Rheem RARL Installation Manual
INSTALLATION INSTRUCTIONS
ISO 9001:2000
AIR-COOLED CONDENSING UNITS
(-)ARL-JEZ 16 SEER AND (-)ASL-JEZ 18 SEER MODELS
EQUIPPED WITH THE INTEGRATED COMFORT CONTROL SYSTEM™
[ ] INDICATES METRIC CONVERSIONS
Featuring Earth-Friendly
R-410A Refrigerant
92-101691-02-04
SUPERSEDES 92-101691-02-03
TABLE OF CONTENTS
Checking Product Received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Electrical & Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
eneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
G
Corrosive Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Locating Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Unit Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Factory-Preferred Tie-Down Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Refrigerant Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tools Required for Installing & Serviciing R-410A Models . . . . . . . . . . . . . .7
Specification of R-410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Quick Reference Guide for R-410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Interconnecting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
Liquid Line Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Evacuation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Start-Up and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Checking Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Checking Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Charging by Liquid Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Charging Units with R-410A Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Charging by Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Final Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Factory Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Comfort Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Status and Diagnostic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29-32
Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-34
CHECKING PRODUCT RECEIVED
Upon receiving unit, inspect it for any shipping damage. Claims for damage, either
apparent or concealed, should be filed immediately with the shipping company.
Check condensing unit model number, electrical characteristics and accessories to
determine if they are correct. Check system components (evaporator coil, condensing unit, evaporator blower, etc.) to make sure they are properly matched.
2
FIGURE 1
A
IR INLETS
(LOUVERS)
A
LLOW 120 [305 mm]
M
IN. CLEARANCE
3
SIDES
AIR DISCHARGE
ALLOW 600 [1524 mm] CLEARANCE
ALLOW 240 [610 mm]
ACCESS CLEARANCE
ACCESS
PANEL
L
W
H
ALTERNATE HIGH VOLTAGE
CONNECTION (KNOCKOUT)
1
11
/320[34 mm]
SERVICE
FITTINGS
LOW VOLTAGE
CONNECTION
7
/8" [22 mm]
HIGH VOLTAGE
CONNECTION
1
11
/32" [34 mm]
LIQUID LINE
CONNECTION
SERVICE ACCESS
TO ELECTRICAL &
VALVES ALLOW
24" [610 mm]
CLEARANCE
ONE SIDE
2
7
/8" [73 mm] DIA.
ACCESSORY
KNOCKOUTS
VAPOR LINE
CONNECTION
A-00002
DIMENSIONS AND INSTALLATION CLEARANCES
AIR DISCHARGE
ALLOW 60" [1524 mm] CLEARANCE
ACCESS
PANEL
ALLOW 24" [610 mm]
ACCESS CLEARANCE
UNIT MODEL NUMBER EXPLANATION
IR INLETS
A
LOUVERS)
(
LLOW 12" [305 mm]
A
IN. CLEARANCE
M
SIDES
3
ALTERNATE LINE VOLTAGE
ENTRY (KNOCKOUT)
111⁄32" [34 MM]
CONNECT THE LINE
VOLTAGE CONDUIT TO
THE BOTTOM OF THE
CONTROL BOX
-)ARL – 036 JEZ
(
= DESIGN SERIES (R-410A)
L
R = 16 SEER
= 18 SEER
S
A = REMOTE CONDENSING UNIT
TRADE NAME
BASE PAN
Z-SCROLL COMPRESSOR
E = EQUIPPED WITH THE
OMFORT CONTROL SYSTEM™
C
- 208/230-1-60
J
(NOMINAL CAPACITY)
24 = 24000 BTU/HR
0
036 - 36000 BTU/HR
48 = 48000 BTU/HR
0
60 = 60000 BTU/HR
0
LINE VOLTAGE
ENTRY
7
⁄8" [22 MM]
LINE VOLTAGE
ENTRY
111⁄32" [34 MM]
CONNECT THE LINE
VOLTAGE CONDUIT TO
THE BOTTOM OF THE
CONTROL BOX
BOTTOM VIEW SHOWING DRAIN OPENINGS
(\\\\\ SHADED AREAS).
