9

Installation
procedure of
air-conditioner
Window and
Split
Training Material Reference
Installation procedure of air-conditioner Window and Split - 2012.ppt

Target Group
Trainers and Technicians

Duration of the Session

45 minutes

Purpose of the Session

To make the participants aware of the right installation procedures - this will lead to the

enhanced system life, optimum performance and more aesthetic look.

Terminal Performance Objectives

At the end of the session, the participants should know:

a) What is quality installation?

b) What are installation procedures for choosing the location and to install the indoor and

outdoor units?

c) What are different thicknesses of copper tubes used in air-conditioner?

d) How to layout the piping?

e) How to adapt the good installation procedure?

Key Message being delivered through this Session

Installation of air-conditioners plays a very important role in terms of machine life, energy

consumption and aesthetic look. The technician has to take a wise decision on selection

of wall, direction of condensing unit and so on. He must also know the right techniques of

unrolling the copper tube, proper swaging, flaring and brazing to avoid future leakage of

refrigerants and avoid complaints.

Tools & Equipments (if any) required for the session

None.
9 Installation procedure of air-conditioner Window and
Split
Installation procedure of air-conditioner Window and Split

This is the title slide. In this general discussions can be made that before installation of any
air-conditioner better to think twice on the location of air-conditioner. No doubt customer
wants to have the location as per own choice but explain him the technical reasons that
why the location chosen by him is not perfect in terms of energy consumption, service
point of view and other factors.

Quality Installation

As mentioned in slide that quality installation stops majority of complaints. Now what
is quality installation i.e. selection of site, indoor unit air-flow, slope, condensing unit
direction, piping layout and ultimately customer education. All this will be discussed in
the coming slides.
Types of Installation

When a window air-conditioner is to be installed then the technician during his visit must
observe and decide in consultation of user that, what type of mounting is to be used, like
wooden frame or section frame of iron or aluminium. If the wall is not having any window
opening then an opening is to be made through wall to install the air conditioner. Check the
thickness of wall and order the same size of wooden frame or other arrangements.

Installation procedure steps

In this slide the eight steps are described and here there is no need to elaborate all the steps
but tell them that one by one you will follow the steps in coming slides.
9 Know the Air-conditioner
Installation procedure of air-conditioner Window and Split

Before the installation, technician should know the dimensions of the air conditioner
for e.g. width, depth & height. How the fixture of grill will taken care of – by locking or
by screwing. The air flow is from right side or left side. Also study the remote control to
educate customer as all the remote control devices are not same.

Determine Air Conditioner Location

The installation site should be selected in such a way that air flow from the condenser
must not be blocked. The installation, maintenance and operation should be convenient
to access and perform. It is advisable to install at a height of approximately 7 ft from the
floor. The allowable space behind the condensing unit is from four to six feet. It starts
from where the condenser ends, not the wall. This air flow will keep the compressor head
pressure comfortable. If this space is less than the circulation of air will be restricted
and the discharged hot air will flow back to the condenser, giving the rise to the air
temperature and ultimately leading to high head pressure and consume more energy.
Choose the window location which is the best location for supply and distribute cool
air evenly within the building and also the best location for heat dissipation outside the
building without any obstacle.
Preparation of Window

The window which has been prepared for installation must carry anti vibration tape or material
or foam sealing. Now a days aluminium frame are very popular. If the foam sealing is not
provided then more vibration sound will take place, So seal all possible air leaks around air
conditioner unit to reduce energy consumption. Make the proper frame and add foam inside
it.

Installation procedure

Install the window air conditioner unit properly at a place that is durable enough to bear the
weight and the vibration of the air conditioner unit.
Fix the properly sized frame into the window & install the chassis of window A/c giving the
slope of 6 to 10 mm towards condenser as shown in the slide. Earlier the brace kit was being
supplied with the air-conditioner to handle the weight.
9 Installation procedure
Installation procedure of air-conditioner Window and Split

Insufficient durability may cause the air conditioner unit to fall down, which may result in
machine damages and accidents. Do not make temporary structure to hold the weight
of air-conditioner e.g. keeping bricks or wooden planks under system body.

Test run before sliding the unit to cabinet

Check the air conditioner if there are any transit lock like strip on the compressor or
base bolts. If these are there remove the same. Test run the unit before sliding the unit
into the cabinet. Check the function of compressor, noise of fan motor and balance of
blades. Operation of remote control to explain in better understanding to customer later
on. The most important is to check the grill temperature and recommended current by
air-conditioner manufacturer.
Determine Split Air Conditioner Location - FCU
air-flow

Install fan coil (FCU) indoor unit at a place that meets the following conditions.

