRV with much refrigerant filled)
8
2. Bending
If the refrigerant piping is folded down, no refrigerant will pass through the piping. To bend the piping by hand, make a large “radius”. If the copper pipes cannot be bent by hand, a bending tool should be used. The method of using the tool differs depending on whether the pipes should be bent to the left or to the right according to the bending dimension. If the pipes are bent in a wrong direction, they cannot be corrected. Therefore, use a proper tool with attention paid to the reference dimensions.
2-1 If the necessary dimension exists on the right side If the necessary dimension exists on the right side, take the dimension from the forward end on the right side of the pipe.
★
Finished shape and dimension
X
Working step 1) Mark the finished bending dimension from the end on the right side. Mark the finished dimension with “X”.
X
2) Be sure to put the copper pipe in the groove of the bender. 0
Align the “0” mark on the fixed lever with the end of handle to provide a proper angle for the rattle-free fitting.
R
3) Align the mark on the copper pipe with the mark “R” on the handle.
0
The finished dimension should point in the right direction.
mark
4) Rotate the handle to a specified angle marked. 0
45 90
9
2-2 If the necessary dimension exists on the left side If the necessary dimension exists on the left side, take the dimension from the forward end on the left side of the pipe.
★
X
Finished shape and dimension
Basically, the working step is the same as that for the bending to the right, except that the dimension should be taken from the forward end on the left side of the pipe. However, there are two types of benders, the one with the “L” mark on the main body and the other without this mark there. As shown in Working step 3) for the bending to the right, the method of alignment of the mark on the copper pipe with that on the bender is different. Bender with the “L” mark on the main unit of the bender
Bend the copper pipe following the Working step 1) and 2) for the bending to the right but taking the dimension from the forward end on the left side of the pipe. Align the mark on the copper pipe shown in the Working step 3) with the “L” mark of the main unit of the bender. Working step 4) is the same as that for the bending to the right.
Bender without the “L” mark on the main unit of the bender
Bend the copper pipe following the Working step 1) and 2) for the bending to the right but taking the dimension from the forward end on the left side of the pipe. For Working step 3), put a copper pipe of the same size in the groove of the bender and bring it in parallel with the fixed lever. Then, align the mark on the piping with the center of piping placed in parallel with the fixed lever, remove the pipe of the same size, and rotate the handle. Bender without the “L” mark Handle Mark
X Copper pipe of the same size
Fixed lever
10
3. Rigid PVC pipe connection
Generally, rigid PVC pipes are used for the drain piping work of air conditioners, and TS joints are used for the pipe joints. 1 Method of cutting rigid PVC pipes Tool to be used: Saw or pipe cutter Use a PVC cutter or saw to cut the pipes at right angles to the pipe axis.
PVC cutter
Saw (for PVC pipe use)
2 Joint method of rigid PVC pipes Tool to be used: Reamer
Reamer 1. Remove burr from both inside and outside cut edges with a reamer. 2. Wipe the contamination on the joint surface clean. 3. Take measurement of an allowance to insert the TS joint and mark from the end of a insert pipe. 4. Apply a light coating of adhesive to the joint surface and, right after that, insert the pipe. 5. Immediately after inserting the pipe, check if the pipe is inserted up to the marking and push the pipe for a period of 30 seconds or more.
Marking
Allowance to insert
Allowance to insert
3 Drain piping For horizontal piping, be sure to provide a downward slope of 1/100 or more.
1/100 or more 1000
11
0 1
4. Wire connection
The electrical wiring work consists of two portions, the one portion for power supply to indoor and outdoor units (power supply work) and the other portion for wire connections between indoor and outdoor units (connection wires or jumper wires). Either of these portions should be conducted on a safety-comes-first basis in accordance with standards such as “Electrical equipment technical standards” and “Regulations regarding extension lines”. In this connection, electrical knowledge is needed and, further, there are some areas in the electrical wiring works which cannot be conducted without a qualification.
Electrical work, which can only be conducted by certified contractors who have a license of electrical work engineer: 1. Power supply work to indoor and outdoor units. 2. Grounding work
Electrical work, which can be conducted even by those who have no license of electrical work engineer: 1. Connection wiring (jumper wiring) work between indoor and outdoor units 2. Transmission wiring work between indoor and indoor units, and indoor and outdoor units.
Wire connection method 1. Using quick disconnect joints for room air conditioners
1) Strip the covering of wire by 15 mm.
2) Remove the wire clamp.
4) Make sure the wires are inserted without fail 5) Pull the wires to make sure they do not through the sight glass. come off, and then fix the wires with wire clamps.
G NIN R WA
3) Check to be sure the colors of wires and insert the wires through the respective insert openings in the terminal board as far as they will go.
6) Mount the wire lid.
NEVER connect any wire at some midpoint in the wiring or use stranded wires, which, otherwise, could possibly result in heat generation, electric shocks, or fire.
12
2. Connection method to terminal board of Sky Air type Wire Round-shape crimp style terminal
Use round-shape crimp type terminals for the connection to the terminal boards. If these terminals cannot be used due to uncontrollable circumstances, be sure to observe the following points. 1) Do not connect two wires of different sizes to the power supply terminal board. (Abnormal heat generation could possibly occur due to loosened wires.) 2) In order to connect wires of one and the same size, follow information shown in the figure below. 3) For wiring, use the specified wires and connect them without fail, and fix the wires so that no external force is transmitted to the terminal board.
Outdoor unit: Power supply terminal board
123RST Connection wiring to indoor unit
Connect wires of one and the same size to the both sides.
Power supply: 3-phase, 200 V
Connection of two wires on one side is prohibited.
3. Connection method to terminal board of remote controller Specification of wires 2 Sheathed vinyl cords or cables of 0.75 to 1.25 mm Connection 1. Loosen the cross-shaped recess screws. 2. Tighten and fix the screws with a Philips screwdriver, being careful not to have the covering of the wire pinched.
13
Connection of wires of different sizes is prohibited.
P
N
5. How to use gauge manifold This is a measuring instrument used to take measurement of pressure as a means of checking whether the machine operating conditions are good or not and also to conduct vacuum drying and refrigerant charging. The measuring instrument is referred to as “Gauge Manifold”, which is in general use on site as a must measuring instrument for handling air conditioners. On the other hand, due to a lack of proper understanding of the structure, there are some cases where refrigerant is discharged to nothing or air is mixed in the piping system. Furthermore, be careful not to use the refrigerant mixing with different types of refrigerant. In particular, the mixing of new refrigerant and R22 shall be avoided.
