AU-X08 (serv.man15). Refrigerant Piping Installation Servicing Manual for Air Condioners Using R-410A — Sharp Air Conditioner Service Manual (repair manual)

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AU-X08 (serv.man15)
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12
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Service Manual
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Device
Air Conditioner / Refrigerant Piping Installation Servicing Manual for Air Condioners Using R-410A
File
au-x08-sm15.pdf
Date

View Sharp AU-X08 (serv.man15) Service Manual online

49
AH/AY-X08CR
AH/AY-X10CR
AH/AY-X13CR
Page
1. Outline .........................................................................................................................................................  49
    1.1 Refrigerant R410A .................................................................................................................................. 50
    1.2 Safety during Installation / Servicing ......................................................................................................  50
2. Refrigerant Piping Installation ..................................................................................................................  50
    2.1 Pipng Materials and Joint Used .............................................................................................................. 50
    2.2 Processing of Piping Materials ................................................................................................................ 51
    2.3 Storage of Piping Materials ....................................................................................................................  53
3. Installation, Removal and Services ..........................................................................................................  53
    3.1 Tools for R410A .....................................................................................................................................  53
    3.2 New Installation Work (When Using New Refrigerant Piping) ...............................................................   55
    3.3 Removal (When Using New Refrigerant Piping) ....................................................................................  57
    3.4 Replacing the UNit (Never Use the Existing Refrigerant Piping) ...........................................................  57
    3.5 Retrofitting ............................................................................................................................................... 57
    3.6 Refrigerant Recharging at Servicing ....................................................................................................... 58
TABLE OF CONTENTS
Refrigerant Piping
Installation / Servicing Manual
for Air Condioners
Using R-410A
50
AH/AY-X08CR
AH/AY-X10CR
AH/AY-X13CR
1. Outline
1. 1 Refrigerant R410A
(1) Adoption of R410A in Air Conditioners
In 1974, it was pointed out that ozone layer in the upper stratosphere (about 20 ~ 40 km above ground) might
have been damaged by the ozone depleting substances such as CFC (chlorofluorocarbon) and HCFC
(hydrochlorofluorocarbon). Since that time, many countries across the world have endeavored to take
countermeasures against the ozone depletion.
As a refrigerant belonging to the HCFCs, the conventional refrigerant (R22) used in air conditioners also tends
to deplete the ozone layer. Therefore, complying with the provisions of the international regulations (i. e.
Montreal Protocol concerning the Ozone Depleting Substances) and national laws & regulations concerned, it
is necessary to replace R22-with other types of refrigerant which do not deplete the ozone layer.
A refrigerant composed of hydrogen (H), fluorine (F) and carbon (C), is called an HFC and does not deplete the
ozone layer. One HFC's is R410A whose pressure is about 1.6 times higher than R22 and whose energy
efficiency is almost comparable to that of R22 at the same refrigerant temperature.
(2) Chemical Characteristics of R410A
a) Chemical Stability
Like R22, R410A is a chemically stable, less toxic and not-flammable refrigerant. However, as in the case
of R22, the specific gravity of its vapour is larger than that of air and should it leak in an airtight room it may
stay at a low level and cause an oxygen starvation accident. It may also, should it come in direct contact
with file, cause a poisonous gas to occur, so be sure to handle it only in a well ventilated area.
Table 1. Comparison of Thermophysical Properties of R410 and R22
Composition (wt%)
R410A
R22
R32/R125 (50/50)
R22 (100)
72.6
86.5
- 51.4
- 40.8
1.56
0.94
64.0
44.4
Nonflammable
Nonflammable
0
0.055
1730
1700
Molecular weight
Boiling point (˚C)
Vapor pressure (25˚C, MPa)
Saturated vapor density (25˚C, kg/m
2
)
Inflammability
Ozone depletion potential (ODP)
Global warming potential (GWP)
Source: List of Thermophysical Properties complied by the Japan Sociery of Refrigeration 
             and Air Conditioning, NIST REFPROP V5.10, etc.
b) Composition Changes (Pseudo-azeotropic Characteristics)
R410A is a pseudo-azeotropic mixed refrigerant composed of two constituents-R32 and
R125. "Quasi-azeotropic" condition refers to a state in which the dew-point curve and boiling-point curve-
gas-liquid equilibrium curves (pressure constant) -almost lie on top of each other, and a multi-constituent
refrigerant having this chemical characteristic incurs less composition changes even when evaporation (or
condensation) as a phase change occurs. Consequently, even when refrigerant leaks from the gas phase
somewhere in the piping installation, the composition of circulated refrigerant incurs less changes.
Therefore, R410A can be treated in almost a same manner as a mono-constituent refrigerant like R22 is
treated. When actually charging R410A, however, do so from the liquid phase side by taking into account
the phenomenon that, when put in a cylinder, the composition changes a little between gas and liquid
phases.
C) Pressure Characteristics
As shown in Table 2, since R410A's
vapor-pressure is about 1.6 times
higher than that of R22 at the same
temperature, perform installation/
service with special toolsand
