INSTALLATION GUIDE

© DAIKIN INDUSTRIES, LTD. TCDB005(EN)

Page 1
 Contents
(1) Sleeve work
(2) Indoor unit installation
(3) Piping support
(4) Refrigerant piping work
(5) Drain piping work
(6) Duct work (indoor)
(7) Insulation work
(8) Control wiring work
(9) Electric wiring work
(10) Outdoor unit installation
(11) Air tight test
(12) Vacuum drying
(13) Additional refrigerant charge
(14) How to check the number of installed indoor units

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 TCDB001A Page Number -p1-
legend
Legend

Caution: Points of caution at the job site

One point lesson: Expertise gained from onsite work

Case example: An actual example of onsite work

*Please note that lengths without any units are all in millimeters (mm) throughout this document.

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(1) Sleeve work-1
Procedure
Meeting Determination Installation Confirmation

~Working points~
Determination of the placement of the through-holes
1.Downward gradient of at least 1/100
2.Consider the thickness of the insulation material
1/100

General sleeve ϕ ID ：50, 80, 100, 125, 150, 175, 200

t
Ref. 19.1×9.5, t=20
ϕＡ t ϕB
Q. How much should you select sleeve ϕID?
t t

A. ϕID=19.1+20+20+9.5+10+10+5+5
5 Liquid Gas 5
=98.6 <=100
Sleeve inner diameter

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(1) Sleeve work-2
 Note that the beam structure limits the allowable area for placement of through-hole

Location into which the sleeve cannot

L1
L1
be inserted through the beam
D

L2
L3
At least 3 x [(R1 + R2)/2] At least D/4 and 150 mm
R1,R2 is at most D/3
At least D/2
“D” stands for beam height

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

Masking tape

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(2) Installation of indoor unit-1
Procedure
Transporting Determination Suspension bolt Installation

~Working points~
Be sure to conduct all work according to the accompanying installation manual.

1) Transporting
(1) Determine the transporting route.
(2) Transport the indoor units to the installation location in the original packing.
(3) When receiving the products, be sure to check for any blemishes or dents.

●How to prevent the installation of the wrong indoor unit model or in the wrong location.

1F reception room
AC1-1 Attach a sheet to visible spot indicated floor, room
name and system number

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(2) Installation of indoor unit-2
2) Determination of installation location
( The following explains the procedure in the event the inserts are not contained )
(1) Confirm the space required for servicing and installation.
(2) Confirm the piping direction and air discharge direction.

Please confirm the details in the installation manual or the like.

Installation space for FXFQ

1,500 mm or more
200 mm
or more

1,500 mm
1,500 mm or more
or more

200 mm or more
1,500 mm or more

Indoor unit Indoor unit

Ventilator
*1 Lighting

1,500 mm Ceiling surface 1,500 mm

1,800 mm or more

1,800 mm or more
or more or more *1 The lighting denotes
1,500 mm or more
the exposed type.
Wall 2000 mm or more Wall There are no restrictions
on concealed type lighting.
Between Indoor units 4,000 mm or more
Floor
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 -p3-
(2) Installation of indoor unit-3
(3) Mark the center of the indoor unit with chalk lines,
using the base point lines drawn on the floor as a guide.

1,000
Base point line
Chalk line
Measuring

800
tape

2,000
Center of the unit
Measuring tape
(4) Using the upper packing material, mark the suspension locations on the floor based on the
center of the unit. (Please use it and then reversing it)

Unit suspension location Upper packing material

Pip
ing
sid
e

Marking of unit Dr
ain

centerline sid
e

Center of the unit

Base point line
Base point line

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(2) Installation of indoor unit-4
(5) Use a laser pointer or the like to transfer the suspension location from the floor to the ceiling
slab, and use a drill to open up a pilot hole.

Ceiling

Laser pointer Suspension location Laser pointer

If a pilot hole for anchors leads to steel beam, be sure to try another location for hole.

Steel Suspension
beam location

Hammer
Drop-in anchor drill

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 (2) Installation of indoor unit-5
Marking

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 (2) Installation of indoor unit-6
 The suspension bolt size (M10 or W3/8) is compatible with all models.
(1) Determine the length of the suspension bolt
according to the height of the installation.

Suspension bracket

L: Length to be calculated
Ceiling material

H：130

A
Washers
FXFQ–P
Suspension bracket

A: Ceiling space height

L: Suspension bolt length Nuts
H: Ceiling surface – Suspension bracket size 50
L = A + 20 – H + 50
H

Example
Answer
H-50
Indoor unit: FXFQ–P
A: 500 mm L = 500 + 20 – 130 + 50 Ceiling surface
L: ? =440 mm

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 (2) Installation of indoor unit-7
(2) Before installing, place the 2 nuts (locally procured) and 2 washers (accessory)
on the suspension bolt. (Double-nut on the lower side of the bolt.)

Washers (accessory)

Upper nut
Suspension bracket
Upper nut
Double-nut tightening Lower nut
Lower nut

Double-nut tightening method

(3) For the upper washer, use the accessory washer plate to secure and prevent it from falling.

Washer plate
(Accessory)
Upper nut

Insert

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 (2) Installation of indoor unit-8
(1) Use the installation guiding tool that comes with the product in order to adjust the height
of the indoor unit.

Indoor unit

Place the short-ended notch here Height from the bottom surface
of the ceiling to the indoor unit
Bottom surface
Bottom surface of ceiling
of the indoor unit

Height from the bottom surface

of the ceiling to the indoor unit
Installation guiding tool
Decorative panel

(2) Adjust the lower nut to the height of the installation.

• The height of the indoor unit can easily

be adjusted by loosening the double nut.
After adjustment, be sure to re-tighten the double nut.
Box wrench

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 (2) Installation of indoor unit-9
 Anti-vibration measures
(1) Use hanger type rubber vibration isolators in the middle of the suspension bolt.
Ceiling

Rubber vibration isolators

Hanger type rubber
vibration isolator

(2) Place rubber vibration isolators above and under the suspension bracket.
Suspension bolt

Rubber vibration isolators

Washer plate

Suspension

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 (2) Installation of indoor unit-10
 Anti-vibration technique
If the suspension bolt is 1.5 m or longer, as shown in the diagram,
attach a steady brace on the longer side of the suspension pitch.

Steady brace bolt

At least 1,500
Clasp for steady
brace bolt

How to use the steady brace bolt

Example of steady brace installation

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 (2) Installation of indoor unit-11
Work on some of the optional parts is easier if they are attached
before installing the indoor unit.
Check the respective installation manual and the like for the installation height
when attaching optional parts.

Example

Model H Model A

A
H

FXFQ25~80 256 FXFQ25~80 306

FXFQ100/125 298 FXFQ100/125 348

Standard When a high performance air filter is used

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 (2) Installation of indoor unit-12
(3) Install the indoor unit level.
(4) When installing manually, first hook the indoor unit's suspension bracket
onto the suspension bolts on opposite corners to suspend (hang) the indoor unit.

Level

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 (2) Installation of indoor unit-13

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 (2) Installation of indoor unit-14
(5) After installing the indoor unit, always protect it with a plastic bag or the like.

How to protect the indoor unit

Plastic covering

 If the indoor unit is not properly protected (covered), it will result in paint and dust getting
on the filter and/or heat exchanger, which will cause a malfunction.

After all the work is complete, remove the protective plastic covering
and the like from the indoor unit.

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 (2) Installation of indoor unit-15
If the ceiling space is likely to be exposed to high temperatures and high humidity,
as shown in the area indicated by the diagonal line on the psychrometric chart,
reinforce the indoor unit's insulation.

This area indicates the need to

reinforce the indoor unit’s installation.

Approx. 26.2ºCDP
Approx.
0.0216 kg/kg (DA)

30ºCDB, RH80%

Absolute humidity [kg/kg (DA)]

Dry bulb temp. (℃DB)
Psychrometric chart

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(3) Piping support (Refrigerant)-1
Procedure
Determination of location Installation of suspension bolt and supporting fixtures

~Working points~
<Support of horizontal pipes>
1.Prevention of sagging due to their own weight
2.Prevention of spot overloading due to pipe expansion and contraction
 Interval for refrigerant piping support

1,500 1,500 1,500

<Horizontal pipes>
ϕ 19.1 Pipe O/D (mm) ≤9.5 ≥12.7
Indoor / ϕ 9.5
unit Support interval (m) ≤1.5 ≤2.0

Supporting fixture

 Adjust based on liquid piping size when liquid and gas piping are suspended together.

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(3) Piping support (Refrigerant)-2
~Working points~
<Support of vertical pipes>
1.Prevention of swaying and buckling due to their own weight

<Vertical pipes>

≤44.45
1,500 Pipe O/D (mm)
Support interval (m) ≤1.5

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(3) Piping support (Drain)-3
 Interval for drain piping support (in the case of polyvinyl-chloride pipes)

1,200 1,200 <Horizontal pipes>

Pipe O/D (mm) ≤44 ≥56
Support interval (m) ≤1.2 ≤1.5

<Vertical pipes>
Pipe O/D (mm) ≤44 ≥56
≤1.5 A
1,500 Support interval (m)

A : At least one spot per floor

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(3) Piping support (Refrigerant and drain)-4
2) Installation of suspension bolts and supporting fixtures
~Working points~
 Attach refrigerant piping support on top of the insulation material.
 With regard to drain piping support, first secure the pipes directly with
the supporting fixtures and then place the insulation materials on top of this.
 Horizontal piping support

Minimize the length of the suspension bolts

Consider downward gradient when determining length of drain piping suspension bolts.
When supporting refrigerant piping, place a hard pad or bind a insulation reinforcement
tape between supporting fixture in order to prevent crushing of insulation material
from weight of piping.

Suspension band

Insulation
Polyvinyl reinforcement tape
pipe

 Never provide additional piping support from the piping.

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(4) Piping support (Refrigerant and drain)-5

Suspension band Suspension band Suspension band

with turnbuckle for refrigerant pipe

Suspension bolt supporting fixture (for flat decks) Suspension bolt supporting fixture
(for shaped steel)

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 (3) Piping support (Refrigerant)-6
 Supporting of horizontal piping

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(3) Piping support (Refrigerant and drain)-7
 Vertical piping support
 Allow sufficient space for maintenance and insulation installation when determining
the distance between the unit body surface and piping as well as the piping interval
when many pipes are laid in parallel.