5-1 Structure of gauge manifold
It is needed to use gauge manifold corresponding to the type of refrigerant.
Compound pressure gauge (Lo)
2
1.5
2 .5
1
3
5 . 0
.5 3
0
.5 3
0
-0 .1
MPaGauge
For measurement of high pressure (red)
2 .5
1
3
5 . 0
-0 .1
2
1.5
Pressure gauge (Hi)
For measurement of low pressure (blue)
MPa Gauge
GAUGE MANIFOLD
Lo
Vapor
R410A
Hi
Liquid
T ASCO JAPAN
Lo
Common
Hi
The gauge manifold is equipped with two knobs (blue used for Lo and red used for Hi). The purpose of these “knobs” is not to shut off the blue Lo gauge or red Hi gauge but used to operate the three hose connection ports (blue for Lo, common, and red for Hi). Opening the blue “knob” connects the blue Lo and the common each other, while opening the red “knob” connects the red Hi and the common each other. Open or close the “knob” to conduct the refrigerant charging or vacuum drying. In order to take measurement of pressure, be sure to check that these “knobs” are closed. (When installing this measuring instrument onto the machine, these “knobs” shall be closed.
Let’s have a good understanding of the structure and operate the gauge manifold!
14
5-2 Types of connection hoses
(Used for new refrigerant R410A)
Generally, hoses are color-coded to red, yellow, and blue. Connect the red hose to Hi (high pressure), blue hose to Lo (low pressure), and the yellow hose to the common (work). Each hose has connection ports on both ends. The one connection port is straight and the other one is slanting. Viewing the inner side of the connection ports, the slanting connection port has a push rod, while the straight one has no push rod.
Straight
Slanting
High and low pressures connection ports on the main unit of the machine have a “plug rod” like air inflating port on the automobile tire. Pushing this rod applies the pressure of the main unit of the machine to the gauge. Thus, connect the slanting connection port to the main unit side of the machine. Generally, connect the straight connection port to the gauge manifold side in advance. (If the slanting connection port is connected to the port with no plug rod, the refrigerant flows or pressure is measured due to clearance remaining around the perimeter of the connection port.) Tighten the hoses by hand since rubber packing used prevents leaks.
5-3 Hose and gauge manifold for new refrigerant The new refrigerant (HFC) includes R134a, R410A, R407C, and others. ● R410C is used for room air conditioners (RA). The machine operating pressure becomes approximately 1.6 times as high as that of R22. Therefore, in order to prevent the dancy action of the hoses when disconnecting, use dedicated hoses with a “cock” equipped. ● R407C is used for packaged air conditioners (PA). The machine operating pressure becomes approximately 1.1 times as high as that of R22. Therefore, even though the hoses used are the same as those for R22, use dedicated pressure-proof hoses. ● The main unit of the gauge manifold is classified by refrigerant used, for R22, for 4-7C, and for R410A. No mixing of different types of refrigerant is allowed. Be sure to use dedicated tools, respectively. Key point Use dedicated gauge manifold and hose corresponding to the type of refrigerant used. No mixing of different types of refrigerant is allowed.
15
5-4 How to operate gauge manifold 1 Pressure measurement
● To take measurement of low and high pressures ➡
Close both the Lo and Hi valves.
1) Check to be sure the gauge reads “0”. 2) Check to be sure the “Lo” and “Hi” knobs are both closed. 3) Remove caps from the low and high pressure service ports of the machine main unit. 4) Fit and connect the connection hose to the respective pressure gauges. (No leaks allowed from the connection
Lo
Hi
To service port on low pressure side
To service port on high pressure side
ports.)
2 Vacuum drying When vacuum drying is conducted, since the air fills around and also the inside of pipes and machine, it shall be discharged as below. 1) Discharge the air from the inside of pipes of indoor and outdoor units. 2) Discharge the air from refrigerant piping newly installed.
1) Vacuum drying of both indoor unit and outdoor unit 1) Connect hose to the low and high pressure sides of the ●
machine or the service port.
To conduct vacuum drying
2) Fully open the stop valve on the machine.
➡
Open both the Lo and Hi valves.
Lo
3) Fully open the Lo and Hi “knobs”.
Hi
4) Make sure no pressure is applied. 5) Connect a hose between the common connection port on the gauge manifold and the vacuum pump.
To service port on low pressure side
To service port on high pressure side To vacuum pump
2) Vacuum drying of refrigerant piping newly installed 1) Connect hoses to the low and high pressure service ports, respectively. 2) Fully close the stop valve on the machine. 3) Fully open the Lo and Hi “knobs”. 4) Connect a hose between the common connection port on the gauge manifold and the vacuum pump.
16
3 Charging refrigerant There are following cases where the refrigerant is to be charged. 1) No refrigerant left in the machine. 2) Refilling refrigerant In the case 1), produce a perfect vacuum and then charge the refrigerant according to a pressure difference. In the case 2), operate the machine and then refill the refrigerant through the low pressure service port.
1) No refrigerant left in the machine 1) As to the connection hose, keep a state in which this hose was connected for the vacuum drying.
● To charge refrigerant ➡ Open the valve on the Lo side.
Lo
2) Connect the charging cylinder with a specified
Hi
quantity of refrigerant measured to the common port. (Refer to Note below.) 3) Purge air from the hose of the common hose through
To service port on low pressure side
the connection port of the gauge manifold.
To service port on high pressure side To charging cylinder
4) Fully open the Lo and Hi “knobs”. (There is a case where the Lo knob is only open.)
2) Refilling refrigerant 1) Connect a blue hose between the low pressure gauge and the service port on the low pressure side of the machine. 2) Connect a hose between the common port and the charging cylinder, thus purging air from the hose. (Refer to Note below.) 3) Open only the Lo “knob”. (Keep the Hi “knob” closed.)
Note) To charge a new refrigerant, the charging cylinder is not applicable. Use a charging scale and refrigerant cylinder. (For details, refer to information in Section “Refrigerant charging”.)
17
6. How to use control valve In order to minimize the discharge of refrigerant, use control valves (charge valves) shown below.
Close
Open
Close
Control valve R22
Open
Close
Control valve R407C
Control valve R410A
How to use 1) Connect the control valves in closed state to the service ports of equipment to be connected. 2) Connect the gauge manifold to the control valves. 3) Open the low and high pressure valves on the gauge manifold and then vacuum them. 4) After the completion of vacuuming, close the low and high pressure valves on the gauge manifold. 5) Open the control valves.
