AboveAir TM Technologies TM Technologies Split System Refrigerant Piping Guide Air Conditioners &...

AboveAir™ Refrigerant GuideAboveAir Technologies 1

Split Systems - Refrigerant Piping Guide

AboveAir

TM TechnologiesSplit System Refrigerant Piping Guide

Air Conditioners & Heat Pumps (DX System Piping)

Installation Manual

Ver 1.6 - 11/11/2015

Refrigerant Piping Guide• Installation Requirements

•Piping & Insulation

•Pipe Routing

•Sizing your line set - Suction or Discharge - Liquid - Risers

AboveAir™ Refrigerant Guide AboveAir Technologies2

Refrigerant Piping GuideThis manual provides general recommendations and requirements for AboveAir Technologies split system refrigerant piping. Read through this manual carefully prior to beginning any installation activity to guarantee that your installation meets the requirements to ensure optimal unit performance.

Installation ConsiderationsLong distances and elevation changes can reduce the overall efficiency of refrigerant based systems. Extended piping runs increase the required line size, the cost of refrigerant piping and the amount of refrigerant required for the system. To minimize piping costs and maximize unit performance, it is recommended to select compo-nent placement to minimize the length of the piping run.

Maximum Recommended LengthsFor optimal unit operation, a maximum total equivalent length (linear feet of horizontal pipe + linear feet of verti-cal pipe + equivalent lengths of all fittings) of 150 feet is permissible. The allowed vertical component varies de-pending on system configuration. Installations in excess of 150 total equivalent feet may void your compressor warranty.

For systems with the condenser located above the evap-orator (compressor located in the evaporator section), the maximum allowable vertical component is 100 feet.

Refrigerant Piping

REFRIGERANT PIPING GUIDEFor systems with the condenser located below the evap-orator (compressor located in the evaporator section), the maximum allowable vertical component is 20 feet.

For systems with a condensing unit (compressors located with the condensing section) located above the evapora-tor, the maximum allowable vertical component is 50 feet.

For systems with a condensing unit (compressors located with the condensing section) located below the evapo-rator, the maximum allowable vertical component is 50 feet.

For heat pump applications: Condensing and Evaporat-ing sections flip functionality during heating operation. Maximum vertical run allowance is determined by the worst case condition.

Condensing Units with Hot gas reheat: Maximum allow-able run is 40 linear feet, inlcuding both horizontal and vertical components, superseding the limits outlined above.

Piping and RoutingUse Type L or K copper refrigerant grade piping for all refrigerant lines. Securely mount all refrigerant lines to the building structure with brackets intended for use with refrigerant/copper piping. Where refrigerant lines pass through walls or floors, provide a sleeve to prevent the line from rubbing. Route piping through chases, ceil-

AboveAir™ Refrigerant GuideAboveAir Technologies 3Refrigerant Piping

REFRIGERANT PIPING GUIDEing plenums, wall cavities, conduit, or similar protected areas to minimize the possibility of damage to the piping.

Slope all refrigerant piping in the direction of flow at 1/4” per ten feet: slope the liquid line towards the evaporator, the hot gas discharge line towards the condenser, and/or the suction line towards the compressor. Piping should be installed without sags or bends.

Use proper transition fittings to transition from evapora-tor and condenser stub out sizes to the refrigerant line sizes calculated herein.

Piping ConfigurationsAboveAir Units are customizable for a variety of configu-rations. Split configurations include:

Remote Condenser: Compressors are located in the evaporator section. Discharge and liquid lines between the evaporator and condenser are required. Hot gas reheat does not require additional lines.

Condensing Unit: Compressors located with the remote condensing section. Suction and liquid lines between the evaporator and condensing unit are required. Hot gas reheat (first circuit only) requires two additional lines: a discharge line supply and a liquid line return connection for the hot gas reheat coil.

Each circuit in a multi-circuited unit will require its own set of lines for connection. For example, a dual circuited condenser will require (2) discharge and (2) liquid lines for connection to the evaporator section.

Pipe ConnectionsBraze all piping connections with a high quality, high temperature brazing compound of 15% silver suitable for use with the refrigerant used in your unit and in accordance with all local, national and ASHRAE code requirements. Take care to avoid introducing debris to the piping system. Run dry nitrogen through the pip-ing continuously during the brazing process to minimize contamination and ensure joint quality.

