Conair EP2 series User Manual
USER GUIDE
UGH041-0718
www.conairgroup.com
EP2 Series Portable Chillers
Portable and Remote Condenser Chillers 4 to 43 Tons
Corporate Office: 724.584.5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861
DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential
Copyright 2018 l Conair l All rights reserved
Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
It’s a good idea to record the model and serial number(s) of your equipment and the date you
received it in the User Guide. Our service department uses this information, along with the manual
number, to provide help for the specific equipment you installed.
Please keep this User Guide and all manuals, engineering prints and parts lists together for
documentation of your equipment.
Date:
Manual Number: UGH041-0718
Serial Number(s):
Model Number(s)
damages in connection with the furnishing, performance or use of this information. Conair makes no warranty
of any kind with regard to this information, including, but not limited to the implied warranties of
merchantability and fitness for a particular purpose.
Table of Contents
Foreword .................................................................................................................................................................................................................. 1
Safety Guidelines .................................................................................................................................................................................................. 1
Pre-Installation ....................................................................................................................................................................................................... 2
Receiving Inspection ....................................................................................................................................................................................... 2
Unit Storage ........................................................................................................................................................................................................ 3
Installation - Chiller .............................................................................................................................................................................................. 3
Foundation .......................................................................................................................................................................................................... 3
Unit Location ...................................................................................................................................................................................................... 3
Rigging ................................................................................................................................................................................................................. 3
Chilled Process Fluid Piping ......................................................................................................................................................................... 3
Figure 1 – Recommended Overhead Piping ..................................................................................................................................... 3
Condenser Water Piping................................................................................................................................................................................ 3
Installation – Remote Condenser ................................................................................................................................................................... 4
Location ................................................................................................................................................................................................................ 4
Lifting ............................................................................................................................................................................................................... 4
Mounting Legs .................................................................................................................................................................................................. 4
Figure 2 - Mounting Remote Condenser Legs ................................................................................................................................ 5
Interconnecting Refrigerant Piping ........................................................................................................................................................... 5
Refrigeration Piping Design ......................................................................................................................................................................... 5
Figure 3 – Condenser Located at Chiller Level ................................................................................................................................. 6
Figure 4 – Condenser Located Above Chiller Unit ......................................................................................................................... 6
Figure 5 - Condenser Located Below Chiller Unit ........................................................................................................................... 6
Determining Equivalent Line Length ........................................................................................................................................................ 6
Table 1 – Equivalent Lengths of Elbows ............................................................................................................................................. 6
Liquid Line Sizing .............................................................................................................................................................................................. 6
Table 2 – Liquid Line Sizes for R410A .................................................................................................................................................. 7
Discharge (Hot Gas) Line Sizing .................................................................................................................................................................. 9
Figure 6 – Vertical Riser Traps ................................................................................................................................................................ 9
Figure 7 - Double Discharge Riser ........................................................................................................................................................ 9
Table 3 - Horizontal or Downflow Discharge Line Sizes for R410A (inches OD).............................................................. 10
Table 4 - Upflow Discharge Line Sizes for R410A (inches OD) ................................................................................................ 10
Calculating Refrigerant and Oil Charge ................................................................................................................................................. 11
Table 5 – Chiller & Condenser Refrigerant Charge ...................................................................................................................... 11
Table 6 - Field Piping R-410A Refrigerant Charges ..................................................................................................................... 11
Oil Charge Determination ........................................................................................................................................................................... 11
Setting Condenser Fan Controls............................................................................................................................................................... 11
Table 7 - Condenser Fan Pressure Settings (psig) ........................................................................................................................ 11
Installation - Electrical ....................................................................................................................................................................................... 12
Standard Controller Operation ...................................................................................................................................................................... 13
Table 8 - Operating Buttons ................................................................................................................................................................. 13
Table 9 - Temperature Displays ........................................................................................................................................................... 14
Table 10 - Operating Lights .................................................................................................................................................................. 14
Program Menu................................................................................................................................................................................................. 15
Table 11 - Controller Program Menu ................................................................................................................................................ 16
Table 12 – Controller Control Fault Logic ........................................................................................................................................ 17
SPI Communications (Optional) ............................................................................................................................................................... 17
Table 13 - SPI Parameters ...................................................................................................................................................................... 18
Modbus RTU (Optional) ............................................................................................................................................................................... 18
Table 14 – Standard Controller Modbus RTU Option Parameters......................................................................................... 18