Compound Pressure gauge gauge High pressure valve Gauge manifold
Control valve Low pressure valve Valve cover Liquid stop valve
Charging hose
Gas stop valve Vacuum pump
Service port
18
Open
7. Pressure measurement Make measurement of pressures to check to be sure the operating conditions during a test run. 1) Remove the caps and service port flare nuts from the liquid and gas stop valves. 2) Check to be sure the liquid and gas valves are fully open. 3) Connect hoses between the gauge manifold and the liquid and gas valves. ∗On the Lo (low pressure) side, connect the hose to the service port of the gas stop valve. ∗On the Hi (high pressure) side, connect the hose to the service port of the liquid stop valve
4) Purge air from the connection hose. ∗Loosen each valve (Lo and Hi) on the gauge manifold and then purge air from the connection hose. 5) Make measurement of pressures. ∗The pressures vary with operating cycles and models. For details, refer to information in Technical
Guide (Service Edition) and others. 6) Remove the gauge manifold. 7) Tighten the caps and flare nuts. ∗Be sure to put copper packing in place and then securely tighten the caps of the stop valves. ∗Failure or negligence in tightening the caps may result in running out of gas.
State of each stop valve while in pressure measurement C ring type
Angle type
Fully open (while in pressure measurement/refrigerant charging/operation)
Fully open
Service port
Piping side
Outdoor unit side
New ball valve type
Fully open (while in operation/pressure measurement/refrigerant charging)
(Flow of refrigerant)
(In open state)
Note) Use ball valve in the same method of use as that above.
19
8. Vacuum drying
If air or moisture mixes into the refrigerant system, the normal operation will not be maintained, thus causing failures in the machine, such as an abnormal increase in pressure, increase in power consumption, and degradation in performance. Furthermore, moisture will result in faulty insulation of the compressor motor or deterioration in the quality of refrigerating machine oil, thus shortening the service life of the machine. In this connection, air or moisture in the refrigerant system should be completely purged.
Conditions resulting in mixing of air or moisture 1) When removing (colleting) the refrigerant for the replacement of parts installed inside the machine or rectifying the leak points in the refrigerant system, air will mix into the machine or refrigerant system. After repairing/rectifying, before charging the refrigerant, purge air from there. (Hereinafter referred to as “the repair”) 2) When conducting new refrigerant piping and connection between outdoor and indoor units, air will mix into the piping and indoor unit. Purge air from there. (Hereinafter referred to as “the new installation”) 3) For piping work in rain, if the preparation for the piping is not properly conducted, moisture may mix into the piping.
Vacuum drying procedure
Tools to be used
Gauge manifold and vacuum pump
Depending on models, the system is provided only with a service port and gas stop valve, or with gas and liquid gas stop valves and service port.
Liquid pipe
1) Repair
Liquid stop valve
Condenser
1) Connect hoses of the gauge manifold to the gas and liquid
Gas pipe
stop valves, respectively (with both valves open). 2) Fully open the Lo and Hi “knobs” on the gauge manifold. (Check to be sure there is no residual pressure.) (The Lo
Muffler
Accumulator Indoorunit
Vacuum pump
Gas stop valve Service port
Compressor
Outdoorunit
knob is only provided depending on models.) 3) Connect a hose equipped at the center (at the common connection port) of the gauge manifold to the vacuum pump. 4) Start the vacuum pump. 5) Run the vacuum pump until the vacuum level reaches -0.1MPa (-760 mmHg). (Note) After it reaches -0.1MPa (-760 mmHg), run the vacuum pump for a period of 60 minutes or more as a guide. Then, extend this period by 30 minutes every time the ambient temperature drops by 5°C, if the current ambient temperature is 20°C or less. Reason: Vacuum dries up the moisture contained in the air in the piping. 6) Fully close the Lo and Hi “knobs” of the gauge manifold. 7) Loosen the charging hose connected to the pump and supply air. (Prevention of the backflow of pump oil) 8) Stop the vacuum pump. 9) After stopping the vacuum pump, leave as is for a period of four to five minutes. Then, check to be sure the pressure remains unchanged. (Leak check)
2) New installation (Vacuum drying of indoor unit/liquid pipe/gas pipe) (The following section only describes items different from those aforementioned.) Follow the step 1) above for the hose connection, but close the stop valve. Steps 2) to 9) are the same as those aforementioned.
20
For reference / Vacuum drying Vacuum drying is a method of drying the inside of refrigerant piping by converting moisture in the refrigerant piping into steam (vapor) and discharging it from the piping, with the use of a vacuum pump. Even though, at one atmospheric pressure, the boiling point of water is 100°C, as the atmospheric pressure in the refrigerant piping comes close to vacuum, the boiling point comes down rapidly. Since the vacuum drying is used to remove moisture from the inside of the refrigerant piping, unless vacuuming is conducted at an ambient temperature until the vacuum reaches a level enabling moisture to evaporate, no effect will be produced. (Vacuum level and Boiling temperature of water)
For example, if the ambient temperature is 7.2°C, moisture will not evaporate unless the vacuum level reduces to 0.1003MPa or less. Therefore, the important point for vacuum drying is to select a vacuum pump, which has an outstanding performance in reaching maximum vacuum level (i.e., can reach –0.1007MPS or less). Furthermore, before vacuum drying, be sure to check that the vacuum pump reaches a vacuum level of –0.1MPa or less.
Vacuum level
For oil-type vacuum pumps, it is important to replace oil once every one or two months and check the maximum vacuum level. (Guideline of vacuum pump operating time) If the ambient temperature is 20°C or less, after no more exhaust air comes out of the vacuum pump, extend the operating time by 30 minutes or more every time the ambient temperature drops by 5°C.
Boiling temperature of water
0.0940MPa(705mmHg)
40°C
0.0965
(724mmHg)
30
0.0980
(735mmHg)
26.7
0.0983
(737mmHg)
24.4
0.0987
(740mmHg)
22.2
0.0989
(742mmHg)
20.6
0.0993
(745mmHg)
17.8
0.0996
(747mmHg)
15.0
0.1000
(750mmHg)
11.7
0.1003
(752mmHg)
7.2
0.1007
(755mmHg)
0
Method of representing vacuum level For atmospheric pressure 0MPa 0mmHg 760Torr For absolute vacuum level -0.101MPa -760mmHg
Vacuum drying on new refrigerant units Vacuum drying on the new refrigerant units has no difference in the procedure from that on conventional units. Use HCF-use (new refrigerant-use) vacuum pump or attach an adapter to the vacuum pump. The vacuum pump is of check valve (solenoid valve) type, thus causing no backflow even if the vacuum pump is deenergized during vacuum drying in process. (Mixing of vacuum pump oil into the unit lubricant shall be avoided.)