Pipe InsulationPipe insulation materials should be provided as required by the project documents and local codes. Piping should be insulated in accordance with the following:

Liquid Line - Operating temperatures for the pipe will typically be in the range of 110-120°F. Insulation is rec-ommended on external installations and where piping is routed through non-conditioned spaces or where the hot

pipe may present a hazard to the space occupants.

Suction Line - Typical temperatures are in the vicinity of 40-50°F. Insulation is required to prevent condensation, minimize temperature loss to the environment, and pre-vent refrigerant from flashing.

Hot Gas Discharge Line - Typical temperatures may be in excess of 150°F. Insulation is not required. Insulation is recommended where the hot pipe may present a hazard to the space occupants.

Pipe TrapsRiser traps should be sizes as small as possible. Traps should be included in the pipe sizing calculations, if re-quired. Traps should be provided as follows:

Liquid Line - No traps required.

Suction Line - Provide vertical risers with a trap at the bottom of the riser and an inverted trap at the top of the riser.

Hot Gas Discharge Line - Provide vertical risers with a trap at the bottom of the riser and an inverted trap at the top of the riser.

In addition to these requirements, any vapor riser not sized for 1,000 fpm minimum pipe velocity must be trapped every 20 feet. Traps may be omitted for risers less than 5 feet in height.

Filter DriersYour unit was shipped with filter-drier(s) either installed in the evaporator section or filter-drier(s) shipped loose with the system.

If the filter-drier was not factory installed, it must in-stalled in the liquid line as close to the evaporator sec-tion as possible. Refer to the labeling on the device and ensure that it is installed with the proper orientation to the flow. For multi-circuited units, each liquid line must have its own filter-drier.

Riser SizingVapor piping must be sized to maintain a minimum velocity of 1,000 fpm for oil transport. Refer to Table 6b (R-410a) or Table 7b (R-407c) for the maximum pipe sizes to maintain this velocity; if your horizontal piping run is larger than the indicated pipe size, use the value from the table for the risers. Note that this may increase sys-tem pressure drop and degrade unit performance - long risers should be avoided, if possible.


Table 1 - Tonnage per CircuitRefrigerant Type R-407c R-410aUnit TonnageNumber of CircuitsTons per Circuit

Table 2 - Initial Pipe Size Estimates

Line Type Total Length x Fitting Al-

lowance =Total

Equivalent Length

Initial Pipe Size

Liquid x 1.5 =Suction x 1.5 =Discharge x 1.5 =

Pipe Sizing MethodPipe sizing is based on the method detailed in the 2010 ASHRAE Refrigeration Handbook. The following charts and recommendations are provided for your convenience - AboveAir Technologies recommends all refrigerant pipe sizes be calculated by an engineer in accordance with the latest ASHRAE Refrigeration sizing guidelines.

To begin the calculation, circle the refrigerant type in Table 1 below. Note the unit tonnage from the unit’s nameplate and the number of refrigeration circuits. Divide the unit tonnage by the number of circuits to determine the tons per circuit. All of the subsequent calculations in this section will be based on tons per circuit.

To determine the pipe size to be used for installation, the total equivalent length must be determined. The following tables will lead you through the iterative process of determine the total equivalent length and unit pipe sizes. To begin the process, record the total length of piping to be installed (horizontal + vertical) in Table 2 below. To make an initial estimate of pipe sizes, multiply this value by 1.5 and record the value under the total equivalent length column.

The initial pipe size can be looked up in either Table 6a (R-410a) or Table 7a (R-407c). To look up the line size, round the total equivalent length up to the next 25 feet. Locate the Tons per Circuit in the column at the top, then follow down to this total equivalent length. Record the values for the initial pipe sizes for your application in Table 2 above.

Note: The following steps are an iterative process and may need to be conducted more than once. It is recommended that you copy the next page to allow for one or more additional iterations.