Optional PLC Operation ................................................................................................................................................................................... 20
System Initialization....................................................................................................................................................................................... 20
Figure 8 – Start-Up Splash Screen ...................................................................................................................................................... 20
Home - System Overview ............................................................................................................................................................................ 20
Figure 9 – Chiller System Overview .................................................................................................................................................... 20
Table 15 – System Overview Functions ............................................................................................................................................ 21
Home – Full Screen ........................................................................................................................................................................................ 21
Figure 10 – Full Screen ............................................................................................................................................................................ 21
Menu 1 - Overview ........................................................................................................................................................................................ 21
Figure 11 – Menu 1 Screen .................................................................................................................................................................... 21
Menu 1 - Alarms Active ............................................................................................................................................................................... 22
Figure 12 – HMI Alarm Handler ........................................................................................................................................................... 22
Alarm Setup ...................................................................................................................................................................................................... 22
Figure 13 – Alarm Setup ......................................................................................................................................................................... 22
Menu 1 – Circuit Details Screen ................................................................................................................................................................ 22
Figure 14 – Circuit Details Screen ....................................................................................................................................................... 22
Circuit Details Screen – Interlocks ............................................................................................................................................................ 22
Figure 15 – Interlocks 1 Screen ............................................................................................................................................................ 22
Figure 16 – Interlocks 2 Screen ............................................................................................................................................................ 23
Menu 2 – Overview ........................................................................................................................................................................................ 23
Figure 17 – Menu 2 ................................................................................................................................................................................... 23
Menu 2 – Default ............................................................................................................................................................................................ 23
Figure 18 – Restore Factory Settings ................................................................................................................................................. 23
Figure 19 – Factory Settings Restored .............................................................................................................................................. 23
Menu 2 – Trending ........................................................................................................................................................................................ 24
Figure 20 – Trending Screen ................................................................................................................................................................. 24
Menu 2 – Logging .......................................................................................................................................................................................... 24
Figure 21 – Logging .................................................................................................................................................................................. 24
Modbus RTU (Optional) ............................................................................................................................................................................... 25
Table 16 – PLC Controller Modbus RTU Parameters ................................................................................................................... 25
Start-Up .................................................................................................................................................................................................................. 28
Step 1 - Connect Main Power ................................................................................................................................................................... 29
Step 2 - Fill Coolant Circuit ......................................................................................................................................................................... 29
System Fill Water Chemistry Requirements .................................................................................................................................... 29
Table 17 – Fill Water Chemistry Requirements .............................................................................................................................. 30
Table 18 - Recommended Glycol Solutions .................................................................................................................................... 30
Step 3 - Check Condenser .......................................................................................................................................................................... 30
Integral Air-Cooled Condenser Check .............................................................................................................................................. 30
Water-Cooled Condenser Check ......................................................................................................................................................... 30
Remote Air-Cooled Condenser Check .............................................................................................................................................. 30
Step 4 – Check Refrigerant Valves ........................................................................................................................................................... 30
Step 5 – Verify Freezestat Setting ............................................................................................................................................................ 30
Step 6 – Turn On Control Power .............................................................................................................................................................. 31
Step 7 – Establish Coolant Flow ................................................................................................................................................................ 31
Step 8 – Intial Unit Operation .................................................................................................................................................................... 31
Preventive Maintenance ................................................................................................................................................................................... 32
Once a Week .................................................................................................................................................................................................... 32
Once a Month .................................................................................................................................................................................................. 32
Every Three Months ....................................................................................................................................................................................... 32
Preventive Maintenance Checklist ............................................................................................................................................................... 33
General Troubleshooting ................................................................................................................................................................................. 34
Drawings................................................................................................................................................................................................................. 35
Page Intentionally Blank
General Warning
Electricity Warning
Sharp Element Warning
Hot Surface Warning
Flammable Material Warning
Explosive Material Warning
General Mandatory Action
Wear Eye Protection
Wear Protective Gloves
Wear Ear Protection
Disconnect Before Carrying Out Maintenance or
Connect an Earth Terminal to Ground
Foreword
The portable chiller is a packaged unit that typically
includes a refrigeration circuit, coolant reservoir, and
pumping system in a cabinet. The purpose is to
provide cooling water or coolant.
