Bohn BDV-01002L6 Installation Manual

0 (0)

Mohave Hot Gas

Defrost Installation

& Operation

H-IM-HGD0307	March 2007	Part Number 25007401

Installation, Start-Up, Operation and Troubleshooting with Wiring Diagrams

Table of Contents
Controller Quick Reference Guide.......................................................	3-5
Receiving and Inspection
General Safety Information..............................................................	6
Warranty Statement.........................................................................	6
System and Components.................................................................	7
Installation
Unit Cooler Installation
Placement...........................................................................	8-9
Condensate Lines..................................................................	9
Condensing Unit Installation
Placement............................................................................	10
Rigging.................................................................................	11
Field Piping Guidelines...................................................	12-21
Optional Controls.................................................................	22
System Wiring...........................................................................	23-33
Operation
Hot Gas Unit Cooler Typical Factory Piping...................................	34
Hot Gas Condensing Unit Typical Factory Piping..........................	35
Refrigeration Operation.............................................................	36-37
Defrost Operation......................................................................	38-41
Evacuation & Leak Detection.........................................................	42
Check Out & Start-Up.....................................................................	43
Program Review........................................................................	43-45
Monitoring & Reviewing Operation Values................................	46-47
Error and Alarm Details..................................................................	48
Refrigerant Charging.................................................................	49-50
Operational Check Out...................................................................	51
Refrigeration Oils............................................................................	52
Troubleshooting.........................................................................	53-55
Preventive Maintenance............................................................	56-57
InterLink Service Parts...................................................................	58
Service Record...............................................................................	59
Factory Default Settings.................................................................	60

Controller Quick Reference Guide

The Mohave™ Hot Gas Controller is located inside the condensing
unit electrical panel. The Service Switch is adjacent to the controller	Program		Reset
on the side of the enclosure.	Program	Enter Monitor	Reset
	Review	Enter Monitor	Time

Control Buttons

Program Review: Review or Change the Program Settings

Enter: Accepts changes into memory

Monitor: View Current Operating Conditions of the System

Reset Time: Resets the time clocks of the microprocessor to 0.

Clear/Test: Clear ignores program selections prior to pressing

Enter and terminates Service Mode. Test causes the system to

cycle through all of the outputs for troubleshooting.

Select Knob: Used for Cycling through Monitoring and

Programming Parameters.

Force Service: Press this button twice to cause the system to

pump down and remain off until the Clear button is pressed.



Clear/	Selection	Force	Force
Test	Knob	Service	Defrost

Force Defrost: System will pump down and begin a defrost cycle. This will not effect the normally scheduled defrosts.

Service Switch

This toggle switch may be placed in the “on” position to force the system into Service Mode. The compressor will pump down and shut off. The evaporator fans will de-energize. The system can be left in service.

Operating Modes

MODE	DESCRIPTION
OFF	Compressor Off
COOL	Compressor On in Cooling Normal Cooling Operation
PMPD	System in Pump Down Mode
SERV	Service Mode, System is Off
DELY	Time Delay
DEF1	Defrost Stage 1
	Pre-Defrost or ByPass Mode
DEF2	Defrost Stage 2
	Defrost Mode
DEF3	Defrost Stage 3
	Post Defrost Equalization or Drain Down Mode
FREZ	Refreeze Mode
TEST	Test Mode
SERV	Service Mode
EVAC	Evacuation Mode

Controller Quick Reference Guide

Program Review Menu

	DISPLAY	DESCRIPTION	FACTORY DEFAULT
	CLKH	Set the Time of Day clock hour value	None
	CLKM	Set the Time of Day clock minute value	None
	°F °C	Set Fahrenheit or Celsius temperature units (°F	°F
		or °C)
	1224	Set Time display method (12 hr. or 24 hr.)	12 hr
	ALRT	Set the Alarm Time (2 to 120 minutes)	20 min
	DF01	Set Defrost 1 starting time (12:00 am to 12:00 pm	12:00AM
		in 30 minute increments)
	DF02	Set Defrost 2 starting time	6:00AM
	DF03	Set Defrost 3 starting time	12:00PM
	DF04	Set Defrost 4 starting time	6:00PM
	DF05 - DF12	Set Defrost XX starting time	--- ---
	REFR	Set Refrigerant type (R-22, R-404A, R-507)	R404A
	APPL	Set Application type (Med., Low)	Med Temp
	MODL	Set Model Number	1502
	XPRT	Expert Mode (To Access Additional Program	Off
		Parameters (On, Off)
(See Program Review Section for additional information)
Monitor Display Menu

DISPLAY	DESCRIPTION
VALP	Defrost Regulator Valve percent of opening (0 to 100%)
SUPH	Superheat (°F.) measured at inlet of Suction Accumulator
SucT	Suction Temperature (°F.) at inlet of Suction Accumulator
SucP	Suction Pressure (PSIG/”HG) at inlet of Suction Accumulator
SSuc	Saturated Suction Temperature (°F.) at inlet of Suction Accumulator
LIQP	Liquid Pressure (PSIG) measured between CU Receiver and Condenser
AMBT	Ambient Air Temperature (°F.) measured entering condenser coil
AUXT	Auxiliary Probe Temperature (°F.)
E1DT	Evaporator 1 Defrost Termination Temp (°F.)
E2DT	Evaporator 2 Defrost Termination Temp (°F.)
ACIN	Control Board voltage (24VAC nominal)
TMMS	Current time minutes and seconds
TMHM	Current time hours and minutes
CCYC	Compressor Cycles since Midnight
RnTM	Compressor Run Time since Midnight
DFTM	Duration Time of Last Defrost
ETLD	Elapsed Time since last Defrost (HH.MM)
RTLD	Run Time since last Defrost (HH.MM)
VERS	Software version

