DOWNLOAD Sharp AU-X08 (serv.man15) Service Manual ↓ Size: 106.39 KB | Pages: 12 in PDF or view online for FREE

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

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

52
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
53
AH/AY-X08CR
AH/AY-X10CR
AH/AY-X13CR
Table 7. Flare and Flare Nut Dimensions for R22
Norminal 
diameter
Norminal 
diameter
(mm)
Dimension (mm)
Flare nut 
width
9.0
13.0
16.2
19.4
A
9.2
13.5
16.0
19.0
B
6.5
9.7
12.9
16.0
C
13
17
22
24
27
20
20
23
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]
45
˚ ~ 46
˚
43
˚ ~ 45
˚
B
C
D
A
Fig. 4 Relations between Flare Nut and Flare Seal Surface
(2) Flare Connecting Procedures and Precautions
a) Make sure that the flare and union portions do not have any scar or dust, etc.
b) Correctly align the processed flare surface with the union axis.
c) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for
R410A is same as that for conventional R22. Incidentally, when the torque is wekd, the gas leakage
may occur. When it is strong, the flare nut may crack and may be made nonremovable. When
choosing the tightening torque, comply with values designated by manufacturers. Table 9 shows
reference values.
Note:When applying oil to the flare surface, be sure to use oil designated by the manufacturer. If any
other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.
Table 8. Tightening Torque of R410A [Reference Values]
Norminal 
diameter
Norminal 
diameter
(mm)
16 (160), 18 (180)
42 (420)
55 (550)
65 (650)
1/4
6.35
9.52
12.70
15.88
14 ~ 18 (140 ~ 180)
33 ~ 42 (330 ~ 420)
50 ~ 62 (500 ~ 620)
63 ~ 77 (630 ~ 770)
3/8
1/2
5/8
Tightening torque
N m (kgf cm)
Tightening torque of torque 
wrenches available on the market
N m (kgf cm)
54
AH/AY-X08CR
AH/AY-X10CR
AH/AY-X13CR
2.3 Storage of Piping Materials
(1) Types and Storage of Piping Materials
Refrigerant piping materials for air conditioners are broadly classified into the following types.
Refrigerant piping
materials
with heat
insulation
without heat
insulation
(bare copper pipe)
with flare processing
without flare processing
without flare processing
General name
: (a) Piping set
: (b) Copper pipe with insulation
: (c) Bare copper pipe
As R410A features pressure about 1.6 times higher than R22, it is necessary to use a copper pipe which has
a thickness stated in Table 3 and which contains less contaminants. It is necessary to carefully treat/store
copper pipes so that they are not collapesd, deformed or damaged. Due care must also be exercised so that
foreign matters such as dust and water do not enter the pipe interior.
A piping set's open end is sealed with a cap, etc. When storing it, make sure that it is sealed securely. When
storing a cladded copper pipe or bare copper pipe, securely seal the opening with pinching, taping, etc.
(2) Identification
a) Piping set
A copper pipe as piping set for R410A must have a thickness as stated in Table 3, and, as shown in Tables
5 and 6, it also differs from R22 in flare processing and flare nut dimensions. So, it is necessary to choose
a piping set suitable for R410A.
b) Copper Pipe with Insulation
Before using a copper pipe with insulation, make sure that is has a thickness designated for R410A.
c) Bare Copper Pipe
It is necessary to use a bare copper pipe which has a thickness desigtnated in Table 3 and contains less
contaminants. As the bare copper pipe surface is naked, it is necessary to treat it with exceeding care and
adopt a means for identification to prevent improper usage by making it easily discriminable from other
piping materials.
(3) Precautions before Installation
Observe the following precautions when performing the piping connection at the site.
a)  Keep any open ends of pipes be sealed with a cap,  etc. until connected with the equipment.
b) Exercise great care when performing piping installation on a rainy day.
When water enters into the piping, the lubricating oil may deteriorate and cause the equipment to fail.
c) Carry out the piping connection in as short a time as possible.
If the piping is left open for a long period, fully purge the interior with nitrogen gas or dry it with a vacuum
pump.
3. Installation, Removal and Servicing
3.1 Tools for R410A
In the case of an air conditioner using R410A, in order to prevent any other refrigerant from being
chargedaccidentally, the service port diameter of the outdoor unit control valve (3-way valve) has been changed.
Also, to increase the pressure resisting strength, flare processing dimensions and sizes of opposite sides of flare
nuts (for copper pipes with nominal diameters 1/2 and 5/8) have been changed. During installation/service,
therefore, prepare tools exclusive for R410A shown in (1) below and general tools shown in (2) on page 48.