This manual is to serve as a guide for installing,
operating, and maintaining the equipment. Improper
installation, operation, and maintenance can lead to
poor performance and/or equipment damage. Use
qualified installers and service technicians for all
installation and maintenance of this equipment.
This manual is for our standard product. The
information in this manual is general in nature. Unitspecific drawings and supplemental documents are
included with the equipment as needed. Additional
copies of documents are available upon request.
Due to the ever-changing nature of applicable
codes, ordinances, and other local laws pertaining to
the use and operation of this equipment, we do not
reference them in this manual.
The equipment uses a hydro fluorocarbon (HFC),
trade named R-410A, as a chemical refrigerant for
heat transfer purposes. This chemical is sealed and
tested in a pressurized system containing ASME
coded vessels; however, a system failure will release
it. Refrigerant gas can cause toxic fumes if exposed
to fire. Place these units in a well-ventilated area,
especially if open flames are present. Failure to
follow these instructions could result in a hazardous
condition. We recommend the use of a refrigerant
management program to document the type and
quantity of refrigerant in the equipment. In addition,
we recommend only licensed and EPA certified
service technicians work on our refrigeration circuits.
Safety Guidelines
Observe all safety precautions during installation,
start-up, and service of this equipment. The
following is a list of symbols used in this manual and
their meaning.
Repair
1
WARNING: Any use or misuse of this equipment
WARNING: Vent all refrigerant relief valves in
oxygen and cause suffocation.
WARNING: This equipment contains hazardous
WARNING: This equipment contains refrigerant under
damage.
WARNING: This equipment may contain fan blades or
protective shields are securely in place.
WARNING: The exposed surfaces of motors, refrigerant
hands.
CAUTION: Disconnect and lock out incoming power
maintenance.
CAUTION: Wear eye protection when installing,
against any sparks, debris, or fluid leaks.
CAUTION: The equipment will exceed 70 dBA sound
proximity to the chiller.
CAUTION: Wear protective gloves when installing,
against any sparks, debris, or fluid leaks.
Only qualified personnel should install, start-up, and
service this equipment. When working on this
equipment, observe precautions in this manual as
well as tags, stickers, and labels on the equipment.
outside of the design intent may cause injury or harm.
accordance to ANSI/ASHRAE Standard 15, Safety Code
for Mechanical Refrigeration. Locate this equipment in
a well-ventilated area. Inhalation of refrigerant can be
hazardous to your health and the accumulation of
refrigerant within an enclosed space can displace
voltages that can cause severe injury or death.
pressure. Accidental release of refrigerant under
pressure can cause personal injury and or property
other sharp edges. Make sure all fan guards and other
piping, and other fluid circuit components can be very
hot and can cause burns if touched with unprotected
before installing, servicing, or maintaining the
equipment. Connecting power to the main terminal
block energizes the entire electric circuitry of the unit.
Shut off the electric power at the main disconnect
before opening access panels for repair or
maintaining, or repairing the equipment to protect
pressure at 1 meter distance and 1 meter elevation
when operating. Wear ear protection as required for
personal comfort when operating or working in close
maintaining, or repairing the equipment to protect
Pre-Installation
Receiving Inspection
When the unit arrives, verify the information on the
unit nameplate agrees with the order
acknowledgement and shipping papers. Inspect the
equipment for any visible damage and verify all
items shown on the bill of lading are present. If
damage is evident, document it on the delivery
receipt by clearly marking any item with damage as
“unit damage” and notify the carrier. Do not install
damaged equipment without getting the equipment
repaired.
Shipping damage is the responsibility of the carrier.
To protect against possible loss due to damage
incurred during shipping and to expedite payment
for damages, it is important to follow proper
procedures and keep records. Photographs of
damaged equipment are excellent documentation
for your records.
Start unpacking the unit, inspect for concealed
damage, and take photos of any damage found.
Once received, equipment owners have the
responsibility to provide reasonable evidence that
the damage did not occur after delivery. Photos of
the equipment damage while the equipment is still
partially packed will help in this regard. Refrigerant
lines can be susceptible to damage in transit. Check
for broken lines, oil leaks, damaged controls, or any
other major component torn loose from its
mounting point.