		Controller Quick Reference Guide
Forced Output Menu

	DISPLAY		DESCRIPTION
	EVPF		Evaporator Fan Contactor
	LIQS		Liquid Line Solenoid
	EVPH		Evaporator Pan Heater
	FAN4		Condenser Fan 4 Contactor
	FAN3		Condenser Fan 3 Contactor
	FAN2		Condenser Fan 2 Contactor
	FAN1		Condenser Fan 1 Contactor
	COMP		Compressor Contactor
	BYPV		Bypass Solenoid
	SucS		Suction Stop Solenoid
	DEFS		Defrost Solenoid
	3WAY		3-Way Valve Solenoid
	ALRM		Alarm Contacts
	VALS		Regulator Valve Control
	EVAC		Activate all Solenoids, Open the Pressure Regulator Valve
System Alarms

	DISPLAY	DESCRIPTION
	Alr1	Persistent input sensor/transducer failure
	Alr2	Combines Err4 and Err8, system off
	Alr3	Repeated Safety Circuit Open condition
	Alr4	Prolonged Cooling Startup Failure
System Errors

	DISPLAY	DESCRIPTION
	Err1	Suction temperature sensor open or short
	Err2	Ambient temp sensor open or short
	Err3	Auxiliary temp sensor open or short
	Err4	Suction Pressure sensor open or short
	Err5	Liquid Pressure sensor open or short
	Err6	Evap 1 defrost temp sensor open or short
	Err7	Evap 2 defrost temp sensor open or short
	Err8	Redundant Low Pressure Switch Open or Short
	Err9	Safety Circuit interruption during normal operation
	Er10	Prolonged Low Suction Pressure during cooling
	Er11	Low Suction Pressure startup failure
	Er12	High Suction Pressure startup failure
	Er13	Post Defrost pump down error

General Safety Information

1.Installation and maintenance to be performed only by qualified personnel who are familiar with this type of equipment.

2.Some units are pressurized with dry air or inert gas. All units must be evacuated before charging the system with refrigerant.

3.Make sure that all field wiring conforms to the requirements of the equipment and all applicable national and local codes.

4.Avoid contact with sharp edges and coil surfaces. They are a potential injury hazard.

5.Make sure all power sources are disconnected before any service work is done on units.

WARNING: Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly. Failure to follow this warning may result in personal injury or death.

Inspection

Responsibility should be assigned to a dependable individual at the job site to receive material. Each shipment should be carefully checked against the bill of lading. The shipping receipt should not be signed until all items listed on the bill of lading have been accounted. Check carefully for concealed damage. Any shortage or damages should be reported to the delivering carrier. Damaged materialbecomesthedeliveringcarrier’sresponsibility,andshould not be returned to the manufacturer unless prior approval is given todoso.Whenuncrating,careshouldbetakentopreventdamage. Heavyequipmentshouldbeleftonitsshippingbaseuntilithasbeen moved to the final location. Check the serial tag information with invoice. Report any discrepancies to your Heatcraft Refrigeration Products Sales Representative.

Warranty Statement

Seller warrants to its direct purchasers that products, including ServiceParts,manufacturedbySELLERshallbeofamerchantable quality, free of defects in material or workmanship, under normal use and service for a period of one (1) year from date of original installation, or eighteen (18) months from date of shipment by SELLER, whichever first occurs.Any product covered by this order found to Seller’s satisfaction to be defective upon examination at Seller’s factory will at SELLER’s option, be repaired or replaced and returned to Buyer via lowest common carrier, or SELLER may at its option grant Buyer a credit for the purchase price of the defective article. Upon return of a defective product to SELLER’s plant, freight prepaid, by Buyer, correction of such defect by repair or replacement, and return freight via lowest common carrier, shall constitute full performance by SELLER of its obligations hereunder.

SELLER shall have no liability for expenses incurred for repairs made by Buyer except by prior, written authorization. Every claim on account of breach of warranty shall be made to SELLER in writing within the warranty period specified above – otherwise such claim shall be deemed waived. Seller shall have no warranty obligation whatsoever if its products have been subjected to alteration, misuse, negligence, free chemicals in system, corrosive atmosphere, accident, or if operation is contrary to SELLER’s or manufacturer’s recommendations, or if the serial number has been altered, defaced, or removed.

MOTOR COMPRESSORS:

Motor compressors furnished by SELLER are subject to the standard warranty terms set forth above, except that motor compressor replacements or exchanges shall be made through the nearest authorized wholesaler of the motor compressor manufacturer (not at SELLER’s factory) and no freight shall be allowed for transportation of the motor compressor to and from the wholesaler. The replacement motor compressor shall be identical to the model of the motor compressor being replaced. Additional charges which may be incurred throughout the substitution of other than identical replacements are not covered by this warranty. An optional, non assignable, four (4) year extended compressor warranty may be purchased within the boundaries of

the United Sates of America, its territories and possessions, and Canada. With this extended compressor warranty, replacements are administered by an authorized compressor distributor only. Replacements within the first year of the warranty area available through the distributor; the second through fifth years, the purchaser must submit a proof-of-purchase of a compressor and supply it to Heatcraft Refrigeration Products Warranty Claims for reimbursement.

Seller makes no express warranties except as noted above. All implied warranties are limited to the duration of the Express Warranty. Liability for incidental and consequential damages is excluded.

