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[Fig. 10.2.3] (P.7)
A
  Example of closure materials (field supply)
B
  Fill the gap at the site
Make sure to seal-off the space around areas where the wires and refrigerant 
pipes enter the unit to ensure that small animals, rainwater, or snow cannot 
enter the unit through such openings and cause damage to the unit.
 Caution:
Make sure to seal-off the openings for the pipe and wire retrieval.
Small animals, rainwater, or snow entering through the openings may 
• 
cause damage to the device.
10.3. Airtight test, evacuation, and 
refrigerant charging
1
 
Airtight test
 
Perform with the valve of the outdoor unit closed, and pressurize the 
connection piping and the indoor unit from the service port provided on the 
valve of the outdoor unit. (Always pressurize from both the liquid pipe and 
the gas pipe service ports.)
[Fig. 10.3.1] (P.8)
A
Nitrogen gas
B
To indoor unit
C
System analyzer
D
Low knob
E
Hi knob
F
Valve
G
Liquid pipe
H
Gas pipe
I
Outdoor unit
J
Service port
Observe the following restrictions when conducting an air tightness test 
to prevent negative effects on the refrigerating machine oil. Also, with 
nonazeotropic refrigerant (R410A), gas leakage causes the composition to 
change and affects performance. Therefore, perform the airtightness test 
cautiously.
 Caution:
Only use refrigerant R410A.  
-  The use of other refrigerants such as R22 or R407C, which contains chlorine, 
will deteriorate the refrigerating machine oil or cause the compressor to 
malfunction.
2
 
Evacuation
 
Evacuate with the valve of the outdoor unit closed and evacuate both the 
connection piping and the indoor unit from the service port provided on the 
valve of the outdoor unit using a vacuum pump. (Always evacuate from the 
service port of both liquid pipe and gas pipe.) After the vacuum reaches  
650 Pa [abs], continue evacuation for at least one hour or more. Then, stop 
the vacuum pump and leave it for 1 hour. Ensure the degree of vacuum 
has not increased. 
(If the degree of vacuum increase is larger than 130 
Pa, water might have entered. Apply pressure to dry nitrogen gas up 
to 0.05 MPa and vacuum again.) Finally, seal in with the liquid refrigerant 
through the liquid pipe, and adjust the gas piping to obtain an appropriate 
amount of the refrigerant during operation.
 
* Never perform air purging using refrigerant.
[Fig. 10.3.2] (P.8)
A
System analyzer
B
Low knob
C
Hi knob
D
Valve
E
Liquid pipe
F
Gas pipe
G
Service port
H
Three-way joint
I
Valve
J
Valve
K
R410A cylinder
L
Scale
M
Vacuum pump
N
To indoor unit
O
Outdoor unit
Note: 
Always add an appropriate amount of refrigerant. Also always charge 
• 
the system with liquid refrigerant.
Use a gauge manifold, charging hose, and other parts for the 
• 
refrigerant indicated on the unit.
Use a graviometer. (One that can measure down to 0.1 kg.)
• 
Use a vacuum pump with a reverse flow check valve.
• 
(Recommended vacuum gauge: ROBINAIR 14830A Thermistor Vacuum 
Gauge)
Also use a vacuum gauge that reaches 65 Pa [abs] or below after 
operating for five minutes.
3
 
Refrigerant Charging
 
Since the refrigerant used with the unit is nonazerotropic, it must be charged 
in the liquid state. Consequently, when charging the unit with refrigerant from 
a cylinder, if the cylinder does not have a syphon pipe, charge the liquid 
refrigerant by turning the cylinder upside-down as shown in Fig.10.3.3. If 
the cylinder has a syphon pipe like that shown in the picture on the right, 
the liquid refrigerant can be charged with the cylinder standing upright. 
Therefore, give careful attention to the cylinder specifications. If the unit 
should be charged with gas refrigerant, replace all the refrigerant with new 
refrigerant. Do not use the refrigerant remaining in the cylinder.
[Fig. 10.3.3] (P.8)
A
Syphon pipe
B
In case of the R410A cylinder having  no syphon pipe.
Airtight test procedure
Restriction
(1) After pressurizing to the design pressure (4.15 MPa) using nitrogen gas, allow it to stand 
for about one day. If the pressure does not drop, airtightness is good.
However, if the pressure drops, since the leaking point is unknown, the following bubble 
test may also be performed.
(2) After the pressurization described above, spray the flare connection parts, brazed parts, and 
other parts that may leak with a bubbling agent (Gupoflex, etc.) and visually check for bubbles.
(3) After the airtight test, wipe off the bubbling agent.
If a flammable gas or air (oxygen) is used as the pressurization 
• 
gas, it may catch fire or explode.
Determine the amount of additional refrigerant charge by using the formula, 
• 
and charge refrigerant additionally through the service port after completing 
piping connection work.
After completing work, tighten the service port and cap securely so as not to 
• 
generate any gas leakage.  (Refer to the table on the below for appropriate 
tightening torque.)
Appropriate tightening torque:
Outer diameter 
of copper pipe 
(mm)
Cap 
(N·m)
Shaft 
(N·m)
Size of 
hexagonal 
wrench (mm)
Service port 
(N·m)
ø9.52
15
6
4
12
ø12.7
20
9
4
ø15.88
25
15
6
ø19.05
25
30
8
ø25.4
25
30
8
ø28.58
25
-
-
16
 Caution:
Keep the valve closed until refrigerant charging to the pipes to be 
• 
added on site has been completed. Opening the valve before charging 
the refrigerant may cause damage to the unit.
Do not use a leak detection additive.
• 
10.4. Thermal insulation of refrigerant piping
Be sure to add insulation work to refrigerant piping by covering liquid pipe and 
gas pipe separately with enough thickness heat-resistant polyethylene, so that 
no gap is observed in the joint between indoor unit and insulating material, and 
insulating materials themselves. When insulation work is insufficient, there is a 
possibility of condensation drip, etc. Pay special attention to insulation work in 
the ceiling plenum.
[Fig. 10.4.1] (P.8)
A
Steel wire
B
Piping
C
Asphaltic oily mastic or asphalt
D
Heat insulation material A
E
Outer covering B
Heat 
insulation 
material A
Glass fiber + Steel wire
Adhesive + Heat - resistant polyethylene foam + Adhesive tape
Outer 
covering B
Indoor
Vinyl tape
Floor exposed Water-proof hemp cloth + Bronze asphalt
Outdoor
Water-proof hemp cloth + Zinc plate + Oily paint
Note:
When using polyethylene cover as covering material, asphalt roofing 
• 
shall not be required.
No heat insulation must be provided for electric wires.
• 
[Fig. 10.4.2] (P.8)
A
Liquid pipe
B
Gas pipe
C
Electric wire
D
Finishing tape
E
Insulator
[Fig. 10.4.3] (P.8)
WT05962X01_GB.indd   18
2010/08/26   19:20:59