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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

(1) PURPOSE:

This method statement is prepared in order to make sure that the installation of DX units and associated
refrigerant piping/ducting and accessories are done as per the applicable requirements and
manufacturers recommendation.

(2) GENERAL REQUIREMENT:

All material received on site should be inspected and checked for any damages and stored in
accordance with the project procedures.
The delivered material has to be inspected for any missing components and should be reported
immediately after opening the packing.
All inspection/installation/testing will be carried out in compliance with the project specification and
manufacturers recommendation.
Special care must be taken to ensure that the DX units are offloaded properly at site. Rough handling
will result in damage and will affect the performance of the unit.

(3) STORAGE:

To ensure that deterioration of the DX units does not occur during storage, it is recommended to store
the equipment in proper sheltered conditions.
All the outdoor units and indoor units should be stored in upright position.
DX units shall be protected with plastic or shall not be removed from the shipping package.
Copper pipes ends should be closed by end caps/tape in the storage area.
Avoid any mechanical shocks during handling operations.
All the equipment should be commissioned maximum within one year from the date of supply.

(4) SAFETY REQUIREMENTS:

All site safety regulations shall be complied with local authority safety procedures / Client safety
regulation.
Site Engineers / Supervisors should conduct the toolbox talk to the technicians relevant to all the
operations involved in the installation and commissioning of units.
Ensure only qualified personnel shall install, test and commission the system.
During brazing operations, proper hot work permit should be arranged from the concerned authorities.

(5) TOOLS REQUIRED:

Screw driver set (star & flat), Allen key set (mm & inch), Spanner set, Nut drivers, Tube cutter, Tube
bender, Swaging tool, Flaring tool, Crimping tool, Drilling machine, Thermometer, Tester, Multi meter,
Clamp meter, Manifold gauge, Micron (vacuum) gauge, Vacuum pump with NRV & Fresh oil.

Leminar Air Conditioning Company Page No: 1


Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

(6) PRE-INSTALLATION GUIDELINES:

Before commencement of installation activity, delivered DX units has to be inspected by the concerned
person at site.
All relevant shop drawings for the installation of the equipment shall be available and approved by the
consultant. No installation shall be done without the approved shop drawings.
Ensure that selection of the equipment is approved by consultant and available with contractor.
Inspect the relevant area for any possible clashes with other services. Civil clearance prior to
installation has been given by the civil contractor.
Safe access should be provided through work permit in coordination with the safety department.

(7) PROCESS:

Leminar Air Conditioning Company Page No: 2


Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

(8) BRAZING REQUIREMENT:

Brazing has to be performed by certified personnel.


Ensure that copper pipes are clean and defect free before brazing works.
Select the brazing rod as per the application. For R410A and bimetal use minimum 10 - 15% silver
content brazing rod.
Regulate oxygen and acetylene amount with suitable nozzle according to copper pipe specification
(Soft / Hard pipe) and sizes.
Use swaging and flaring tools for joining of the pipes.
Use tube bender only for bending the pipe and avoid bending by hand.
Use wet cloth on the service valves and expansion valves during brazing.
Pass Nitrogen (5-10PSIG) to prevent the carbon formation inside the copper pipes.

(9) INSTALLATION GUIDELINES:


Recommended guidelines for the Installation of DX units:

(9.1) INDOOR UNITS:

Check the equipment to be free from debris and dust.


Install the equipment in accordance with the approved drawing.
Hang the units with the threaded rods without any inclination.

Use anti vibration element while hanging the indoor units.


Provide flexible connector between indoor unit and ducting.
Keep minimum clearance between the wall and the filter side of the indoor unit should be 450mm
to 600mm.
Avoid elbows and offsets immediately after the mouth connection of the indoor unit.

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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

Provide sufficient maintenance space to access filter, drain connection, blower motor section, coil
and electrical control box.
Provide positive slope towards drain connection.
Suitable size access panel should be provided for unit servicing.
The mouth piece of the indoor unit should have concentric taper (Equal reducer).