The forgoing is in lieu of all other warranties, express or implied, notwithstanding the provisions of the uniform commercial code, the Magnuson-Moss Warranty - Federal Trade Commission Improvement Act, or any other statutory or common law, federal or state.

SELLER makes no warranty, express or implied, of fitness for any particular purpose, or of any nature whatsoever, with respect to products manufactures or sold by seller hereunder, except as specifically set forth above and on the face hereof. It is expressly understood and agreed that SELLER shall not be liable to buyer, or any customer of buyer, for direct or indirect, special, incidental, consequential or penal damages, or for any expenses incurred by reason of the use or misuse by buyer or third parties of said products.Totheextentsaidproductsmaybeconsidered"consumer products,"As defined in Sec. 101 of the Magnuson-Moss Warranty - FederalTrade Commission ImprovementAct, SELLER makes no warranty of any kind, express or implied, to "consumers," except as specifically set forth above and on the face hereof.

The following conditions should be adhered to when installing this unit to maintain the manufacturers warranty:

(a)System piping must be in accordance with good refrigeration practices.

(b)Inertgasmustbechargedintothepipingduring brazing.

(c)The power supply to the unit must meet the following conditions:

A.Three phase voltages must be +/- 10% of nameplate ratings. Single phase must be within +10% or -5% of nameplate ratings.

B.Phase imbalance cannot exceed 2%.

(d)All control and safety switch circuits must be properly connected according to the wiring diagram.

(e)The factory installed wiring must not be changed without written factory approval.

(f)All equipment is installed in accordance with Heatcraft Refrigeration Products specified minimum clearances.

System and Components

Condensing Unit		Evaporators
(Vertical Air Discharge Design)		(Medium Profile & High Profile Unit Coolers)
Standard Features:		Standard Features:
• Electronic Hot Gas Defrost Controller includes Defrost		•	All Components are factory installed and wired
	Initiation and Termination Control, Pressure Fan Cycling for	•	Power Supply Independent from Condensing Unit
	Head Pressure Control, Ambient Fan Cycling Option, Anti-	•	Mounted Fan Control Contactors and Drain Pan Heater
	Short Cycling Protection, and Low Pressure Control		Contactors if specified
• Electronic Pressure Regulator for Defrost Control		•	Four or Six Fins Per Inch Models
•	Suction Accumulator	•	Mounted TXV and Distributor Nozzle
• High Pressure and Redundant Low Pressure Control		•	Mounted Check Valves
• Oil Pressure Safety Control		•	Mounted Liquid Line Solenoid
• High Efficiency Copeland Discus Compressors with POE		•	Suction P-Trap
	oil	•	Thermally Protected Permanently Lubricated Evaporator
• Thermally Protected Permanently Lubricated Ball Bearing			Fan Motors
	Condenser Fan Motors	• Mounted Electric Drain Pan Heaters
• Electrical Controls located in easily accessible control box		• Insulated Drain Pan (Low Temperature Systems)
	with a hinged cover
• Receivers are sized for sufficient pump down capacity with		Optional Features:
	inlet and outlet service valves	• Mounted Hot Gas Drain Pan Loop
• Cabinet is constructed from painted galvanized steel		• Evaporator Powered from Condensing Unit
• Convenient Access Panels for easy servicing to internal
	components
• Suction and Discharge Vibration Eliminators
• Separate Sub-cooling Circuit.
• Replaceable Liquid Line Filter Drier
• Replaceable Core Suction Filter
•	Sight Glass
• Compressor Head Fan on L6 Models

Optional Features:

•Head Pressure Valves (ORI/ORD)

•Oil Separator

•Insulated and Heated Receiver

•Fused Disconnect Switch

•Non-fused Disconnect Switch

•Coated Condenser Coils for protection against harsh environments (ETO Only)

•Phase Loss Monitor

•Mounted Evaporator Control Contactors

Unit Cooler Installation

Most evaporators can be mounted with rod hangers, lag screws, or bolts. Use 5/16" bolt and washers or rod for up to 250 pounds, 3/8" for up to 600 pounds and 5/8" for over 600 pounds. Care should be taken to mount the units level so that condensate drains properly. Adequate support must be provided to hold the weight of the unit.

When using rod hangers, allow adequate space between the top of the unit and the ceiling for cleaning. To comply with NSF Standard 7, the area above the unit cooler must be sealed or

exposed in such a way to facilitate hand cleaning without the use of tools. When lagging or bolting the unit flush to the ceiling, seal the joint between the top and the ceiling with an NSF listed sealant and ends of open hanger channels must be sealed to prevent accumulation of foreign matter.

When locating unit coolers in a cooler or freezer, refer to Figure 1-2 for guidelines.

Figure 1. Large Coolers and Freezers Placement.
Figure 1. Large Coolers and Freezers Placement.	NOTE: Always avoid placement of Unit Coolers
	directly above doors and door openings.
	Baffled Unit

Where one wall evaporator	Cooler or Freezers where one
mounting is satisfactory.	wall will not accommodate all
	required evaporators or where
	air throw distance must be
	considered.

Cooler or Freezer with Glass

Display Doors

Allowsufficientspacebetween rear of Unit Cooler and wall to permit free return of air. Refer to Figures 1 - 2 for proper space.

Elevation view of glass display door coolerorfreezer. Besureairdischarge blows above, not directly at doors. Provide baffle if door extends above blower level.

Unit Cooler Installation & Condensate Lines

Unit Coolers (continued)

Recommended Unit Cooler Placement

Some general rules for evaporator placement which must be followed are:

1.The air pattern must cover the entire room

2.NEVER locate evaporators over doors

3.Location of aisles, racks, etc. must be known

4.Location relative to compressors for minimum pipe runs

5.Location of condensate drains for minimum run.