TABLE 1
(-)ARL AND (-)ASL ELECTRICAL DATA
Phase
Model
Number
(-)ARL-024JEZ 1-60-208/230 10.3/10.3 52 0.8 14/14 20/20 20/20 15.8 [1.47] 1 2285 [1078] 117 [3311] 190 [86.2] 200 [90.7] 23 44-3/8 31-1/2
(-)ARL-036JEZ 1-60-208/230 16.7/16.7 82 1.0 22/22 30/30 35/35 15.8 [1.47] 1 3900 [1841] 157 [4445] 236 [107] 246 [111.6] 33 44-3/8 31-1/2
Frequency
(Hz)
Voltage
(Volts)
Compressor
(RLA) (LRA)
(-)ARL-048JEZ 1-60-208/230 21.2/21.2 96 1.0 28/28 35/35 45/45 15.8 [1.47] 1 3900 [1841] 154 [4354] 236 [107] 246 [111.6] 33 44-3/8 31-1/2
(-)ARL-060JEZ 1-60-208/230 25.6/25.6 118 2.8 35/35 45/45 60/60 23.0 [2.14] 2
(-)ASL-024JEZ 1-60-208/230 10.3/10.3 52 0.5 14/14 20/20 20/20 15.8 [1.47] 1
(-)ASL-036JEZ 1-60-208/230 16.7/16.7 82 2.8 24/24 30/30 40/40 23.0 [2.14] 1
*HS = high speed
*LS = low speed
ELECTRICAL PHYSICAL DIMENSIONAL DATA
Fan
Min. Circuit
Motor
Ampacity
(FLA)
Amperes
Fuse or HACR
Circuit Breaker
Min.
Amperes
Amperes
Max.
Outdoor Coil Weight
Face Area
Sq. Ft. [m
2
]
No.
Rows
CFM [L/s}
HS* 3500 [1652]
LS* 2800 [1322]
HS* 2500 [1180]
HS* 2200 [1038]
HS* 3400 [1605]
HS* 2800 [1322]
R-410a
Oz. [g]
224 [6350] 305 [138] 315 [143] 33 44-3/8 31-1/2
144 [4082] 236 [107] 246 [111.6] 33 44-3/8 31-1/2
155 [4394] 236 [107] 246 [111.6] 33 44-3/8 31-1/2
Net
Lbs. [kg]
Shipping
Lbs. [kg]
Height
“H”
(Inches)
Length
“L”
(Inches)
Width
“W”
(Inches)
3
WARNING
!
TH E MANUFACT UR ER’S WA RRANTY DOES NOT COVER ANY
DA MAGE OR DEFECT TO THE
AIR CONDITIONER CAUSED BY
THE ATTACHMENT OR USE OF
ANY COM PON ENT S. AC CESSORIES OR DEVICES (OTHER
THAN THOSE AUTHORIZED BY
THE MANU FACTURE R) IN TO,
ONT O OR IN CON JUNCT ION
WI TH THE AIR CON DI TIONER.
YOU SHOULD BE AWARE THAT
THE USE OF UNAUT HOR IZE D
COMPONENTS, ACCESSORIES
OR DEVICES MAY ADVERSELY
AFF ECT TH E OP ERATION
OF THE AIR CONDITIONER AND
MAY ALS O EN DAN GER LIF E
AND PROPERTY. THE MANUFACTUR ER DISCLAIM S ANY
RES PONSIBIL ITY F OR SU CH
LO SS OR INJU RY RESULTING
FRO M T HE USE OF SUC H
UNAUTHORIZED COMPONENTS,
ACCESSORIES OR DEVICES.
MATCH ALL COMPONENTS:
• OUTDOOR UNIT
• INDOOR COIL/METERING DEVICE
• INDOOR AIR HANDLER/FURNACE
• REFRIGERANT LINES
GENERAL
The information contained in this manual has been prepared to assist in the proper
installation, operation and maintenance of the air conditioning system. Improper
installation, or installation not made in accordance with these instructions, can
result in unsatisfactory operation and/or dangerous conditions (noise and component failure), and can cause the related warranty not to apply.
Read this manual and any instructions packaged with separate equipment required
to make up the system prior to installation. Retain this manual for future reference.
To achieve optimum efficiency and capacity, the indoor cooling coils listed in the
condensing unit specification sheet should be used.
APPLICATION
Before specifying any air conditioning equipment, a survey of the structure and a
heat gain calculation must be made. A heat gain calculation begins by measuring
all external surfaces and openings that gain heat from the surrounding air and
quantifying that heat gain. A heat gain calculation also calculates the extra heat
load caused by sunlight and by humidity removal.
Air conditioning systems are sized on the cooling load calculation. There are two
capacities that enable the equipment to provide comfort. The first is sensible capacity.
Sensible heat is the heat energy measured on the dry bulb thermometer as it is
added or removed.