TYPICAL INDOOR UNIT INSTALLATION DETAILS:

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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

CORRECT INCORRECT

Use Concentric tapered Mouth piece Avoid Eccentric tapered mouth piece
Use return air elbow with acoustic insulation in case of return air grille located nearby the
indoor unit.
CORRECT INCORRECT

Use Elbow with acoustic liner at the Do not install return air grille near to
Return air grille the filter side of the indoor unit

(9.2) CONDENSATE DRAIN:

All indoor units should be provided with proper U trap with drain plug for condensate drain pipe.
Size of the drain pipe should be minimum 3/4
Height of the U trap should be in accordance with the static of the indoor unit.
Main drain line should be higher than the unit drain pipe.
Slope to be provided.
Air vent should be provided after Condensate U trap if the same condensate drain line is connected

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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

with multiple indoor units or if the Drain pipe line is more than 5 meters.
Insulate the drain pipe as per the consultant specification.
s s
Incase of multiple units connecting to common drain pipe, the main drain line size should be higher
than the individual unit drain pipe.

(9.3) OUTDOOR UNITS:

Check the equipment to be free from debris and dust.


Install the equipment in accordance with the approved drawing.
Provide the clearance as per the following drawing.
Provide Anti-vibration elements below the units.
Provide the foundation as per the drawing.
Refer drawing number Fig.9.3.1 and Fig.9.3.2.

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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

Fig. 9.3.2

(9.4) PIPING:
Follow the Refrigerant pipe sizing as per the following table.

Line Size chart for DX Ducted Split Units: (Table: 9.4.1)

RHEEM DUCTED SPLIT UNITS


REFRIGERANT PIPE SIZES FOR LONG LINE APPLICATIONS
EQUIVALENT LENGTH FROM CONDENSING UNIT TO EVAPORATOR
SL EQUIPMENT
0 ft to 25 ft 26 ft to 50 ft UNIT 51 ft to 100 ft 101 ft - 150 ft
NO MODEL
SL LL SL LL SL LL SL LL
1 18 5/8 5/16 5/8 5/16 3/4 5/16 3/4 5/16
2 24 5/8 5/16 3/4 3/8 3/4 3/8 7/8 3/8
3 30 3/4 3/8 3/4 3/8 7/8 3/8 7/8 3/8
4 36 3/4 3/8 3/4 3/8 7/8 3/8 7/8 3/8
5 42 3/4 3/8 7/8 3/8 7/8 3/8 7/8 3/8
6 48 7/8 3/8 7/8 3/8 1 1/8 1/2 1 1/8 1/2
7 60 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 3/8 1/2
8 65 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 3/8 1/2

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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

Notes:
The total equivalent length up to 150 Ft. [45.72 m.] is permissible in both the cases i.e.
outdoor unit above the indoor unit and outdoor unit below the indoor unit.
Maximum vertical separation when outdoor unit is below indoor unit is 31 feet / 9.4 meters.
In case of outdoor units below indoor unit, the maximum vertical separation limit should be
followed for intended performance of the units. Avoid open ends of Copper pipes as well as
equipment.
For satisfactory performance of the R410A systems please follow the guidelines below.
Operating pressure of R410A is 60% higher than R22 and experienced and skilled
technicians are required to carry out the installation.
Brazing rod with minimum 15% silver content to be used.
Vacuum pump should be heavy duty type and pressure gauge used should be suitable for
R410A.
There is no requirement of adding oil to the system, however if site conditions call for
additional oil quantity, then only POE Oil should be used which should kept in a tight
container to avoid moisture absorption by the oil.
Tie the TXV bulb touching entire surface to the suction pipe at 2o clock or 10 o clock position.
Use Proper supports for the refrigerant pipe lines at every minimum 1.2 meter.
Use 13mm thick insulation for unexposed piping and 19 mm thick insulation for exposed piping.
Inside diameter of insulation should be exactly the size of the copper pipe.
For the models SDMA/SDMB both the liquid and suction line should be insulated.
Long piping:
For high rise buildings, please take the following precautions in addition to the Guidelines
mentioned above.
P v s v y 10 meter vertical length.
Charge additional oil in case of total equivalent length is more than 50 meters

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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

(9.5) DUCTING:

Use low velocity Ducts for comfort application.