T-shape leg

Battledore bolt T-shape leg

with washer

Legs for vertical band Vertical band Vertical band

Battledore bolt with washer

Brazing areas

Special supporting fixtures for vertical piping Vertical band

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 (3) Piping support (Refrigerant)-8
- For vertical piping with a large level difference, take the necessary measures to prevent buckling
due to the contraction of the insulation material or thermal expansion/contraction of the refrigerant piping.
- The amount of thermal expansion/contraction can be roughly 10 mm every 10 m,
so create a space to compensate for this expansion.
Pipe shaft

The contraction of insulation

or thermal
expansion/contraction of
piping can cause piping to
slip downward.

The load is concentrated Brazing spots

here, causing buckling.
Supporting fixtures for vertical piping
Buckled piping (down stopper, pipe rack)

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 (3) Piping support (Refrigerant)-9
 Supporting of Vertical piping

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(3) Piping support (Refrigerant)-10
 Spot support (refrigerant piping)

~Purposes~
1. Prevention of overload on areas due to expansion
2. Prevention of overload on the connecting area to the unit due to expansion
3. Prevention of impact on waterproofing due to expansion

 Support of refrigerant piping branch and bend

≤300

Main pipe Branch pipe

side side
≤300

Support Support
points points

As per the red circles, it is easy to work on the supports for the branch side
of the REFNET joint if slightly different support intervals are used.

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(3) Piping support (Refrigerant)-11
 Support around the indoor unit (Refrigerant piping)
Support point

A B

Connection point
Ａ＋Ｂ＋Ｃ＝300～500

 Through-hole support
Support point

Sealant

300~500

Waterproofing
300~500

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 (3) Piping support (drain)-12
Use the proper support points.

Supports around indoor unit (Drain piping)

･Make the horizontal piping after drain-up as short as possible

Support point

･Accessory drain hose

･In order to prevent air from remaining in the drain hose,
install the piping so the drain hose is level or has a slight upward gradient.

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 (3) Piping support (drain)-13
Use the proper support points.

Spot supports (drain piping)

Through-hole supports Bend supports

Support points

300~500
300~500
Support points

Waterproofing
(caulking, waterproof mortar, etc.)
Vertical cross section view Horizontal view

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(4) Refrigerant piping work-1
Procedure
protection Pipe processing Unit connection

~Working points~
 Adhere to the following three basic principles
[The 3 basic principles of refrigerant piping]
Dry Clean Tight

No water/moisture inside No dust/contaminants inside

No leakage of refrigerant
Do not let water/moisture in Do not let dust/contaminants in

Dust/
Dust/
Water/
Water/ contaminants Leak
contaminants
moisture
moisture

1) Protection (covering)
Protection (covering) during storage and work involving refrigerant piping is the most important type of work
in order to prevent water/moisture, contaminants or dust from entering into the piping.

 If water/moisture, contaminants or dust enter into refrigerant piping, not only will it
prevent AC from operating normally but it will cause malfunction and inconvenience
for customer. Your utmost effort is required in preventing this from occurring.

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 -p9-
(4) Refrigerant piping work-2
During storage
(1)Make sure to protect both pipe ends.

Do not use piping that has not been protected.

(2)Do not lay refrigerant pipes directly onto floor surface, but use table or the like when placing them.
During work
(1)Be sure to protect (cover) the ends even when leaving the pipes for a short period of time.
(2)Be sure to protect (cover) the ends when pushing a pipe through a through-hole.

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(4) Refrigerant piping work-3
< How to protect >
The most reliable is the 'pinch method,' but taping can also be selected as an easy method
depending on the site and time frame.

Site Work period Protecting (covering) method

1 month or more Pinching

Outdoor Less than 1
Pinching or taping
month

Indoor Not considered Pinching or taping

<Pinching> <Taping>
A method by which the ends of the copper A method by which the ends of the copper
tube are closed off and the gaps are brazed. tube are covered with vinyl tape
Cut flat

Pipe end
Copper tube Fold down Wrap with
tape again
Wrap the copper
Brazing filler metal tube with tape.

Braze

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(4) Refrigerant piping work-4
2) Pipe processing
Flaring
This is one method of connecting refrigerant piping of a diameter of 15.9 mm or smaller
to an air conditioner.
<Tools>

File

Reamer

Pipe cutter Scraper Flaring tool

< Working procedure >

(1)Pipe cutting
Use a pipe cutter with left rotation.
Feed the blade of the pipe cutter bit by bit into the pipe with each rotation.

Excessive feeding of the blade can disfigure the pipe so special care is required.

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(4) Refrigerant piping work-5
How to use the pipe cutter rollers blade handle

Pipe cutter

For right-handed

For left-handed
Key points
1. Rotate pipe cutter as shown
2. Feed blade bit by bit per rotation
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 (4) Refrigerant piping work-6
Pipe cutting

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 -p11-
(4) Refrigerant piping work-7
Check the cut surface
There are burrs with the pipe after cutting!!

Burrs

Detail drawing
Key point
1. Remove all burrs

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 -p11-
(4) Refrigerant piping work-8
Reason to remove burrs
Wave pattern Refrigeran
Flare
t leak
nut
Union
Burrs

Refrigerant
Flare with burrs Joint of the flare parts pipe

Section drawing
Key point
1. Burrs cause leakage of flare surely

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(4) Refrigerant piping work-9
How to remove the burrs from the ends of the cut surface

Burrs
Burrs

cut surface cut surface with

with all burrs inner burrs

Key points
1. Use the file
2. Keep cut surface downward and hold on pipe firmly
3. Move file as shown
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(4) Refrigerant piping work-10
How to remove the inner burrs from the cut surface

burrs

cut surface cut surface

with inner burrs without burrs
Key points
1. Use the reamer
2. Keep cut surface downward and hold on pipe firmly
3. Rotate reamer as shown
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 -p11-
(4) Refrigerant piping work-11
To make flare more perfectly

Key points
1. Use the file
2. Keep cut surface downward and hold on pipe firmly
3. Move file as shown
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 -p11-
(4) Refrigerant piping work-12
To make flare more perfectly

Key points
1. Use the reamer
2. Keep cut surface downward and hold on pipe firmly
3. Rotate reamer as shown
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 -p11-
(4) Refrigerant piping work-13
Keep 3 principles of refrigerant piping

Key points
1. Use non-fuzzing cotton waste to remove swarf
2. Keep cut surface downward during cleaning

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 -p11-
(4) Refrigerant piping work-14
The care before flaring

Flare nut

Key point
1. Insert flare nut onto the pipe before flaring

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(4) Refrigerant piping work-15
How to set pipe in the flaring block
Feed handle
Main body

Flaring block
Flaring
cone

Stopper bolt

Key points
1. Confirm top position of feed handle before moving
main body
2. Move main body to stopper bolt to open flaring block

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 -p11-
(4) Refrigerant piping work-16
The dimension “A” of the protruded
pipe

A
Copper pipe
Flaring
block

Key points
1. Dimension “A” varies depending on each tool maker
2. “A” dimension is 0 to 0.5mm generally
3. Keep “A” dimension to make proper size of flare
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 -p11-
(4) Refrigerant piping work-17
How to set the main body

Main body

Clamp handle

Key points
1. Align the main body and the pipe
2. Tighten clamp handle firmly
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 -p11-
(4) Refrigerant piping work-18
How to make flare

Feed handle

Key point
1. Rotate feed handle 3 or 4 times after clicking sound

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 -p11-
(4) Refrigerant piping work-19
How to detach the pipe from flaring tool

Feed handle
Main body

Flaring block

Stopper bolt Clamp handle

Key points
1. Rotate feed handle until top position and
move main body
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 -p11-
(4) Refrigerant piping work-20
How to check the flare size
◆ Table of flare & union size
Nominal
A (mm) B (mm)
diameter
1/4” 8.7 ~ 9.1 9.2
A B 3/8” 12.8 ~ 13.2 13.5
1/2” 16.2 ~ 16.6 16.0
5/8” 19.3 ~ 19.7 19.0
Flare Union 3/4” 23.6 ~ 24.0 24.0

Key point
1. Compare flare size with union size after flaring
2. Use the “Flare size gauge”

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 -p11-
(4) Refrigerant piping work-21
Examples of bad flare

1.With burrs 2.With burrs 3.Scratch

4.Allaxis 5.Too small

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 -p21-
(4) Refrigerant piping work-22
1-3. Applying refrigerant oil to the flare

Apply the refrigerant oil

to the inner surface of the flare

Seal surface Flare

Spray type refrigerant oil

Cross section of the union and flare

Key points
1. Synthetic refrigerant oil can be used on air conditioners using R410A or R22.
2. Applying refrigerant oil to the flare's outer surface, union screws
or flare nuts is strictly prohibited.

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(4) Refrigerant piping work-23
1-4. Tightening of the flare nut – Preparation –
1 2 3

Align the flare axis Connect the flare surface Screw in the flare nut by hand.
with the union axis. to the union surface.

Key points
1. Connect promptly after applying the refrigerant oil.
2. Screw in the flare nut by turning it 4 or 5 times by hand.

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1-4. Tightening of the flare nut – Torque wrench –

Torque wrench

Nominal Dimension B
Flare nut
Torque N∙cm
diameter
ϕ 6.4 1420~1720
Nominal Dimension B (mm)
ϕ 9.5 3270~3990 diameter R410A R22
ϕ 12.7 4950~6030
ϕ 6.4 26 24
ϕ 15.9 6180~7540
ϕ 15.9 29 27
ϕ 19.1 9720~11860

Key points
1. A torque wrench allows tightening of the flare nut with a predetermined torque.
2. Dimension B for torque wrenches with nominal diameters of 1/2 and 5/8
of an inch differs depending on the type of refrigerant being used.

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1-4. Tightening of the flare nut – How to use the torque wrench –

"Click!"
Spanner

Torque wrench

Key points

1. Tighten only in the direction of the arrow stamped on the torque wrench.
2. Always use both the spanner and torque wrench when tightening.
3. Tighten until the torque wrench clicks.

