METHOD OF STATEMENT FOR AIR-CONITIONING & MECHANICAL VENTILATION INSTALLATION Contents 1. Tools and materials used. 2. Procedure for beam penetration For Refrigerant 3. Installation of Condensate Pipe. 4. Installation of refrigerant copper pipes. 5. Installation of fan coil unit. 6. Installation of condensing unit. 7. Air-conditioning system testing. Pipes. (1) Tools and materials used Materials • • • • • • • • • • • • • • • UPVC Drain Pipe Soft Drawn Copper Pipe Insulation Insulation Tape Foam Tape Aluminium Tape Clear Tape PVC Glue Mapp Gas Wire Rod Sliver Rod Stud Rod Steel Bend Powder R410a Refrigerant Tools • • • • • • • • • • • • UPVC pipe cutter Copper pipe cutter Copper pipe bender Gas torch Hacker Grinder Level gauge Flareing tools Wire tigthener Hack saw blade Vacuum pump Manifold gauges (2) Procedure for beam penetration for Refrigerant Pipes 1. 2. 3. 3. 4. 5. 6. Check the location of the beam penetration from shop drawing & CSD drawing. Determine the actual penetration location on site and take measurement. Prepare the appropriate size and length of PVC trunking sealed with both end. Insert the PVC trunking to the location after the beam re-bar in placed. Secure the PVC trunking firmly to the beam re-bar at the location. Casting by main contractor. After formwork removed check the beam penetration. (3) Installation of Condensate Pipe 1) Condensate pipe (Horizontal part) installation- Cast in concrete slab 1. Check the condensate pipe routing from the shop drawing & CSD drawing. 2. Determine the wall dropper location and take measurement. 3. Prepare Ø20mm PVC pipe connected one piece 90° elbow insulated with 12mm thickness insulation sleeves. 4. Use hole saw to drill an Ø20mm hole on the floor trap cast in socket. 5. Insert one end of PVC pipe into the floor trap cast in socket (inner and outer apply with silicon). The other end with 90° connected with short length of pipe and sealed off with wired tape secured at the dropper location. 6. Secure the PVC pipe permanently to maintain at least gradient of 25mm per 6 meter flow direction toward the floor trap, using level instrument to check the check the proper gradient flow. 2) Condensate pipe (Vertical part) installation – Concealed in brick wall 1. Check the condensate pipe routing from the shop drawing & CSD drawing. 2. Locate the pipe dropper location and mark out the condensate pipe routing of width 50mm on brick wall to be cut and chase. 3. Using electric concrete cutter and electric hammer jack to cut and chase the brick wall downward to the cast in pipe dropper location. 4. Prepare Ø20mm PVC pipe insulated with 12mm thickness insulation sleeves. 5. Connect the PVC pipe with socket at the cast in dropper on the chased wall and straight up to the FCU location and elbow with short pipe protrude out of wall about 50mm. 6. Conduct water flood test, plug up the pipe outlet at the floor trap area and hold for 2hours with marking on the transparent water hose at the end of the FCU protrude pipe area. If no sight of leak relief the plug at the floor trap area to conduct flow test, to check the gradient flow. 7. After testing completed, patch up the chasing wall by using cement mortar. 3) Condensate pipe installation – Install within false ceiling space 1. Check the PVC condensate pipe routing from the shop drawing & CSD drawing. 2. Determine the FCU location and actual condensate pipe routing on site and take measurement. 3. Prepare the PVC condensate pipe complete with insulation, use steel bend cushion with insulation to support insulated condensate pipe. 4. Install the condensate pipe complete with fittings. 5. Using the level gauge to check the gradient of the condensate pipe to ensure proper flow above false ceiling space. . (4) Installation of refrigerant copper pipes 1. Determine the location and routing of related FCU and CU from the shop drawing & CSD drawing. 2. Verify the cooling capacity and opt for the correct size of copper pipe and insulation. 3. Measure and determine all the essential bends. 4. Insulate it with insulation sleeve. 5. Secure the insulated refrigerant copper pipes on the wall, and cushion in between the steel bend and pipes’ insulation. 6. PVC trunking will be housed to those refrigerant copper pipes that operate at the outer surface. 7. After completing the installation of refrigerant copper pipes, control wires will be place along with it. 8. Conduct pressure test, put in the pressure 400 PSI (Nitrogen) at the refrigerant copper pipes and hold for 24 hrs to check the leakage of gas pressure. If no sight of pressure leak at pressure gauge, witness with RTO and release the pressure. 9. After completing testing, all the inlet/outlet of copper pipes are properly cover to prevent the dust and others going in. (5) Installation of FCU (1) Install rear panel 1. Check the location and routing of the related FCU from shop drawing & CSD drawing. 