Record any signs of concealed damage and file a
shipping damage claim immediately with the
shipping company. Most carriers require concealed
damages be reported within 15 days of receipt of
the equipment.
Chillers with an integral water-cooled or air-cooled
condenser ship with a full refrigerant charge. Chillers
designed for use with a remote air-cooled condenser
and the remote condensers themselves ship with a
nitrogen holding charge. Check the remote
condenser for signs of leaks prior to rigging. This will
ensure no coil damage has occurred after the unit
left the factory. The condenser ships with the legs
removed. Mount the legs to the condenser using the
provided nuts, bolts, and washers.
2
NOTE:
If piping is above chiller and exceeds 90 feet in total
length, install an inverted P-trap and vacuum break
valve in return line and add a check valve to the
supply line.
Check valve
1/2 inch vacum break valve
12 inches above highest
point in piping system
12 inches above highest point
in the piping system
½ inch vacuum
break valve
Check valve
Unit Storage
When storing the unit it is important to protect it
from damage. Blow out any water from the unit;
cover it to keep dirt and debris from accumulating or
getting in, and store in an indoor sheltered area that
does not exceed 145°F.
Installation - Chiller
Foundation
Install the chiller on a rigid, non-warping mounting
pad, concrete foundation, or level floor suitable to
support the full operating weight of the equipment.
When installed the equipment must be level within
¼ inch over its length and width.
Unit Location
The unit is available in many different configurations
for various environments. Refer to the proposal and
order acknowledgement document for the
equipment to verify the specific design conditions in
which it can operate.
To ensure proper airflow and clearance space for
proper operation and maintenance allow a minimum
of 36 inches of clearance between the sides of the
equipment and any walls or obstructions. Avoid
locating piping or conduit over the unit to ensure
easy access with an overhead crane or lift to lift out
heavier components during replacement or service.
In addition, ensure the condenser and evaporator
refrigerant pressure relief valves can vent in
accordance with all local and national codes.
Air-cooled chillers use the surrounding air for
cooling the condenser and require free passage of
air in and out of the chiller and provision for remove
of the warm air from the area.
Rigging
The chiller has a frame to facilitate easy movement
and positioning with a crane or forklift. Follow
proper rigging methods to prevent damage to
components. Avoid impact loading caused by
sudden jerking when lifting or lowering the chiller.
Use pads where abrasive surface contact may occur.
Chilled Process Fluid Piping
Proper insulation of chilled process fluid piping is
crucial to prevent condensation. The formation of
condensation adds a substantial heat load to the
chiller.
The importance of properly sized piping cannot be
overemphasized. See the ASHRAE Handbook or
other suitable design guide for proper pipe sizing. In
general, run full size piping out to the process and
reduce pipe size at connections as needed. One of
the most common causes of unsatisfactory chiller
performance is poor piping system design. Avoid
long lengths of hoses, quick disconnect fittings, and
manifolds wherever possible as they offer high
resistance to water flow. When manifolds are
required, install them as close to the use point as
possible. Provide flow-balancing valves at each
machine to assure adequate water distribution in the
entire system. Typically, when piping is overhead
with a total run length over 90 feet there should be a
valve in the supply line and an inverted P trap with a
vacuum break valve installed as shown in Figure 1.
Figure 1 – Recommended Overhead Piping
All standard portable chillers include an internal
coolant pump and reservoir. Nominal coolant flow
rates assume a 10°F rise across the evaporator at
50°F set point and 85°F entering condenser water for
water-cooled chillers or 95°F entering air for integral
air-cooled or remote air-cooled condenser chillers.
Condenser Water Piping
(Water-Cooled Condenser Chillers Only)
The performance of a water-cooled condenser is
dependent on the flow and temperature of the
cooling water used. Insufficient cooling of the
condenser will result in the reduction of cooling
capacity of the chiller and under extreme conditions
may result in the chiller shutting down due to high
3
refrigerant pressure. Allowing the condenser to plug
up from contaminants in the condenser water
stream adversely affects performance. In order to
reduce maintenance costs and chiller downtime, a
water treatment program is highly recommended for
the condenser cooling water. Contact our Customer
Service Department for assistance in the proper
procedure for cleaning out any plugged condenser.