materials which are exclusive for
R410A and can withstand high
pressure.
Table 2. Comparison of Saturated Vapor Pressure of R410 and R22
Source: List of Thermophysical Properties complied by the 
Japan Sociery of Refrigeration and Air Conditioning, 
NIST REFPROP V5.10, etc.
Temperature (˚C)
Refrigerant
R410A
R22
0.30
0.14
0.70
0.40
1.35
0.81
2.32
1.43
3.73
2.33
4.15
2.60
- 20
0
20
40
60
65
51
AH/AY-X08CR
AH/AY-X10CR
AH/AY-X13CR
(3) Lubricationg Oils for R410A
As the lubricating oils for R22, mineral oils, alkylbenze synthetic oils, etc. have so far been used. As R410A
features less solubility with these conventional lubricating oils such as mineral oils, the lubricating oils tend
to stay within the refrigeration cycle. As the lubricating oils highly soluble with R410A, ester, ethereal and
other synthetic oils are available. However, as these synthetic oils are very hygroscopic, they must be
treated even more carefully than the conventional lubricating oils. Furthermore, if these synthetic oils are
mixed with mineral oils, alkylbenzene synthetic oils, etc., they may deteriorate, and block the capillary
tubes, or cause the compressor to fail. So, never mix these synthetic oils.
1.2 Safety during Installation/Servicing
As R410A's pressure is about 1.6 times higher than that of R22, improper installation/servicing may cause a
serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing
safely while taking the following precautions into consideration.
1) Never use refrigerant other than R410A in an air conditioner which is designed to operate with R410A.
2) If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully.
If the refrigerant gas comes into contact with fire, a poisonous gas may occur.
3) When installing or removing an air conditioner, do not allow air or moisture to remain in the refrigeration cycle.
Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury
may be caused.
4) After completion of installation work, check to make sure that there is no refrigeration gas leakage.
If the refrigerant gas leaks into the room, coming into contact with fire in the fandriven heater, space heater,
etc., a poisonous gas may occur.
5) When an air conditioning system charged with a large volume of refrigerant (e. g. multi type air conditioner) is
installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration
does not exceed the marginal level.
If teh refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation
accident may result.
6) Be sure to carry out installation or removal according to the installation manual. Improper installation may
cause refrigeration troule, water leakage, electric shock, fire, etc.
7) Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a
qualified air conditioner technician or electrician.
Improper repair's may result in water leakage, electric shock and file, etc.
2. Refrigerant Piping Installation
2.1 Piping Materials and Joints Used
For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for
the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints
whose interior surfaces are less affected by contaminants.
(1) Copper Pipes
It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is
desirable that the amount of residual oil is less than 40 mg/10m. Do not use copper pipes having a collapsed,
deformed or discolored portion (especially on the interior surface). Otherwise, the expansion valve or capillary
tube may become blocked with contaminants.
As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose
adequate materials.
Thicknesses of copper pipes used with R410A are as shown in Table 3. Never use copper pipes thinner than
0.8 mm even when it is available on the market.
Table 3. Thicknesses of Annealed Copper Pipes
Normal diameter
Thicknesses (mm)
Outer diameter (mm)
[ref.] R22
6.35
0.80
9.52
0.80
12.70
0.80
15.88
1.00
R410
0.80
0.80
0.80
1.00
1/4
3/8
1/2
5/8
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AH/AY-X08CR
AH/AY-X10CR
AH/AY-X13CR
2.2 Processing of Piping Materials
When performing the refrigerant piping installation, care should be taken to ensure that water or dust does
not enter the pipe interior, that no other oil other than lubricating oils used in the installed air conditioner is
used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such
lubricating oils whose water content has been removed. When stored, be sure to seal the container with an
airtight cap or any other cover.
(1) Flare Processing Procedures and Precautions
a) Cutting the Pipe
By means of a pipe cutter, slowly cut the pipe so that it is not deformed.
b) Removing Burrs and Chips
If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and
clean the cut surface before installation.
c) Insertion of Flare Nut
d) Flare Processing
Make certain that a clamp bar and copper pipe have been cleaned.
By means of the clamp bar, perform the flare processing correctly.
Use either a flare tool for R410A or conventional flare tool.
Flare processing dimensions differ according to the type of flare
tool. Be careful. When using a conventional flare tool, be sure to
secure "dimension A" by using a gage for size adjustment.
Table 4. Dimensions related to Flare Processing for R410A
Norminal 
diameter
Norminal 
diameter
(mm)
A (mm)
Conventional flare tool
Clutch type
Wing nut type
1.5 ~ 2.0
1.5 ~ 2.0
2.0 ~ 2.5
2.0 ~ 2.5
1.0 ~ 1.5
1.0 ~ 1.5
1.0 ~ 1.5
1.0 ~ 1.5
0 ~ 0.5
0 ~ 0.5
0 ~ 0.5
0 ~ 0.5
Flare tool fot R410A
Clutch type
1/4
6.35
9.52
12.70
15.88
Thickness
(mm)
0.8
0.8
0.8
1.0
3/8
1/2
5/8
Table 5. Dimensions related to Flare Processing for R22
Norminal 
diameter
Norminal 
diameter
(mm)
A (mm)
Conventional flare tool
Clutch type
Wing nut type
1.0 ~ 1.5
1.0 ~ 1.5
1.5 ~ 2.0
1.5 ~ 2.0
0.5 ~ 1.0
0.5 ~ 1.0
0.5 ~ 1.0
0.5 ~ 1.0
0 ~ 0.5
0 ~ 0.5
0 ~ 0.5
0 ~ 0.5
Flare tool fot R410A
Clutch type
1/4
6.35
9.52
12.70
15.88
Thickness
(mm)
0.8
0.8
0.8
1.0
3/8
1/2
5/8
Table 6. Flare and Flare Nut Dimensions for R410A
Norminal 
diameter
Norminal 
diameter
(mm)
Dimension (mm)
Flare nut 
width
9.1
13.2
16.6
19.7
A
9.2
13.5
16.0
19.0
B
6.5
9.7
12.9
16.0
C
13
17
22
26
29
20
23
25
D
1/4
6.35
9.52
12.70
15.88
Thickness
(mm)
0.8
0.8
0.8
1.0
3/8
1/2
5/8
[Unit: mm]
ØD
A
Fig. 3 Flare Processing DImensions
Page of 12

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