The size and shape of the storage will generally determine the type and number of evaporators to be used and their location. The following are some typical examples:

NOTE: Leave space equal to unit height between bottom of unit and product. Do not stack product in front of fans.

Minimum Unit Clearances

Traps on low temperature units must be outside of refrigerated enclosures.Trapssubjecttofreezingtemperaturesmustbewrapped with heat tape and insulated.

NOTE: Always trap single evaporator system drain lines individually to prevent humidity migration.

Figure 2. Medium Profile and Large Unit Coolers

NOTE:

W = Total width of evaporator coil surface.

One evaporator

Condensate Drain Lines

Either copper or steel drain lines should be used and properly protected from freezing. In running drain lines, provide a minimum 4 inches per foot pitch for proper drainage. Drain lines should be at least as large as the evaporator drain connection. All plumbing connections should be made in accordance with local plumbing codes. All condensate drain lines must be trapped, and run to an open drain. They must never be connected directly to the sewer system. Traps in the drain line must be located in a warm ambient. We recommend a trap on each evaporator drain line prior to any tee connections. Traps located outside, or extensive outside runs of drain line must be wrapped with a drain line heater. The heater should be connected so that it operates continuously. It is recommended that the drain line be insulated to prevent heat loss. A heat input of 20 watts per linear foot of drain line for 0˚F (-18˚C) room applications and 30 watts per linear foot for -20˚F (-29˚C) rooms is satisfactory. In freezers, the evaporator drain pan fitting should be included when heating and insulating the drain line.

Inspectdrainpanperiodicallytoinsurefreedrainageofcondensate. If drain pan contains standing water, check for proper installation. The drain pan should be cleaned regularly with warm soapy water.

WARNING: All power must be disconnected before cleaning. Drain pan also serves as cover of hazardous moving parts. Operation of unit without drain pan constitutes a hazard.

Two evaporators

Condensate Drain Lines

Condensing Unit Installation

Space & Location Requirements for Air Cooled Condensing Units and Remote Condensers

Themostimportantconsiderationwhichmustbetakenintoaccount when deciding upon the location of air-cooled equipment is the provision for a supply of ambient air to the condenser, and removal of heated air from the condensing unit or remote condenser area. Where this essential requirement is not adhered to, it will result in higher head pressures, which cause poor operation and potential failure of equipment. Units must not be located in the vicinity of steam, hot air or fume exhausts. Corrosive atmospheres require custom designed condensers.

Another consideration which must be taken is that the unit should be mounted away from noise sensitive spaces and must have adequate support to avoid vibration and noise transmission into the building. Units should be mounted over corridors, utility areas, restroomsandotherauxiliaryareaswherehighlevelsofsoundare not an important factor. Sound and structural consultants should be retained for recommendations.

Space and Location Requirements for Condensing Units and Remote Condensers

Walls or Obstructions

Multiple Units

The unit should be located so that air may circulate freely and not be recirculated. For proper air flow and access all sides of the unit should be a minimum of “W” away from any wall or obstruction. It is preferred that this distance be increased whenever possible. Care should be taken to see that ample room is left for maintenance work through access doors and panels. Overhead obstructions are not permitted. When the unit is in an area where it is enclosed by three walls the unit must be installed as indicated for units in a pit.

Units in Pits

The top of the unit should be level with the top of the pit, and side distance increased to “2W”.

If the top of the unit is not level with the top of pit, discharge cones or stacks must be used to raise discharge air to the top of the pit. This is a minimum requirement.

For units placed side by side, the minimum distance between units is the width of the largest unit. If units are placed end to end, the minimum distance between units is 4 feet.

Decorative Fences

Fences must have 50% free area, with 1 foot undercut, a “W” minimum clearance, and must not exceed the top of unit. If these requirements are not met, unit must be installed as indicated for “Units in pits”.

Walls or Obstructions for Horizontal Air Flow

Multiple Units with Horizontal Air Flow

* “W” = Total width of the condensing unit or condenser.

Condensing Unit Installation

Condensing Unit Rigging and Mounting

Rigging holes are provided on all units. Caution should be exercised when moving these units. To prevent damage to the unit housing during rigging, cables or chains used must be held apart by spacer bars. The mounting platform or base should be level and located so as to permit free access of supply air.

Ground Mounting

Concrete slab raised six inches above ground level provides a suitablebase.Raisingthebaseabovegroundlevelprovidessome protection from ground water and wind blown matter. Before tightening mounting bolts, recheck level of unit. The unit should in all cases be located with a clear space in all directions that is at a minimum, equal to the height of the unit above the mounting surface. A condensing unit mounted in a corner formed by two walls, may result in discharge air recirculation with resulting loss of capacity.

Roof Mounting

Due to the weight of the units, a structural analysis by a qualified engineer may be required before mounting. Roof mounted units should be installed level on steel channels or an I-beam frame capable of supporting the weight of the unit. Vibration absorbing pads or springs should be installed between the condensing unit legs or frame and the roof mounting assembly.

Access

Provide adequate space at the compressor end of the unit for servicing. Provide adequate space on the connection side to permit service of components.

Spring Mounted Compressor

Compressors are secured rigidly to make sure there is no transit damage. Before operating the unit, it is necessary to follow these steps:

a.Remove the upper nuts and washers.

b.Discard the shipping spacers.

c.Install the neoprene spacers. (Spacers located in the electrical panel or tied to compressor.)

d.Replace the upper mounting nuts and washers.

e.Allow 1/16 inch space between the mounting nut/ washer and the neoprene spacer. See Figure 3 below.