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1-4. Tightening of the flare nut – If you do not have a torque wrench –
(1) The tightening torque increases rapidly.
(2) Only tighten to the following angles.
Nominal Tightening angles Recommended tool
diameter (approximate) arm length (L)
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 25~35 Approx. 450 mm

Tightening angle

Key points
1. Do not use any tools with arm lengths longer than those recommended
in the table above.
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 (4) Refrigerant piping work-27
1. Flare connection procedures
1-4. Tightening of the flare nut – Examples of problems –
When the flare nut is When not tightening with a
excessively tightened: spanner and torque wrench:

(1) The flare nut may crack. (1) The piping within the air conditioner can become twisted.
(2) The flare can be crushed.
(3) The union seal surface can be dented.

Cracked flare nut Crushed flare Around the indoor unit heat exchanger

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Marking the flare nut with a magic marker or the like after it has been tightened
prevents the worker from forgetting to tighten the flare nut.

Marking

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 (4) Refrigerant piping work-29
Flaring

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 (4) Refrigerant piping work-30
Bending
1 . Hand bending  Appropriate when bending narrow pipes
with a small diameter
(ϕ6. 4~1 2. 7 mm)

2. Bending work using a spring  Allows for hand bending without crushing
bender the pipes
(ϕ6. 4~1 9. 1 mm)

3. Bending work using a pipe  Allows for bending at the standard radius
bender for each pipe size
(ϕ6. 4~1 9. 1 mm)

4. Bending work using an  Allows for bending of pipes from a small
electric bender to large diameter
(ϕ6. 4~50. 8 mm)

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 (4) Refrigerant piping work-31
(1 ) Measurement (2) Pipe setting (3) Bending work
Pattern 1 Pattern 2
X Y

Clockwise
X Y Clockwise

■Note: The pipe setting method differs between Patterns 1

and 2.
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 (4) Refrigerant piping work-32
(1 ) Measurement (2) Pipe setting (3) Bending work
Counterclockwise

After

A
A
bending

Invert the pipe

Clockwise

Pattern 1

A
A

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 (4) Refrigerant piping work-33
(1 ) Measurement (2) Pipe setting (3) Bending work

◆ Pipe setting procedures (in Pattern 1 )

1. Open the handle

Handle

Handle

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 (4) Refrigerant piping work-34
(1 ) Measurement (2) Pipe setting (3) Bending work

◆ Pipe setting procedures (in Pattern 1 )

1. Open the handle
2. Insert the pipe into the shoe Pipe Shoe
シュー

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 (4) Refrigerant piping work-35
(1 ) Measurement (2) Pipe setting (3) Bending work

◆ Pipe setting procedures (in Pattern 1 )

1. Open the handle Shoe angle at 0°

2. Insert the pipe into the shoe

3. Align the guide end with the 0°
mark on the shoe

Guide end

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 (4) Refrigerant piping work-36
(1 ) Measurement (2) Pipe setting (3) Bending work

◆ Pipe setting procedures (in Pattern 1 )

1. Open the handle Mark

2. Insert the pipe into the shoe

3. Align the guide end with the 0°
mark on the shoe
4. Align the mark on the pipe with
"R" on the guide
“R” on
the guide

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(1 ) Measurement (2) Pipe setting (3) Bending work

◆ Pipe setting procedures (in Pattern 1 )

1. Open the handle
2. Insert the pipe into the shoe
3. Align the guide end with the 0°
mark on the shoe
4. Align the mark on the pipe with
"R" on the guide
5. Hang the hook on the pipe Hook

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(1 ) Measurement (2) Pipe setting (3) Bending work

◆ Pipe setting procedures (in Pattern 2)

A pipe of the
1. Open the handle Mark same size
The center of
2. Insert the pipe into the shoe the pipe

3. Align the guide end with the 0° Shoe

mark on the shoe
4. Insert another pipe of the
same size into the shoe parallel
to the fixed lever
and align the mark with the
center of that pipe Fixed lever

5. Hang the hook on the pipe

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 (4) Refrigerant piping work-39
(1 ) Measurement (2) Pipe setting (3) Bending work

◆ Bending work procedures (in both Patterns 1 and 2)

1. Reconfirm that the guide end is aligned with the 0° mark on the shoe
2. Slowly move the handle so that the guide end moves to the
designated angle shown on the shoe

Guide end ⇒ 0° Guide end ⇒ 45° Guide end ⇒ 90°

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Bend the pipe slowly to prevent pleating or deformation of the inner curve of the pipe.
Do not bend beyond 90°.

Pleating Deformation Appropriate bend Buckling

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 (4) Refrigerant piping work-41
Bending

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 (4) Refrigerant piping work-42
 Around the indoor unit

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Two copper pipes can be joined by expanding the end of one copper pipe, inserting the other pipe
into the expanded pipe, and brazing the joint.

<Tools>

Expander Reamer Scraper

<Work procedures>
Procedure 1: Remove any burrs on the cut surface using a
reamer or scraper.

Burrs

Note that excessive deburring can thin the pipe walls and
cause vertical (lengthwise) cracking during pipe expansion. Cracking

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Procedure 2: Slightly expand the pipe end using the tip of the
expander head.

Procedure 3: Fully insert the expander head into the pipe and gently
press the lever to expand the pipe a little. (So as to not
crack the pipe, do not press the lever strongly.)

Procedure 4: Release the expander lever a little, rotate the pipe, and
then gently press the lever again. ①
②

Procedure 5: Repeat Procedure 4 a couple of times until the pipe has

been expanded as desired. ③
④

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 (4) Refrigerant piping work-45
 Pipe expansion work at the installation site
Correct example

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 (4) Refrigerant piping work-46

 Expansion work Bad example

There is cracking on the copper pipe because it

was expanded all at once with force.
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TCDB005(AE(E
NN)
) D
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Brazing

Brazing is a method of joining metals using a molten brazing filler metal or alloy that has a lower
melting point than that of the base metals to be joined without melting them.
A combustion flame using flammable gas (acetylene gas, natural gas, propane gas, etc.) and
oxygen is used to heat (melt) the filler metal.
In this course, we will learn about the brazing procedures using acetylene gas.

 Have a certified individual perform brazing if required by the law.

 Always wear protective gear (welding/brazing eyewear, leather gloves, etc.) as a flame is
used for brazing.
 Have fire prevention equipment such as a fire extinguisher at hand.

 Use a phosphor copper filler metal (silver composition of 0 to 2%) for brazing.

 Always use a nozzle designed for brazing. Do not use a cutting torch nozzle.

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<Tools for brazing>

Oxygen Acetylene regulator Welding torch Twin hoses

regulator (with flashback arrestor) Acetylene Oxygen
gas gas

*Use an acetylene regulator with a flashback arrestor to ensure safety when lighting the flame.

Acetylene gas Oxygen Oxygen gas

regulator

Acetylene regulator
(with flashback arrestor)

Welding
torch

15 MPa
1.5 MPa

Twin hoses
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Standards for selecting the outer diameter of the copper pipe to be brazed and nozzle
diameter (French standards)
Copper pipe outer Nozzle diameter (mm) Nozzle number
diameter Nozzle
ϕ 6.4
ϕ 9.5
ϕ12.7 1.2 #200
ϕ15.9 Welding torch

ϕ19.1
ϕ22.2 1.3 #225
ϕ25.4 1.4 #250
ϕ31.8 1.5 #315
ϕ38.1 1.6 #400
ϕ44.5 1.7~1.8 #450~500
If the nozzle diameter is too large, the flame temperature will be too high, causing the base
metal to melt.
If the nozzle diameter is too small, brazing will take too long.
Use a nozzle that suits the outer diameter of the copper pipe to be brazed.
Do not use a nozzle designed for cutting torches.

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<Working procedure>
Procedure 2. Nitrogen replacement
 Purpose
A voluminous oxide film develops on the inner surface of the pipe during brazing.
The film can clog, among other parts, the solenoid valve and capillary tube,
hampering normal operation. In order to prevent this from occurring, it is necessary
to replace the air within the pipe with nitrogen. This work is referred to as nitrogen
replacement.

<Tools for nitrogen replacement>

Tapered
nozzle

Nitrogen Nitrogen gas Pressure

cylinder regulator hose
Valve

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(1) Set up the required tools as shown below.
Taping Taping Pressure hose

0.02 MPa
N2 N2

Tapered nozzle Nitrogen gas

regulator

Cover the pipe end with tape Valve

and make an incision on the Nitrogen cylinder
tape. (purity of 99.99%)

(2) Adjust the nitrogen gas pressure to 0.02 MPaG.

Let the nitrogen gas escape by opening the pipe end opposite the end from where the nitrogen gas is sent.
It is more economical to reduce the amount of nitrogen gas that escapes by covering the end of the copper pipe
with tape or the like and making an incision on it.
Use of the tapered nozzle is effective as it allows connection with copper pipes of different diameters.

 Note that if the nitrogen pressure is too high, it may cause the brazing filler metal not to reach completely
around the pipe or pinholes to develop in it.
 Use of nitrogen gas with a purity of at least 99.99% is recommended. If nitrogen gas with a purity of less than
99.99% is used, it may cause oxide film formation.

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 Nitrogen replacement

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The effects of nitrogen replacement

With nitrogen replacement Without nitrogen replacement

The inner surface of the pipe is clean. The inner surface of the pipe has blackened
due to the oxide film.

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Procedure 3. Cooling

 Cool the brazed location with a moist cloth or the like to enable work afterward
and prevent burns.

 Do not turn off the nitrogen until the pipe is completely cooled down.
If the nitrogen gas is stopped before the pipe has sufficiently been cooled down,
it will result in the development of an oxide film on the inner surface of the pipe.

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Downward Horizontal Upward

(Facing down) (Facing sideways) (Facing up)

Relatively easy Difficult

It is relatively easy to distribute the brazing filler metal when the pipe is facing down or
sideways. But, if the pipe is facing up, it will be difficult to distribute the filler metal properly
and this can result in a refrigerant leak. Therefore, make efforts to perform the brazing
with the pipe facing down or sideways.

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 (4) Refrigerant piping work-56
Procedure 1: Cleaning and checking the brazing area
Point 1: Remove any foreign materials such as oxides, coating materials, rust, or oil on the
brazing area.
Point 2: Make sure there are no chamfers or deformation.

Procedure 2: Flame adjustment

Point: Use a reducing flame with a carburizing flame of roughly 50 mm.

Carburizing Outer Acetylene flame

flame flame (It contains soot due to the presence of
Flame core a small amount of oxygen.)