• A place that provides good air circulation into the room. Normally it is 6-7.5 feet from floor.
• A place easy for connecting with the outdoor unit.
• A place easy for connecting with condensate drain.
• Keep the air inlet and outlet at a far distance from the blockage.
• Mount on the place solid enough to bear the weight of the FCU unit and not cause any
vibration.
• A place that is away at least 1m from the electronic gadgets.
9 Determine Split Air Conditioner Location - placing
Electronic Gadgets
Installation procedure of air-conditioner Window and Split

Indoor unit must not be installed very near to microwave, TV, radio or other electronic
device as it can malfunction by noise or Harmon’s generation due to high voltage. There
must be a distance of approximately 1 m or more from the indoor unit.

Determine Split Air Conditioner Location- CDU air

flow

Install condensing unit (CDU) or outdoor unit at a place that meets as far as possible
the following conditions
• A well-ventilated place provides good heat dissipation
• A place that is not exposed CDU to rain or direct sunlight
• A place that does not increase the operating noise or vibration of the CDU unit.
• Install the CDU unit so that the discharge air is set in a way that it does not counter
flow with the wind direction. This is very specific where the air conditioners are in-
stalled on the sea shore buildings.
Determine Split Air Conditioner Location- CDU air flow

The air conditioner does have effect of rain on the outdoor chassis; it must be placed under
canopy. The rust formation can ultimately leads to shorter life of the equipment if not maintained
properly. The airflow must not be restricted as it has shown in this installation. Only canospy
is not required but air flow is much more required.

Determination of CDU air flow

Never install the condensing unit in series as it will lead to one air-conditioners hot air enter
into the second CDU’s inlet and so on. It will lead to high head pressure and ultimately
consuming more energy. Exhaust of one air conditioner must not be allowed to flow through
the adjacent CDU unit.
9 Determine Split Air Conditioner Location from wall
Installation procedure of air-conditioner Window and Split

o A place which is free from obstacles near the air inlets and air outlet of the CDU.
o Keep a distance 1 feet from behind and 1.5feet on sides or more between the
CDU unit and the wall surface.

Piping layout for split air-conditioner

It is in pertinence with horizontal connecting refrigerants lines between condensing unit

and evaporating unit.

The refrigerant pipes should be tilted suction lines should be inclined 1/8 inch per foot
(10.4 mm/m) in the direction of refrigerant flow. This method helps in returning oil back
to compressor.

1. Do the clamping after every 3feet or less.

2. Do not run piping in air take support of the wall.
3. Use the tape at every joint to avoid water leakages.
4. Piping should be designed to use a minimum number of bends and fittings.
Insulation

The slides shows how to insulate the copper tube when the metering device (capillary tube)
is installed at the inlet of evaporator (in the FCU indoor unit). Only the vapor line or the bigger
copper tube must be insulated, the liquid line or smaller copper tube does not require the
insulation because the refrigerant at this stage needs to dissipate heat from the system.

If the metering device (capillary tube) is installed at the outlet of condenser (in the CDU
outdoor unit), both the vapor line or the bigger copper tube and the liquid line or smaller
copper tube need insulation separately in order to save energy and prevent the condensation
at the tube surface.
9 Drainage
Installation procedure of air-conditioner Window and Split

Condensate drain pans must be installed in a tilt position that allows the water drainage
flow out from FCU unit by gravity. To drain the condensate water easily, the drain hose
should be declined downwards. If the end of drain pipe is near the sump of waste water,
the undesirable odour could transfer to the air conditioning room due to the draw force
from evaporator fan.

The prevention of this problem can be done by making u-bend at the end or drain pipe.
The u-bend collects the condensate water and blocks the undesirable odour.