Increase the duct size as per acoustic insulation thickness.
Do not use Combination grille (Supply & Return) to avoid air short cycling.
Avoid using flexible ducts more than 1.0 meter.
Avoid sharp Bends and U turns.
Avoid gaps between the collar of the duct and the air terminals.
Use 100 150 mm shoe collar for branch ducts.
Use appropriate plenum box with collars for air terminals.
Avoid termination of flexible ducts top side of the plenum.
Avoid elbows and offsets immediately after the mouth connection of the indoor unit.
The elbows in the duct should have minimum 150mm radius at the inner curve.
CORRECT INCORRECT

Use 150mm at inner curve Avoid sharp bends

(9.6) THERMOSTAT:

Thermostat should be installed near the return air terminal / Return air path.
Avoid exposing the thermostat to direct heating / cooling by means of sun radiation, supply air,
etc.
Use duct sensor thermostat in case of common unit feeding to multiple areas.
Avoid setting the room set temperature too low.
Do not install the thermostat where there is no movement of the air.

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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

(9.7) WIRING:

1. Recommended wire sizes:


a. From thermostat to indoor unit (3 speeds)
Up to 3 Ton - 1.5 sq.mm x 6 core.
Above 3 Ton - 2.5 sq.mm x 6 core.
b. From thermostat to indoor unit (1 speed) 1.5 sq.mm x 4 core.
c. From indoor unit to outdoor unit 1.5 sq.mm x 3 core.
d. From indoor unit and outdoor unit (Decorative unit 1 to 2 TR) 2.5 sq.mm x 3 core.

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Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

Leminar Air Conditioning Company Page No: 11


Leminar Air Conditioning Company LEM-IG-MS-01

Issue No. : 01, Rev: 00 Prepared By : Michael


Issue Date: 20/12/2015 INSTALLATION GUIDELINES FOR DX SYSTEM Approved By: Syed Siraj

INSTALLATION CHECK LIST


PROJECT
SUB CONTRACTOR
DATE OF VISIT
LOCATION / AREA SERVING

OUTDOOR UNIT MODEL NO: SERIAL NO:


REF.NO ITEM YES NO REMARKS
1 Equipment Installed as per Specification / Schedule
2 Equipment located as per the approved drawing.
3 Equipment is free from physical damages.
4 Proper Space Maintained between two Outdoor units and Walls
5 Provision for Servicing
6 Vibration Pads Installed
Equipment is free from the recirculation of Condensed Air from
7 nearby Outdoor unit
8 No Oil Tracing found inside the Unit
9 Electrical Connections Properly done
10 Equipment is Properly Grounded
Power Wiring is Connected through the bottom of the Control box
11 and Isolator
12 Condensor Fan rotates Freely
13 Filter Drier Installed

INDOOR UNIT MODEL NO: SERIAL NO:


REF.NO ITEM YES NO REMARKS
1 Equipment Installed as per approved Drawing
2 Equipment Installed as per Specification/Schedule
3 Electrical Connections Properly done
4 Enough Space provided for Return Air to the unit
5 Return air path is free from blockages
6 Proper Access for Servicing
7 Access Door Provided for removing Motor incase of Failure
8 Air Filters Installed in the Unit
9 Alignment and Leveling of the Equipment is done properly
10 Hanging rods are installed properly and levelled
11 Slope provided in the indoor unit at the condensate drain line side
12 Blower Rotates Freely and free from Noise
13 Thermostat located at the return air path
14 Condensate drain line is insulated
15 Condenstate Drain U trap properly installed
Air Vent is Installed at Condensate Drain Line (If the same drain
line is connected with multiple indoor units or if the drain line is
16 more than 5 meter)
Name: Name:
Company: Company:
Date: Date:
Signed: Signed:

* Warranty will not be applicable if the above mentioned installations guidelines are not followed.

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