Reducing flame

Roughly 50 mm
Standard flame (Neutral flame)

Oxidizing flame
(The percentage of oxygen is too high.)

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 (4) Refrigerant piping work-57
Procedure 3: Preheating
<The five key points of preheating>
Point 1: Heat both base metals to be brazed evenly. (Inner and outer pipes and the circumference)

Inner pipe Inner 500°C 500°C 200°C 300°C

pipe

Heating
range is Heating
appropriate. range is
A too broad.
A
B
Outer B
Outer 500°C 500°C 500°C 400°C
pipe
pipe

The temperatures of The temperatures of The temperature around the The temperature around the
A and B are the same. A and B differ greatly. circumference is uniform. circumference is not uniform.

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 (4) Refrigerant piping work-58
<The five key points of preheating>
Point 2: Heat until the brazing area reaches an appropriate temperature to distribute the brazing
filler metal.
- 640 to 780°C (where the base metals change color from reddish black to pink)

Too soon to distribute the filler metal Appropriate time to distribute the Too late to distribute the filler metal
(base metal temp. of 500 to 600°C) filler metal (base metal temp. of 800 to 1,000°C)
(base metal temp. of 640 to 780°C)

Heating

Bronze ⇒ Black ⇒ Blackish red ⇒ Reddish black ⇒ Pink ⇒ Red ⇒ Orange

Meltdown (1,083°C)
Appropriate range

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 (4) Refrigerant piping work-59
<The five key points of preheating>
Point 3: Adjustment of the flame and flame intensity
- Conduct brazing with a reducing flame. (Carburizing flame of roughly 50 mm)
- Adjust the flame intensity according to the size of the base metal (copper pipe diameter).
Adjustment of flame intensity

Carburizing flame
Outer flame
Flame core

Roughly 50 mm

Point 4: Flame angle (heat control)

- Hold the flame at an angle of 80 to 85° 80-85°
to the copper pipe.

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 (4) Refrigerant piping work-60
<The five key points of preheating>
Point 5: Confirmation of the flame position
(1) Distance from the carburizing flame tip (2) Position where the flame is applied (3) Flame direction

Carburizing Carburizing flame

Carburizing flame flame

5-10 mm

Boundary between
the inner and outer
pipes
2-3 mm Less than
0 mm (2) Position where the
(1) Distance from the flame is applied
carburizing flame tip

Preheating
Flame loss

2-3 mm

(3) Flame direction

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 (4) Refrigerant piping work-61
Procedure 4: Distribution of the brazing filler metal

<Five key points when distributing the brazing filler metal>

Point 1: Confirm the range of brazing filler metal distribution (spreading range).

Overlap Not overlapping

results in a gas
leak.

Point 2: Confirm the amount of brazing filler metal distribution (which differs depending on the
heating range of the base metal).

The heating
Appropriate The heating
range is too
heating range range is too
narrow
broad

Excessive filler metal Insufficient filler metal

distribution distribution
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 (4) Refrigerant piping work-62
Point 3: Melt the brazing filler metal from the tip. (Melt it gradually by gently applying the flame to
the base metal)
Brazing filler metal Brazing filler metal

Point 4: The angle of the flame and brazing filler metal

(1) Hold the flame slightly more vertically (2) Maintain the angle between the flame and filler metal at
compared to when preheating. roughly 90°.
75-80° Brazing filler metal
Brazing filler
During brazing
80-85° metal
Roughly 90°

During preheating

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 (4) Refrigerant piping work-63
Point 5: Flame position and final confirmation

(1) Distance from the carburizing flame tip (2) Position where the flame is applied (3) Flame direction (4) Final confirmation

1-2 mm

2-3 mm

(3) Flame direction (Move the

(1) Distance from the (2) Position where flame from side to side at an
angle of roughly 90° to the pipe.) (4) Final confirmation
carburizing flame tip the flame is applied

Distribution of the
brazing filler metal

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 (4) Refrigerant piping work-64
Downward brazing work Correct example

*Note that a test piece for training is used here so nitrogen

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Page 97
 (4) Refrigerant piping work-65
"Procedure 1: Cleaning and checking of brazing area" and "Procedure 2: Flame adjustment" are omitted as they are the
same as that for downward brazing.

Procedure 3: Preheating
Preheating
Inner pipe

Outer Outer
A A Inner pipe
pipe pipe

B Heating
Heating range range is
is appropriate. inappropriate.
The temperatures of A and The temperatures of A and B
B are the same. differ greatly.

Side view

2-3 mm
5-10 mm 90° Slowly move the
flame forward and
Carburizing flame backward

Distance from the Position and angle where the Flame movement
carburizing flame tip
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is applied Daikin Training
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 (4) Refrigerant piping work-66
Procedure 4: Distribution of the brazing filler metal
Point 1: Distribute the filler metal little by little from the bottom side.

Side view Bottom view

④Quickly (Far left to far right) ②Quickly (Near right to near left)
Do not directly apply the flame to the pipe. Do not directly apply the flame to the pipe.
② Brazing filler metal
③Slowly ①Quickly ③Slowly
(Near to far ④ ③ ①
(Far to near side) (Near to far ①Quickly
side) ③ ① side) (Far to near side)
2-3 mm ④
②Quickly
(Near right to near left) ② ④Quickly (Far left to far right)
Do not directly apply the flame Do not directly apply the flame Dripping of the
to the pipe. to the pipe. brazing filler metal
Brazing filler metal Carburizing flame Roughly 5-10 mm If the filler metal is
A: Arrow view excessively distributed,
A it will drip down.
Distance from the carburizing flame tip Position where the flame is applied

Distribution of the
brazing filler metal
(Bottom side)

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 (4) Refrigerant piping work-67
Procedure 4: Distribution of the brazing filler metal
Point 2: After the bottom side of the joint gap is filled with the filler metal, move the flame from the
bottom to the top on the far (back) side of the copper pipe to pull the filler metal up in that
same direction.

Front side view Back side view

Pulling up of the brazing filler metal
(bottom to top side)
A: Arrow view

Slowly

Roughly 5-10 mm
A: Arrow view
Pull the filler metal up from the
bottom to the top by moving the Position where the
flame in that same direction on the flame is applied
back side of the copper pipe.

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 (4) Refrigerant piping work-68
Procedure 4: Distribution of the brazing filler metal
Point 3: Distribute the filler metal little by little from the top side

Side view Top view

Distribution of the brazing filler metal
④Quickly
Do not directly apply (top side)
A the flame to the pipe.
④
Carburizing
Brazing filler flame
metal ③Slowly ③ ①Quickly
①
2-3 mm ② Brazing filler metal
②Quickly
Do not directly apply
the flame to the pipe.
Roughly 5-10 mm
A: Arrow view
Distance from the Position where the flame is applied
carburizing flame tip

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 (4) Refrigerant piping work-69
Procedure 4: Distribution of the brazing filler metal
Point 4: Distance from the carburizing flame tip/Position where the flame is applied

Side view

Outer flame Final distribution of the brazing filler

metal (top side)

Brazing filler metal

150-300 mm

Final distribution (overlaying) Final distribution

of the brazing filler metal

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 (4) Refrigerant piping work-70
Horizontal brazing work Correct example

*Note that a test piece for training is used here so nitrogen

TCDB002TCDB005A(EN)
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Page 103
 (4) Refrigerant piping work-71
"Procedure 1: Cleaning and checking of brazing area" and "Procedure 2: Flame adjustment" are omitted as they are
the same as that for downward brazing.

Procedure 3: Preheating

Carburizing flame
5 mm below the boundary

Flame Flame Flame

2-3 mm 90°
(1) Distance from the (2) Angle between the (3) Position where the
carburizing flame tip flame and base metal flame is applied – 1

Preheating

Flame
The temperatures
Heat the upper brazing of the inner and
area immediately before outer pipes are
distributing the brazing the same.
filler metal.

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(3) PositionLTD.
where the flame is applied – 2
Page 104
 (4) Refrigerant piping work-72
Procedure 4: Distribution of the brazing filler metal
Point 1: Distribute the filler metal little by little from the back side.

Flame
movement
Slowly
Slowly
Slowly Move the flame along
Move the flame the side of the pipe.
along the side Brazing temperature
0.5 mm below
of the pipe. the boundary
Quickly
Once the filler metal is
Flame distributed, do not lower It is necessary to have a
80-85° the flame more than 0.5
(A narrower angle than mm below the boundary. temperature that allows the
that for preheating) filler metal to liquefy so the
filler metal can be drawn up by
(1) Angle between the flame (2) Position where the capillary action.
and base metal flame is applied

Distribution of the brazing filler

metal (back side).
Distribute the filler metal little
by little from the back side.

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TCDB005A(EN)
Page 105
 (4) Refrigerant piping work-73
Procedure 4: Distribution of the brazing filler metal
Point 2: After distributing the filler metal from the bottom side, move the flame upward to pull the
filler metal up by capillary action.

Brazing Do not melt too

filler metal much filler Little by little
metal all at continuously
once.

Insert the filler metal from The filler metal drips down Liquefy the molten filler metal
the center. due to gravity. as quickly as possible.

Distribution of the brazing filler metal (front side).

After the joint gap on the back side is filled with filler
metal, heat the brazing area from the front side.
After the filler metal on the back side comes around
to the front side, distribute the filler metal from the
front side.

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TCDB005A(EN)
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 (4) Refrigerant piping work-74
Final confirmation
Confirmation of the amount of the filler metal (right and left).
Confirm the amount of the filler metal on the left and right sides. If
there are any insufficiencies, add more filler metal.

Final confirmation

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TCDB005A(EN)
Page 107
 (4) Refrigerant piping work-75
Upward brazing work Correct example

*Note that a test piece for training is used here so nitrogen

© DAIKIN INDUSTRIES, LTD. replacement is not conducted.TCDB005A(EN)
TCDB005(EN)
Page 108
 (5) Refrigerant piping work-75
Brazing on site

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TCDB005A(EN)
Page 109
 -p20-
(5) Refrigerant piping work-76
 Refrigerant branch pipe (REFNET joint)
<Installation standards>
1. Install the REFNET joint horizontally or perpendicularly.