1. Do the clamping after every 3 feet (Approx.1m) or less.

2. Do not run piping in air. Take support of wall
3. Make a proper joint to avoid leakage.
4. Plan drain pipe as short as possible.
5. Maintain a slope of 1 inch (approx. 25 mm) for every 3 feet (approx. 1m)

Indoor test for dipping of water

The simplest way to test this by pouring the water into the condensate drain pan after
the installation or assembly the FCU unit and looking at the water drainage flow. If the
water drops falls inside this shows that drain slope is not proper. If the whole water flows
out side the drain that means slope is well maintained.
Air Conditioning Tubing v/s. Plumbing tubing

The most common tube fitting you will find on refrigeration systems is made of copper. It is
sized by the actual outside diameter and comes in lengths of 16 to 20 feet (5 to 6 m) in hard
copper and coils of 50 to 165 feet (15 to 50 m) in soft copper. There are two common types
of copper tubes:

Hard Copper: Hard Copper tube is rigid and is identified by size and name. This type of tube
makes a neater installation, but it is time consuming and difficult to install. It needs very little
mechanical support to keep it in position, compared to soft copper tubes. There are three
types of hard copper tubes (K, L, M)

Soft Copper: Soft, flexible copper tube is really more versatile than a hard copper tube. It
comes in much longer lengths which are rolled and requires fewer joints which reduce leak
potential. Due to its fairly flexible nature it can be positioned and bend easily which saves
time.

The major difference between plumbing and air-conditioning and refrigeration (ACR) tube
is, when you will ask ½” it will be measured by inner diameter whereas if you will ask ½” in
ACR you will get outer diameter. Specially designed and prepared copper pipes are used in
refrigeration as they can be used for higher pressures. They arrive from the producer sealed
at both ends to prevent contamination by moisture or dust.
9 Copper Tube data
Installation procedure of air-conditioner Window and Split

This is overloaded chart with data of different kind of tubes. One can see the diameter
and the tolerance of pressure. Accordingly to working pressures one can opt for the
size.

Un-rolling Copper Tube rolls

First and far most thing is to keep the both end of the roll closed until technician wants to
use for the work. Secondly when the tube is un-rolled, it must be kept or lay down on the
plane surface. Hold the one end of the tube and try to unroll the role slowly and softly
moving your first hand closely to the roll. No kinking should be formed during unrolling
of the copper tube.
Tube cutting, swaging and flaring

Because of its exceptional formability, copper can be formed as desired at the job site. While
a copper tube is usually joined by soldering and brazing. Flaring is a mechanical way of
joining copper tubes. A mechanical joint may be required or preferred at times. Flared fittings
are an alternative when the use of an open flame is either not desired or impractical. Flared
joints (and screwed connections) should be kept as minimal as possible. Leak prevention
requires the design of a ‘sealed system’ as far as possible.

Check the availability of ‘brazed in’ components and use them wherever possible.

Copper pipe outer Diameter (mm) Tightening Force N.m ((Kgf.cm)

Dia 6.35 14 to 18 ( 140 to 180)
Dia 9.52 34 to 42 (340 to 420)
Dia 12.70 49 to 61 (490 to 610)
Dia 15.88 68 to 82 (680 to 820)
Dia 19.05 100 to 120 (1000 to 1200)

(Also see more on Best Service Practices Dos and Don’ts)

9 Tube bending
Installation procedure of air-conditioner Window and Split

It is much easier to install the system than rectify it later.. There is no excuse for allowing
unnecessary pressure drop to affect a system for its entire operational life. It is most
important to minimize pressure drop in the suction line so plan your piping layout around
the optimum route for the suction line. If you are manually bending some soft copper
and you accidentally kink the pipe, cut and discard the kinked section and try again.
Copper tube, properly bend will not kink on the outside of the bend and will not buckle
on the inside of the bend. Because copper is easily formed, expansion loops and other
bends necessary in an assembly are quickly and simply made, if the proper method and
equipment are used. The proper size of bender for each tube size must be used. Indeed
some smaller benders up to 22 mm can be carried in a tool kit. The minimum radius for
a tubing bends is between 5-10 times dia of the tubing.
Tubes brazing

Brazing and soldering techniques are the most common methods of joining copper tubes and
fittings. Good brazing joints are strong, durable and stay tight. Brazing is necessary to provide
joints that can withstand vibration, temperature and thermal cycling stress. The basic theory
and techniques of soldering and brazing are the same for all diameters of copper tubes.
The only variables are the filler metal and the amount of time and heat required to complete
a given joint. Soldering is the joining process that takes place below 450°C (840°F) and
brazing as a process that takes place above 450°C (840°F), but below the melting point of
the base metals. Most brazing is done at temperatures ranging from 600°C to 815°C (1100°F
to 1500°F). Brazing carried out while using copper-phosphorus, filler metals is the preferred
method for making non-detachable joints. No flux is needed as the vaporized phosphorus will
remove the copper oxide film. Flux is used with silver mixed rods used for brazing.

