Split System Refrigerant Piping

A Primer & Spreadsheet

 The goal of this session
• Provide you an alternative method for
demonstrating line sizing to your students
• Briefly discuss refrigeration line sizing
requirements
– Not intended as a complete line sizing course
• Demonstrate the use of an excel spreadsheet
designed to simplify the line sizing process

jackbartell@virginiaair.com
 “Friendly”
game of wooden spoons
 “Friendly”
game of wooden spoons
Items Impacted by Refrigerant Piping
• System Performance
– Capacity
– Efficiency
– Reliability
– Oil Return to the compressor
• Costs to the HVAC Contractor
– Labor
– Material
– Warranty
• Customer Satisfaction
 The 7 Questions you need to ask to
properly size refrigeration lines
1. What refrigerant is being used, R-22 or R410A?
2. What is the tonnage of the unit?
3. Does the system have more than one stage of
compressor operation, or multiple compressors?
4. What is the total length of the line?
5. What is the equivalent length of the line?
 How many elbows will be used?
6. What is the unit Geography?
7. Is the system a heat Pump?
 Lubricant Miscibility Summary
HCFC’s 2 phases
w / Mineral oil -50C 2 phases
+65C +72 C

w / Alkylbenzene -50C 2 phases 1 phase +72 C

+66C
w / Polyolester 1 phase
-50C +72 C

HFC’s
-60C 2 phases +52C 2 phases +80 C
w / Mineral oil

-60C 2 phases +57C 2 phases +80 C

w / Alkylbenzene

w / Polyolester -60C 1 phase +80 C

Source: DuPont HP P.U.S.H.

 Lubricant movement in
a typical system
In a properly designed R-410A system, 3 to 5% of
the oil is in circulation at all times

• POE lubricants with HFC’s are 100% miscible

• 176° F (+80° C) through – 76° F (-60° C)
• As such, the circulating lubricant travels in suspension
• By contrast, MO/AB is approximately 30% miscible
• Remaining oil travels by peristalsis caused by the refrigerant’s
velocity
 Definition of “RISER”
• Any section of line that has an upward
direction of flow
– Direction of flow works against gravity
– Gas velocity carries the oil up the pipe & back to
the compressor sump
 “Liquid RISER”

Pressure
Loss
“Vapor RISER”

“RISER”

Pressure
GAIN
 NET RISE
When liquid flows downhill, it gains pressure,
when pushed uphill, it losses pressure

5’ Evap.

10’ 20’
10’
10’
25’
15 Ton Cooling only
90’ total length
10’ 6 elbows
Cond.
35’ net liquid line rise
 Reduced Suction Riser
Sometimes required in multi stage applications to
insure proper oil return and keep total pressure drop
low, reduce the riser line size
75’ 15 Ton Cond. HP

60’

40’
Evap.
•Suction
•Liquid
•WhatWhat
Line
Line
about
pressure
pressure
about
heat traps?
pumps?
drop
Drop
•Suction
•Liquid Line
Line velocity
pressure gain
•Returning
•Liquid Line
Oilvelocity
to compressor
Total Line Length vs Equivalent Line Length
Use Proper Assembly Techniques
• Evacuation
– Has always been highly important for R-22
– Critically important for R-410a!
• POE oil used with R-410a
• VERY hygroscopic
– Meaning it readily absorbs moisture
– At a rate about 15 times faster than the
mineral oil used with R-22
 Use Proper Assembly Techniques
• Hangers & Supports
– Attached to a solid surface
– Within 2’ from each change in direction
• Preferably on the side with the longest run
– Isolated to prevent noise/vibration transmission to the
structure
– Spaced for the following maximum span for tubing size
• 5’ max span >>> 1/2 & 5/8” OD
• 6’ max span >>> 3/4 & 7/8” OD
• 7’ max span >>> 1-1/8” OD
• 8’ max span >>> 1-3/8” OD
• 9’ max span >>> 1-5/8” OD
• 10’ max span >>> 2-1/8” OD and up
 Use Proper Assembly Techniques
• Use curved plates or sleeves to
maintain the insulation integrity
• Slope horizontal Vapor Lines
– 1” per 20’ in direction of flow
 Use Proper Assembly Techniques
• Evacuation Tips
– Pump oil must be changed
after each use
– Use a schrader tool to
reduce the time needed to
reach a deep vacuum
– Triple
Evacuation/Blot/Sweep
method is a fast & effective
technique
 Use Proper Assembly Techniques
• Evacuation
– Length of time spent with
vacuum pump running is
not a good indicator
– CFM rating of vacuum
pump has little to do with
depth of vacuum
– Use a micron gauge to
measure vacuum
– Moisture does not begin to
boil off until the vacuum
drops below 1000 microns
– Evacuate to 500 microns
 Use Proper Assembly Techniques

• Don’t be kinky
• Use cleaned, sealed, dehydrated ACR tubing
• Properly cut and ream tubing
 Use Proper Assembly Techniques
• Keep trash & moisture out of the piping
– Sweat on a cap or crimp & braze the ends of open
tubing
 Use Proper Assembly Techniques
• Clean socket and tube of
joints
• Use 5% or better silver
brazing material
– Less time spent brazing
joints
– Less chance of leaks
• Flow nitrogen while
brazing
 Use Proper Assembly Techniques
• Evacuation Tips
– Pump oil must be changed
after each use
– Use a schrader tool to
reduce the time needed to
reach a deep vacuum
Use Proper Assembly Techniques
• Refrigerant charging
– Weight
– Superheat/Subcooling
 Vapor Line Summary (R-22)
• 800 fpm minimum Velocity on Horizontal lines.
– Oil Return
• 1000 fpm minimum Velocity on Vertical lines.
– Oil Return
• 3000 fpm maximum Velocity to avoid:
– Refrigerant Noise
– Vibrating lines, especially at elbows
• Pressure Drop Causes Capacity Loss
– A 1 lb. pressure drop = 1% of capacity Loss
– Our recommendation is a maximum 3 lbs. Drop
 Vapor Line Summary (R-410A)
• 800 fpm minimum Velocity on Horizontal lines.
– Oil Return
• 1000 fpm minimum Velocity on Vertical lines.
– Oil Return
• 3000 fpm maximum Velocity to avoid:
– Refrigerant Noise
– Vibrating lines, especially at elbows
• Pressure Drop Causes Capacity Loss
– A 0.6 lb. pressure drop = 1% of capacity Loss
– Our recommendation is a maximum 5 lbs. Drop
 R-22 Liquid Line Summary
• 35 lb Max Total System Pressure Drop
• Fictional Loss of Pipe
• Liquid Riser = 1/2 lb pressure drop Per Foot
• Liquid Fall = 1/2 lb pressure gain Per Foot
• 3 lb Pressure Drop = 1 Degree Sub-Cooling Loss
 R-410A Liquid Line Summary

• 60 lb Max Total System Pressure Drop

• Fictional Loss of Pipe
• Liquid Riser = .43 lb pressure drop Per Foot
• Liquid Fall = .43 lb pressure gain Per Foot
• 5 lb Pressure Drop = 1 Degree Subcooling Loss
Questions