2. Determine and confirm the FCU model and size, from the equipment schedule before installation. 3. For FCU to be installed on box-up, extra frame works needed to be provided by main-con so as to strengthen the real panel. 4. Mark the center line of the FCU on the wall. 5. Removed the rear panel from the FCU and place it on the wall marked. Make sure that the unit is horizontal. 6. Install the wall plug and screw, into the 12 pre-determined spots on the panel. 7. Ensure that the panel is level after inserting 2 screws. Then, insert the 10 wall plugs and screws. (2) Refrigerant Pipes Connection 1. Next, use the flare nut to connect the refrigerant tubes. 2. Cut the copper pipe tube to the required length. 3. Removed burrs at the end of the copper tube. 4. When reaming, hold the tube end downwards and ensure that no copper scraps fall into the tube. 5. Use flaring tool to flare the jointing part. Apply refrigerant lubricant at threaded nut before tightening them. 6. Hang the two mounted slots of the FCU on the upper tabs of the rear panel. 7. After tightening the pipes and checking that they are properly joint, the tubes will then be insulated with insulation sleeve and tape. (3) Condensate Drain Pipe Connection 1. The drain pipe hose from the FCU is connected to the outside condensate pipe by an elbow at an 90dec. The condensate pipe and the elbow are then joined together by PVC glue. 2. The drain pipe are to be insulated with an insulation sleeve. 3. The condensate hose and pipe should be tapped together with wire tape 4. After finish taping over the tubing, use sealant putty to seal off the affected wall at FCU. 5. Press the FCU down, to hook onto the rear panel clips. 6. Connect the power and signal cable to the respective terminal. (4) Wiring Precautions 1. Before wiring, ensure that the rated voltage of the unit as shown on its nameplate. Then, carry out the wiring closely following the wire diagram. 2. Each wiring connection must be done tightly and in accordance with the wiring system diagram. Wrong wiring may cause the unit not functioning or get damaged. 3. Prevent the wires to touch the refrigerant tubing or any moving parts of the fan. (5) After FCU installation completed 1. Verify the FCU gap to the wall, or box-up, need to be consistent and the gap should not exceed more than 6mm. (6) Installation of CU 1. Check the location and routing of the CU from the shop drawing & CSD drawing. 2. Mark the diagonal leg of CU and use anchor sleeve and bolt to tighten the CU firmly onto the CU-ledge. Rubber padding is place underneath each leg to reduce vibration. 3. The insulated copper tubes are flare at the end and insert nut. 4. Remove burrs at the end of the copper tube. 5. When reaming, hold the tube end downward and ensure that no copper scraps fall into the tube. 6. Apply refrigerant lubricant round the threaded portion of the matching surfaces. 7. Tighten up the flared pipes to the service valve and then push down the insulation to cover up the expose portion. 8. Connect the wires from the isolator to the power terminal and FCU power and signal cable to respective terminal shown on the wiring diagram. 9. Before wiring up, ensure the rated voltage of the unit as shown on it nameplate, then carry out the wiring following the wiring diagram. 10. Each wiring connection must be done tightly and in accordance to the wiring system diagram. 11. Do not allow any wires to touch the refrigerant tubing, compressor, or any moving parts of the fan. Method of Statement for Air-conditioning System testing 1. Remove all the protection materials from the indoor and outdoor unit. 2. Check both tubing (Liquid & Gas Line) between the indoor and outdoor unit have been properly installed. 3. Check all inter-control wiring between the indoor and outdoor unit is correctly connected and electrical connection are tight. 4. Leak test to all connecting parts and pressurize the system with dry nitrogen gas (150200psi). 5. After the system if found to be free of leaks, relieve the nitrogen pressure. 6. Using the vacuum pump to evacuate the tubing and indoor unit. 7. After vacuum is completed, charging in additional refrigerant gas (R410a) to the tubing. 8. Fully open the service valve when ready to test run the system. 9. Check and ensure that the in-coming power source from the isolator is correctly provided. 10. Turn on the isolator power supply to the air-conditioners; use the remote controller to conduct the test run. 11. Check the refrigerant gas working pressure and measure running ampere according to the manufacturer recommendation. 12. Check the indoor unit ON coil/OFF coil temperature and measure room temperature after two (2) hours operated. 13. Record down all the reading taking.