Outdoor unit
Service port
Gauge manifold
(PartA)
Adapter
Vacuum pump
21
Indoor unit
0Torr
9. Airtight test
Airtightness (sealing performance) is one of three principles in regard to refrigerant piping. The purpose of the
airtight test is to check whether or not there are any leaks from connections or repaired sections when refrigerant piping work or repairs are completed. Even though there are differences in the test methods between comparatively simple piping (separate type) and complicated piping (VRV type), the test is conducted through the pressurization with gas in either method. Gas used for the airtight teat shall be nitrogen gas. Any flammable gas or “nonflammable gas” such as oxygen shall not be used. Furthermore, any leak tests with water or air are not conducted since that runs counter to the three principles in regard to drying.
9-1 Gas leak test with refrigerant gas Primary leak check After vacuuming with a vacuum pump, leave the piping as it for a period of four or five minutes, and then check to be sure the gauge pressure remains unchanged. (Be aware that vacuuming cannot locate leak points.) Secondary leak check After the completion of the new installation or repair of piping, conduct vacuum drying, open the stop valve on the outdoor unit, and apply pressure with refrigerant gas (through making use of refrigerant gas of the unit). Check respective screw sections, joints, welded sections for any leaks using foam liquid (e.g. Güpoflex), fluorocarbon gas detector, or Mckinley fluorocarbon gas detector.
9-2 Airtight test with nitrogen gas This airtight test is conducted before connecting the piping to the outdoor unit (i.e., only on piping) or using the stop valve, with nitrogen gas charged at a specified pressure.
1) Leak check only on piping (in the case of using a jig with nitrogen gas charged) There is a method of checking leaks on the complicated piping system after the completion of every work. However, it results in complicated checking work or dropouts with leak checks. Consequently, conduct leak checks every time piping work is completed on a single system. If piping work takes several days to complete, it is recommended to ensure the daily workload.
Tools to be used
Pressure gauge
Nitrogen gas charging jig (To be procured locally) Close this three-way valve it n u r o o d n I
it n u
Liquid pipe Close this ball valve.
r o o d t u O
Gas pipe
Pressure gauge (3.5MPa to 5.0MPa) 2 (35 kg/cm to 50 kg/cm2) Nitrogen gas charging jig Nitrogen gas cylinder regulator
Nitrogen gas charging jig (To be procured locally) r e d n i l y c s a g n e
g o r t i N
Nitrogen gas cylinder Connection hose/joint and the like ●
If R22 is used, apply the pressure of 2.8MPa. In the case of new refrigerants, apply the pressure of 3.3MPa to R407C and 4.15MPa to R410A (for room air conditioners). For Sky Air, use pressure values specified on the nameplate of outdoor unit.
Use the nitrogen gas charging jigs at both ends of the piping.
Working procedure 1) As shown in figure right, use the nitrogen gas charging jig to connect pipes, nitrogen gas cylinder, and pressure gauge. 2) Conduct airtight test in the same manner as Steps 4) and 5) of the procedure on the following page.
22
2) Making use of stop valve In order to conduct accurate leak checks on the existing equipment, make use of the stop valve service port on the unit. To conduct leak checks only on the piping, set the stop valve on the unit to “Closed” and do not apply pressure to the inside of the unit. To apply pressure to the piping and the whole of unit, set the stop valve to “Open” (e.g. for repairing inside of the unit.)
Close
it n u r o o d In
L H Open
Close this three-way valve.
r e d n il y c s a g n e g o r it N
Liquid pipe Close this ball valve.
ti n u r o td u O
Gas pipe
Tools to be used Gauge manifold, nitrogen gas cylinder regulator, and nitrogen gas cylinder
Working procedure 1) Connect the (high pressure side) of the gauge manifold to the stop valve service port. 2) Connect the nitrogen gas cylinder regulator to the common port (connection port at the center) of the gauge manifold. (The nitrogen gas cylinder and regulator are connected.) 3) To only test the piping, set the stop valve to “Closed”. To test the whole of unit, set it to “Open”. 4) Slowly increase the pressure of nitrogen gas in the following steps. (Do not apply the total pressure from the start.) a) Step 1 Increase the pressure to 0.3MPa (3 kg/cm 2). ⇒ Check for any major leaks. Check for any leaks. b) Step 2 Increase the pressure to 1.5MPa (15 kg/cm 2). ⇒ Check for any leaks. c) Step 3 Increase the pressure to 2.8MPa (28 kg/cm 2). ⇒ Check for any minor leaks. Check for any leaks. Apply the following pressure to new refrigerants. R407C: 3.3MPa R410A: Room air conditioners – 4.15MPa Sky Air: Use pressure values specified on the nameplate of outdoor unit.
However, if the pressure application time is short even though the 2.8-MPa pressure is applied, no minor leaks are detected. Therefore, apply pressure for a period of consecutive 24 hours and leave as is, thus conducting airtight test. After the elapse of 24 hours, comparing to the charged pressure, check the pressure for any drop and make sure no leaks occur. 5) After that, completely purge the nitrogen gas charged with care paid not to cause any accident for lack of air. 6) After making sure there is no residual pressure, purge air through vacuum drying and then charge the refrigerant.
23
10. Gas leak test Major leaks of fluorocarbon gas can be detected the blowout noise of refrigerant, while minor leaks are detected by the use of a leakage detector. Three types of detectors are available, battery-operated gas detector, Mckinley gas detector, and gas detector liquid.
