PRESSURE TESTING

After completion of the piping circuit installation, the entire installation shall be
pressure tested with dry nitrogen gas at the following pressures.:-

----------------------------------------------------------------------------------------
Test pressure
KG / Sqcm (gauge)
Refrigerant --------------------------------------------------------
High Pressure Low Pressure
side side

R – 134a 25 14

This test shall be carried out for both 400V, 3Ph, 50Hz units in steps as follows :-

A. The system shall be charged with Nitrogen or inert gas to 1.0Kg/Sqcm gauge
and all points shall be checked for large leakages with a mixture of four parts
water, one part liquid soap and a small amount of glycerene. Leaks shall be
marked, pressure released and repairs done. Brazed joints which leaks shall
be opened and redone. These shall not be repaired by addition of brazing alloy
to the joint.
B. The system shall now be charged with Nitrogen gas to the pressure specified
in the above table and the process of locating leaks and repairs shall be
repeated.

PRESSURE HOLDING TEST

The system shall hold the pressure for a minimum period of 24 hours without
revealing any leaks. After the leak test had been completed successfully,
Nitrogen gas in the system shall be used to blow out the system.

VACUUMISING
The system shall then be dehydrated by drawing a vacuum to achieve at least
as deep as 0.3 microns absolute and shall be maintained for a period of at
least FOUR HOURS with the vacuum pumps running. After this period, the
pump shall be disconnected and refrigerant system shall be sealed.

VACUUM HOLD TEST

The vacuum should be maintained for 24 hours. The Contractor shall certify
that such vacuum was maintained.

The following method shall be followed :-

FIRST EVACUATION
The vacuum pump shall be operated to reduce the pressure to 0.01 Kg/Sqcm
absolute as low as the pump will bring it and then allowed to operate at the
minimum period of 6 hours. The system shall then be isolated and allowed to
stand for 6 hours.

SECOND EVACUATION

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 The first evacuation shall be broken with dry Nitrogen and the system shall be
again similarly vacumised and allowed to stand for 3 hours. The drier and
moisture indicator shall now be installed in the system.

THIRD EVACUATION
The system shall again be evacuated and vacuum of 0.01 Kg/Sqcm absolute
shall be maintained for 24 hours before charging with correct quantity of
refrigerant and oil and tested for leaks with a halide torch.

PRE-START CHECKS
Before starting the unit for the first time, rotate both fans to be sure they are
free to move, inspect all drives for proper alignment and check the fan belts for
proper adjustment. Test the entire refrigeration circuits for leaks. Test all
electrical circuits for continuity. Check supply voltage and compare the reading
with the compressor and unit nameplate voltage.

With the compressor operating, check the line voltage at the unit. The
voltage should be within the range shown on the nameplate.

PRE-START UP INSPECTION : CHECK LIST TO ENSURE THAT

- EQUIPMENT LOCATED TO PROVIDE ADEQUATE SERVICE ACCESS.
- PROPER ELECTRICAL SUPPLY VOLTAGE AVAILABLE.
- FUSED DISCONNECT SWITCH SIZED IN ACCORDANCE WITH
REQUIREMENT.
- PROPER SIZE FUSES IN DISCONNECTED SWITCH.
- PROPER SIZE WIRING TO UNIT.
- ALL WIRING INSIDE THE UNIT CONNECTED TIGHTLY TO THE
TERMINALS.
- THERMOSTAT PROVIDED AND WIRED-IN PROPERLY.
- ALL WIRING CHECKED FOR PROPER HOOK-UP.
- FAN TURN OVER FREELY BY HAND.
- CONDENSER AND EVAPORATOR FAN SET SCREWS TIGHTENED ON
FLAT OF SHAFT.
- ALL BEARINGS LUBRICATED WHEREVER APPLICABLE.
- UNIT FREE FROM REFRIGERATION LEAKS.

START UP CHECKS TO ENSURE THAT

- FANS RUNNING WITH CORRECT ROTATION.

- MOTOR CURRENT - COMPRESSOR
- CONDENSER FAN
- EVAPORATOR FAN
- VOLTAGE AT UNIT (UNIT RUNNING).
- SUPPLY AIR TEMPERATURE.
- RETURN AIR TEMPERATURE .
- AMBIENT TEMPERATURE AT CONDENSER COIL.
- ALL CAPILLARY TUBES TIED DOWN TO PREVENT EXCESS
VIBRATION.
- UNIT FREE FROM RATTLES.
- UNIT CLEAN INSIDE AND OUTSIDE.
- PROCEDURES EXPLAINED TO THE EMPLOYER / OWNER.

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INSTALLATION REQUIREMENTS : CHECK LIST

a. Allow space around the unit for removal of the access panels and for performing
normal service functions such as compressor maintenance, electrical panel
checking and cleaning the evaporator coils / condenser coils.

- 500 mm minimum clearance from the wall is to be maintained on the inlet air
louver side.
- 1000 mm clear distance from the wall is to be maintained on the discharge grill
side of the condensing unit.
- 1200 mm minimum clearance must be provided above the unit to prevent re-
circulation of warm condensing air.