The second form of heat is called latent or hidden heat. This is heat held in the
humidity in the air.
A properly-sized unit removes both forms of heat, producing a comfortable living
space. An oversized system cycles on and off too quickly and does not properly
remove humidity, producing an uncomfortable living space. Select the indoor and
outdoor equipment combination based on the manufacturer’s engineering data.
After the equipment combination has been selected, satisfying both sensible and
latent conditioning requirements, the system must be properly installed. Only then
can the unit provide the comfort the manufacturer intends.
There are several factors that the installers must consider:
• Outdoor unit location • Proper equipment evacuation
• System refrigerant charge • Indoor unit airflow
• Indoor unit blower speed • Supply and return air duct design and sizing
• System air balancing • Diffuser and return air grille location and sizing
CORROSIVE ENVIRONMENT
The metal parts of this unit may be subject to rust or deterioration if exposed to a
corrosive environment. This oxidation could shorten the equipment’s useful life.
Corrosive elements include, but are not limited to, salt spray, fog or mist in seacoast
areas, sulphur or chlorine from lawn watering systems, and various chemical contaminants from industries such as paper mills and petroleum refineries.
If the unit is to be installed in an area where contaminants are likely to be a problem, special attention should be given to the equipment location and exposure.
• Avoid having lawn sprinkler heads spray directly on the unit cabinet.
• In coastal areas, locate the unit on the side of the building away from the waterfront.
• Shielding provided by a fence or shrubs may give some protection, but cannot
violate minimum airflow and service access clearances.
• Elevating the unit off its slab or base enough to allow air circulation will help
avoid holding water against the basepan.
Regular maintenance will reduce the build-up of contaminants and help to protect
the unit’s finish.
WARNING
!
DIS CONNECT ALL POWER TO UNIT BEF ORE S TAR TIN G
MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK
RESULTING IN SEVERE PERSONAL INJURY OR DEATH.
4
• Frequent washing of the cabinet, fan blade and coil with fresh water will remove
most of the salt or other contaminants that build up on the unit.
• Regular cleaning and waxing of the cabinet with a good automobile polish will
provide some protection.
• A good liquid cleaner may be used several times a year to remove matter on
the cabinet that will not wash off with water.
Several different types of protective coatings are offered in some areas. These
coatings may provide some benefit, but the effectiveness of such coating materials
cannot be verified by the equipment manufacturer.
LOCATING UNIT
CONDENSER LOCATION
Consult local and national building codes and ordinances for special installation
requirements. Following location information will provide longer life and simplified
servicing of the outdoor condenser.
NOTE: These units must be installed outdoors. No ductwork can be attached, or
other modifications made, to the discharge grille. Modifications will affect performance or operation.
OPERATIONAL ISSUES
• IMPORTANT: Locate the condenser in a manner that will not prevent, impair or
compromise the performance of other equipment horizontally installed in proximity to the unit. Maintain all required minimum distances to gas and electric
meters, dryer vents, exhaust and inlet openings. In the absence of National
Codes, or manaufacturers’ recommendations, local code recommendations
and requirements will take presidence.
• Refrigerant piping and wiring should be properly sized and kept as short as
possible to avoid capacity losses and increased operating costs.
• Locate the condenser where water run off will not create a problem with the
equipment. Position the unit away from the drip edge of the roof whenever possible. Units are weatherized, but can be affected by the following:
• Water pouring into the unit from the junction of rooflines, without protective
guttering. Large volumes of water entering the condenser while in operation
can impact fan blade or motor life.
• Refer to clearance recommendations on Page 3.
o 24” to the service panel access
o 60” above condenser fan discharge (unit top) to prevent recirculation
o 12” to condenser coil grille air inlets (per condenser).
FOR CONDENSERS WITH SPACE LIMITATIONS
In the event that a space limitation exists, we will permit the following clearances:
Single Unit Applications: One condenser inlet air grille side may be reduced to no
less than an 8-inch clearance. Clearances below 8 inches will reduce unit capacity
and efficiency. Do not reduce the 60-inch discharge, or the 24-inch service clearances.
Multiple Unit Applications: When multiple unit (2 or more condensers) air inlet
grilles are placed side by side, a 12-inch per unit clearance is recommended, for a
total of 24” between two units. When multiple condenser grille sides are aligned, a
4-inch per unit spacing can be used, for a total of 8 inches between multiple units.
Two combined clearances below 8 inches will reduce capacity and efficiency. Do
not reduce the 60-inch discharge, or 24-inch service, clearances.