10-1 Gas detector liquid This gas detector liquid is a “foam liquid”, which is produced by mixing a few drops of glycerin into a proper concentration of soap solution. If any foam liquid available on the market is
Gas detector liquid
Gas detector liquid
used, select a foam liquid, which is easy to foam with a spraytype of gas detector and has a continuation of foaming. The gas detector liquid features the facilitation of locating leak points only by spraying. After the completion of the test, completely wipe the “liquid” off (otherwise, resulting in leaks due to corrosion). Güpoflex
Eye G
10-2 Battery-operated gas detector Several types of sensor units with a high level of accuracy are available on the market as battery-operated detectors. Since they are of battery-operated type, the lifetime of battery should be controlled and attention should be paid to the type of gas to be detected. The following section shows “examples” of battery-operated gas detectors available on the market. Gas detector
Type: TA430F Applicable gas: R12, R22, R134a, R407C, and R410A Detection system: Hydrogen detection Power supply: Size AA battery × 6 numbers
24
Gas detector
Type: TN430F Applicable gas: R407C, R410A, R134a, and R507A Detection system: Hydrogen detection Power supply: Size AA battery × 6 number
How to use battery-operated gas detector (Example: Fluorocarbon gas leak detector Model TN430F from Tasco Japan) Specifications Power supply: 9 VDC
Detection LED “Red”
Detection indication: “Red” five-segmented LED and buzzer Current-carrying LED “Green” (Serving as indicator of battery
Measurable indication: “Green” LED ON Probe
lifetime) Switch (Serving as Power-Sensitivity selection)
Sensitivity: 14 g/year for R134a L-H selection Operating temperature: 0°C to 40°C
Battery cover Sensor unit Extension probe
How to use 1 Install batteries. (Size AA battery × 6 numbers)
3 Set the switch to “L”.
● Check to be sure + and – marked on the main unit and then install the batteries.
Battery cover
● ●
Buzzing sound is a suction sound from the motor. When the “Green” current-carrying LED turns from “blinking” to “lighting”, the detector becomes measurable.
4 Bring the sensor unit to the
Sensor unit
inspection place. The detector alerts you to gas leaking places through the “Red” detection LED and buzzer.
2 While rotating the probe, set it to the measuring point. Extensionp robe
●
5 If there are not many gas leaks and the “Red”
Probe
detection LED lights up only at level 1 or level 2, set the switch to “H”. (The sensitivity becomes approximately 10 times as high as that of “L”.)
If the leak test should be conducted in a confined place, install the extension probe to use the detector.
6 If the “Green” current-carrying LED starts blinking at quick intervals, replace the battery in good time. (The lifetime of battery is indicated.)
Indication When the battery reaches the end of its lifetime
Operation
Set the switch from “Off” to L (or H). “Red”
When the detector becomes measurable
If a gas leak is detected Thin gas
Rich gas
5
5
5
5
5
5
5
5
4
4
4
4
4
4
4
4
3
3 “Red”
3
3
3
3
3
3
2
2
2
2
2
2
2
1
1
1
1
1
1
1
2 1
Indication
“Green”
The “Green” LED blinks approx. 4 times/second.
Buzzer
The “Green” LED blinks approx. once/second.
The “Green” LED turns ON
Level indication on “Red” LED
Makes one beep.
Makes three beeps.
At intervals of At intervals of approx. eight At intervals of At intervals of At intervals of approx. once approx. twice approx. three times approx. five times times per seconds to per seconds per seconds continuously per seconds per seconds
25
11. Refrigerant charging The “refrigerant charging” work means to remove (collect) the refrigerant from the piping system of the unit for repairs, refill a specified amount of refrigerant after repairs, and additionally charge the refrigerant according to the length of piping. In any case, charge a specified amount of refrigerant in proper working procedure. To charge the refrigerant, never fail to conduct “Vacuum drying” positively.
1) Refrigerant charging to new refrigerant (HCF) unit ● Identification of new refrigerant
Structure of new refrigerant cylinder
(HCF) cylinder (Color-coding) Coated paint color R407C: Brown R410A: Light pink Siphon tube
Label of siphon tube affixed on the cylinder
No label affixed
(Diakin’s cylinders come with a siphon tube.)
● Since R407C and R410A are non-azeotropic refrigerants, these refrigerants should be charged in liquid state.
Furthermore, if they are measured with a charging cylinder or the like, the mixing ratio will vary. Therefore, place the refrigerant cylinder on a scale to measure it.
● New refrigerant charging method
Tools to be used
Charging scale (scale), connection hose, adapter, and refrigerant cylinder
If the refrigerant cylinder has a siphon tube:
If the refrigerant cylinder has no siphon tube:
Refrigerant cylinder
Refrigerant cylinder
Place the cylinder in an inversed position.
Place the cylinder in an upright position.
The figure above shows a reference to use any cylinder other than that from Daikin, with no siphon tube equipped. Safety unit against overturning is separately needed for the cylinder.
26
Example of the use of charging scale:
Example of connection using refrigerant cylinder with siphon tube equipped
Electronic charging scale
Put the cylinder in an upright position. IN
OUT
Vacuum pump Charging scale
1) Turn the charging scale ON and then set a charging amount. 2) Slowly place the cylinder on the scale table. 3) Connect the charging hoses from the cylinder to the IN port and from the gauge manifold to the OUT port, respectively. 4) Use the vacuum pump to vacuum inside of the refrigeration cycle (not required in the case of additional charging), charging hose, and charging scale. At this time, keep the valve of the cylinder closed and the valves of the gauge manifold open on both sides. 5) After the completion of vacuum drying, close the valve on the vacuum pump side of the gauge manifold and then open the valve of the cylinder. 6) Set the figure of the charging scale to “0”. 7) Press the “Start” button. 8) When the charging amount reaches a set amount, the solenoid valve of the charging cylinder will be closed, thus completing refrigerant charging.
2) Refrigerant charging to R22 unit Use a cylinder, gauge manifold, and connection hose dedicated to R22. The charging procedure is the same as that aforementioned.
27
12. Pump down Pump down, what does it mean? The “pump down” means to collect the refrigerant from the refrigerant system such as each indoor unit and refrigerant piping to the condenser and liquid receiver of the outdoor unit. This pump down operation is conducted to remove or relocate separate-type or multi-type unit, connect additional multi-type indoor unit, replace indoor unit, or replace refrigerant piping.
Basic pump down operation method In order to collect the refrigerant to the condenser and liquid receiver, take the refrigerant, which the refrigerant piping and evaporator (indoor unit) contain, in the outdoor unit, through the operation of the stop valve on the unit. This operation is conducted in cooling mode.
