Sanyo XMHX1252, XMHX1852 Air Purging with a Vacuum Pump for Test Run Preparation, Leak test

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7. AIR PURGING

Air and moisture in the refrigerant system may have undesirable effects as indicated below.

pressure in the system rises

operating current rises

cooling (or heating) efficiency drops

moisture in the refrigerant circuit may freeze and block capillary tubing

water may lead to corrosion of parts in the refrigerant system

Therefore, the indoor unit and tubing between the indoor and outdoor unit must be leak tested and evacu- ated to remove any noncondensables and moisture from the system.

Air Purging with a Vacuum Pump (for Test Run) Preparation

Check that each tube between the indoor and outdoor units have been properly connected and all wiring for the test run has been completed. Remove the valve caps from all service ports on the outdoor unit. (Fig.

7-2) Note that all service valves on the outdoor unit are kept closed at this stage.

The balance tube leak test is not necessary if only 1 outdoor unit is installed.

Leak test

(1)Attach a manifold valve (with pressure gauges) and dry nitrogen gas cylinder to all service ports with charge hoses.

The balance tube leak test is not necessary if only 1

outdoor unit is installed.

Use a manifold valve for air CAUTION purging. If it is not available, use a stop valve for this pur-

pose. The “Hi” knob of the manifold valve must always be kept closed.

(2)Pressurize the system to no more than 469 psig

(33 kgf/cm2G) with dry nitrogen gas and close the cyl- inder valve when the gauge reading reaches 469 psig (33 kgf/cm2G). Then, test for leaks with liquid soap.

To avoid nitrogen entering CAUTION the refrigerant system in a liquid state, the top of the

cylinder must be higher than the bottom when you pres- surize the system. Usually, the cylinder is used in a ver- tical standing position.

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Manifold gauge

Vacuum pump

 

Outlet

 

Inlet

Fig. 7-1a

Fig. 7-1b

Valve cap

Flare nut

Service port cap

Fig. 7-2

 

Manifold valve

Pressure

Lo

Hi

gauge

Charge hose

Cylinder valve

Nitrogen gas cylinder (In vertical standing position)