Rigid Mounted Compressor

Some products use rigid mounted compressors. Check the compressor mounting bolts to insure they have not vibrated loose during shipment. See Figure 3 and 5 below.

Figure 3. Spring Mount	Figure 4. Solid Mount for Mobile or Deep
	Sump Application.

Figure 5. Spring Mount

Piping

Recommended Refrigerant Piping Practices

ThesystemassuppliedbyHeatcraftRefrigerationProducts, wasthoroughlycleanedanddehydratedatthefactory. Foreign matter may enter the system by way of the evaporator to condensing unit piping. Therefore, care must be used during installation of the piping to prevent entrance of foreign matter.

Install all refrigeration system components in accordance with applicable local and national codes and in conformance with good practice required for the proper operation of the system.

The refrigerant pipe size should be selected from the tables on pages 15-21. The interconnecting pipe size is not necessarily the same size as the stub-out on the condensing unit or the evaporator.

The following procedures should be followed:

(a)Do not leave dehydrated compressors or filter driers on condensing units open to the atmosphere any longer than is absolutely necessary.

(b)Use only refrigeration grade copper tubing, properly sealed against contamination.

(c)Suction lines should slope 1/4" per 10 feet towards the compressor.

(d)Suitable P-type oil traps should be located at the base of each suction riser of four (4) feet or more to enhance oil return to the compressor.

(e)For desired method of superheat measurement, a pressure tap should be installed in each evaporator suction line in the proximity of the expansion valve bulb.

(f)When brazing refrigerant lines, an inert gas should be passed through the line at low pressure to prevent scaling and oxidation inside the tubing. Dry nitrogen is preferred.

(g)Use only a suitable silver solder alloy on suction

and liquid lines.

(h)Limit the soldering paste or flux to the minimum required to prevent contamination of the solder joint internally. Flux only the male portion of the connection, never the female. After brazing, remove excess flux.

(i)If isolation valves are installed at the evaporator, full port ball valves should be used.

Refrigerant Pipe Support

1.Normally, any straight run of tubing must be supported in at least two locations near each end of the run.

Long runs require additional supports. The refrigerant lines should be supported and fastened properly. As a guide, 3/8 to 7/8 should be supported every 5 feet; 1-1/8 and

1-3/8 every 7 feet; and 1-5/8 and 2-1/8 every 9 to 10 feet.

2.When changing directions in a run of tubing, no corner should be left unsupported. Supports should be placed a maximum of 2 feet in each direction from the corner.

3.Piping attached to a vibrating object (such as a compressor or compressor base) must be supported in such a manner that will not restrict the movement of the vibrating object.

Rigid mounting will fatigue the copper tubing.

4.Do not use short radius ells. Short radius elbows have points of excessive stress concentration and are subject to breakage at these points.

5.Thoroughly inspect all piping after the equipment is in operation and add supports wherever line vibration is significantly greater than most of the other piping. Extra supports are relatively inexpensive as compared to refrigerant loss.

Example of Pipe Support

Condensing Unit / Compressor to Wall Support.

Piping

The following are examples of proper piping layout for typical system configurations

Piping

Unit Cooler Piping

Pipe size example:

Given: -10°F Freezer with one system having (2) evaporators

•One condensing unit rated at 24,000 BTUH’s @ -20°F SST R404A refrigerant.

•Two evaporators each rated at 12,000 BTUH’s @ 10°F TD.

•75 feet of actual line run between condensing unit to first evaporator and 20 feet of actual line run between the first evaporator and the second evaporator (see figure below).

How to figure line sizes:

1.Determine equivalent line run = actual run + valves and fitting allowances.

2.Use Line Sizing Tables on pages 16-19 to size lines.

3.Note any special considerations.

Evap. 2

Evap. 1

NOTE: This is a line sizing example. Use diagrams on page 13-14 for piping orientation.

Fittings in this system:

•(6) 90° elbows in main line plus a 90° turn through a tee.

•(5) addtional 90° elbows to first evaporator.

•(4) additional 90° elbows to second evaporator.

Determine line size 1 (main line from	Determine line size 2 (evaporators):
condensing unit):	1.	Line sizing to each evaporator is based on 12,000 BTUH’s
1. Main line from the condensing unit to be sized for the total		andequivalentrunfrom condensingunit. Firstevaporator has
		an 80 ft. run and the second evaporator has a 95 ft. run.
capacity (balance) of the whole system of 24,000 BTUH’s		an 80 ft. run and the second evaporator has a 95 ft. run.
capacity (balance) of the whole system of 24,000 BTUH’s
(Table 2 and 2A).	2.	Table2indicates7/8"suctionforthefirstevaporatorandTable
2. Refer to 24,000 @75 feet at -20°F SST R404A on the chart.		2A indicates 1 1/8" suction for the second evaporator.

You will find the suction line to be 1 1/8" and 1/2" liquid line.	3.	Refer to Table 5. Each 7/8" 90° elbow adds 2 equivalent feet
3. Refer to Table 5. For every 1 1/8" 90° elbow you must	add	of pipe. Each 1 1/8" 90° elbow adds 3 equivalent feet and a
3 equivalent feet of pipe and 2 equivalent feet of pipe for each		90° turn through a 1 1/8" tee adds 6 equivalent feet.
1 1/8" tee.	4.	Actual line run (evap 1)	80 feet
Therefore, total equivalent line run =		+ (5) 7/8" elbows @ 2'	10 feet

Actual line run			75 feet
+ (6)	1	1/8" elbows @ 3'	18 feet
+ (1)	1	1/8" tee @ 2'	2 feet
Total equivalent line run			95 feet

4.Refer to Table 2A. For 95 total equivalent feet, the suction line size should be 1 3/8" and the liquid line stays at 1/2" line.