(1) Tools Exclusive for R410A
a) Gauge Manifold
As R410A is characterized by high pressure, conventional tools cannot be used.
Table 9. Differences between Conventional High/Low Pressure Gauges and Those for R410A
High pressure
gauge (red)
Conventional gauges
Gauges exclusive for R410A
- 0.1 ~ 3.5 MPa
- 76 cmHg ~ 35 kgf/cm
2
- 0.1 ~ 1.7 MPa
- 76 cmHg ~ 17 kgf/cm
2
- 0.1 ~ 5.3 MPa
- 76 cmHg ~ 53 kgf/cm
2
- 0.1 ~ 3.8 MPa
- 76 cmHg ~ 38 kgf/cm
2
Compound
gauge (blue)
In order to prevent any other refrigerant from being charged accidentally, each port of yhe manifold has
been changed in shape.
55
AH/AY-X08CR
AH/AY-X10CR
AH/AY-X13CR
Table 10. Differences in Port Size between Conventional Manifold and That for R410A
Port size
Conventional manifold
Manifold for R410A
7/16 UNF
20 threads per inch
1/2 UNF
20 threads per inch
b) Charge Hose
As R410A is characterized by high pressure, the pressure resistance of the charge hose has been
increased. The material has also been changed to an HFC resistant type, and, as is the case of each
port of the manifold, the hose cap size has been changed. Furthermore, for prevention of gas pressure
reaction, a charge hose with a valve placed near the cap is also available.
Table 11. Differences between Conventional Charge Hose and That for R410A
Pressure
resistance
Conventional charge hose
Charge hose for R410A
3.4 MPa (34 kgf/cm
2
)
17.2 MPa (172 kgf/cm
2
)
NBR rubber
7/16 UNF
20 threads per inch
5.1 MPa (51 kgf/cm
2
)
27.4 MPa (274 kgf/cm
2
)
HNBR rubber
internally coated with nylon
1/2 UNF
20 threads per inch
Engineering material
Normal pressure
Breaking pressure
Cap size
c) Electronic Balance for Refrigerant Charging
As R410A belonging to the HFCs features high pressure and high evaporating speed, when R410A is
charged by using a charging cylinder, R410A in the cylinder cannot be kept in a liquefied state and
gasified  refrigerant bubbles in the charging cylinder, it becomes difficult to read values. Therefore, it is
advisable to adequately use an electronic balance for refrigerant charging.
An electronic balance for refrigerant charging has higher strength due to its structure
with four points of support for refrigerant cylinder weight detection. As the charge hose connecting part
has two ports-one for R22 (7/16 UNF 20 threads per inch) and the other for R410A (1/2 UNF 20 threads
per inch)-it can also be used for charging the conventional refrigerant.
Two types of electronic balance for refrigerant charging are available-one for 10 kg cylinder and the other
for 20 kg cylinder.
Electronic balance for 10 kg cylinder ...... precision 
±
 2g
Electronic balance for 20 kg cylinder ...... precision 
±
 5g
Refrigerant is charged maunally by opening/closing the valve.
d) Torque Wrench (for nominal diameters 1/2 and 5/8)
Along with changes is flare nut sizes for enhanced pressure resisting strength, torque wrenches for
R410A differ in opposite side size.
Table 12. Differences between Conventional Wrenches and Those for R410A
For 1/2 
(opposite x torque)
For 5/8 
(opposite x torque)
Conventional torque wrench
Torque wrench for R410A
24 mm x 55 N m
(550 kgf cm)
27 mm x 65 N m
(650 kgf cm)
26 mm x 55 N m
(550 kgf cm)
29 mm x 65 N m
(650 kgf cm)
e) Flare Tool (clutch trpe)
A flare tool for R410A is provided with a large clamp bar receiving hole so that the projection of the copper
pipe from the clamp bar can be se at 0 ~ 0.5 mm in flare processing, and also features higher spring
strength for increased expansion pipe torque. This flare tool can also be used for R22 copper pipe.
f)
Gauge for Projection Adjustment (used when flare processing is made by using conventional flare
tool [clutch type] )
A gauge 1.0 mm in thickness which helps in easily setting the projection of the copper pipe from the
clamp bar at 1.0 ~1.5 mm.
g) Vacuum Pump Adapter
It is necessary to use an adapter for preventing vacuum pump oil from flowing back to the charge hose.
The charge hose connecting part has two ports-one for conventional refrigerant (7/16 UNF 20 threads
per inch) and the other for R410A. If the vacuum pump oil (mineral) mixes with R410A, a sludge may
occur and damage the equipment.
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  • Here you can View online or download the Service Manual for the Sharp AU-X08 (serv.man15) in PDF for free, which will help you to disassemble, recover, fix and repair Sharp AU-X08 (serv.man15) Air Conditioner. Information contained in Sharp AU-X08 (serv.man15) Service Manual (repair manual) includes:
  • Disassembly, troubleshooting, maintenance, adjustment, installation and setup instructions.
  • Schematics, Circuit, Wiring and Block diagrams.
  • Printed wiring boards (PWB) and printed circuit boards (PCB).
  • Exploded View and Parts List.