When heat is applied to copper in the presence of air (oxygen), oxides form on the surfaces
of the tube. This is very harmful for a durable functioning of the refrigeration system in general
but primarily for the compressor’s lubricating system. Oxide scale on the inside of refrigerant
pipelines can lead to problems once the refrigerant and the lubricant is circulating in the
system. Refrigerants have a scouring effect that will lift the scale from the tubing and this can
be carried through the system and lead to form sludge. The formation of oxides when brazing
can be easily prevented: this is achieved by slowly passing Nitrogen through the pipe-work
whilst the heat is being applied. The nitrogen introduction as protective gas (very low flow rate
inside the pipe assembly during brazing process) is a common method to avoid oxidation.
9 Trap, P & S Trap and Invert Trap
Installation procedure of air-conditioner Window and Split

P-Trap
For oil return, the suction pipe is the most critical. A P-trap should be used at the base
of any suction riser greater than 8 ft in length. A suction riser is any vertical line that has
an upward refrigerant flow.

P - Trap and S - Trap

In long suction risers, P-traps should be used for every 25 ft of vertical rise. In addition,
it is good practice to install a P-trap at the outlet of the evaporator if the suction line
rises above the bottom of the evaporator. This trap will ensure that oil can flow freely
out of the evaporator. The reason for the suction P-trap is to help the return of oil to the
compressor. The refrigerant gas returning from the evaporator will contain drops of oil
that can collect and mix in the turbulence of the trap. This turbulent action breaks up the
larger drops of oil into smaller droplets carried upto the riser pipe by the gas velocity.

Be careful of piping installations where the pipe is being routed over, around, or under
obstacles. This can inadvertently create unwanted traps in the return line and collect
oil. If possible, the refrigerant line should travel a direct and straight course between the
evaporator and compressor.
Invert Trap
While operating, the suction line is filled with superheated refrigerant vapor and oil. The oil
flows on the bottom of the pipe and is moved along by the refrigerant gas flowing above it.
When the system stops, the refrigerant may condense in the pipe depending on the ambient
conditions. This may result in slugging if the liquid refrigerant is drawn into the compressor
when the system restarts. To promote good oil return, suction lines should be inclined 1/8 inch
per foot (10.4 mm/m) in the direction of refrigerant flow. To minimize slugging of condensed
refrigerant, the evaporators should be isolated from the suction line with an inverted trap. The
trap should extend above the top of the evaporator before leading to the compressor.

Pressure Test, Evacuation & Gas Charging

Here the trainer need not to again explain the complete details of the process of leak testing,
evacuation and gas charging but simply convey to them that this we have already gone
through the best servicing practices. So follow these steps.
9 Leak test with electronic leak detector
Installation procedure of air-conditioner Window and Split

A small amount of refrigerant can be charged in the system and balance dry nitrogen for
raising the pressure at desired level. Then use the electronic leak detector for leak test.

Soap solution is equally good to check the leakage.

Hold the pressure at least for three hours.

Measure Recommended Current of OEM

During the test run, working electrical current should be equal to the rating current
indicated in the name plate by the original equipment manufacturer (OEM).
Customer Education

Normally technicians are delivered with technical inputs at large, but these slides have been
introduced for him to convey to customer about “Avoid bad practices” and for himself how
to deal with Customer in all situations. It can Save Energy and keep AC and Environment
healthy.

Customer Education

If the customer/user have knowledge about the good practice in using the air conditioner, this
will help to save energy during the system operation and keep the machine healthy.

But if the customer is a beginner in this field then educate him not to block cooling coil or
condenser exhaust with unwanted items. Never give water to plants inside the air-conditioned
room as it increase run time. Never put the wet cloth in the room to dry as run time will go high
which leads to high energy consumption.
9 Customer Education
Installation procedure of air-conditioner Window and Split

This slide show that never cook the food inside the room when air conditioner is ON. The
air conditioner will run continuously due to extra load without any reason and consume
more energy.

Dealing with complaints

This slide explains that technician must become a good listener also. He must listen
to the customer very carefully and then answer. Even if the customer is wrong the
reply from the technician must go explanatory. He should not ignore the queries of the
customer. Always be polite with the customer.
Evaluation Questions
1) Why the gap behind the condenser is required in case of window air-conditioner?

2) What are the basics for piping layout?

3) Should we fix the air-conditioner’s condensing unit parallel to each other or one behind

another?

4) How to un-roll the copper tubes’ roll?

5) Is customer education necessary? What are the key steps we must take care?