Horizontal
Ａ
A. Arrow view
A
Perpendicular
<Horizontal pipe> <Vertical pipe>

2. Install the REFNET header horizontally .

Ceiling Ceiling
Supporting fixture
(locally procured)
Horizontal
Horizontal
Mount
(locally procured)

Example of liquid-side header installation Example of gas-side header installation

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TCDB005A(EN)
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 (4) Refrigerant piping work-78
 Refrigerant branch pipe (T joint)

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TCDB005A(EN)
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 (4) Refrigerant piping work-79
 Refrigerant branch pipe (REFNET joint)

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TCDB005A(EN)
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 -p20-
(4) Refrigerant piping work-80
Create at least 500 mm of a straight pipe section before and after branches
when connecting refrigerant branch pipe to the field pipe.

<Reason>
Bending the pipe too close to the branch can lead to complaints about abnormal noise.

At least 500 At least 1,000

At least 500

<Top view>

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 -p20-
(4) Refrigerant piping work-81

 Example of refrigerant branch pipe installation

<Installed at a 90° angle> <Installed horizontally>

 Installing the REFNET joint while it is leaning at an angle can cause

refrigerant drift, resulting in abnormal noise or preventing normal
operation. Be sure to install it horizontally.

© DAIKIN INDUSTRIES, LTD. TCDB005(EN)

TCDB005A(EN)
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 -p22-
(5) Drain piping work-1
Procedure
Indoor unit Indoor unit side Collective Drain flow
installation drain piping drain piping test

~Working points~
 Ensure a downward gradient of the drain piping of at least 1/100.
 Keep the drain piping as short as possible and prevent air pockets.

Indoor Level gauge

unit Downward gradient of at least 1/100
(1 cm/1 m)

Do not connect drain pipes to the building‘s sanitary sewer pipes or waste
pipes as it may cause an odor problem.

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 -p23-
(5) Drain piping work-2
1) Indoor unit side drain piping

1. Be sure to use a drain hose if it comes with the product.

 This prevents excessive force on the drain pan.

 It compensates for a certain misalignment of the drain piping with the indoor unit's drain connection port.

2. Tighten the indoor unit's drain connection port and accessory drain hose
using the clamp that comes with the product.

 Do not use adhesive to connect the indoor unit's drain connection port and accessory drain hose.
If adhesive is used, it will be difficult to attach/detach the hose during maintenance and the like.

3. The diameter of the piping beyond the accessory drain hose should be
at least the same as the connecting piping.

 The diameter of the drain-up piping should be the same as that of the drain hose.

Clamp
Accessory drain hose
Indoor unit Insulation (piping portion)

Drain pan
(made
© DAIKIN INDUSTRIES, LTD. of polystyrene foam) TCDB005A(EN)
TCDB005(EN)
Insulation (piping portion)
Page 116
 -p23-
(5) Drain piping work-3
4. Do not bend the drain hose more than 75 mm.

Bending of no more than 75 mm

Drain hose (accessory)

5. Run the piping vertically up within 300 mm when draining up

Run the piping vertically up within 300 mm of the indoor unit

The piping diameter beyond the drain-up piping
should be at least the same as the drain-up piping.
Clamp (accessory)
Piping diameter should be the same as that of the drain hose

Level or on an upward gradient

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 -p23-
(5) Drain piping work-4
6. Fit the branch piping on the main piping from above.

Make the horizontal piping Fit the branch piping

Use two elbows as short as possible on the main piping from above.
The angle can be adjusted Branch piping

Main piping

OK

OK
Drain

×
Drain water flows in reverse
Installation example from the main piping

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TCDB005A(EN)
Page 118
 (5) Drain piping work-5
 Around the indoor unit

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 -p24-
(5) Drain piping work-6
2) Collective drain piping

When connecting horizontal piping to vertical piping, either connect it

after lowering the piping by at least 100 mm or use a Y joint.

90-degree elbow

Connect after lowering

by at least 100 mm

45-degree elbow
T joint
Y joint

Example of connection Example of connection

to the vertical piping using a Y joint to the vertical piping using a T joint

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 -p24-
(5) Drain piping work-7
●For the main piping, use piping with an inner diameter of at least 30 mm.
Try to make it as large as possible.
●Fit the branch piping on the main piping from above.
●Install a clean-out on the very top of the main piping for water flow tests and
cleaning of the piping.
●Install the piping so as to minimize the length of the horizontal piping and the
number of indoor units connected.
●Install a vent pipe at the top of the vertical piping to improve the drain water flow.

Drain branch piping

Drain branch piping

Clean-out
Vent pipe
Vent pipe with
insect screen

Fit from above

Insect screen
Main drain piping
(inner diameter of at least 30 mm)
© DAIKIN INDUSTRIES, LTD. TCDB005A(EN)
TCDB005(EN) Vertical drain piping
Example of drain piping installation Page 121
 -p24-
(5) Drain piping work-8
Processing
1. Cut piping straight
2. Remove burrs and chamfer piping
3. Remove foreign matter on the surface where
the adhesive will be applied
4. Apply adhesive to both the straight piping and joint

Colored quick-drying adhesive Appropriate amount Too much

 Use of colored adhesive on polyvinyl chloride piping prevents one from forgetting to apply the adhesive.

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 -p24-
(5) Drain piping work-9
3) Drain flow test
1.Conduct the water flow test after the drain piping installation
before installing the insulation at the connection.
2. Use the cleanout on the main drain pipe for the water flow test

Example: Indoor unit with a built-in drain pump

If power has not been
connected to the indoor unit From the clean-out

Water pouring
container
Clean-out
Clean-out

From the water filling port

If power can be supplied
to the indoor unit From air outlet
Water
filling port
Water pouring
container

Page 123
 (5) Drain piping work-10
Drain flow test

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 -p25-
(5) Drain piping work-11
Piping selection
Calculate the flow rate of the drainage going through the drain piping based on the
indoor unit capacity and determine the piping size that will allow for such a flow rate.

1) Drainage flow rate calculation

Example) Calculate the drainage flow rate when three 2HP indoor units and two 3HP indoor units
are connected to the drain piping.
«Drainage flow rate based on the indoor unit capacity: Approx. 6 liters per hour per 1HP»
(6 ℓ/hr × 2HP × 3 units) + (6 ℓ/hr × 3HP × 2 units) = 72 ℓ/hr

6 ℓ/hr × 2HP 6 ℓ/hr × 2HP 6 ℓ/hr × 2HP 6 ℓ/hr × 3HP 6 ℓ/hr × 3HP
= 12 ℓ/hr = 12 ℓ/hr = 12 ℓ/hr = 18 ℓ/hr = 18 ℓ/hr

2HP 2HP 2HP 3HP 3HP

Main horizontal piping Main vertical piping

72 ℓ/hr

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TCDB005A(EN)
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 -p25-
(5) Drain piping work-12
･ Use a VP30 pipe or larger for collective piping.

2) The relationship between the inner diameter of the main drain piping
and allowable flow rate
Drainage flow rate: 72 ℓ/hr
Horizontal piping
PVC VP Allowable flow rate (ℓ/hr)
inner piping JIS inner piping
PVC Diameter nomenclature diameter Gradient Gradient Remarks
(mm) (mm) = 1/50 = 1/100
PVC25 19 VP20 20 39 27 (Reference values)
Cannot be used
PVC32 27 VP25 25 70 50 for collective piping

PVC40 34 VP30 31 125 88

Can be used
PVC50 44 VP40 40 247 175
for collective piping
PVC63 56 VP50 51 473 334

Notes:
- Calculated assuming that the water ratio within the piping is 10%.
- Round off the allowable flow rate to the nearest whole number.
- Use at least a VP30 pipe for collective piping.

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 -p25-
(5) Drain piping work-13
･ Use a VP30 pipe or larger for collective piping.

3) The relationship between the inner diameter of the vertical drain piping
and allowable flow rate
Drainage flow rate: 72 ℓ/hr
Vertical drain piping
PVC VP
Allowable
inner piping JIS inner piping
PVC flow rate Remarks
diameter diameter
nomenclature (ℓ/hr)
(mm) (mm)

PVC25 19 VP20 20 220 (Reference values)

Cannot be used
PVC32 27 VP25 25 410 for collective piping
PVC40 34 VP30 31 730

PVC50 44 VP40 40 1440

Can be used
PVC63 56 VP50 51 2760
for collective piping
PVC75 66 VP65 67 5710

PVC90 79 VP75 77 8280

Notes:
- Round off the allowable flow rate to the nearest whole number.
- Use at least a VP30 pipe for collective piping.
© DAIKIN INDUSTRIES, LTD. TCDB005(EN)
TCDB005A(EN)
Page 127
 -p26-
(6) Duct work (indoor)
Procedure

Indoor unit installation Duct connection Air intake/outlet installation

~Noise and vibration considerations~

 Be sure to use canvas joints between the indoor unit and suction ducts as well as indoor unit
and discharge ducts. This is because they are useful in preventing reverberations when the
product's vibrations and operating noise travel through the building and ducts.

Suspension bolt

Canvas duct Canvas duct

Indoor
unit
 Select suction and discharge grilles in consideration of the airflow rate so as to prevent any
air distribution noise (wind roar).

 Be sure to insulate the discharge duct.

 Use canvas ducts with a metal framework on the inlet side.
Consider positioning of suction and discharge grilles so as to prevent short-circuiting.
Check the static pressure so the prescribed discharge air flow rate is being produced.
 Make it so the air filter is easy to remove when necessary.

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TCDB005A(EN)
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 -p27-
(7) Insulation work-1
Procedure
Refrigerant Insulation work Air tight Insulation work
piping work (other than connections) test (connections)

Drain piping Insulation work Flow Insulation work

work (other than connections) test (connections)

~Working points~
 Insulation work does not allow for checks/tests, so ensure that any maintenance
and repair on the insulation joints and the like is done properly.

[Materials]
For the insulation, use materials that can sufficiently withstand the temperature of the piping.
<Refrigerant piping>
 Heat-pump type… Heat resistant polyethylene foam (that can withstand temperatures over 120°C)
 Cooling-only type… Polyethylene foam (that can withstand temperatures over 70°C)
temperature of the piping.
<Drain piping>
 Polyethylene foam (heat resistant temperature: –70 ~ 80°C)

© DAIKIN INDUSTRIES, LTD. TCDB005(EN)

TCDB005A(EN)
Page 129
 -p27-
(7) Insulation work-2 (Refrigerant piping)
If you assume that the temperature and humidity around the refrigerant pipe might
exceed 30°C and RH80%, please use insulation with a thickness of 20 mm or more.
Polyethylene foam insulation material cannot be used in some areas (Hong Kong)
due to the fire codes. Therefore, confirm this in advance.
Be sure to insulate connections (brazed, flared, etc.) after they have passed air
tightness tests.
 Be sure to insulate both the gas and liquid piping individually.