Note: The gray shaded areas on Table 2. For 24,000 BTUH’s, the maximum suction riser is 1 1/8" to insure proper oil return and pressure drop from the bottom p-trap to the top p-trap.

+ (1)	90° turn through tee @ 6'	6 feet
Total equivalent line run		96 feet
Actual line run (evap 2)		95 feet
+ (4)	1 1/8" elbows @ 3'	12 feet
Total equivalent line run		107 feet

5.Table 2A indicates 1 1/8" suction line and 3/8" liquid line from main line to both evaporators.

Line Sizing

Table 1. Recommended Line Sizes for R-22 *

SUCTION LINE SIZE

SUCTION TEMPERATURE

SYSTEM

+40˚F

+20˚F

+10˚F

0˚F

CAPACITY

Equivalent Lengths

Equivalent

BTU/H

25'

50'

75'

100'

150'

200'

25'

50'

75'

100'

150'

200'

25'

50'

75'

100'

150'

200'

25'

50'

75'

1,000

3/8

1/2

3/8

3,000

3/8

1/2

3/8

1/2

5/8

3/8

1/2

5/8

1/2

4,000

3/8

1/2

3/8

1/2

5/8

1/2

5/8

1/2

5/8

6,000

1/2

5/8

1/2

5/8

1/2

5/8

7/8

5/8

9,000

1/2

5/8

7/8

1/2

5/8

7/8

5/8

7/8

5/8

7/8

12,000

5/8

7/8

5/8

7/8

5/8

7/8

5/8

7/8

15,000

5/8

7/8

5/8

7/8

1 1/8

7/8

18,000

5/8

7/8

1 1/8

5/8

7/8

1 1/8

7/8

1 1/8

7/8

1 1/8

24,000

5/8

7/8

1 1/8

7/8

1 1/8

7/8

1 1/8

7/8

1 1/8

30,000

7/8

1 1/8

7/8

1 1/8

7/8

1 1/8

1 3/8

7/8

1 1/8

36,000

7/8

1 1/8

1 3/8

7/8

1 1/8

1 3/8

7/8

1 1/8

1 3/8

1 1/8

42,000

7/8

1 1/8

1 3/8

7/8

1 1/8

1 3/8

1 1/8

1 3/8

1 1/8

1 3/8

48,000

7/8

1 1/8

1 3/8

7/8

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

54,000

7/8

1 1/8

1 3/8

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

60,000

7/8

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

66,000

7/8

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

72,000

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 3/8

1 5/8

78,000

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

84,000

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

90,000

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

120,000

1 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 5/8

2 1/8

150,000

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 5/8

2 1/8

2 5/8

1 5/8

2 1/8

180,000

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 5/8

2 1/8

2 5/8

1 5/8

2 1/8

210,000

1 3/8

1 5/8

2 1/8

1 5/8

2 1/8

2 5/8

1 5/8

2 1/8

2 5/8

2 1/8

240,000

1 5/8

2 1/8

2 5/8

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

2 1/8

2 5/8

300,000

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

360,000

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

480,000

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

3 1/8

3 5/8

2 5/8

3 1/8

600,000

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

3 1/8

3 5/8

2 5/8

3 1/8

3 5/8

2 5/8

3 1/8

* NOTES:

1.Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.

2.Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3.If system load drops below 40% of design, consideration to installing double suction risers should be made.

Line Sizing

Table 1A. Recommended Line Sizes for R-22 (continued) *

	LIQUID LINE SIZE

		Receiver to
	Expansion Valve					SYSTEM
	Equivalent Lengths					CAPACITY
						BTU/H
25'	50'	75'	100'	150'	200'	BTU/H

3/8	3/8	3/8	3/8	3/8	3/8	1,000
3/8	3/8	3/8	3/8	3/8	3/8	3,000
3/8	3/8	3/8	3/8	3/8	3/8	4,000

3/8	3/8	3/8	3/8	3/8	3/8	6,000
3/8	3/8	3/8	3/8	3/8	3/8	9,000
3/8	3/8	3/8	3/8	3/8	3/8	12,000

3/8	3/8	3/8	3/8	3/8	1/2	15,000
3/8	3/8	3/8	3/8	1/2	1/2	18,000
3/8	3/8	1/2	1/2	1/2	1/2	24,000

3/8	3/8	1/2	1/2	1/2	1/2	30,000
3/8	1/2	1/2	1/2	1/2	1/2	36,000
3/8	1/2	1/2	1/2	1/2	5/8	42,000

1/2	1/2	1/2	1/2	1/2	5/8	48,000
1/2	1/2	1/2	1/2	5/8	5/8	54,000
1/2	1/2	1/2	5/8	5/8	5/8	60,000

1/2	1/2	5/8	5/8	5/8	5/8	66,000
1/2	1/2	5/8	5/8	5/8	5/8	72,000
1/2	1/2	5/8	5/8	5/8	7/8	78,000

1/2	5/8	5/8	5/8	5/8	7/8	84,000
1/2	5/8	5/8	5/8	7/8	7/8	90,000
5/8	5/8	5/8	7/8	7/8	7/8	120,000

5/8	7/8	7/8	7/8	7/8	7/8	150,000
5/8	7/8	7/8	7/8	7/8	1 1/8	180,000
7/8	7/8	7/8	7/8	7/8	1 1/8	210,000
7/8	7/8	7/8	7/8	1 1/8	1 1/8	240,000
7/8	7/8	1 1/8	1 1/8	1 1/8	1 1/8	300,000
7/8	7/8	1 1/8	1 1/8	1 1/8	1 1/8	360,000