IMPORTANT :When possible turn the condensing unit so that the draft
diverter faces away from the direction of prevailing winds. Otherwise provide
wind deflectors.

b. The foundation may be of any convenient height for the aircooled condenser
units and the same is included in the scope of airconditioning contractor.
- for roof top installation, FRP coated steel pipe supports are recommended for
foundation materials.
- for ground level installation, construct a level slab (100 mm thick) extending a
minimum 150 mm beyond the sides of the cabinet. Provide a gravel apron
atleast 300 mm wide on the sides at which air enters the unit.
A gravel apron is not required if some other means is used to protect the
growth of vegetation close to the coil. The unit must be installed level in all
locations.

c. Easily removable panels shall be provided to access all the components from
one side of the unit.

d. Drain holes are to be provided in condensing units for elimination of rain.

e. All controls are to be mounted in a central location and access for installation
and service is from one side of the casing. Preferably an independent control
box access panel shall be provided.

f. All drain pans shall be coated with thermal insulation to prevent casing
condensation.

g. To assure proper drainage, pitch the drain line downwards from the unit and
avoid long horizontal runs. Install a trap and fill with water to provide an air
seal.

h. Drain pans shall be extended under coil and fan section with drain connections.

i. Panels shall be internally lined with 25 mm thick fibre glass for thermal
insulation and acoustic lining.

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j. The evaporator fan motor shall be designed for quiet operation and motor
speed shall not exceed 1500 rpm.

k. Belts shall be of the oil-resistant type

l. Maximum fan outlet velocity shall be restricted to 450 Mtrs. per minute.

m. Air velocity across the evaporator coil shall not e ceed 150 Mtrs. per minute.

n. Evaporator coil shall be factory tested at 21 KSC air pressure under water.

o. Fins spacing shall be 11 to 16 fins per inch

p. Unit shall be selected for the lowest operating noise level.

q. The installation of on-the-job electrical wiring must in accordance with the

standards mentioned in these specification.

r. Wherever the soft copper tubing is employed as refrigeration piping, the same
shall be encased within PVC enclosure. These PVC pipe / box sections are
to be supported properly and uniformly to avoid sagging. The PVC joints
should be properly sealed with necessry adhesives / hardner so that the
same may not be dis- located afterwards. Before encasing the refrigerant
piping, the insulated surfaces, shall be adequately stiffened with G.I. wire at
short intervals so that the insulation will not be disturbed. Wherever hard
drawn copper refrigerant piping are installed (above the false ceiling and
wherever exposed to sun) the same shall be laid on G.I. sheet metal slotted
tray and protected suitably. Sheet metal tray shall be adequately supported at
close interval not exceeding 2 meter apart to avoid sagging.

t. Only G.I. screws shall be used wherever required.

u. Since the top panels of condensing units are exposed to rain and hot
sunrays, the same should be properly protected as follows :
- It will be preferable to have insulation be-neath the top panel to minimize
the temperature rise within the condensing unit.
- the top panel should be properly sloped downwards so that the rain water
will not
stagger above the panel.

v. Notice points for soft copper tubing piping

- Pipes should be extended with unwindings.
- Never bend the pipe repeatedly for amendment.
- Bending radius of piping should be above 80 mm, it is easy to bend the
low pressure side pipes by using the bender.
- Cut the pipes using a pipe cutter & deburr it without flare
- For no saw-dust to enter, direct the copper pipe down wards.
- Using a flaring tool, flare the pipe end with the flare nut inserted
into the pipe end without fail.
- Apply a refrigerant oil to the union and the flared portion of the pipe and
to the service valves.

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- After completing the piping, purge the air from the connected piping and
cooling unit.

STANDARD MOUNTING KIT

Each Unit shall be provided with the following Standard Mounting kits.
Custom-built /Conventional/Precision Package Airconditioners:-

a) 50X50X6mm MS angular prefabricated brackets with platform having

adequate spaces for service and staywires/fasteners , ribbed pads (to be
designed to take care of vibratory operating loads) for the wall mounting
condensing units.

b) 200mm high pre-fabricated angle iron frame and pair of 100 X 100X 12mm
thick serrated rubber pads for the floor mounted condensing units.

c) 50X50X 6mm MS angular pre-fabricated brackets with platform having

adequate spaces for service and staywires/fasteners , ribbed pads (to be
designed to take care of vibratory operating loads) for the wall mounting
evaporator unit

d) 4 Nos. minimum 5mm thick angle cleat with holes (suitable to use 12mm
anchor /grip fast bolts) for anchor bolts tightening on one leg of the angle and
with a slot for insertion of a 12mm rod with a ‘U’ bend for suspending the unit
on the other leg of the angle, 4 nos. suitably dimensioned 12mm dia hanger
rods with ‘U’ bend on one end (which is to be inserted in the slot of the angle)
and M12X75mm threaded length with double check nuts arrangement on the
other end for tightening on to the indoor unit base angles , spring isolator
/rubber grommets etc., for suspending evaporator units.

STANDARD ELECTRICAL KIT

Each Packaged air=conditioning system shall be provided with the following

standard electrical kit.

Custom-built/Conventional/Precision Packaged Airconditioners:-

a) 1 No. Local control station (LCS) for each split unit (located preferably near
evaporator ) consists of cubical type, dead front sheet steel wall mounted
control panels, including anchoring into the wall. All MCBs shall be of motor
duty and shall be suitable for 9 kA fault current. Thermal settings fo MCBs
should match the motor full load current. All internal wiring , power cabling ,
earthing of split unit motors from the LCS and control wiring shall be included.
Bimettalic lugs shall be used at copper to aluminium joints. The LCS panel
shall include the following accessories.
- 4 Pole 100Amps. MCCB , 25kA incoming switch (motor duty)
- Terminal block for power distribution.
- Control contactor - MLO 12 Amps or equivalent.
- Evaporator fan contactor
- Overload relay for evaporator.
- Control fuse 4 Amps.

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