5
CUSTOMER SATISFACTION ISSUES
• The condenser should be located away from the living, sleeping and recreational spaces of the owner and those spaces of adjoining property.
• To prevent noise transmission, the mounting pad for the outdoor unit should
not be connected to the structure, and should be located sufficient distance
above grade to prevent ground water from entering the unit.
NOTE: Tubing installed in walls may cause noise issues.
UNIT MOUNTING
If elevating the condensing unit, either on a flat roof or on a slab, observe the
following guidelines.
• The base pan provided elevates the condenser coil 3/4” above the base pad.
• If elevating a unit on a flat roof, use 4” x 4” (or equivalent) stringers positioned
to distribute unit weight evenly and prevent noise and vibration.
NOTE: Do not block drain openings shown in Figure 1.
FACTORY-PREFERRED TIE-DOWN METHOD
FOR CONDENSING UNITS
IMPORTANT: These instructions are intended as a guide to securing equipment for
wind-load ratings of “120 MPH sustained wind load” and “3-second, 150 MPH gust.”
While this procedure is not mandatory, the Manufacturer does recommend that
equipment be properly secured in areas where high wind damage may occur.
STEP 1: Before installing, clear pad of any dirt or debris.
IMPORTANT: The pad must be constructed of industry-approved materials,
and must be thick enough to accommodate the concrete fastener.
STEP 2: Center base pan on pad, ensuring it is level.
STEP 3: Using basepad as a guide, mark spots on concrete where 4 holes will be
drilled (see Figure 2).
STEP 4: Drill four pilot holes in pad, ensuring that the hole is at least 1/4” deeper
than the concrete screw being used.
STEP 5: Center basepan over pre-drilled holes and insert concrete screws.
STEP 6: Tighten concrete screws.
NOTE: Do not over-tighten the concrete screws. Doing so can weaken the
integrity of the concrete screw and cause it to break.
STEP 7: Finish unit assembly per unit’s installation instructions.
6
FIGURE 2
SCREW LOCATIONS
411⁄2
38
13
9
2
⁄16
1
6
2
31⁄2
5
1
⁄2
REFRIGERANT CONNECTIONS
All units are factory charged with Refrigerant R-410A. All models are supplied with
service valves. Keep tube ends sealed until connection is to be made to prevent
system contamination.
TOOLS REQUIRED FOR INSTALLING &
SERVICING R-410A MODELS
Manifold Sets:
-Up to 800 PSIG High side
-Up to 250 PSIG Low Side
-550 PSIG Low Side Retard
Manifold Hoses:
-Service Pressure Rating of 800 PSIG
Recovery Cylinders:
-400 PSIG Pressure Rating
-Dept. of Transportation 4BA400 or BW400
!
CAUTION
R-410A systems operate at higher pressures than R-22 systems. Do not use
R-22 service equipment or components on R-410A equipment.
7
SPECIFICATION OF R-410A:
Application: R-410A is not a drop-in replacement for R-22; equipment designs
must accommodate its higher pressures. It cannot be retrofitted into R-22 condensing units.
Pressure: The pressure of R-410A is approximately 60% (1.6 times) greater
than R-22. Recovery and recycle equipment, pumps, hoses and the like need to
have design pressure ratings appropriate for R-410A. Manifold sets need to range
up to 800 psig high-side and 250 psig low-side with a 550 psig low-side retard.
Hoses need to have a service pressure rating of 800 psig. Recovery cylinders need
to have a 400 psig service pressure rating. DOT 4BA400 or DOT BW400.
Combustibility: At pressures above 1 atmosphere, mixture of R-410A and air can
become combustible. R-410A and air should never be mixed in tanks or supply
lines, or be allowed to accumulate in storage tanks. Leak checking should
never be done with a mixture of R-410A and air. Leak checking can be per-
formed safely with nitrogen or a mixture of R-410A and nitrogen.
QUICK REFERENCE GUIDE FOR R-410A
• R-410A refrigerant operates at approximately 60% higher pressure (1.6 times)
than R-22. Ensure that servicing equipment is designed to operate with R-410A.
• R-410A refrigerant cylinders are pink.
• R-410A, as with other HFC’s is only compatible with POE oils.
• Vacuum pumps will not remove moisture from POE oil.
• R-410A systems are to be charged with liquid refrigerants. Prior to March 1999,
R-410A refrigerant cylinders had a dip tube. These cylinders should be kept
upright for equipment charging. Post March 1999 cylinders do not have a dip
tube and should be inverted to ensure liquid charging of the equipment.