Liquid stop valve
Condenser Capillary r to a r o
p a v E
Gas stop valve
Four way valve r o s s e r p m o C
Working procedure 1) Remove the cap from the liquid and gas stop valves and the service port flare nut only from the gas stop valve (low pressure side). 2) Connect the gauge manifold to the gas stop valve. Connect the Lo (low pressure side) to the service port of the gas stop valve. 3) Fully close the liquid stop valve. During operation, the liquid stop valve may be closed. Three methods of closing the stop valve are available, i.e., by using a valve key, hexagonal wrench, or slotted screwdriver. 4) After completely close the gas stop valve, open it by two or three rotations, thus providing a ready-to-close condition. This step is conducted for the valve-key or hexagonal-wrench type of stop valve. 5) Conduct cooling operation. (NEVER conduct heating operation.) Operate the ON switch or PUMP DOWN switch on the PC board of the outdoor unit. 6) When the low pressure reaches 0MPa (0 kg/cm 2), fully close the gas stop valve. 7) Stop operation. 8) Remove the gauge manifold and tighten all caps. Failure or negligence in tightening the caps may cause gas leaks.
28
13. How to use measuring instruments This Section describes one of references for methods of using the measuring instruments. The methods of using the measuring instruments vary with their manufacturers and models. Therefore, it is recommended to master proper using methods referring to the instruction manuals of measuring instruments.
13-1 Voltage and resistance (continuity) measurement The voltage measurement is needed to check whether or not the unit is ready for proper operation, such as whether the type of power supply is the same as that of air conditioner or the voltage falls within the operative voltage range, or what about the difference in voltage between the supply voltage and the running voltage. This measurement is conducted at test run or on servicing site. The resistance (continuity) measurement is used to check the wire connections for the quality or electrical parts for the conditions of contacts or resistance values.
1) Range of allowable operating voltage (100-V units: 90 to 110 V) (200-V units: 180 to 220 V) If the supply voltage does not fall within this range, the compressor will cause faulty startup, thus resulting in activation of safety circuit breaker or overcurrent relay. Even though it falls within this range, the unit is not functional unless the voltage drop is within the range of 2% of the supply voltage.
2) Voltage drop The difference in voltage between the supply voltage (applied to the unit in stop mode) and the running voltage (applied to the unit in operation) shall be within the range of 2% of the supply voltage (100 V × 0.02 = 2 V or 200 V × 0.02 = 4 V).
The purpose of checking the voltage drop is to check the power supply cables (to the unit) for the quality. Large voltage drops result from thin size of electric wires, thus generating heat to cause a fire.
3) Measurable range of multiple meter
Example of HIOKI 3030-10
1) DC (Direct Current) V (Voltage): 3 to 600 V
1)
1k 3k
0 50
0 20
100
2)
2) DC (Direct Current) A (Amperage): 30 to 300 mA
10
15
10
20
40
0
10
4 100
30
DC AC
12
5
60 8 0
0.9 1.2 1.5
3030-10
0
25
8
3
2
1
0
6) 5
20
6
4
2
0
0
3) AC (Alternating Current) V (Voltage): 12 to 600 V
30 20
40
50
5
6
15 0
TAMP(°C) BATT
1.8
HiTESTER
20k k/v DC 9k k/v AC
TAUT BAND
3)
4) (Resistance/Continuity): 0 to 1M
7) V
4)
600
OFF 600
300
~V 300
8)
120
120
30
30
12 12
+
9)
× 1k
3 × 100
5)
0.3u v 60
A
30m 3 00m BATT 1.5v
×10 ×1
(TEMP)
(LED)
Ω
600V M AX
-
CAT III
10)
Name of each part 1) Panel 2) Pointer 3) Pack case 4) Indication nameplate 5) Range selector knob 6) Scale board 7) Zero adjuster 8) Zero ohm adjuster 9) Positive terminal 10) Negative terminal
29
4) How to use multiple meter Voltage measurement
1) Make zero position adjustment of the pointer. Check to be sure the pointer is in alignment with the zero V position (on the
leftmost line) of the calibration. If misaligned, turn the zero adjuster (see figure 7) on the preceding page) and
correct the alignment.
Lead wire
Pin plug
2) Connect the lead wire. Connect the pin plug of the black lead wire to the - (negative) terminal. Connect the pin plug of the red lead wire to the + (positive) terminal.
3) Select a voltage range. Set the range selector knob to ACV range (e.g. to 300 V for 200-V supply
voltage or 120 V for 100-V supply voltage) of the indication board. If the supply voltage is unknown, change the range from highest to lowest.
(If higher voltage is applied to lower range, the multiple meter will be instantaneously damaged.) Be sure to select the range with the test pin removed from the item to be
measured.
4) Make measurement of voltage in the following procedure. Hold the test pin by right hand (considering safety if an electric shock occurs,
since left hand is close to a heart). Make the test pin contact with the power supply terminal. Black
Do not misread the calibrations.
Red
30
Resistance measurement 1) Connect the lead wire. Connect the pin plug of the black lead wire to the - (negative) terminal. Connect the pin plug of the red lead wire to the + (positive) terminal. Red
Black
2) Select a range. Set the range selector knob to a proper (ohm) (resistance/continuity).
(Do not input voltage in the resistance range. Inputting voltage will simultaneously damage the multiple meter.) Be sure to select the range with the test pin removed from the item to be
measured.
3) Make zero adjustment. Short-circuit between the tips of two test pins (red and black). Turn the knob of the zero adjuster (see figure 8) on one before the
preceding page) to make the zero adjustment.
Black
Red
If the pointer does not reach zero even though the knob of the zero
adjuster is turned to the limit, replace by a new battery. (The zero position varies with the range. Therefore, make zero position adjustment by range.)
Red
Black
4) Make measurement of resistance. Judgment The meter is off-scale. (Position of zero )
No resistance = There is a continuity.
fuse
The pointer reads the srcinal position. (Position of ∞ )
Disconnection = There is no continuity. The pointer stops reading in progress. The pointer reads the resistance value of the measuring item.
5) In order to prevent the exhaustion of battery, set the range switch to OFF upon completion of the resistance measurement.
~V V
600
OFF 600
300
120 300 30
120
12 30
+
× 1k
12
× 100
(TEMP)
3 0 .3 v 60u
A
31
30m 300m BATT 1.5 v
×10 ×1
(LED)
Ω
600V M AX
-
CAT III
13-2 Amperage and voltage measurement The amperage is one of criteria to judge whether or not the unit is normal. Even though the amperage varies with the operating conditions, the numerical value indicated on the nameplate is a value at an outdoor temperature of 35°C in cooling operation. An increase in temperature increases the amperage, and an decrease in temperature decreases the amperage, in the range of 70 to 110%. This measurement should be made approximately 15 minutes after the unit starts up, in a stabilized operating condition of the unit.