The nominal water-cooled condenser is designed for
85°F condenser cooling water supply. Under normal
operation there will be about a 10°F rise through the
condenser resulting in 95°F exiting water. To ensure
proper water flow through the condenser, ensure the
condenser water pump provides at least 25 psi or
water at a flow rate of 3 gpm per ton of chiller
capacity.
Each condenser has a two-way condenser waterregulating valve. The condenser water-regulating
valve controls the amount of water allowed to pass
through the condenser in order to maintain proper
refrigeration pressures in the circuit.
To prevent damage to the condenser and/or waterregulating valve, the water pressure should not
exceed 150 psig.
Installation – Remote Condenser
Chillers designed for use with a remote air-cooled
condenser include a factory-selected remote
condenser. The remote air-cooled condenser
typically ships separately from a different location
than the chiller.
Location
The remote air-cooled condenser is for outdoor use.
Locate the remote condenser in an accessible area.
The vertical air discharge must be unobstructed. The
vertical air discharge must be unobstructed. Allow a
minimum of 48 inches of clearance between the
sides and ends of the condenser and any walls or
obstructions. For installations with multiple
condensers, allow a minimum of 96 inches between
condensers placed side-by-side or 48 inches for
condensers placed end-to-end.
When locating the condenser it is important to
consider access to the components to allow for
proper maintenance and servicing of the unit. Avoid
locating piping or conduit over the unit to ensure
easy access with an overhead crane or lift to lift out
heavier components during replacement or service.
Proper ventilation is another important
consideration when locating the condenser. In
general, locate the unit in an area that will not rise
above 110°F.
Install the unit on a firm, level base no closer than its
width from walls or other condensers. Avoid
locations near exhaust fans, plumbing vents, flues, or
chimneys. Fasten the mounting legs at their base to
the steel or concrete of the supporting structure. For
units mounted on a roof structure, the steel support
base holding the condenser should be elevated
above the roof and attached to the building.
Avoid areas that can create a “micro-climate” such as
an alcove with east, north, and west walls that can be
significantly warmer than surrounding areas. The
condenser needs to have unrestricted airways so it
can easily move cool air in and heated air away.
Consider locating the condenser where fan noise
and vibration transmission into nearby workspaces is
unlikely.
The unit ships on its side with the legs removed to
reduce shipping dimensions and provide more
protection to the coil from possible damage caused
by impact loading over rough roads and transit
conditions.
Lifting
Use only qualified personnel using the proper
equipment when lifting and positioning the
condenser. Lifting brackets or holes are at the
corners for attaching lifting slings. Use spreader bars
when lifting to apply the lifting force vertically.
Under no circumstances use the coil headers or
return bends in the lifting or moving of the
condenser.
Mounting Legs
Assemble the corner legs to the bottom flanges on
the unit side panels and end panels using the
hardware provided and the matching mounting
hole-patterns. All corner legs are the same. For units
that are longer than three fans, assemble the center
leg. Remove two bolts from the bottom flange of the
unit side panels that match the hole-pattern on the
4
CAUTION: Only use refrigerant grade copper tubing
for sizes 5/8” ODS or smaller.
CAUTION: Do not use soft solders. For copper-to-
brazing.
WARNING: The POE oil contained within the
installing the interconnecting refrigerant tubing.
Center Leg
(Right-hand Side Facing Header)
top flanges of both legs. Attached the center legs
using the hardware provide at the center-divider
panel location. Replace the bolts removed from the
side panels to secure the leg assembly to the bottom
flanges of the condenser side panels.
Figure 2 - Mounting Remote Condenser Legs
Interconnecting Refrigerant Piping
The chiller and remote condenser ship with a
nitrogen holding charge. Evacuation of this charge is
required before charging with refrigerant. The chiller
is for use only with the air-cooled condenser
provided with the unit. The following section covers
the required piping between the chiller and the
provided air-cooled condenser.
The discharge and liquid lines leaving the chiller
have caps. These line sizes do not necessarily reflect
the actual line sizes required for the piping between
the chiller and the air-cooled condenser.
