LLOYD
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS
REVISION NO Compressor Fixing SHAMS VINOD PANT VISHAWARUP
00 / / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
Load the assembly base out on the A B
pallet as shown in picture A.
Manual &
Then apply oil on Grommet and Pneumatic Gun
place it on compressor mounting Torque meter
bolt.Place the compressor on the
compressor mounting bolt carefully
and tighten the compressor with M8
hex nut as shown in picture B.
Input part
Part name/ Part Number Qty /unit
BASE OUT 01 Important check point
03 Check compressor & base out for dent , paint Damage & rust.
NUT
Check Compressor & grommet part code as per the model.
GROMMET 03
Check compressor mounting torque spec. is 100-150Kgf-cm
COMPRESSOR 01 Check the N2 Pressure of compressor while removing the the
rubber caps.
LLOYD
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS Tube FIXING SHAMS VINOD PANT VISHAWARUP
REVISION NO
00 / / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
A B
Manual
Insert the capillary pipe into
cond out (10~12mm)and
suction pipe into the
accumulator port (14~16mm)
Manual
Insert one end of discharge
tube into compressor port
(14~16mm) and other end
into cond in (10~12mm)
Input part
Part name/ Part Number Qty /unit
Important check point
Discharge Pipe: 01
Check all the tubings for dent, deep scratches
Suction pipe : 01 and bending
Capillary :
01
LLOYD
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS Brazing SHAMS VINOD PANT VISHAWARUP
REVISION NO
00 / / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
Manual A
Adjust the flame to neutral
and heat the joint and apply
Filler material from the Suction Valve
Opposite side of heating Manual &
N2 Purging
Do brazing of the below Brazing torch
mentioned joints:
Accumulator - Suction B
Compressor - Discharge
Discharge - Condenser Inlet
Condenser Out - Capillary inlet Manual &
Brazing torch
Input part
Part name/ Part Number Qty /unit
Important check point
Check for the inclination of the piping.
Brazing Rod As required Check for LPG and Oxygen pressure as per specs before
starting brazing
LLOYD
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS
N2 Leak Test SHAMS VINOD PANT VISHAWARUP
REVISION NO
/ / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
• Fix the coupler at the suction
charging joint and the condenser Manual
charging joint.
• Plug the output of the hose pipe
to the coupler and switch ON the
DP machine. Manual &
• Press the start button until the DP test
green light in DP machine gets machine
ON.
• Do soap bubble test during leak
test
• After the test is done remove the Manual &
hose output and send the DP test
machine to next stage. machine
Input part
Part name/ Part Number Qty /unit
Important check point
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
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS
Vacuumization SHAMS VINOD PANT VISHAWARUP
REVISION NO
01 / / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
Connect the female coupler A
Manual
of vacuum pump with male
Couplers of the set.
Reset the timer and send the set
for vacuuming
Manual
Allow vacuum level as per specs
till green light is on.
At the end of vacuum stage
Manual
remove the couplers from the
connectors and send the
machine for gas charging
Input part
Part name/ Part Number Qty /unit
Important check point
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.
LLOYD
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS Gas Charging SHAMS VINOD PANT VISHAWARUP
REVISION NO
/ / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
Manual A
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 Manual &
Galileo machine with the male Galileo Gas
coupler at the charging joint and charging Machine
Start the program by pressing the
start button on the charging gun
Disconnect the gas charging gun
After gas is charged. Brazing tools
remove the coupler.
.
Input part
Part name/ Part Number Qty /unit
R22 Gas: As per model Important check point
Perform the bomb test in every 2 hrs.
Brazing rod: As per required Evacuation level should be achieved below 40Pa in 20secs
and Leak Test should not exceed 250 Pa in 05 secs
LLOYD
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS LQC SHAMS VINOD PANT VISHAWARUP
REVISION NO
00 / / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
Connect the suction & discharge Manual
couplers with the dummy And
Open the discharge & suction
valve
Put the supply on and check the Manual & VAW
rated volt., Amps. & Watt. Meter
Run the machine as per specs.
After testing close discharge valve
then close suction valve.
Switch off the dummy and send it Manual
To further operation
Input part
Part name/ Part Number Qty /unit Important check point
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>=10˚C,low pressure 4-6 kgf-cm,high pressure 6-8
kgf-cm
LLOYD
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS HLD Leak Test SHAMS VINOD PANT VISHAWARUP
REVISION NO
01 / / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
Check service couplers should be
Manual A B
removed before performing the
HLD test
Check setting of the HLD Manual
machine (<1.0gm/annum)
Move probe on all U Bends & Manual &
brazed joints(0.5sec/joint) Inficon 5000
Check leakage in service valves
by keeping probe at 20mm
distance from valve as shown in
Pic-B Manual
There will be an alarm beep from
the leakage point.
In case of any leakage send M/C
to repair area with defect slip else
Manual
send to the next stage.
Input part
Part name/ Part Number Qty /unit
Important check point
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
DRAFT CHECK APPROVE
WORK MANUAL MODEL
ALL ODU
PROCESS NAME
MODELS FQC Testing & SHAMS VINOD PANT VISHAWARUP
REVISION NO
Cover Control fixing
00 / / / / / /
Work instructions Specification/Tools DIAGRAMS/FIGURES
Connect the power cord of the A
Safety analyzer with the odu unit with
As shown in picture A
Start the analyzer for automatic
operation and check all the
readings displayed on the
analyzer board
AC failure is indicated by a
beep sound in that particular
test.
Screw the cover control after safety
Test completed.
Input part
Part name/ Part Number Qty /unit
Important check point
Terminal cover: 01 1. High Voltage - 1 KV For 2 sec.
Screw: 01 2. IR Test - More than 1 M Ohm at 500 VDC
Caution sticker: 01 3. Ground Test - Less than 0.1 Ohm
4. Leakage Current Test- Less than3. 5 Milli Amp.
CRITICAL CHECK POINT
▲T>=10˚C