In Table 3, record the actual quantity of fittings to be installed on all applicable line types. Using the Initial Pipe Sizes recorded in Table 2, look up the equivalent fitting lengths in Table 4. For each line type, multiply the quantity of fit-tings by the equivalent fitting lengths. Record this value as indicated in the table, then add the values as indicated to determine the total equivalent fitting lengths for each line type. Record these values in i, ii, or ii as applicable.

Refrigerant Piping

REFRIGERANT PIPING GUIDE


Table 3 - Fitting Equivalent LengthsLiquid Line

Fitting Type Quantity x

Value from Table 4 for ini-tial pipe size

=Total Fitting Equivalent

Length90° x = (a)

45° x = (b)

Traps x = (c)

Total Liquid Fitting Equivalent Length (a + b + c) = (i)

Suction Line90° x = (d)

45° x = (e)

Traps x = (f)

Total Suction Fitting Equivalent Length (d + e + f) = (ii)

Hot Gas Discharge Line90° x = (g)

45° x = (h)

Traps x = (i)

Total Suction Fitting Equivalent Length (g + h + i) = (iii)

Table 5 - Calculated Pipe Size

Line Type Total Length +

Fitting Equivalent

Lengths=

Total Equivalent

LengthPipe Size

Liquid + (i) =Suction + (ii) =Discharge + (iii) =

Record the total line length and the total equivalent fitting lengths (i, ii, and iii) calculated in Table 3 in Table 5 below. Add these two values together to determine the total equivalent length. Using Table 6a (R-410a) or Table 7a (R-407c) and the procedure described previously, record the pipe sizes in Table 5.

Table 4 - Fitting Equivalent Lengths

Pipe Size

Fitting Type90° 45° Trap

3/8 0.9 0.7 2.31/2 1.0 0.8 2.55/8 1.2 0.9 2.93/4 1.4 0.9 3.2

1 1/8 2.0 1.4 4.91 3/8 2.5 1.8 6.01 5/8 2.8 2.2 6.82 1/8 3.5 2.8 8.7

Note: this calculation should be repeated with the new line size as a new initial value if there are significant changes in the line size. Use the pipe size calculated in Table 5 instead of the initial pipe size and recalculate Tables 3 and 5.

Refrigerant Piping



Table 6a - Refrigerant Line Sizing Charge for R-410aTotal Equivalent Length

Line Type Tonnage per Circuit1 1.5 2 2.5 3 4 5 6 7.5 8 10 15

25 ft (7.6 m)

Liquid 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4Suction 1/2 1/2 5/8 5/8 5/8 3/4 3/4 7/8 7/8 7/8 1 1/8 1 1/8Discharge 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 7/8 1 1/8

50 ft (15.2 m)

Liquid 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4Suction 1/2 5/8 5/8 3/4 3/4 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8Discharge 1/2 1/2 5/8 5/8 5/8 3/4 3/4 7/8 7/8 7/8 1 1/8 1 1/8

75 ft (22.9 m)

Liquid 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4Suction 1/2 5/8 3/4 3/4 3/4 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8Discharge 1/2 1/2 5/8 5/8 3/4 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8

100 ft (30.5 m)

Liquid 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 7/8Suction 5/8 5/8 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8Discharge 3/8 5/8 5/8 5/8 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8

125 ft (38.1 m)

Liquid ** 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 7/8Suction ** 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8Discharge ** 5/8 5/8 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8

150 ft (45.7 m)

Liquid ** 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 7/8Suction ** 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8Discharge ** 5/8 5/8 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8

** Installation not recommended.

Table 6b - Maximum Riser Size for oil return (R-410a)

Line TypeCircuit Tonnage

1 1.5 2 2.5 3 4 5 6 7.5 8 10 15Discharge 3/8 3/8 1/2 1/2 5/8 5/8 3/4 7/8 7/8 7/8 1 1/8 1 3/8

Suction 1/2 5/8 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 2 1/8

Table 6c - Flooded Condenser to Receiver Sizing (R-410a)Circuit Tonnage

1 1.5 2 2.5 3 4 5 6 7.5 8 10 153/8 1/2 1/2 5/8 5/8 3/4 3/4 7/8 1 1/8 1 1/8 1 1/8 1 3/8

Refrigerant Piping



Table 7a - Refrigerant Line Sizing Charge for R-407cTotal Equivalent Length

Line TypeTonnage per Circuit

1 1.5 2 2.5 3 4 5 6 7.5 8 10 15

25 ft (7.6 m)