Refrigerant piping size and piping design have a
significant impact on system performance and
reliability. All piping should conform to the
applicable local and state codes.
ASTM B280 and isolate the refrigeration lines from
building structures to prevent transfer of vibration. All
copper tubing must have a pressure rating suitable for
R-410A: tubing that is 3/4” OD or larger must be Type
K rigid tubing. ACR annealed tubing coil may be used
Do not use a saw to remove end caps. This might
allow copper chips to contaminate the system. Use a
tube cutter or heat to remove the caps. When
sweating copper joints it is important to evacuate all
refrigerant present and flow dry nitrogen through
the system. This prevents the formation of toxic
gases, corrosive acids, and scale.
copper joints use a copper-phosphorus braze alloy
(BCuP per the American Welding Society) with 5%
(BCuP-3) to 15% (BCuP-5) silver content. Only use a
high silver content brazing alloy (BAg per AWS) for
copper-to-brass or copper-to-steel joints such as a
45% (BAg-5) silver content. Only use oxy-acetylene
compressor is hygroscopic and has the ability to
absorb water vapor from the atmosphere. Take
necessary steps to prevent an open system from
exposure to the atmosphere for extended periods while
Refrigeration Piping Design
The system is configurable in any of the
arrangements as shown in Figure 3, Figure 4, and
Figure 5. The configuration and its associated
elevation, along with the total distance between the
chiller and the air-cooled condenser are important
factors in determining the liquid line and discharge
line sizes. This will also affect the field refrigerant
charges. Consequently, it is important to adhere to
certain physical limitations to ensure the system
operates as designed.
General design considerations are:
1. The total distance between the chiller and the
air-cooled condenser must not exceed 200
actual feet or 300 equivalent feet. Keep the
distance as short as possible.
2. Liquid line risers must not exceed 15 feet in
height from the condenser liquid line
connection.
3. Discharge line risers cannot exceed an elevation
difference greater than 100 actual feet without a
minimum of 2% efficiency decrease.
4. To form a proper liquid seal at the condenser,
immediately drop at least 15 inches down from
the liquid outlet before routing the piping to the
chiller. Make the drop leg before any bends or
angles connecting to the remainder of the liquid
connection piping.
5
Caution: Liquid line sizing for each chiller capacity is
Handbook or other suitable design guide.
CAUTION: When calculating the equivalent length, do
must be considered.
Line
Size OD
Equivalent Lengths of Refrigerant Pipe (feet)
90°
Standard
90°Long
Radius
90°
Street
45°
Standard
45°
Street ⅞ 2.0
1.4
3.2
0.9
1.6
1⅛
2.6
1.7
4.1
1.3
2.1
1⅜
3.3
2.3
5.6
1.7
3.0
1⅝
4.0
2.6
6.3
2.1
3.4
2⅛
5.0
3.3
8.2
2.6
4.5
2⅝
6.0
4.1
10.0
3.2
5.2
3⅛
7.5
5.0
12.0
4.0
6.4
3⅝
9.0
5.9
15.0
4.7
7.3
4⅛
10.0
6.7
17.0
5.2
8.5
Figure 3 – Condenser Located at Chiller Level
Figure 4 – Condenser Located Above Chiller Unit
Figure 5 - Condenser Located Below Chiller Unit
the same pressure loss. See the ASHRAE
Refrigeration Handbook for more information.
Follow these steps when calculating line size:
1. Start with an initial approximation of equivalent
length by assuming that the equivalent length of
pipe is 1.5 times the actual pipe length.
2. Determine approximate line sizes by referring to
Table 2 for liquid lines, Table 3 and Table 4 for
the discharge lines.
3. Check the line size by calculating the actual
equivalent length using the equivalent lengths
as shown in Table 1.
not include piping of the chiller unit. Only field piping
Table 1 – Equivalent Lengths of Elbows
(in)
shown in Table 2. These line sizes are listed per circuit
and apply where leaving water temperature (LWT) is
40°F or higher. For applications where the LWT is
below 40°F, size lines using the ASHRAE Refrigeration
Determining Equivalent Line Length
To determine the appropriate size for field installed
liquid and discharge lines, it is first necessary to
establish the equivalent length of pipe for each line.