Insulate both the gas and Insulate only the gas Insulate the gas and
liquid piping together piping liquid piping individually

Liquid Liquid
Gas Liquid Gas Gas
piping piping
piping piping piping piping

Insulation Insulation Insulation Insulation

material material material material

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TCDB005A(EN)
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 -p27-
(7) Insulation work-3
 Be careful not to leave any gaps in the insulation joints.
 Be careful not to use damaged insulation material.

Gap in the insulation joint Damaged insulation material

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TCDB005A(EN)
Page 131
 -p28-
(7) Insulation work-4 (Refrigerant piping)
 Indoor unit flares
 Use the following guide to conduct insulation work properly up to the base of the refrigerant piping
on the indoor units.
Flare insulation work guide Piping insulation Wind from the base of the
Joint insulation material material unit to the upper portion of
(accessory (8),(9)) (machine side) the flare nut connection
Flare nut
Face the Attach to the base
connection
joint
upward
Piping insulation
material Clamp material Gas piping
(locally procured) (accessory(4)) Sealer (accessory(11),(12))
Liquid piping
(only gas piping side)
Tighten the section that overlaps
with the piping insulation material

(1) Wind the joint insulation material (accessory (8),(9)) around the flares on both liquid and gas piping.

Always face the joint of the insulation material upward.

(2) Securely fasten both ends of the joint insulation material with the clamp material (accessory (4)).
(3) Wind sealer over the joint insulation material only for flares on the gas piping side.

Be sure to always conduct the above work after the air tightness test.

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 -p28-
(7) Insulation work-5 (Refrigerant piping)
 Supporting fixture insulation
When supporting the horizontal piping, the weight of the piping tends to crush
the insulation at the support spots and cause condensation.
At support spots, either reinforce insulation material using tape with insulating
properties or provide support with a hard-type wide polyvinyl tube to spread weight.
 Be careful not to wind any adhesive tape used for a temporary hold too tightly.

Insulating reinforcement Suspension band

tape (5t × 75w) with turnbuckle
Supporting
fixture Insulation material
Polyvinyl tube

Example Insulation reinforcement tape

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 -p28-
(7) Insulation work-6 (Refrigerant piping)
 Reinforcement of the insulation material cuts

Insulation material shrinks with time, so it is recommended that insulation material cuts
be reinforced with tape with insulation material after applying a special adhesive.

Special adhesive

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 -p29-
(7) Insulation work-7 (Refrigerant piping)
 When inserting the insulation material into a gap

In consideration of possible shrinking of the insulation material in the future,

insert insulation material that is 200 mm longer than the gap into the gap.
The work that follows is the same as the pre-page

L + Approx. 200 mm of
insulation material

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 -p29-
(7) Insulation work-8 (Refrigerant piping)
 Reinforcement of insulation material at bends

 Try to minimize the number of cuts in the insulation material (one cut is ideal).
Consider where to cut the insulation material so that its reinforcement after bending
can be conducted at a straight pipe portion.

Special
adhesive

Reinforcement tape with

insulation material

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TCDB005A(EN)
Page 136
 (7) Insulation work-9 (Refrigerant piping)
Insulation work

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TCDB005A(EN)
Page 137
 (7) Insulation work-10 (Drain Piping)
Cut the insulation material used for straight piping
Be sure to insulate the joints. so that it can be used to fit the joints

Commercially sold For the elbow For the T joint

joint insulation

Cut the insulation Cut the insulation

material as necessary material as necessary
to make it fit. to make it fit.

Secure with tape Attach to the elbow Secure Attach

with tape to the T joint

© DAIKIN INDUSTRIES, LTD. TCDB005(EN)

TCDB005A(EN)
Page 138
 (8) Control wiring work-1
1. Overview
The Daikin DIII-NET is used as a transmission system for VRV control wiring.

VRV outdoor unit

VRV indoor unit

Control wiring
Control wiring between indoor and outdoor units
between outdoor units

DIII-NET

Daisy-chain
wiring
Centralized
controller

© DAIKIN INDUSTRIES, LTD. TCDB005(EN)

TCDB005A(EN)
Page 139
 -p30-
(8) Control wiring work-2
2. Precautions when wiring
1) Types of wiring: Sheathed vinyl cord or cable
Copper wire Insulation

Sheath

★When using shielded wire, be sure to ground

only one side of the shielded wire.
Ground only one side
◆If shielded wire is not properly grounded on one side,
it could disrupt communications.
★Use the same type of wire for all control wiring within the same system.

◆Mixing different types of wires within a system

Sheathed
can result in poor communication. Shielded wire
cable
Page 140
 -p30-
(8) Control wiring work-3
2) Copper wire size: 0.75 - 1.25 mm2

<When using a size other than specified>

◆ Undersized wire:
Lengthy wiring results in unstable transmission due to a drop in voltage.
Moreover, it allows the control wiring to be more easily affected by noise.

◆ Oversized wire:
In daisy-chain wiring, two wires cannot be inserted into the terminal block if
they are too thick.

Two wires cannot be

inserted into the terminal
block if they are thick.

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Page 141
 -p30-
(8) Control wiring work-4
3) Use of multi-core cables with more than 2 cores is prohibited.

<If multi-core cables (more than 2 cores) are used>

Signal interference occurs, resulting in transmission malfunction.

[Example when multi-core cables are used: VRV Series]

Transmission signal waveform Signal interference

Indoor Outdoor unit

Indoor Outdoor unit

4-core cable
Normal state (interwire stray Interference state
(when sending) capacitance) (when sending)

Use of multi-core cables causes a similar phenomenon to that occurs when many
single-core wires are bundled and passed through a conduit.

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TCDB005A(EN)
Page 142
 (8) Control wiring work-5
4) Maximum wiring length A ：200m

Outdoor
unit
Indoor unit Indoor unit Indoor unit Indoor unit

D： 10m
B： 100m

Outdoor
unit
Indoor unit Indoor unit Indoor unit Indoor unit

E ：10m
C： 500m

Outdoor
unit
Indoor unit Indoor unit Indoor unit Indoor unit

F： 20m
Maximum length should be no longer than 1,000 m
E.g.: Centralized
controller
Max. length = A + D + E + C =
200 + 10 + 10 + 500 = 720 m ≤ 1,000 m

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TCDB005A(EN)
Page 143
 (8) Control wiring work-6
5) Total wiring length A：200m

Outdoor
unit
Indoor unit Indoor unit Indoor unit Indoor unit

D：10m
B：100m

Outdoor
unit
Indoor unit Indoor unit Indoor unit Indoor unit

E：10m
C：500m

Outdoor
unit
Indoor unit Indoor unit Indoor unit Indoor unit

F：20m
Total wiring length should be no longer than 2,000 m
Note: If shielded wires are used, it is reduced to no longer than 1,500 m. Centralized
controller
E.g.: Total length = A + B + C + D + E + F =
200 + 100 + 500 + 10 + 10 + 20 = 840 m ≤ 2,000 m

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TCDB005A(EN)
Page 144
 (8) Control wiring work-7
6) Number of indoor and outdoor units connected
Up to
10 outdoor units

Outdoor
unit
Indoor unit Indoor unit Indoor unit Indoor unit

Up to
128 indoor units

Outdoor
unit
Indoor unit Indoor unit Indoor unit Indoor unit

54 HP system
18 HP 18 HP 18 HP

Outdoor

Outdoor
Outdoor
unit

unit

unit
Indoor unit Indoor unit Indoor unit Indoor unit

In the case of VRV II or III, Centralized

controller
the Multi outdoor units are considered as one unit.

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 -p31-
(8) Control wiring work-8
7) Distance from power wiring
Distance between power and Distance between power wiring for
Power wiring capacity control wiring for Daikin air other equipment and control wiring
conditioners for Daikin air conditioners
10A or less 300 mm or more
Power supply box
220V or 50A 500 mm or more
more 50 mm or more
100A 1,000 mm or more
100A or more 1,500 mm or more

Control wiring Indoor unit

100A
Outdoor unit

300 mm or more
30A
Warehouse
fan

10A
50 mm or more
3F
Office
30A
AC
500 mm or more
Roof
pump
20A

Power wiring for Power wiring

© DAIKIN INDUSTRIES, LTD. equipment other TCDB005(EN)
TCDB005A(EN)
for Daikin
than Daikin's equipment Page 146
 (8) Control wiring work-9
8) Polarity

DC16V

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Page 147
 -p31-
(8) Control wiring work-10
9) Prohibition on bundling

Never bundle the control wiring over an extended distance.

<If the control wiring is bundled>

The insulation distance between the wiring gets shorter, subjecting the
transmission signals to interference.

Outdoor
Indoor unit
unit

Outdoor
Indoor unit
unit

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TCDB005A(EN)
Page 148
 (8) Control wiring work-11
10) Terminal block connection

 Do not connect wires with different sizes.

Insertion of differently-sized wires into a terminal block results in
insufficient tightening on the thinner wire side.

Outdoor unit side Indoor unit side

If differently-sized wires are used,

the tightening on the thinner wire side weakens.

 Up to two wires can be connected per terminal block. Three wires cannot
be inserted into a terminal block on the indoor unit.

Three wires cannot be inserted

into a terminal block.

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Page 149
 (8) Control wiring work-12
11) Single system

F1 F2 F1 F2 F1 F2

Indoor Indoor Indoor

unit unit unit

Up to two wires can be inserted into a terminal block.

Master outdoor unit

Slave outdoor unit
F1 F2 Q1 Q2
Q1 Q2

Always use non-polar 2-core wire

for the control wiring.
Page 150
(8) Control wiring work-13
12) Multiple systems
Indoor Indoor Indoor Indoor Master Slave
unit unit unit unit outdoor outdoor
unit unit

OUT-OUT
F1 F2
Master outdoor unit Slave outdoor unit

Indoor Indoor Indoor Indoor

unit unit unit unit

Centralized controller

OUT-OUT
F1 F2

F1 F2
Page 151
 (8) Control wiring work-14
13) Other

• Align the wiring with the space

between the gas and liquid piping.
Wiring

• In some countries, the wiring cannot be bundled with the piping.

