Installation / Service Technical Reference
R32 Flareless Joint Pull-Out - Installation Guidance
Applies to all R32 models using flareless pipe connections
More than 100 cases were reported where a flareless joint separated because the refrigerant pipe had not been inserted sufficiently during installation. The issue was attributed to installation error, but additional preventative measures were introduced because of the number of cases.
Applies To
| Products | All R32 models using the relevant flareless connection method |
| Reported cases | More than 100 |
| Main risk | Flareless joint separation due to insufficient pipe insertion |
Problem Description
If the pipe is not inserted sufficiently into the flareless joint during installation, the connection can separate when refrigerant pressure rises during heating operation.
The investigation considered this to be an installation error. However, because the number of occurrences was high, additional warnings and installation controls were introduced.
Cause
The reported failures were attributed to insufficient pipe insertion during installation.
The broader finding was that additional installer guidance and warnings were required to make the correct insertion method and verification process clearer.
Corrective Measures
- Pressure testing was added to the installation manual.
- The pipe insertion instructions were improved using clearer figures.
- A warning letter was added to the product packaging to draw installer attention to the issue.
These measures were introduced from 11 October 2014.
FGL Pressure Test Evaluation
Test Conditions
| Test unit | ASTG24KMCA |
| Pipe diameter | 6.35 mm / 12.70 mm |
| Pipe length | 5 m |
| Ambient temperature | Approximately 20 to 25°C |
| Insertion condition | Insertion length set to the prescribed value, with low tightening torque |
Pipe Restraint Conditions Tested
- Pipe free / not fixed
- Pipe fixed tightly
- Pipe pushed upward from below
Test Result
Under all three conditions, the pipe separated when pressure reached approximately 1 to 2 MPa.
The test found no injury risk when the pipe separated under these conditions.
The key conclusion was that a pressure test can identify an incorrect connection before the system is placed into normal operation.
Packaging Test
FGL also completed a packaging test for the installer warning notice.
Result: No packaging issue was identified with inclusion of the installer notice.
Product Action
| Product Status | Action |
|---|---|
| Already installed | Address locally if the problem occurs. A Service Hint was released to reinforce installer awareness. |
| Stock product | No product action specified. |
| Current manufacture | Corrective measures implemented. |
Installation Guidance
- Ensure the refrigerant pipe is inserted to the full prescribed depth before tightening the flareless joint.
- Follow the installation manual figures and insertion method exactly.
- Complete the specified pressure test before commissioning.
- If the joint separates during the pressure test, correct the pipe insertion and connection before operation.
- Do not rely on pipe restraint, clamping or support to compensate for an incorrectly assembled joint.
Important: The historical investigation identified insufficient pipe insertion as an installation issue. Correct insertion and pressure testing are the key controls for preventing flareless joint separation.
Information to Collect if the Issue Occurs
| Item | Details Required |
|---|---|
| Unit identification | Full indoor/outdoor model and serial numbers |
| Pipe sizes | Liquid and gas pipe diameters |
| Connection condition | Photos showing pipe insertion and joint condition |
| Pressure test | Test pressure and result |
| Installation history | Installer details and whether the connection had previously been disturbed |