1 1/8	1 1/8	1 1/8	1 1/8	1 3/8	1 3/8	480,000
1 1/8	1 1/8	1 1/8	1 3/8	1 3/8	1 3/8	600,000

* NOTES:

1. All sizes shown are for O.D. Type L copper tubing.

Line Sizing

Table 2. Recommended Line Sizes for R-404A and R507 *

SUCTION LINE SIZE

SUCTION TEMPERATURE

SYSTEM

+20˚F

+10˚F

-10˚F

-20˚F

CAPACITY

Equivalent Lengths

Equivalent

BTU/H

25'

50'

75'

100'

150'

200'

25'

50'

75'

100'

150'

200'

25'

50'

75'

100'

150'

200'

25'

50'

75'

1,000

3/8

1/2

3/8

1/2

3/8

1/2

3,000

3/8

1/2

5/8

3/8

1/2

5/8

1/2

5/8

7/8

1/2

5/8

4,000

3/8

1/2

5/8

1/2

5/8

7/8

1/2

5/8

7/8

1/2

5/8

6,000

1/2

5/8

7/8

1/2

5/8

7/8

1/2

5/8

7/8

5/8

7/8

9,000

5/8

7/8

5/8

7/8

5/8

7/8

1 1/8

5/8

7/8

12,000

5/8

7/8

5/8

7/8

1 1/8

7/8

1 1/8

7/8

15,000

5/8

7/8

1 1/8

7/8

1 1/8

7/8

1 1/8

7/8

1 1/8

18,000

7/8

1 1/8

7/8

1 1/8

7/8

1 1/8

1 3/8

7/8

1 1/8

24,000

7/8

1 1/8

7/8

1 1/8

1 3/8

7/8

1 1/8

1 3/8

1 1/8

30,000

7/8

1 1/8

1 3/8

7/8

1 1/8

1 3/8

1 1/8

1 3/8

1 1/8

36,000

7/8

1 1/8

1 3/8

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

42,000

1 1 /8

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

48,000

1 1/8

1 3/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

54,000

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 3/8

1 5/8

1 3/8

1 5/8

60,000

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

66,000

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 3/8

1 5/8

1 3/8

1 5/8

72,000

1 1/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1 3/8

1 5/8

1 3/8

1 5/8

78,000

1 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 5/8

84,000

1 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 5/8

90,000

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 5/8

2 1/8

2 5/8

1 5/8

2 1/8

120,000

1 3/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1 5/8

2 1/8

2 5/8

1 5/8

2 1/8

150,000

1 5/8

2 1/8

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

2 1/8

180,000

1 5/8

2 1/8

2 5/8

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

210,000

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

240,000

1 5/8

2 1/8

2 5/8

2 1/8

2 5/8

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

300,000

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

3 1/8

2 5/8

3 1/8

3 5/8

2 5/8

360,000

2 1/8

2 5/8

3 1/8

2 1/8

2 5/8

3 1/8

2 5/8

3 1/8

3 5/8

2 5/8

3 1/8

480,000

2 1/8

2 5/8

3 1/8

3 5/8

2 5/8

3 5/8

2 5/8

3 1/8

3 5/8

4 1/8

2 5/8

3 1/8

600,000

2 5/8

3 1/8

3 5/8

2 5/8

3 1/8

3 5/8

3 1/8

3 5/8

4 1/8

3 1/8

* NOTES:

All sizes shown are for O.D. Type L copper tubing.

2.Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3.If system load drops below 40% of design, consideration to installing double suction risers should be made.

Line Sizing

Table 2A. Recommended Line Sizes for R-404A and R507 (continued) *

SUCTION LINE SIZE

LIQUID LINE SIZE

SUCTION TEMPERATURE

Receiver to

Expansion Valve

SYSTEM

-20˚F

-30˚F

-40˚F

Lengths

Equivalent Lengths

CAPACITY

BTU/H

100'

150'

200'

25'

50'

75'

100'

150'

200'

25'

50'

75'

100'

150'

200'

25'

50'

75'

100'

150'

200'