Open

Suction tube

Close

Open

Outdoor unit

Discharge tube

Close

Open

Liquid tube

Close

Open

Balance tube

Close

Fig. 7-3

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Contents Sanyo Commercial Solutions R410A Models Indoor UnitsOutdoor Units Optional ControllersFor safe installation and trouble-free operation, you must …In a Room…In Moist or Uneven Locations …In an Area with High WindsAmount 353 oz Amount 529 oz CountermeasuresCare regarding tubing Be sure to recharge the refrigerant only in liquid formDifferent tools required Manifold gauge Vacuum pumpCompressor specifications are different Single-outlet valveExisting tubing cannot be used especially R22 Refrigerating machine oil differs R22Contents Electrical Wiring 5-1. General Precautions on Wiring HOW to Process TubingAIR Purging Test RUN 8-1. Preparing for Test RunTools Required for Installation not supplied Accessories SuppliedOutdoor Unit Part name Type of Copper Tube and Insulation MaterialFor sealing recessed portion of power supply 4-Way Air Discharge Semi-Concealed X-Type1-Way Air Discharge Semi-Concealed Concealed DuctConcealed Duct High-Static Pressure Ceiling-MountedWall-Mounted 4-Way Air Discharge Semi-Concealed XM TypeTubing Length H3 CTubing Size 10 Main Tubing Size LA 11 Main Tubing Size After Distribution LB, LC12 Outdoor Unit Tubing Connection Size a D BTU/h 95.500 153.60015 Refrigerant tubing Existing tubing can be used Common solenoid valve kit 17 Refrigerant Charge Amount at Shipment for outdoor unitSystem Limitations 18 System Limitations Header joint system Indoor Header joint systemTube branching methods horizontal use Tubing size with thermal insulation Model name Cooling capacity after distribution RemarksSuction Tube Size Part B Part C Part D Part E Part F Part G Part H Inch21 Dimensions for connections of each part Discharge Tube Liquid TubePrecautions on Installation of Solenoid Valve Kit Types and specificationsSpecifications Optional Solenoid Valve KitUnit Installation of Solenoid Valve Kit Relay kit FrontR410A additional charging absolutely must Be done through liquid chargingExample Use the same tools for R22 and for R410A Main tubing Distribution joint tubingMain tubing RemarkCeiling-MountedType Wall-Mounted TypeIndoor Unit Front viewOutdoor Unit Precautions When Installing in Heavy Snow Areas Without snow- proof ducting Without platformUnit installation Ceiling panelUnit Ceiling panel Air direction Front directionAir direction Suspending the Indoor Unit Placing the Unit Inside the CeilingInstalling the Drain Piping On the indoor control board Start when you short the pinBe careful since the fan will Removing the corner cover Installing the Ceiling Panel Wiring the Ceiling Panel Attaching the air-intake grilleChecking After Installation When Removing the Ceiling Panel for ServicingAdjusting the Auto Flap Special Remarks DC Fan Tap Change ProcedureSuspending the Indoor Unit Placing the Unit Inside the CeilingInstalling the Drain Piping Do not install an air bleeder asThis may cause water to spray From the drain pipe outletHow to Install the Ceiling Panel Main unit Before Installing the Ceiling PanelChecking the Drainage Checking the unit positionInstalling the Ceiling Panel Wiring the Ceiling PanelHow to Attach the Corner & Air-Intake Grille Checking After InstallationWhen Removing the Ceiling Panel for Servicing Adjusting the Auto Flap22-3/64 23-5/8Confirm that the unit is Level. If it is not level, waterLeakage may occur Be sure to use a level gaugeInstalling the Drain Piping 3WAYECO-iUS.indd 2008/02/07 Electrical Power Wiring Wiring connections WiringM5 ss40 Ss12 or 5/32 ss15/32 For fasteningRemoving the intake grille Removing the side panelAir leakage Installing the side panel and intake grille Installing the intake grilleOthers Check after installation If a wireless remote controller is usedInspection access 27/32 Indoor unitAir outlet duct flange Refrigerant tubingEnough to support the weight of the unit It is important that you use extreme careSupporting the indoor unit inside Ceiling. Ensure that the ceiling is strong19-11/16, as this could result in water leaks. Fig Section directly after the connection port can be raised aMaximum of 19-11/16. Do not raise it any higher than How to read the diagram Be careful since the fan will start when youShort the pin on the indoor control board Increasing the Fan Speed23-5/8 for checking and servicing the electrical system 17-23/3231/32 Indoor Fan Performance How to Read the Diagram Min -31/32 Inspection plugRefrigerant tubing drain hose position Wall and ceiling side opening position It is important that you useExtreme care in supporting Indoor unit from the ceilFixture Double nut Field supply Approx 63/64 Ceiling Surface Washer NutDuct for Fresh Air Shaping the TubingRear cover Downward gradient Min /100How to carry out power supply wiring Check local electrical codesRegulations before wir Ing. Also, check any specifiedIf the Wall is Wooden Installing the Rear Panel onto the WallSelecting and Making a Hole Removing the Grille to Install the Indoor Unit If the Wall is Brick, Concrete or SimilarRemoving the grille Attaching the grilleInstalling the Drain Hose Do not supply power to the unit or operateShaping the Tubing Right-rear tubing Left or left-rear tubingKHX0752 / 0952 / 1252 KHX2452Transporting Installing the Outdoor UnitPositions where anchor bolts are fastened Remove the Brackets Used for Transport Routing the TubingPrepare the Tubing Connect the TubingRefrigerant tube port Tubing size mm Outer dia ThicknessTightening torque for each cap Work methodGeneral Precautions on Wiring Outdoor unit Time delay fuse or Circuit capacityInter-outdoor unit control wiring Use shielded wiringWiring System Diagram PowerWiring Controller For K, A, X, T, U and D TypesFor XM Type XM TypeOutdoor unit Indoor unit How to connect wiring to the terminal For stranded wiring Important Note When Wiring for Common Type TypeType Important Note When Wiring for XM Type XM TypeConnecting the Refrigerant Tubing Flaring Procedure with a Flare ToolUse of the Flaring Method DeburringTube diameter Tightening torque ApproximateFour tubes arranged together Two tubes arranged togetherThree tubes arranged together Finishing the Installation Taping the TubesManifold gauge Vacuum pump Air Purging with a Vacuum Pump for Test Run PreparationLeak test Evacuation 45 min. or more 90 min. or moreFinishing the job Charging additional refrigerantUse a cylinder designed for use with R410A Test RUN Unit with the unit Test Run ProcedureItems to Check Before the Test Run Indoor unit setting S004 Rotary switch, red Address setting of main outdoor unit S007 Unit No. settingMain Outdoor Unit PCB Setting Auto Address Setting Basic wiring diagram Example Automatic Address Setting from the Outdoor UnitNo main unit Settings Outdoor main/sub22-9 3 OFF Automatic Address Setting no compressor operationAutomatic Address Setting from Outdoor Unit Automatic Address Setting in Heating Mode Automatic Address Setting in Cooling Mode Automatic Address Setting* from the Remote ControllerBlink alternately Display during automatic address settingLED 2 Checking the indoor unit addresses If 1 indoor unit is connected to 1 remote controllerRemote Controller Test Run Settings Possible cause of malfunction LEDMessage Alarm messages displayed on system controller Way Air Discharge Semi-Concealed Type X, XM Types Soot Should the power fail while the unit is runningTips for Energy Saving Type 1-WAY Way air discharge semi-concealed type aTroubleshooting 100Concealed Duct High-Static Pressure Type U, D Types Type standard static pressureType high static pressure 101On the wired remote control unit 102CEILING-MOUNTED 103Or soot 104105 Tips for Energy Saving 106