1) Measurable range of clamp meter
Example of HIOKI Model 3127 1) 3)
1) AC (Alternating Current) V (Voltage): 150 V to 750 V
2)
2) AC (Alternating Current) A (Amperage): 6 A to 300 A
7
ON MP CLA
KI HIO
3) (Resistance/Continuity): 0 to 1M
2 TER 31E S Hi T
15 6 60
ACA0Hz
4)
150
50/5
300 750 300
6)
ACVMAX
750V
+
150 V DC75 OK
-
V
7) 9) 8)
1) Clamp core 3) Dial of range 5) Zero adjuster 8) Meter scale 10) Hand strap
2) How to use clamp meter Amperage measurement 1) Set the pointer lock to measurement side. Slide the meter lock (stopper) 2) to unlock the pointer.
2) Make “zero” position adjustment of the pointer. Check to be sure the pointer is in alignment with the “0” position of the
calibration. If misaligned, turn the adjustment screw and correct the alignment. Make this adjustment viewing the pointer from the front.
3) Select an amperage range. Set the range to the proper amperage referring to the numerical value
indicated on the nameplate of the air conditioner.
32
5)
1
×
P) TEM 100 (
E LO MET
0
10 50 0 100 50 30 20
0
0 50 10
200 100 20
150 30
5
400 0 0 2 40
V0 7
0
0 0 3 60
A
0 5 0 2 50 50
Mounting of strap
10)
2) Knob of meter lock 4) terminal 6) V terminal 7) Pointer 9) Zero adjustment knob
4) Clamp one phase of the measuring wire with the arm. Make the tips of the arm into positive engagement. While measuring, bring the wire clamped to the center of the arm. If single phase (two wires) or three phases (three wires) are clamped
together, no measurement will be made.
5) Make amperage measurement. Through the swinging of the pointer, read the numerical value on the
calibrations of the range. To make this measurement in places where the numerical value is hard to
be read, lock the pointer and then read the amperage with the clamp disconnected. Push here to the right to lock the pointer.
Voltage measurement
1) Set the pointer lock to measurement side. Slide the meter lock (stopper) to unlock the pointer.
2) Make “zero” position adjustment of the pointer. Check to be sure the pointer is in alignment with the “0” position of the
calibration. If misaligned, turn the adjustment screw and correct the alignment. Make this adjustment viewing the pointer from the front.
3) Connect the lead wire. Insert the red voltage measurement lead wire in the “+” voltage measurement
hole and black one in the “-” voltage measurement hole.
4) Set the range selector knob to V. If the voltage is unknown, set the range to larger one. Then, if the pointer swings a
little, change the range. (If higher voltage is applied to lower range, the multiple meter will be damaged.)
33
5) Make voltage measurement Make the “+” red lead wire and “-” black lead wire (of a needle shape)
contact into the measuring circuit. Be careful not to short-circuit between the wires. Make positive contact into the circuit. To make this measurement in places where the numerical value is hard
to be read, lock the pointer and then read the voltage.
Push here to the right to lock the pointer.
34
13-3 Measurement of insulation resistance What is “insulation resistance”? The insulation resistance means a resistance of path, where the current leaks to other live parts or metal casing of equipment from a conductor through insulation. If this resistance value is low, leak current will increase, thus resulting in higher possibility of hazards from a fire due to electric shocks or superheat, or from burnout due to short circuit. Therefore, the resistance values are specified under the electrical technique standards (Article 14 through Article 17).
Example of HIOKI Model 3118
Insulation resistance Object
Leak current
(Min. value)
Low-voltage indoor cable ways (if voltage to ground is 150 V or less)
0.1 M or more
1mA
30
10
50
5 0
1
2
2
3
5
4
10
100
20
1
20 0
50 0
30
0
M
Low-voltage indoor cable ways (if voltage to ground exceeds 150 V)
0.2 M or more
1mA
1 M or more
-
Low-voltage motors and electrical equipment
ON
500V 8CH
1000V ACV
(Reference) M: Megohm
1M=1000 K
∞:
1K=1000
Infinite
1) Measurement range
(Example of HIOKI Model 3118) Rated measurement voltage/Effective maximum scale: 250 V/50 , 500 V/100 Effective measurement range: 0.1 M to 100 M Effective maximum scale value: 100 M
The insulation resistance is measured with the use of a insulation resistance meter (megger). For low-voltage indoor cable ways, 500-V megger is used. The megger has four types, 100 V, 250 V, 500 V, and 1000 V, which should be selected according to the voltage applied.
2) How to use the megger 1) Connect lead wires. Red
Connect the black lead wire to the grounding (E) terminal.
(The opposite side of the lead wire connection terminal is of a clip shape.) Connect the red lead wire to the line (L) terminal.
(The opposite side of the lead wire connection terminal is of a needle shape.)
Grounding terminal
35
2) Check the battery. Short-circuit between the line (L) terminal and the 2-pole terminal
<> on the right side. (Do not press the switch.) At this time, if the pointer comes off the Mark B on the scale, replace the battery.
3) Connect the grounding (E) terminal. Red
For the grounding connection, ensure to pinch this terminal in a place with
no paint coated, with a clip.
Grounding terminal
4) Check the operation. Short-circuit between the line (L) terminal and the grounding (E) terminal
and then press the switch, and the pointer will read 0 M . Thus, check the meter for proper operation.
5) Make measurement of insulation resistance.
Power supply OFF
Be sure to turn the power supply of a measuring item OFF before the measurement.
Connect the line (L) terminal to the measuring item and then press the
switch, and the pointer will read measured value.
Note 1. Do not touch the measuring item while in measurement. 2. Make measurement by placing the measuring instrument in a horizontal position, where possible. 3. By pulling the button in an upright position, the switch can be locked in the ON state. The specified value shall be 1 M or more.
[Note] Since electronic circuits are used in the operation circuit these days, making measurement of the electronic circuits with megger may damage part of the electronic circuits. Consequently, unless any necessity arises, it will be safe to avoid making measurement on the operation circuit and to make measurement only on the main circuit or the compressor circuit. Since the single phase power supply cord is linked with the electronic circuits as is, there is a hazard to damage the circuits.
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13-4 Temperature measurement (TNA-20 from Tasco Japan) This digital thermometer is available to make measurement of air temperatures and surface temperatures of piping and others. For the measurement, use a sensor probe matching to the measuring item.
1) Measurement range
TNA200 digital thermometer from Tasco Japan
Temperature: -50 to +200°C
Sensor from Tasco Japan
Resolution: 0.1 °C Accuracy: ±0.3%rdg. ± 1 dgt Power supply: Battery (9 V) × 1 number HO L D O N O F F
Surface-use
2) How to use
Open the lid.