• Do not install a suction line filter drier in the liquid line.
• A liquid line filter drier is standard on every unit.
• Desiccant (drying agent) must be compatible for POE oils and R-410A.
EVAPORATOR COIL
REF ER TO EVA PORATOR C OIL MA NUF ACT URE R’S I NST ALL ATI ON
INSTRUCTIONS.
IMPORTANT: The manufacturer is not responsible for the performance and opera-
tion of a mismatched system, or for a match listed with another manufacturer’s coil.
CAUTION
!
Only use evaporators rated and approved for use on (-)ARL and (-)ASL R-410A
systems.
8
The thermostatic expansion valve is specifically designed to operate with R-410A.
DO NOT use an R-22 TXV or evaporator. The existing evaporator must be
replaced with the factory specified TXV evaporator specifically designed for
R-410A.
LOCATION
Do not install the indoor evaporator coil in the return duct system of a gas or oil furnace. Provide a service inlet to the coil for inspection and cleaning. Keep the coil
pitched toward the drain connection.
CAUTION
!
When coil is installed over a finished ceiling and/or living area, it is recommended that a secondary sheet metal condensate pan be constructed and installed
under entire unit. Failure to do so can result in property damage.
INTERCONNECTING TUBING
VAPOR AND LIQUID LINES
Keep all lines sealed until connection is made.
Make connections at the indoor coil first.
Refer to Line Size Information in Tables 2 through 4 for correct size and multipliers to
be used to determine capacity for various vapor line diameters and lengths of run.
The losses due to the lines being exposed to outdoor conditions are not included.
The factory refrigeration charge in the outdoor unit is sufficient for 15 feet of interconnecting lines. The factory refrigeration charge in the outdoor unit is sufficient for
the unit and 15 feet of standard size interconnecting liquid and vapor lines. For different lengths, adjust the charge as indicated below.
1/4” ± .3 oz. per foot
5/16” ± .4 oz. per foot
3/8” ± .6 oz. per foot
1/2” ± 1.2 oz. per foot
OUTDOOR UNIT INSTALLED ABOVE INDOOR COIL
Keep the vertical separation between coils to a minimum. However, the vertical distance can be as great as 120 feet with the condensing unit ABOVE the indoor coil.
Use the following guidelines when installing the unit:
NOTE: If exceeding these measurements, the system must be an engineered system.
OUTDOOR UNIT BELOW INDOOR COIL
Keep the vertical separation to a minimum. Use the following guidelines when
installing the unit:
1. DO NOT exceed the vertical separations as indicated on Table 4.
2. Always use the smallest liquid line size permitted to minimize system charge.
3. Table 4 may be used for sizing horizontal runs.
Vertical separation is limited to the total line length as defined in the liquid line sizing
charts.
Examples:
1. A 2-ton condensing unit with a 1/4" liquid line cannot exceed a total line length
of 25 ft.
2. A 3-ton unit with a 5/16" liquid line cannot exceed a total line length of 125 ft.
3. A 4-ton unit with a 5/16" liquid line cannot exceed a total line length of 50 ft.
IMPORTANT: Do not exceed a total line length of 125 feet in all systems.
9
TUBING INSTALLATION
Observe the following when installing correctly sized type “L” refrigerant tubing
between the condensing unit and evaporator coil:
• If a portion of the liquid line passes through a hot area where liquid refrigerant
can be heated to form vapor, insulating the liquid line is required.
• Use clean, dehydrated, sealed refrigeration grade tubing.
• Always keep tubing sealed until tubing is in place and connections are to be
made.
• Blow out the liquid and vapor lines with dry nitrogen before connecting to the
outdoor unit and indoor coil. Any debris in the line set will end up plugging the
expansion device.
• Do not allow the vapor line and liquid line to be in contact with each other. This
causes an undesirable heat transfer resulting in capacity loss and increased
power consumption. The vapor line must be insulated.
• If tubing has been cut, make sure ends are deburred while holding in a position
to prevent chips from falling into tubing. Burrs such as those caused by tubing
cutters can affect performance dramatically, particularly on small liquid line
sizes.
• For best operation, keep tubing run as short as possible with a minimum number of elbows or bends.
• Locations where the tubing will be exposed to mechanical damage should be
avoided. If it is necessary to use such locations, the copper tubing should be
housed to prevent damage.
• If tubing is to be run underground, it must be run in a sealed watertight chase.
• Use care in routing tubing and do not kink or twist. Use a tubing bender on the
vapor line to prevent kinking.
