Installation Manual

AboveAir TM Technologies
Split System Refrigerant Piping Guide
Air Conditioners & Heat Pumps
(DX System Piping)

Refrigerant Piping Guide

• Installation Requirements

• Piping & Insulation

• Pipe Routing

• Sizing your line set

- Suction or Discharge
- Liquid
- Risers

Split Systems - Refrigerant Piping Guide

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 REFRIGERANT PIPING GUIDE
Refrigerant Piping Guide For systems with the condenser located below the evap-
This manual provides general recommenda ons and orator (compressor located in the evaporator sec on),
requirements for AboveAir Technologies split system the maximum allowable ver cal component is 20 feet.
refrigerant piping. Read through this manual carefully
prior to beginning any installa on ac vity to guarantee
that your installa on meets the requirements to ensure
op mal unit performance.

Installation Considerations
Long distances and eleva on 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.
For systems with a condensing unit (compressors located
with the condensing sec on) located above the evapora-
Maximum Recommended Lengths
tor, the maximum allowable ver cal component is 50
For op mal unit opera on, a maximum total equivalent
feet.
length (linear feet of horizontal pipe + linear feet of ver -
cal pipe + equivalent lengths of all fi ngs) of 150 feet is
permissible. The allowed ver cal component varies de-
pending on system configura on. InstallaƟons in excess
of 150 total equivalent feet may void your compressor
warranty.

For systems with a condensing unit (compressors located

with the condensing sec on) located below the evapo-
rator, the maximum allowable ver cal component is 50
feet.

For heat pump applicaƟons: Condensing and Evaporat-

For systems with the condenser located above the evap-
ing secƟons flip funcƟonality during heaƟng operaƟon.
orator (compressor located in the evaporator sec on),
Maximum verƟcal run allowance is determined by the
the maximum allowable ver cal component is 100 feet.
worst case condiƟon.

Piping and Routing

Use 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-
ing plenums, wall cavi es, conduit, or similar protected
areas to minimize the possibility of damage to the piping.

Slope all refrigerant piping in the direc on of flow at 1/4”

2 Refrigerant Piping
AboveAir™ Refrigerant Guide AboveAir Technologies
 REFRIGERANT PIPING GUIDE
per ten feet: slope the liquid line towards the evaporator,
the hot gas discharge line towards the condenser, and/or
the suc on line towards the compressor. Piping should
be installed without sags or bends.
Use proper transi on fi ngs to transi on from evapora-
tor and condenser stub out sizes to the refrigerant line
sizes calculated herein.
Piping Configurations
AboveAir Units are customizable for a variety of configu-
ra ons. Split configura ons include:
Remote Condenser: Compressors are located in the
evaporator sec on. Discharge and liquid lines between
the evaporator and condenser are required.
Condensing Unit: Compressors located with the remote
condensing sec on. SucƟon and liquid lines to between
the evaporator and condensing unit are required.
Each circuit in a mul -circuited unit will require its own
set of lines for connec on. For example, a dual circuited
condenser will require (2) discharge and (2) liquid lines
for connec on to the evaporator sec on.
Pipe Connections
Braze all piping connec ons 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, na onal and ASHRAE code
requirements. Take care to avoid introducing debris to
the piping system. Run dry nitrogen through the pip-
ing con nuously during the brazing process to minimize
contamina on and ensure joint quality.
Pipe Insulation
Pipe insula on materials should be provided as required
by the project documents and local codes. Piping should
be insulated in accordance with the following:
Liquid Line - Opera ng temperatures for the pipe will
typically be in the range of 110-120°F. Insula on is rec-
ommended on external installa ons and where piping is
routed through non-condi oned spaces or where the hot
pipe may present a hazard to the space occupants.
Suc on Line - Typical temperatures are in the vicinity of
40-50°F. Insula on is required to prevent condensa on,
minimize temperature loss to the environment, and pre-
vent refrigerant from flashing.
Hot Gas Discharge Line - Typical temperatures may be in
Refrigerant Piping
AboveAir Technologies
excess of 150°F. Insula on is not required. Insula on is
recommended where the hot pipe may present a hazard
to the space occupants.
Pipe Traps
Riser traps should be sizes as small as possible. Traps
should be included in the pipe sizing calcula ons, if re-
quired. Traps should be provided as follows:
Liquid Line - No traps required.
Suc on Line - Provide ver cal risers with a trap at the
bo om of the riser and an inverted trap at the top of the
riser.
Hot Gas Discharge Line - Provide ver cal risers with a
trap at the bo om of the riser and an inverted trap at
the top of the riser.
In addi on to these requirements, any vapor riser not
sized for 1,000 fpm minimum pipe velocity must be
trapped every 20 feet. Traps may be omi ed for risers
less than 5 feet in height.
Filter Driers
Your unit was shipped with filter-drier(s) either installed
in the evaporator sec on 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-
on as possible. Refer to the labeling on the device and
ensure that it is installed with the proper orienta on to
the flow.
For mul -circuited units, each liquid line must have its
own filter-drier.
Riser Sizing
Vapor 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.
Flooded Condenser Sizing
Pipes from a remote flooded condenser to a receiver
should be sized for a maximum of 100 fpm. Refer to
Table 6c (R-410a) or Table 7c (R-407c) for the required
pipe sizes for maximum liquid line sizes.
3
AboveAir™ Refrigerant Guide
 REFRIGERANT PIPING GUIDE
Pipe Sizing Method
Pipe sizing is based on the method detailed in the 2010 ASHRAE Refrigera on Handbook. The following charts and
recommenda ons are provided for your convenience - AboveAir Technologies recommends all refrigerant pipe sizes be
calculated by an engineer in accordance with the latest ASHRAE Refrigera on sizing guidelines.