1/2

3/8

1/2

5/8

3/8

1/2

5/8

3/8

1,000

5/8

7/8

1/2

5/8

7/8

1/2

5/8

7/8

3/8

3,000

7/8

5/8

7/8

1/2

5/8

7/8

3/8

4,000

7/8

5/8

7/8

5/8

7/8

1 1/8

3/8

6,000

7/8

1 1/8

5/8

7/8

1 1/8

5/8

7/8

1 1/8

3/8

9,000

1 1/8

7/8

1/8

1 1/8

7/8

1 1/8

3/8

1/2

12,000

1 1/8

1 3/8

7/8

1 1/8

1/8

1 1/8

1 3/8

7/8

1 1/8

1 3/8

3/8

1/2

15,000

1 1/8

1 3/8

7/8

1 1/8

1/8

1 3/8

7/8

1 1/8

1 3/8

3/8

1/2

18,000

1 3/8

1 1/8

3/8

1 3/8

1 1/8

1 3/8

3/8

1/2

24,000

1 3/8

1 5/8

1 1/8

1 3/8

3/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

3/8

1/2

30,000

1 3/8

1 5/8

1 1/8

1 3/8

3/8

1 3/8

1 5/8

1 1/8

1 3/8

1 5/8

1/2

5/8

36,000

1 5/8

1 1/8

1 3/8

3/8

1 5/8

1 1/8

1 3/8

1 5/8

1/2

5/8

42,000

1 5/8

1 1/8

1 3/8

3/8

1 5/8

1 1/8

1 3/8

1 5/8

1/2

5/8

48,000

1 5/8

1 3/8

5/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1/2

5/8

54,000

1 5/8

2 1/8

1 3/8

1 5/8

5/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1/2

5/8

60,000

1 5/8

2 1/8

1 3/8

1 5/8

5/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1/2

5/8

66,000

1 5/8

2 1/8

1 3/8

1 5/8

5/8

1 5/8

2 1/8

1 3/8

1 5/8

2 1/8

1/2

5/8

72,000

1 5/8

2 1/8

1 5/8

5/8

2 1/8

1 5/8

2 1/8

5/8

7/8

78,000

2 1/8

1 5/8

1/8

2 1/8

1 5/8

2 1/8

5/8

7/8

84,000

2 1/8

2 5/8

1 5/8

2 1/8

1/8

2 1/8

2 5/8

1 5/8

2 1/8

2 5/8

5/8

7/8

90,000

2 1/8

2 5/8

1 5/8

2 1/8

1/8

2 5/8

1 5/8

2 1/8

2 5/8

5/8

7/8

120,000

2 5/8

2 1/8

5/8

2 5/8

2 1/8

2 5/8

5/8

7/8

1 1/8

150,000

2 5/8

3 1/8

2 1/8

2 5/8

5/8

2 5/8

3 1/8

2 1/8

2 5/8

3 1/8

7/8

1 1/8

180,000

2 5/8

3 1/8

2 1/8

2 5/8

5/8

3 1/8

2 1/8

2 5/8

3 1/8

7/8

1 1/8

210,000

2 5/8

3 1/8

2 5/8

1/8

3 1/8

3 5/8

2 5/8

3 1/8

3 5/8

7/8

1 1/8

1 3/8

240,000

3 1/8

3 5/8

2 5/8

3 1/8

1/8

3 5/8

4 1/8

2 5/8

3 1/8

3 5/8

4 1/8

7/8

1 1/8

1 3/8

300,000

3 5/8

4 1/8

2 5/8

3 1/8

5/8

3 5/8

4 1/8

2 5/8

3 1/8

3 5/8

4 1/8

1 1/8

1 3/8

1 5/8

360,000

3 5/8

4 1/8

3 1/8

3 5/8

1/8

4 1/8

3 1/8

3 5/8

4 1/8

1 1/8

1 3/8

1 5/8

480,000

3 5/8

4 1/8

3 1/8

3 5/8

1/8

4 1/8

5 1/8

3 1/8

3 5/8

4 1/8

5 1/8

1 1/8

1 3/8

1 5/8

600,000

* NOTES:

All sizes shown are for O.D. Type L copper tubing.

2.Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3.If system load drops below 40% of design, consideration to installing double suction risers should be made.

Line Sizing

Table 3. Weight of Refrigerants in Copper Lines During Operation (Pounds per 100 lineal feet of type "L" tubing)

Line Size				Suction Line at Suction Temperature
O.D.		Liquid
in Inches	Refrigerant	Line	-40˚F		-20˚F	0˚F	+20˚F	+40˚F
	134a	4.0	.01		.01	.02	.04	.06
3/8	22	3.9	.02		.03	.04	.06	.08
	R507, 404A	3.4	.03		.04	.06	.09	.13
	134a	7.4	.01		.03	.04	.07	.11
1/2	22	7.4	.03		.05	.07	.11	.15
	R507, 404A	6.4	.04		.07	.13	.16	.24
	134a	11.9	.02		.05	.07	.12	.17
5/8	22	11.8	.05		.08	.12	.17	.25
	R507, 404A	10.3	.07		.11	.17	.25	.35
	134a	24.7	.05		.10	.15	.24	.36
7/8	22	24.4	.10		.16	.24	.36	.51
	R507, 404A	21.2	.15		.23	.37	.51	.72
	134a	42.2	.08		.17	.26	.41	.60
1 1/8	22	41.6	.17		.28	.42	.61	.87
	R507, 404A	36.1	.26		.39	.63	.86	1.24
	134a	64.2	.14		.26	.40	.61	1.91
1 3/8	22	63.5	.27		.42	.64	.93	1.33
	R507, 404A	55.0	.40		.58	.95	1.32	1.87
	134a	90.9	.20		.37	.57	.87	1.30
1 5/8	22	90.0	.37		.59	.90	1.33	1.88
	R507, 404A	78.0	.56		.82	1.35	1.86	2.64

	134a	158	.34		.64	.98	1.51	2.24
2 1/8	22	156	.65		1.03	1.57	2.30	3.26
	R507, 404A	134	.98		1.43	2.35	3.23	4.58
	134a	244	.52		.99	1.51	2.32	3.47
2 5/8	22	241	1.01		1.59	2.42	3.54	5.03
	R507, 404A	209	1.51		2.21	3.62	5.00	7.07
	134a	348	.75		1.41	2.16	3.31	4.96
3 1/8	22	344	1.44		2.28	3.45	5.05	7.18
	R507, 404A	298	2.16		3.15	5.17	7.14	9.95

	134a	471	.99		1.91	2.92	4.48	6.69
3 5/8	22	465	1.94		3.08	4.67	6.83	9.74
	R507, 404A	403	2.92		4.25	6.97	19.65	13.67
	134a	612	1.29		2.49	3.81	5.84	8.75
4 1/8	22	605	2.53		4.01	6.08	8.90	12.70
	R507, 404A	526	3.80		5.55	9.09	12.58	17.80

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