If this is the case, it is necessary to use a conduit.

• The wiring must be seamless.

Rain

Short circuit
Ground fault

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 (8) Control wiring work-15
3. Examples of miswiring
1) Branching is prohibited.

Only daisy-chain (series)

wiring is allowed.
Any branching is prohibited.

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TCDB005(EN)
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(8) Control wiring work-16
2) Bus wiring is prohibited.

Centralized
First branch controller

Only daisy-chain (series)

wiring is allowed.
Any branching is prohibited.

Second branch

Third branch

Page 154
(8) Control wiring work-17
3) Star wiring is prohibited.

Only daisy-chain (series)

wiring is allowed.
Any branching is prohibited.

Second branch
Centralized
controller

Page 155
(8) Control wiring work-18
4) Mismatched wiring

Mismatched wiring
Refrigerant piping system 1

Control wiring
Refrigerant piping system 2 Centralized
controller

Refrigerant piping and control wiring are mismatched.

Refrigerant piping and control wiring for many

systems are concentrated in an area where outdoor
units are installed (outlet side)
Page 156
 (8) Control wiring work-19
5) Loop
System 1

Miswiring System 2

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 (8) Control wiring work-20

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 (9) Electric wiring work-1

1. Example of electric wiring work for power supply

Power supply

1ϕ220V

Earth leakage
circuit breaker
Indoor unit Indoor unit Indoor unit Indoor unit
Power supply

1. Conduct the electric wiring work correctly

3ϕ380V
according to the law of your own country.
2. Don't share the power supply circuit.
Earth leakage 3. Work after intercepting a power supply.
circuit breaker 4. Conduct the ground wiring work.

Outdoor unit
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 (9) Electric wiring work-2
2. Example of failure
1) Heat generation and ignition - 1

Do not connect electric

wiring halfway to the
destination unit/device.
3ϕ380V

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 (9) Electric wiring work-3
1) Heat generation and ignition - 2

Power supply box

100A
Outdoor unit
Do not use electric
wiring that is too long or
too small in diameter. 30A
Warehouse
fan
10A

3F
Office
30A AC

Roof
20A pump

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 (9) Electric wiring work-4
1) Heat generation and ignition - 3
Connect the electric wire correctly.

Loose
connection

Power supply terminal

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 (9) Electric wiring work-5
2) Reverse phase

Power wiring reconnection procedure in the case of reverse rotation

Outdoor unit
wiring

L1 L2 L3 Outdoor unit terminal

Field wiring
Switch the connection between
any two of L1, L2, and L3.
Change on this side.

(This example shows how to

reconnect L1 and L2.)

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 -p32-
(10) Outdoor unit installation-1
2-1) Are the selection of the foundation bolts and bolt interval appropriate?
A
B 4-15×22.5 (Foundation bolt hole)

Model A mm B mm

At least 765
722～737

RXYQ5P 635 497

631
RXYQ8P
930 792
RXYQ10P
RXYQ12P,14P
1240 1102
RXYQ16P,18P
At least 67
Foundation drawing for outdoor unit

2-2) Has the foundation height been taken into account?

A 5 HP outdoor unit can

be supported at the four
corners using four block
foundations (bases). At least Necessary if Necessary if
150 at least 8HP at least 8HP
An outdoor unit of 8 HP or above cannot be supported at
the four corners using four block foundations.
Center of the long
Center of the long
side of the unit
side of the unit
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 (10) Outdoor unit installation-2
2-3) Has the adhesion between the foundation and floor/roof been taken into
account?
When installing outdoor units on a roof, be sure to check the strength of the floor and waterproof it.

Example of exposed waterproofing Example of protective waterproofing

*1 for the foundation on the roof for the foundation on the roof
Outdoor unit foundation Joint bar Outdoor unit foundation
Surface
Rubber mat chipping Waterproof concrete
Waterproof layer overlay
Waterproof
*If the waterproof layer is going to be exposed, Rooftop slab layer
be sure to install it so that waterproofing
Rooftop slab
maintenance can be done later.

*1: Refers to a waterproofing layer that is exposed without any concrete or mortar to protect it. It is primarily used on roofs
where people do not usually walk.

Example of installation on the ground

Outdoor unit foundation

Rubble stones

Ground

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 -p33-
(10) Outdoor unit installation-3

No service space!!
(Impossible to replace the
compressor)

Foundation

If the piping runs in front of the outdoor unit, If the piping runs in front of the compressor, it makes
pedestrians or service persons may step on it. the compressor difficult to replace.

Take sufficient service space

It is a good idea to place the refrigerant piping within a piping duct that can be walked on or
construct a catwalk above the piping.
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 -p33-
(10) Outdoor unit installation-4
♦Prevention of short-circuiting

★Note that it may be necessary to install a discharge duct in the cases as shown in the
illustrations below.

*In the case of the high static pressure setting

(Refer to the precautions regarding the high static
pressure setting.)

L<3m
L≥1m N M
L<1m
(Be sure to
remove the
discharge
grill.)
K

<If there is a horizontal obstacle overhead>

No special measures are necessary when L ≥ 3 m.
N ≥ M when L ≥ 1 m. K ≥ M when L < 1 m. When L < 3 m, it is necessary to install a discharge duct
whose duct resistance is up to 78.4 Pa (8 mmH20).

Countermeasures for
When installing under an eave (single unit installation) overhead obstacles

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 -p33-
(10) Outdoor unit installation-5
Example of installation on each floor

Level to 20˚
Downward-
facing louver

Discharge velocity
VD = 5-8 m/s
VD
Discharge Remove the
duct discharge grille

VS
Place directly onto the
Suction velocity louver
VS ≤ 1.6 m/s
Set at the high static
pressure
<Example of bad installation>

At least At least
0.3 m 0.5 m
<Example of improvement>

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 -p33-
(10) Outdoor unit installation-6
Level difference between
outdoor units
Outdoor unit C

Outdoor unit B
5 m or less
Outdoor unit A

Installation conditions by
outdoor unit capacity Outdoor unit A Outdoor unit B Outdoor unit C

Connection piping kit ≥ ≥

To indoor unit(s)

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 -p33-
(10) Outdoor unit installation-7

Protection with vinyl sheets

- If there is any damage to the external casing, be sure to repair it.

- Until the installation work is complete, be sure to cover and protect the outdoor units
with, for example, vinyl sheets to prevent dust and dirt from collecting on or getting into
the heat exchanger.

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 (10) Outdoor unit installation-8

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 -p34-
(11) Air tightness test-1
Procedure
Completion of Nitrogen Check for
Evacuation Pass
refrigerant pressurization drop in
piping work pressure

Leak check

~Working points~
 Be sure to evacuate the piping before the air tightness test.
 Be sure to always use nitrogen gas for the air tightness test.
 The air tightness test pressure is the design pressure for air conditioners.

1) Evacuation of refrigerant piping

<Work procedure>
• Connect the gauge manifold to the service ports on the liquid and gas piping. Operate the vacuum
pump until the pressure reaches below –100.7kPaG (–755mmHg). Operate the vacuum pump for
about 30 minutes, though it may differ depending the respective piping length..

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 -p34-
(11) Air tightness test-2
2) Method of pressurization in the air tightness test

Nitrogen gas Gauge manifold

pressure regulator Low-pressure side valve

High-pressure side valve

Nitrogen

Charge valve
Gas side stop valve
Indoor unit Closed

Outdoor
Charge valve unit
Liquid side stop valve

Closed
Refrigeration
charge

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 -p34-
(11) Air tightness test-3
3) Leak checks

Pressure leak test Temperature Temperature

measurement measurement

Step 3
4.0 No leak if there is
no pressure drop.

Step 2
1.5

0.01MPa/℃
0.3 Step 1

Pressure 0
5 5
MPaG min. min. 2 hours 24 hours
Time

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 -p35-
(11) Air tightness test-4
3) Leak checks
･If a drop in pressure has been detected, search for the leak site by applying soapy water to the
surface of the piping connections (flares, brazed spots) and charge the hose connections.

It is rare to conduct an air tightness test on everything from O/U to I/U at the same time.
If a pressure drop has been detected, it takes a lot of time to check where the leak is.
An efficient method to check is on a block-by-block basis in accordance with work schedule.
After conducting the air tightness test, leaving the pressure between 0.2 and 0.3 MPaG in
the piping allows for the prevention of contamination in the piping.
(3)

(1) Shaft

(2)

The work can be conducted efficiently if pressurization assembly is prepared beforehand.

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 -p35-
(11) Air tightness test-5
4) Check for pressure drop
 If there is no pressure drop, it has passed the test.
Any differences in ambient temperature between during pressurization and during check for pressure
drops will necessitate correction because pressure changes by roughly 0.01 MPaG per 1˚C.

Correction value: (Temperature during pressurization – Temperature during check) x 0.01 MPaG

(Example)

Pressure used for pressurization Ambient temperature

Pressurization 4.00MPaG 25°C

24 hours later 3.95MPaG 20°C

In this case, the correction would be 0.05 MPaG so you can determine there has been
no pressure drop (indicating a PASS).

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 (11) Air tightness test-6

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 -p36-
(12) Vacuum drying-1
1. What is vacuum drying?

Graph of vacuum degree and boiling point

100
MPa MPa
Atmospheric pressure
0
0 0.10
-100
-0.01 0.09
-200
-0.02 0.08
-300

Absolute pressure
-0.03 0.07
Gauge pressure

-400
-0.04 0.06
-500
-0.05 0.05
-600
-0.06 0.04
-700
-0.07 0.03
-800
-0.08 0.02
-900
-0.09 0.01
-1000
Vacuum
0 010 15 2020 30 40
40 60
60 8080 100 100
°C
Temperature
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 -p36-
(12) Vacuum drying-2
Procedure

After passing air tightness test Vacuum drying Vacuum test

~ Noise and vibration considerations ~

Using a vacuum pump, the moisture (liquid) in the piping is changed to vapor (gas) and expelled out of
the piping in order to dry the inside of the piping. At 1 atmospheric pressure (101.3 kPa or 760 mmHg),
the boiling point (evaporation temperature) for water is 100°C. However, the closer the pressure within
the piping comes to reaching a vacuum state as a result of using the vacuum
pump, the lower the boiling point becomes. Once the boiling point falls below the outdoor temperature,
the water will evaporate. kPa kPaG
101.3
<Example> Water boiling Absolute Gauge
point kPa pressuremmHg kPaGpressure mmHgG
If the outdoor air temperature is 7.2°C, ℃

80
vacuum drying cannot be conducted
unless the pressure is lowered
Absolute pressure

below −100.3 kPaG (−752mmHg).