The equivalent length is the approximate friction loss
from the combined linear run of pipe and the
equivalent feet of elbows, valves, and other
components in the refrigeration piping. The sum
total is the equivalent length of pipe that would have
Liquid Line Sizing
The liquid line diameter should be as small as
possible while maintaining acceptable pressure drop.
This is necessary to minimize refrigerant charge. The
total length between the chiller unit and the aircooled condenser must not exceed 200 actual feet
or 300 equivalent feet. It is best to pipe the liquid
line so that there is an immediate drop of at least 15
inches at the condenser outlets to make a liquid seal.
Liquid line risers in the system will require an
additional 0.5 psig pressure drop per foot of vertical
rise. When it is necessary to have a liquid line riser,
make the vertical run immediately after the
condenser before any additional restrictions. The
liquid line risers must not exceed 10 feet in height
from the condenser liquid line connection. The liquid
line does not require pitching. Install a pressure tap
6
5 Ton Circuit (R410A) Liquid Line Size (Inch OD)
7½ Ton Circuit (R410A) Liquid Line Size (Inch OD)
Up Flow (Feet of Run)
Up Flow (Feet of Run)
0 to 5
6 to 10
11 to 15
0 to 5
6 to 10
11 to 15
25
1/2
1/2
1/2
1/2
25
5/8
5/8
5/8
5/8
50
1/2
1/2
1/2
5/8
50
5/8
5/8
5/8
5/8
75
1/2
1/2
1/2
5/8
75
5/8
5/8
5/8
3/4
100
1/2
1/2
5/8
5/8
100
5/8
5/8
5/8
3/4
125
1/2
1/2
5/8
3/4
125
5/8
5/8
3/4
3/4
150
1/2
5/8
5/8
3/4
150
5/8
5/8
3/4
7/8
175
5/8
5/8
5/8
3/4
175
5/8
5/8
3/4
7/8
200
5/8
5/8
5/8
3/4
200
5/8
3/4
3/4
7/8
225
5/8
5/8
5/8
3/4
225
5/8
3/4
3/4
7/8
250
5/8
5/8
5/8
3/4
250
5/8
3/4
3/4
7/8
275
5/8
5/8
3/4
3/4
275
3/4
3/4
3/4
7/8
300
5/8
5/8
3/4
7/8
300
3/4
3/4
3/4
7/8
10 Ton Circuit (R410A) Liquid Line Size (Inch OD)
15 Ton Circuit (R410A) Liquid Line Size (Inch OD)
Equivalent
Horizontal or
Up Flow (Feet of Run)
Equivalent
Horizontal or
Up Flow (Feet of Run)
0 to 5
6 to 10
11 to 15
0 to 5
6 to 10
11 to 15
25
3/4
3/4
3/4
3/4
25
7/8
7/8
7/8
7/8
50
3/4
3/4
3/4
3/4
50
7/8
7/8
7/8
7/8
75
3/4
3/4
3/4
3/4
75
7/8
7/8
7/8
7/8
100
3/4
3/4
3/4
7/8
100
7/8
7/8
7/8
1 1/8
125
3/4
3/4
3/4
7/8
125
7/8
7/8
7/8
1 1/8
150
3/4
3/4
3/4
7/8
150
7/8
7/8
7/8
1 1/8
175
3/4
3/4
3/4
7/8
175
7/8
7/8
7/8
1 1/8
200
3/4
3/4
7/8
1 1/8
200
7/8
7/8
1 1/8
1 1/8
225
3/4
3/4
7/8
1 1/8
225
7/8
7/8
1 1/8
1 1/8
250
3/4
3/4
7/8
1 1/8
250
7/8
7/8
1 1/8
1 1/8
275
3/4
3/4
7/8
1 1/8
275
7/8
7/8
1 1/8
1 1/8
300
3/4
7/8
7/8
1 1/8
300
7/8
7/8
1 1/8
1 1/8
valve at the condenser to facilitate measuring
pressure for service.
Liquid lines do not typically require insulation.
However, if exposing the lines to solar heat gain or
temperatures exceeding 110 °F, there is a negative
Table 2 – Liquid Line Sizes for R410A
Equivalent
Length (Ft)
Horizontal or
Down Flow
effect on sub-cooling. In these situations, insulate
the liquid lines.