Liquid-use
Connect the battery cord to the battery.
1) Put a battery in place in the following manner. Open the lid for the battery. Connect the battery cord to the battery. Close the lid.
Note: If the battery is not used for an extended period of time, remote the battery since the battery liquid may leak. 2) How to mount or dismount the sensor. How to mount
How to dismount.
Press here.
Press the sensor stopper and then pull the sensor.
3) Measuring method Note) Be sure to turn the switch OFF after use. (Otherwise, the battery exhausts rapidly.) How to turn power supply ON HOLD ON
How to fit the sensor
OFF
Fit the sensor to contact surface in a vertical position.
Indicator
9
Switch ON: Power supply ON, ready to measure. OFF: Indicator locked, not measurable.
If the surface is not smooth or flat, no correct temperatures cannot be measured. Pay attention to this p oint.
0
°
4) Indication Indicationofburnout
Indicationofbattery
If any thermocouple becomes disconnected, this indication will appear.
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Air-use
If battery voltage drops, the “battery low” indication will appear. At this time, replace the battery.
13-5 Frequency measurement This high tester enables the following Example of HIOKI Model 3261 and Model 3262
measurement. Alternating current amperage (ACA),
Name of each part
Alternating current voltage (ACV),
1) Clamp core 2) Power supply switch 3) Function switch 4) Mode switch 5) Zero adjustment/Reset switch 6) 10-A range switch 7) Hold switch 8) Indicator 9) Hold mark 10) Zero adjustment/Reset mark 11) Battery exhaustion mark 12) Unit symbol 13) Voltage measuring terminal 14) Resistance (temperature) measuring terminal
1)
Resistance (), Temperature (°C), and Frequency (Hz)
3) 2) 4) 5)
6) 7)
13)
9)
14)
11)10)
8) (Model 3262: Specification of rectification effective value in mean value) (Model 3262: Indication of real effective value (with a high degree of accuracy))
12)
Amperage (ACA)
10/100/1000A
±1.0%rdg. ±5dgt
50/60 Hz
Frequency (Hz)
10 – 999 Hz
±0.3%rdg. ±1dgt
50/60 Hz
Voltage (ACV)
100 – 1000V
±1.0%rdg. ±3dgt
50/60 Hz
Resistance () Temperat ure (°C)
1/10K –50 – 150°C
±1.0%rdg. ±3dgt ±1.0%rdg Remarks: rdg: Reading value dgt: Number of counts
Preparation for measurement
1) Remove the pack case and put the battery in place. 2) Check to be sure the HOLD switch is not pressed. 3) Turn the POWER SUPPLY switch ON and check to be sure
1A, 600V FUSE (For 3261-500 or 3262-50)
all segments light up for a period of approximately one second. 4) For general cautions in use, thoroughly read the instruction manual.
0.5A, 250V FUSE Figure 1
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Battery (006P)
1) Measurement of frequency (Hz) This measurement is enabled through mode selection while in measurement of alternating-current amperage
(ACA) or alternating-current voltage (ACV). Press the MODE SELECTION button to set to frequency mode. The measurement of frequency can be made in the range of 10 Hz to 999 Hz. While in this mode, if the input is several percentage or more of the full scale value (10 A in the 10-A range) of Up range, the frequency will be indicated.
If the frequency exceeds 999 Hz, “O.L.” will be indicated. However, if the frequency is 2 KHz or more, a certain
numerical value will be indicated in some cases. Furthermore, if the frequency is less than 10 Hz, “00.0” will be indicated. If there is no input, a certain numerical value will be indicated in some cases. However, that results from the
internal processing and has no effects on the measurement. Model 3261 is not available to the measurement of frequencies on cable ways with special waveform like
inverters in some cases, while Model 3262 is designed to make measurement of the said frequencies through the internal processing. (However, be aware that this measurement is disabled on cable ways using a special inverter in some cases.)
2) Measurement of alternating-current amperage (ACA) / Normal measurement (NORMAL) 1) Set the function switch to A (amperage). 2) Open the tip of the clamp core, and pinch (clamp) the conductor approximately at the center of inside of the clamp core. 3) Be sure to only clamp a single conductor. If single phase (two wires) or three phases (three wires) are clamped together, no measurement will be made. 4) Since the range is automatically selected, read the value indicated as is. However, the 10-A range is manually selected. To make measurement of small amperage, i.e., 10 A or less, press the 10-A switch and then make this measurement.
3) Measurement of alternating-current voltage (ACV) Set the function switch to V (voltage) and then insert the test lead wire to the voltage measuring terminal.
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4) Measurement of resistance (Ω) 1) Set the function switch to and then insert the test lead wire to the voltage measuring terminal. 2) Make a short circuit in the test lead wire and, one or two seconds later, press the zero adjustment switch, thus making sure “000” is indicated. ( ADJ
is indicated for a period of approximately 0.5 seconds.) At this time, if “O.L.” is indicated, the fuse
becomes disconnected. Replace the fuse in this case. 3) In order to make this adjustment, check to be sure there is no residual voltage in the measurement circuit. 4) If no short circuit is made in the resistance input terminal or the zero adjustment switch is pressed while the measurement is in progress, no accurate measurement cannot be made. 5) If the zero adjustment switch is incidentally pressed, make zero adjustment again.
5) Measurement of temperature (°C) 1) In order to make measurement of temperature, Model 9029 temperature probe (temperature sensor) is needed. 2) Set the function switch on Model 3261 or 3262 to . 3) Insert the reticule plug 1) in the common terminal at the center and the black lead plug 2) in the other terminal of the . Then, press the zero adjustment switch to make zero adjustment. (Refer to Figure 2.) 4) After the completion of this adjustment, remove the black lead plug and insert the red plug 3) in place. Then, set mode to °C and read the value indicated. (Refer to Figure 3.) 5) As to the reading of the value indicated, read the value after it is brought to stable state.
3)
2)
1)
2)
Figure 2
Figure 3
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1)
3)
Daikin Europe N.V. is approved by LRQA for its Quality Management System in accordance with the ISO9001 standard. ISO9001 pertains to quality assurance regarding design, development, manufacturing as well as to services related to the product.
Daikin units comply with the European regulations that guarantee the safety of the product.
ISO14001 assures an effective environmental management system in order to help protect human health and the environment from the potential impact of our activities, products and services and to assist in maintaining and improving the quality of t he environment. Specifications are subject to change without prior notice
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