TESTING & COMMISSIONING PROCEDURE FOR DVM-S AIRCONDITIONERS PRE-TESTING & COMMISSIONING 1. Confirm to installation group of the following activities: A. Flushing of Refrigerant Pipes PROCEDURE A.1 Install the pressure - reducing valve on the nitrogen gas cylinder. A.2 Connect the charging hose leading from the pressure reducing valve to the service port at the flare-connected ‘outdoor unit liquid pipe side & gas pipe side A.3 Open the main valve of the nitrogen gas cylinder, and adjust the pressure - reducing valve to bring the pressure up. ‘A.4 Block the end of the pipe with the palm of your hand to ralse the pressure. When flushing the pipe, place a rag gently against the ‘end of the copper pipe and check the type and quantity of foreign matters. If any moisture inside the pipe (vacuum dry). |A.5 When the pressure has risen to the extent where you cannot keep your hand in place, quickly remave your hand fram the pipe (First flushing). A.6 Block the end of the pipe again with rag on the palm of your hand (Second flushing). A.7 Close the pressure-reducing valve of the nitrogen gas cylinder.A.8 Tighten the flare-connection fitting of the liquid & gas pipe ‘of the indoor unit. B. Leak Testing of Refrigerant Pipes PROCEDURE B.1 Connect the charging hose leading from the gauge manifold to the nitrogen gas cylinder and another hose leading from the service port at the flare - connected outdoor unit liquid pipe side and gas pipe side. B.2 Open the nitrogen gas cylinder valve gradually. B.3 Open the valve gradually and start raising the pressure of the nitrogen gas as follows: 8.3.1 Initial leak testing of refrigerant pipe only {without machine connection) >» 550 PSI for 24 Hours B.3.2 Final leak testing of refrigerant pipe (with machine connection) + 450 PSI for 24 Hours 8.4 Close the valve once the pressure has risen to the prescribed level B.5 Inspect for gas leaks + Dip a brush into a soapy water & apply it to the inspection — Asatisfactory state __ is indicated if no bubbles formed within 10 seconds. The rear side ts inspected using a mirror since it ts otherwise hard to see what is happening even when the soapy water is applied. It is important to check carefully that no bubbles has formed. B.6 Check if the gas pressure doesn’t change during the leak inspection. ee ah E eeC. Wacuuming of Refrigerant System (Excluding Outdoor Unit) VACUUMING - the objective of vacuuming is to discharge the non-condensable gases (air) inside the refrigerant circuit. PROCEDURE €.1 Connect the charging hose leading from the gauge manifold to the service port at the flare-connected outdoor unit liquid pipe side and gas pipe side and another hose leading to the vacuum pump. C.2 Open the valve of the gauge manifold. C.3 Operate the vacuum pump. After the vacuum gauge indicator reading has exceeded 30 in Hg (76 cm Hg.) proceed with vacuuming for at least 5 hours, and then close the valve and shut down the vacuum pump. C.4 Leave the equipment standing for 5 minutes. Check that the vacuum gauge painter does not rise during this time. (C.5 Remove the hose of the vacuum pump from the gauge manifold and connect hose from the nitrogen canister in its place. C.6 Open the valve on the gauge manifold and the valve on the nitrogen cylinder. Charge with nitrogen until the compound gauge indicates 2 kg/cm2 (30 psi), and then close both valves. €.7 Leave the equipment standing for 10 minutes. C.8 Discharge the nitrogen down to 5 psi. C.9 Repeat steps C.1 to C.8 twice. €.10 Repeat steps C.3 and C.4. Charge with the proper refrigerant. up to 30 psig C.11 Discharge the refrigerant down to 5 psig C.12 Repeat steps c and d. C.13 Charge with the proper refrigerant up to 2 kgs (initial charge)2. Check the location of FCU / ACCU (Proper ventilation and service maintenance purposes) 3. Check power supply voltage. See equipment schedule A. FCU 220 Volts 18 B. ACCU 220 Volts 30 4, Check sizes of actual installed refrigerant pipe / joint pipes / twinning kit as per Design Tool. 5. Check drain pipe lay-out & proper sloping Make sure that proper sloping was observed. 6. Check wire sizes (FCU/ACCU/ Transmission Wire / Controller Wire) 7. Addressing of FCU / ACCU 3 digit decimal system 8. Check if all the address of FCU were registered to main board of ACCU TESTING & COMMISSIONING 1, Before starting the test run, turn-on the power at least 2 hours before starting operation. 2, Necessary tools for installers during testing & commissioning: a. multi tester and clamp meter b. system analyzer w/ hose ¢. adjustable wrench d. screwdrivers (+ and -) e. pliers f. thermometer g. allen wrench 7 h. refrigerant R410A oh i. weighing scale ne3. Checkpoints for testing & commissioning: a. equipment setting (indoor/outdoor). b. equipment clearances (for service purpases). c. length and size of refrigerant pipes. d. size of rubber insulation for piping. e. possible leak of refrigerant piping and drain line. f. size of electrical wire & breaker capacity. g. wiring connections and tightness. h. power supply voltage. 1, serial numbers (indoor/outdoor). 4. Test run the FCU’s: - check fan operation + check airflow (low/high) + check swing louver (if available) 5. Operate all units in cooling mode. 6. Check all readings / data using maintenance tools Standard range Value: Low Pressure 100 PSI - 130 PSI High Pressure 310 PSI - 480 PSI Standing Pressure 230 PSI - 270 PSI 7. Charging R410A as per method of calculating additional Refrigerant charge. 8. Check room temperature (22°C - 25°C) and ambient temperature (37°C below) using digital thermometer. 9. Prepare Start-up report. gE ane f Gig <