Gauge pressure
60

Therefore, when conducting vacuum

40
drying, 'selection and maintenance of
the vacuum pump' is important..
20
7.4 -94
4.2 -97
1.1 -100.3

0 10 20 30 40 50 60 70 80 90 100 ℃

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TCDB005A(EN) Water boiling point
Page 179
 (12) Vacuum drying-3
2) Vacuum drying operation
[Indoor unit]

[Outdoor unit]
Gas side
service port
Valves [Open]

Liquid side
service port Closed

Closed

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 (12) Vacuum drying-4

3) Vacuum pump operation time

Vacuum drying

 Evacuation: Evacuation of the air containing moisture

in the refrigerant circuit
Operation time … Until the gauge reads [–0.1 MPa]

 Drying: Removal of the moisture from the refrigerant circuit

by boiling and evaporating
Operation time … At least 1 hour

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 (12) Vacuum drying-5
4) Selection of the vacuum pump

Throughput 40ℓ/min

Atmospheric pressure 760 mmHg

0 MPa
1 mmHg
Ultimate vacuum 5–15 microns

Absolute pressure
Gauge pressure
15 Microns
 Oil change 1–2 months 10 Microns
5 Microns
–0.1 MPa 0 mmHg
＝
0 mmHg

–760 mmHg
–0.1 MPa

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 (12) Vacuum drying-6

Air conditioners that use an HFC refrigerant, such as R410A Use synthetic oil

Do not mix
Vacuum pump Use mineral oil

Backflow preventer
(solenoid valve)

R410A refrigerant air conditioner

Service port size 5/16 inches

(The size of the service port for air conditioners using any other type of refrigerant is 1/4 inches.)

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 -p37-
(12) Vacuum drying-7
<Work procedure>
There are two methods of vacuum drying depending on the onsite conditions so selectively use them.
1) Normal vacuum drying…This is the common method.

(1) Vacuum drying (1st time) [Normal vacuum drying time chart]
・Connect a gauge manifold to the service ports of
the liquid and gas piping and operate the
vacuum pump for at least 2 hours. Pressurized side
(The pressure must be below −100.7 kPaG or
−755 mmHg.)
Atmospheric
・If the pressure does not fall below −100.7 kPaG pressure 0 MPaG
or −755 mmHg even after vacuuming for 2 hours,
there may either be moisture or a leak in the Vacuumed side
circuit. Vacuum for 1 more hour to confirm this.
・ If the pressure does not fall below −100.7 kPaG or
−755 mmHg even after vacuuming for 3 hours,
check for the leak site. -100.7 kPaG
(2) Vacuum test
Leave the system in a vacuum state below Additional refrigerant charge
−100.7 kPaG or −755 mmHg for at least 1 hour Vacuum
drying
Vacuum (Refer to the following chapter.)
state
and confirm that the gauge indicator does not rise. (2 hours) (1 hour)

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 -p37-
(12) Vacuum drying-8
 Conduct evacuation from both the liquid and gas piping. There are various types of
functioning components in an indoor unit and evacuating only from one (liquid or gas)
piping may result in a break in the vacuum state.

 If the gauge indicator rises, there may be moisture remaining or a leak in the circuit.

2) Special vacuum drying

Special vacuum drying is conducted when there is a risk of moisture within the piping.
For example,
 When work has been done during the rainy season and there is a risk of condensation within the piping
 When the work has taken a long time and there is a risk of condensation within the piping
 When there is a risk that rain has entered into the piping during work
The special vacuum drying incorporates at least one vacuum break process using nitrogen gas during
the normal vacuum drying process.

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 -p38-
(12) Vacuum drying-9
(1) Vacuum drying (1st time)
 The procedure is the same as [Special vacuum drying time chart]
“Normal vacuum drying”
(2) Vacuum break (1st time) Pressurized side
Pressurize with nitrogen to 0.05 MPaG.
(The nitrogen gas is a dry nitrogen,
so breaking the vacuum state with it increases Atmospheri
c pressure 0 MPaG
the effectiveness of the vacuum drying.)
Vacuumed side
(3) Vacuum drying (2nd time)
Operate the vacuum pump for at least 1 hour.
Determinations: The pressure must reach at
least −100.7 kPaG or −755 mmHg.
If it does not even after 2 hours of operation, -100.7 kPaG
repeat steps (2) (vacuum break) and Vacuum
drying Additional
(3) (vacuum drying). (2 hours) refrigerant
Vacuum breaking charge
(4) Vacuum test Vacuum drying(1 hours) Vacuum state(1 hour)
 The procedure is the same as
“Normal vacuum drying”

 Be sure to use nitrogen gas when conducting vacuum break.

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 (12) Vacuum drying-10

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 -p39-
(13) Additional refrigerant charge-1
Procedure

After completion of Calculation of additional Additional refrigerant

vacuum drying refrigerant amount charge

<Work procedure>

(1) Calculation of the additional refrigerant charge amount

･Accurately assess the length of the refrigerant piping to calculate the amount of additional
refrigerant charge.
(For calculating the formula, refer to the equipment design materials for the respective models.)

 Be sure to enter the calculated additional refrigerant charge amount on the 'additional
refrigerant charge instruction label' on the outdoor unit.
(The data will be needed for maintenance.)

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 -p39-
(13) Additional refrigerant charge-2
Refrigerant charge port
Outdoor unit Gauge
Liquid side stop valve
manifold Refrigerant
Valve A
cylinder
with siphon
Valve Gauge
B

Indoor unit

Gas side stop valve

(2) After completing the vacuum drying, leave the air conditioner OFF, open Valve A and charge
the calculated additional refrigerant from the cylinder via the liquid side stop valve service
port using pressure difference.

 Be sure to charge the refrigerant in a liquid state.

(Cylinders with siphons allow for charging of liquid refrigerant in a standing position.)
 Use a digital scale to measure.

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 -p39-
(13) Additional refrigerant charge-3
･ Why is it necessary to charge R410A in a liquid state?

R410A is a non-azeotropic refrigerant

Pressure
R410A
R32 R125 Liquid Gas
50% 50%
Liquid Gas
R32 begins to evaporate
Liquid Gas

R32 R125 begins to evaporate

Gas
R125
0MPaG

：R32 Liquid
：R125
Temp.
R410A refrigerant cylinder
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 -p39-
(13) Additional refrigerant charge-4
･ Required equipment
① ② ③
Hexagonal
wrenches

R410A
Valve key

Flathead
screwdriver Refrigerant
Required tools : R410A Digital scale ⑥

④-1 ④-2 ⑤

Vacuum pump with

Gauge manifold Charge hoses Charge valve oil check valve

- Be sure to use the appropriate equipment

and tools according to the type of air conditioner and refrigerant.
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 -p39-
(13) Additional refrigerant charge-5
If the refrigerant cannot be charged due to pressure equalization,

Refrigerant charge port

Liquid side stop valve Outdoor unit Gauge
Open
manifold Refrigerant
Valve A
Close cylinder
with siphon
Gauge
Valve B
Open

Indoor unit

Gas side stop valve

Open

(3) Close Valve A and then open Valve B.

(4) Turn on the outdoor and indoor unit power supplies.
(5) Completely open up the gas and liquid side stop valves.

 Be sure to charge refrigerant from the refrigerant charge port.

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 -p39-
(13) Additional refrigerant charge-6
(6) Turn the additional refrigerant charge operation to ON using the “setting mode 2 No.20” while
leaving the air conditioner OFF.

No. Setting item Description

20 Additional refrigerant Carries out additional refrigerant charge operation

charge operation setting

Refer to the 'Service Precautions' label on the outdoor unit's electrical box
cover for the procedures regarding additional refrigerant charge operation.

(7) Once the required volume of refrigerant has been charged, push the mode button (BS3) on the
PCB (A1P) to stop the operation.

Setting mode 2 (H1P ON)

Change to setting mode 2 from
setting mode 1

Press and hold the BS1 (MODE )

for 5 seconds
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Page 193
 -p39-
(13) Additional refrigerant charge-7
How to set the “ Additional
16 + 4 =20 32 16 8 4 2 1
refrigerant charge”
Set the LED display BS2
to No.20

Decide the item. BS3

Change LED from

OFF to ON BS2
(Operation starts)

Decide the item.

(Additional refrigerant BS3
charge operation starts)

If all ref. charged, terminate the

operation by pressing the BS3 BS3
and return to the initial status
of “Setting mode 2”
Page 194
 (13) Additional refrigerant charge-8

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 (14) How to check the number of installed indoor units-1

7 indoor units have been installed.

Outdoor How many indoor units are Confirm using Item No. 5
unit
recognized by the outdoor unit? in the Monitor mode.

If it differs from the

Indoor Indoor Indoor Indoor Indoor Indoor Indoor actual number of
unit 1 unit 2 unit 3 unit 4 unit 5 unit 6 unit 7
units installed.

R/C R/C

Check the power wiring and

control wiring connections.

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 (14) How to check the number of installed indoor units-3
Monitor mode(H1P Blinking） Blinking On Off

Setting item display

C/H selection
No. Low
MODE TEST Deman
Setting item IND Master Slave noise
H1P H2P d H7P
H3P H4P H5P H6P

5 Number of connected indoor units       Lower 6 digits

Press the BS1 button once to switch

from Setting mode 1 to the Monitor mode.

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 (14) How to check the number of installed indoor units-4
Button
No. Operation LED
name

1 Press the BS2 button five times to set the LED display to
Item No. 5 "Number of connected indoor units." BS2
4+1=5 32 16 8 4 2 1

2 Press the BS3 button once to show the number of

connected indoor units on the LED display. BS3

32 16 8 4 2 1
Number of indoor units connected: 4 + 2 + 1= 7 units
Confirm the number of units with the
H2P to H7P LED display.

Number of units installed = Number of units connected

Power wiring and control wiring are properly connected.

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© DAIKIN INDUSTRIES, LTD. TCDB005(EN)
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