• Route the tubing using temporary hangers, then straighten the tubing and
install permanent hangers. Line must be adequately supported.
• The vapor line must be insulated to prevent dripping (sweating) and prevent
performance losses. Armaflex and Rubatex are satisfactory insulations for this
purpose. Use 1/2” minimum insulation thickness, additional insulation may be
required for long runs.
• Check Table 2 for the correct vapor line size. Check Table 3 for the correct liquid line size.
10
TUBING CONNECTIONS
Indoor evaporator coils have only a holding charge of dry nitrogen. Keep all tube
ends sealed until connections are to be made.
• Use type “L” copper refrigeration tubing. Braze the connections with the following alloys:
– copper to copper - 5%
– Silver alloy (no flux)
– copper to steel or brass - 35%
– silver alloy (with flux)
• Be certain both refrigerant shutoff valves at the outdoor unit are closed.
• Clean the inside of the fittings and outside of the tubing with steel wool or sand
cloth before brazing. Always keep chips, steel wool, dirt, etc., out of the inside
when cleaning.
• Assemble tubing part way into fitting. Apply flux all around the outside of the
tubing and push tubing into stop. This procedure will keep the flux from getting
inside the system.
• Remove the cap and schrader core from service port to protect seals from heat
damage.
TABLE 2
UCTION LINE LENGTH SIZE VS. CAPACITY MULTIPLIER (2-STAGE R-410A)
S
Unit Size
Suction Line
Connection
Size
Suction Line
Run Feet
Optional
25'
Standard
Optional
Optional
50'
Standard
Optional
Optional
100'
Standard
Optional
Optional
150'
Standard
Optional
*Standard Line Size
Note: Using suction line larger than shown in chart will result in poor oil return.
2 Ton
3/4" I.D. 3/4" I.D. 7/8" I.D. 7/8" I.D.
—
5/8*
3/4
—
1.00
1.00
—
0.99
1.00
—
0.97
0.98
—
0.95
0.97
3 Ton
5/8 3/4 3/4
3/4*
—
0.99
1.00
—
0.98
0.99
—
0.95
0.97
—
0.91
0.95
—
• Use an appropriate heatsink material around the copper stub and the service
valves before applying heat.
• IMPORTANT: Do not braze any fitting with the TEV sensing bulb attached.
• Braze the tubing between the outdoor unit and indoor coil. Flow dry nitrogen
into a service port and through the tubing while brazing.
• After brazing:
• Use an appropriate heatsink material to cool the joint and remove any flux
residue.
• Clamp the TXV bulb securely on the suction line at the 2 o’clock position with
the strap provided in the parts bag.
• Insulate the TXV sensing bulb and suction line with the provided pressure
sensitive insulation (size 4" x 7") and secure with provided wire ties.
• NOTE: TXV SENSING BULB SHOULD BE LOCATED ON A HORIZONTAL
SECTION OF SUCTION LINE, JUST OUTSIDE OF COIL BOX.
• The service valves are not backseating valves. To open the valves, remove the
valve cap with an adjustable wrench. Insert a 3/16” or 5/16” hex wrench into the
stem. Back out counterclockwise.
• Replace the valve cap finger tight then tighten an additional 1/2 hex flat for a
metal-to-metal seal.
4 Ton
7/8* 7/8*
——
1.00
1.00
—
0.98
0.99
—
0.95
0.97
—
0.93
0.95
—
5 Ton
0.99
1.00
—
0.98
0.99
—
0.94
0.97
—
0.91
0.95
—
TABLE 3
ELBOW EQUIVALENT LENGTHS, FT.
Short Long
Size Radius Radius
1/4 0.4 0.2
5/16 0.5 0.3
3/8 0.5 0.3
1/2 0.6 0.4
5/8 0.8 0.6
3/4 0.9 0.8
7/8 1.0 1.0
1-1/8 1.2 1.2
1-3/8 2.1 1.4
1-5/8 2.5 1.5
LEAK TESTING
• Pressurize line set and coil through service fittings with dry nitrogen to 150 psig
maximum. Leak test all joints using liquid detergent. If a leak is found, recover
pressure and repair.
WARNING
!
DO NOT USE OXYGEN TO PURGE LINES OR PRESSURIZE SYSTEM FOR
LEAK T EST. OXYGEN REACTS VIOLEN TLY WI TH OIL, W HICH CAN
CAUSE AN EXPLOSION RESULTING IN SEVERE PERSONAL INJURY OR
DEATH.
11
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