ODU Work Manual(f)

8/9/2019 ODU Work Manual(f)

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MODEL PROCESS NAME DRAFT CHECK APPROVE

REVISION NO

DIAGRAMS/FIGURES

LLOYD

/ / / / / /

Work instructions Specification/Tools

Input part

Part name/ Part Number Qty /unit

Important check point

00

Compressor Fixing

BASE OUT

NUT

GROMMET

COMPRESSOR

Manual &

Pneumatic Gun

Torque meter

01

.

Load the assembly base out on the

pallet as shown in picture A.

Then apply oil on Grommet and

place it on compressor mounting

bolt.Place the compressor on the

compressor mounting bolt carefullyand tighten the compressor with M8

hex nut as shown in picture B.

Check compressor & base out for dent , paint Damage & rust. Check Compressor & grommet part code as per the model. Check compressor mounting torque spec. is 100-150Kgf-cm

Check the N2 Pressure of compressor while removing the the

rubber caps.

ALL ODU

MODELS

A

SHAMS VINOD PANT VISHAWARUP

B

03

03

01

WORK MANUAL




REVISION NO

DIAGRAMS/FIGURES

/ / / / / /


Input part



00

Discharge Pipe:

Suction pipe :

Capillary :

Manual

01

01

01

.

Tube FIXING

Insert the capillary pipe intocond out (10~12mm)and

suction pipe into the

accumulator port (14~16mm)

Insert one end of dischargetube into compressor port

(14~16mm) and other end

into cond in (10~12mm)

Manual

Check all the tubings for dent, deep scratchesand bending

LLOYD

A B

WORK MANUALALL ODU

MODELSSHAMS VINOD PANT VISHAWARUP




REVISION NO

DIAGRAMS/FIGURES

/ / / / / /


Input part



00

Brazing Rod

Manual

As required

.

Brazing

Adjust the flame to neutral

and heat the joint and apply

Filler material from the

Opposite side of heating

Do brazing of the belowmentioned joints: Accumulator - SuctionCompressor - DischargeDischarge - Condenser InletCondenser Out - Capillary inlet

Manual &

Brazing torch

Manual &

Brazing torch

Check for the inclination of the piping.Check for LPG and Oxygen pressure as per specs before

starting brazing

N2 Purging

Suction Valve

LLOYD

WORK MANUALALL ODU

MODELS

A

B





REVISION NO

DIAGRAMS/FIGURES

/ / / / / /


Input part



Manual

.

N2 Leak Test

Fix the coupler at the suction

charging joint and the condenser

charging joint.

Plug the output of the hose pipe

to the coupler and switch ON the

DP machine.

Press the start button until thegreen light in DP machine gets

ON. Do soap bubble test during leak

test After the test is done remove the

hose output and send the

machine to next stage.

Manual &

DP test

machine

Manual &

DP test

machine

Total leak testing time 15sec.Couplers should be fixed properly while testing.The pressure of the nitrogen should reach 400 PSI.

Reject the Air Con if the DP machine indicates fail and alarms.

LLOYD

WORK MANUALALL ODU





REVISION NO

DIAGRAMS/FIGURES

/ / / / / /


Input part



01

ManualA

Manual

.

Vacuumization

Connect the female coupler

of vacuum pump with male

Couplers of the set.

Reset the timer and send the set

for vacuuming

Allow vacuum level as per specs

till green light is on.

At the end of vacuum stageremove the couplers from the

connectors and send the

machine for gas charging

All the couplers should be properly fixed

Coupler should be gently removed aftr achieving vacum level

Vacuum level <0.05 mbar and time of vacuum time 6

mins.

Manual

LLOYD

WORK MANUALALL ODU





REVISION NO

DIAGRAMS/FIGURES

/ / / / / /


Input part



Manual A

Brazing tools

.

Switch the machine ON and Set

the program in the Galileo

machine as per the model and

perform the bomb test

Connect the female coupler of the

Galileo machine with the male

coupler at the charging joint and

Start the program by pressing the

start button on the charging gun

Disconnect the gas charging gun

After gas is charged.

remove the coupler..

Manual &Galileo Gas

charging Machine

Perform the bomb test in every 2 hrs.

Evacuation level should be achieved below 40Pa in 20secs

and Leak Test should not exceed 250 Pa in 05 secs

R22 Gas:

Brazing rod:

As per model

As per required

Gas Charging

LLOYD

WORK MANUALALL ODU





REVISION NO

DIAGRAMS/FIGURES

/ / / / / /


Input part

Part name/ Part Number Qty /unit Important check point

00

Manual & VAW

Meter .

Connect the suction & discharge

couplers with the dummy AndOpen the discharge & suction

valve

Put the supply on and check therated volt., Amps. & Watt.

Run the machine as per specs.

After testing close discharge valvethen close suction valve.

Switch off the dummy and send itTo further operation

LQC

Parameters to be maintained as per model spec.

Check ODU thoroughly for any dent or physical damage.

Maintain Temperature of LQC Chamber as per specs.(28-35)Dg.C.

T>=10ÛC,low pressure 4-6 kgf-cm,high pressure 6-8

kgf-cm

Manual

Manual

LLOYD

WORK MANUALALL ODU





REVISION NO

DIAGRAMS/FIGURES

/ / / / / /


Input part



01

A

.

HLD Leak Test

Check service couplers should be

removed before performing theHLD test

Check setting of the HLDmachine (<1.0gm/annum)

Move probe on all U Bends &

brazed joints(0.5sec/joint) Check leakage in service valves

by keeping probe at 20mm

distance from valve as shown inPic-B

There will be an alarm beep fromthe leakage point.

In case of any leakage send M/Cto repair area with defect slip elsesend to the next stage.

Manual

Manual

Manual &

Inficon 5000

Manual

Manual

No Dead cap on service valves. The sensor probe should be moved through the joints at the

specified speed. In case of doubt on sensitivity, calibrate the probe using auto

calibration. Check the accuracy of the HLD with a coupler <1gm/annum

LLOYD

WORK MANUALALL ODU

MODELS

B





REVISION NO

DIAGRAMS/FIGURES

/ / / / / /


Input part



00

A

.

FQC Testing &Cover Control fixing

Connect the power cord of theSafety analyzer with the odu unit with

As shown in picture A

Start the analyzer for automatic

operation and check all the

readings displayed on theanalyzer board

AC failure is indicated by a

beep sound in that particular

test.

Screw the cover control after safety

Test completed.

1. High Voltage - 1 KV For 2 sec.2. IR Test - More than 1 M Ohm at 500 VDC

3. Ground Test - Less than 0.1 Ohm

4. Leakage Current Test- Less than3. 5 Milli Amp.

LLOYD

01

01

01

WORK MANUALALL ODU

MODELS

Terminal cover:

Screw:

Caution sticker:




CRITICAL CHECK POINT

T>=10ÛC

ODU Work Manual(f)

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