Equivalent
Length (Ft)
Horizontal or
Down Flow
Length (Ft)
Down Flow
Length (Ft)
Down Flow
7
20 Ton Circuit (R410A) Liquid Line Size (Inch OD)
25 Ton Circuit (R410A) Liquid Line Size (Inch OD)
Equivalent
Horizontal or
Up Flow (Feet of Run)
Equivalent
Horizontal or
Up Flow (Feet of Run)
0 to 5
6 to 10
11 to 15
0 to 5
6 to 10
11 to 15
25
1 1/8
1 1/8
1 1/8
1 1/8
25
1 1/8
1 1/8
1 1/8
1 1/8
50
1 1/8
1 1/8
1 1/8
1 1/8
50
1 1/8
1 1/8
1 1/8
1 1/8
75
1 1/8
1 1/8
1 1/8
1 1/8
75
1 1/8
1 1/8
1 1/8
1 1/8
100
1 1/8
1 1/8
1 1/8
1 1/8
100
1 1/8
1 1/8
1 1/8
1 1/8
125
1 1/8
1 1/8
1 1/8
1 1/8
125
1 1/8
1 1/8
1 1/8
1 1/8
150
1 1/8
1 1/8
1 1/8
1 1/8
150
1 1/8
1 1/8
1 1/8
1 3/8
175
1 1/8
1 1/8
1 1/8
1 1/8
175
1 1/8
1 1/8
1 1/8
1 3/8
200
1 1/8
1 1/8
1 1/8
1 3/8
200
1 1/8
1 1/8
1 1/8
1 3/8
225
1 1/8
1 1/8
1 1/8
1 3/8
225
1 1/8
1 1/8
1 1/8
1 3/8
250
1 1/8
1 1/8
1 1/8
1 3/8
250
1 1/8
1 1/8
1 1/8
1 3/8
275
1 1/8
1 1/8
1 1/8
1 3/8
275
1 1/8
1 1/8
1 1/8
1 3/8
300
1 1/8
1 1/8
1 1/8
1 3/8
300
1 1/8
1 1/8
1 3/8
1 3/8
30 Ton Circuit (R410A) Liquid Line Size (Inch OD)
35 Ton Circuit (R410A) Liquid Line Size (Inch OD)
Equivalent
Horizontal or
Up Flow (Feet of Run)
Equivalent
Horizontal or
Up Flow (Feet of Run)
0 to 5
6 to 10
11 to 15
0 to 5
6 to 10
11 to 15
25
1 1/8
1 1/8
1 1/8
1 1/8
25
1 3/8
1 3/8
1 3/8
1 3/8
50
1 1/8
1 1/8
1 1/8
1 1/8
50
1 3/8
1 3/8
1 3/8
1 3/8
75
1 1/8
1 1/8
1 1/8
1 1/8
75
1 3/8
1 3/8
1 3/8
1 3/8
100
1 1/8
1 1/8
1 1/8
1 3/8
100
1 3/8
1 3/8
1 3/8
1 3/8
125
1 1/8
1 1/8
1 1/8
1 3/8
125
1 3/8
1 3/8
1 3/8
1 3/8
150
1 1/8
1 1/8
1 1/8
1 3/8
150
1 3/8
1 3/8
1 3/8
1 3/8
175
1 1/8
1 1/8
1 1/8
1 3/8
175
1 3/8
1 3/8
1 3/8
1 3/8
200
1 1/8
1 1/8
1 1/8
1 3/8
200
1 3/8
1 3/8
1 3/8
1 5/8
225
1 1/8
1 1/8
1 3/8
1 3/8
225
1 3/8
1 3/8
1 3/8
1 5/8
250
1 1/8
1 1/8
1 3/8
1 5/8
250
1 3/8
1 3/8
1 3/8
1 5/8
275
1 1/8
1 1/8
1 3/8
1 5/8
275
1 3/8
1 3/8
1 3/8
1 5/8
300
1 1/8
1 1/8
1 3/8
1 5/8
300
1 3/8
1 3/8
1 3/8
1 5/8
Table 2 – Liquid Line Sizes for R410A (continued)
Length (Ft)
Length (Ft)
Down Flow
Down Flow
Length (Ft)
Length (Ft)
Down Flow
Down Flow
8
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