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

Table 1 - Tonnage per Circuit

Refrigerant Type R-407c R-410a
Unit Tonnage
Number of Circuits
Tons per Circuit

To determine the pipe size to be used for installa on, the total equivalent length must be determined. The following
tables will lead you through the itera ve 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 + ver cal) in Table 2 below. To make an ini al
es mate of pipe sizes, mul ply this value by 1.5 and record the value under the total equivalent length column.

Table 2 - Initial Pipe Size Estimates

Total
Total Fi ng Al- Ini al Pipe
Line Type x = Equivalent
Length lowance Size
Length
Liquid x 1.5 =
Suc on x 1.5 =
Discharge x 1.5 =

The ini al 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 ini al pipe sizes for your applica on in Table 2 above.

Note: The following steps are an iteraƟve 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 addiƟonal iteraƟons.

In Table 3, record the actual quan ty of fi ngs to be installed on all applicable line types. Using the Ini al Pipe Sizes
recorded in Table 2, look up the equivalent fi ng lengths in Table 4. For each line type, mul ply the quan ty of fit-
ngs by the equivalent fi ng lengths. Record this value as indicated in the table, then add the values as indicated to
determine the total equivalent fi ng lengths for each line type. Record these values in i, ii, or ii as applicable.

4 Refrigerant Piping
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 REFRIGERANT PIPING GUIDE

Table 3 - Fitting Equivalent Lengths

Liquid Line
Value from Total Fi ng
Fi ng
Quan ty x Table 7 for ini- = Equivalent
Type Table 4 - Fitting
al pipe size Length
90° x = (a) Equivalent Lengths
45° x = (b) Pipe Fi ng Type
Size 90° 45° Trap
Traps x = (c)

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

3/8 0.9 0.7 2.3
Suc on Line 1/2 1.0 0.8 2.5
5/8 1.2 0.9 2.9
90° x = (d)
3/4 1.4 0.9 3.2
45° x = (e)
1 1/8 2.0 1.4 4.9
Traps x = (f)
1 3/8 2.5 1.8 6.0
Total Suc on Fi ng Equivalent Length (d + e + f) = (ii)
1 5/8 2.8 2.2 6.8
Hot Gas Discharge Line
2 1/8 3.5 2.8 8.7
90° x = (g)

45° x = (h)

Traps x = (i)

Total Suc on Fi ng Equivalent Length (g + h + i) = (iii)

Record the total line length and the total equivalent fi ng 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 5 - Calculated Pipe Size

Fi ng Total
Total
Line Type + Equivalent = Equivalent Pipe Size
Length
Lengths Length
Liquid + (i) =
Suc on + (ii) =
Discharge + (iii) =

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

Refrigerant Piping 5
AboveAir Technologies AboveAir™ Refrigerant Guide
 REFRIGERANT PIPING GUIDE

Table 6a - Refrigerant Line Sizing Charge for R-410a

Total Line Type Tonnage per Circuit
Equivalent 1 1.5 2 2.5 3 4 5 6 7.5 8 10 15
Length
25 Liquid 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4
(7.6 m) Suc on 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
Discharge 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 Liquid 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4
(15.2 m) Suc on 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 1/8
Discharge 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 Liquid 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4
(22.9 m) Suc on 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 3/8
Discharge 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 Liquid 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 7/8
(30.5 m) Suc on 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 3/8
Discharge 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 Liquid ** 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 7/8
(38.1 m) Suc on ** 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 5/8
Discharge ** 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 Liquid ** 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 7/8
(45.7 m) Suc on ** 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
Discharge ** 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
** Installa on not recommended.

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

Circuit Tonnage
Line Type
1 1.5 2 2.5 3 4 5 6 7.5 8 10 15
Discharge 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
Suc on 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 15
3/8 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

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 REFRIGERANT PIPING GUIDE

Table 7a - Refrigerant Line Sizing Charge for R-407c

Total Tonnage per Circuit
Equivalent Line Type
Length 1 1.5 2 2.5 3 4 5 6 7.5 8 10 15
Liquid 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4
25
Suc on 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 3/8
(7.6 m)
Discharge 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
Liquid 3/8 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4
50
Suc on 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 5/8
(15.2 m)
Discharge 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
Liquid 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 5/8 3/4 7/8
75
Suc on 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 5/8
(22.9 m)
Discharge 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
Liquid 3/8 3/8 1/2 1/2 1/2 1/2 5/8 5/8 3/4 3/4 3/4 7/8
100
Suc on 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 1/8
(30.5 m)
Discharge 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
Liquid ** 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 7/8
125
Suc on ** 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 1/8
(38.1 m)
Discharge ** 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
Liquid ** 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 7/8
150
Suc on ** 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 1/8
(45.7 m)
Discharge ** 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
** Installa on not recommended.

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

Circuit Tonnage
Line Type
1 1.5 2 2.5 3 4 5 6 7.5 8 10 15
Discharge 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
Suc on 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 15
3/8 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 7
AboveAir Technologies AboveAir™ Refrigerant Guide
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