Liquid 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4Suction 1/2 5/8 5/8 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8Discharge 3/8 1/2 1/2 5/8 5/8 5/8 3/4 3/4 7/8 7/8 7/8 1 1/8

50 ft (15.2 m)

Liquid 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4Suction 5/8 3/4 3/4 3/4 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8Discharge 1/2 1/2 5/8 5/8 3/4 3/4 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8

75 ft (22.9 m)

Liquid 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 7/8Suction 5/8 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8Discharge 1/2 5/8 5/8 3/4 3/4 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8

100 ft (30.5 m)

Liquid 3/8 3/8 1/2 1/2 1/2 1/2 5/8 5/8 3/4 3/4 3/4 7/8Suction 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 2 1/8Discharge 1/2 5/8 3/4 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8

125 ft (38.1 m)

Liquid ** 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 7/8Suction ** 3/4 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 2 1/8Discharge ** 5/8 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8

150 ft (45.7 m)

Liquid ** 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 7/8Suction ** 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8Discharge ** 5/8 3/4 3/4 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 5/8

** Installation not recommended.

Table 7b - Maximum Riser Size for oil return (R-407c)

Line TypeCircuit Tonnage

1 1.5 2 2.5 3 4 5 6 7.5 8 10 15Discharge 3/8 1/2 1/2 5/8 5/8 3/4 7/8 7/8 7/8 1 1/8 1 1/8 1 3/8

Suction 5/8 3/4 7/8 7/8 1 1/8 1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8

Table 7c - Flooded Condenser to Receiver Sizing (R-407c)Circuit Tonnage

1 1.5 2 2.5 3 4 5 6 7.5 8 10 153/8 1/2 1/2 5/8 5/8 3/4 3/4 7/8 1 1/8 1 1/8 1 1/8 1 3/8

Refrigerant Piping



I n n o v a t i v e H V A C S o l u t i o n s

www.aboveair.com

5179 Mountville RoadFrederick, Maryland 21703, U.S.A.

Phone: 301-874-1130, Facsimile: 301-874-1131

Email: [email protected]

Copyright 03/13

Specifications are subject to change without notice.

Comfort - Packaged & SplitVertical Floor Mounted

Air Conditioners(1 to 30 Tons)

VK-ConsoleTM - Up-Flow & Down-FlowFloor Console Mounted Air Conditioners

(1 to 5 Tons)

Remote Air Cooled Condensers, Condensing Units &

Glycol Drycoolers(1 to 180 Tons of THR)

Precision - Vertical Floor Mount-ed Computer Room

Air Conditioners(1 to 30 Tons)

Ducted “Same-Face”Ceiling Mounted A/C’s

(1 to 30 Tons)

2x4 “Spot-Cooler”Ceiling Mounted A/C’s

(1 to 3 Tons)

Single & DualGlycol Pump Packages

(1/2 to 50 HP)

Ceiling Air ConditionersSpotCool

™ - 2x4 T-Bar “Spot-Cooler” Comfort & Precision Ceiling Mounted A/C’s

HK ™ Horizontal - Hi-Static Ducted “Same-

Face” Comfort & Precision Ceiling Mounted A/C’s

HK-OA ™ - Horizontal Up to 100% DOAS High-

Percentage Outside Air Ceiling Mounted A/C’s

Floor Air ConditionersVK™ Vertical - SCAV, Vertical Floor Mounted Self-Contained & Split Comfort Constant Air Volume and Variable Air Volume (VAV) A/C’s & Heat Pumps

VK-OA ™ - Vertical Up to 100% DOAS High- Per-

centage Outside Air Vertical Floor Mounted A/C’s

MissionCritical ™ - Precision Vertical Floor

Mounted Computer Room A/C’s

VK™ Console - Vertical Floor Console Mounted Self-Contained & Split A/C’s & Heat Pumps

Remote Heat RejectionFluidCool

™ - Indoor & Outdoor Remote Glycol Drycoolers

PumpAll ™ - Single, Dual & Triplex Standard &

Variable (VFD) Speed Glycol Pump Packages

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