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
HCFCs 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

HFCs
-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 HFCs 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 refrigerants
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

Dont 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