Mini-Space Series Installation, Operation & Maintenance Manual

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Mini-Space Series Installation, Operation & Maintenance Manual2.7 Piping Connections2.7.1 Refrigerant2.7.1.1 Self-Contained SystemsNo refrigerant connections are required for self-contained,water/glycol-cooled systems (models CC( )-041/201-W/G)and chilled water systems (models CC( )-110/200-CW).2.7.1.2 Split SystemsSplit air-cooled systems with a remote condenser willrequire field installed refrigerant piping. All split systemsare shipped with a dry nitrogen charge of 50 psig.NOTEMini-Space precision A/C units are not availablein a remote condensing unit configuration.Split systems coupled with a remote condenser willrequire a copper discharge line and copper liquid line.The following instructions should be followed to ensureproper installation:1. Loosen the two clamps located on the bracket inthe floor of the cabinet. Run the refrigerant linesthrough the openings in the cabinet and then securethem with the clamps. The clamps are labeled;i.e. “Discharge”, “Liquid Line” to indicate which lineit secures.2. Measure the distance to the refrigerant lines in thecabinet. Mark each pipe and cut to length.3. Join the piping together and solder using standardrefrigeration practices. Tighten the clamps.All refrigeration piping should be installed with hightemperature soldered joints. Use standard refrigerationpractices for piping supports, leak testing, dehydrationand charging of the refrigeration circuits. The refrigerationpiping should be isolated from the building by theuse of vibration isolating supports. To prevent tubedamage when sealing openings in walls and to reducevibration transmission, use a soft flexible material topack around the tubes.Refrigerant lines for split systems must be sized accordingto the piping distance between the evaporatorand the condenser/condensing unit. Each valve,fi tting and bend in the refrigerant line must be consideredin this calculation. Refer to the following chartprovided for determining the standard equivalentlengths, in feet, of straight pipe.Equivalent Length (ft) of Straight PipeOD (In.) Globe Angle 90º 45º Tee TeeLine Size Valve Valve Elbow Elbow Line Branch1/2 9.0 5.0 0.9 0.4 0.6 2.05/8 12 6.0 1.0 0.5 0.8 2.57/8 15 8.0 1.5 0.7 1.0 3.51 1/8 22 12 1.8 0.9 1.5 4.51 3/8 28 15 2.4 1.2 1.8 6.01 5/8 35 17 2.8 1.4 2.0 7.02 1/8 45 22 3.9 1.8 3.0 102 5/8 51 26 4.6 2.2 3.5 123 1/8 65 34 5.5 2.7 4.5 153 5/8 80 40 6.5 3.0 5.0 17When installing remote condenser(s) above theevaporator, the discharge line should include a shallowP-trap at the evaporator. The highest point in thedischarge line should be above the condenser coil.An inverted trap is required on the discharge line atthe remote condenser to help prevent oil and liquidrefrigerant from fl ooding back to the compressor.Oil traps must be included every 20 feet in the verticalrisers and the refrigerant lines must be sloped ¼inch for every 10 feet in the horizontal lines to ensureproper oil return to the compressor.Clear all pipe connections of debris and prepare theconnections for soldering. Use only “L” or “K” graderefrigerant copper piping. Be careful not to allow solder/piping debris to get inside refrigerant lines. Silver soldercontaining a minimum of 15% silver is recommended.Dry nitrogen should be flowing through the tubing whilesoldering at a rate of not less than 1-2 CFM (.03 - .06M 3 /minute).2-7(©April, 2008)Air Technology Systems, Inc.
Mini-Space Series Installation, Operation & Maintenance ManualRefer to line size charts provided below for recommendedline sizing.Total Unit*Equivalent Ft. accounts for the linear pipe length as well asequivalent length of Valves, Elbows & Tee’s as shown in the charton the previous page.Total Unit(©April, 2008)Recommended Liquid Line Sizes(For R22 or R407C Refrigerant)Receiver to Evaporator (Equivalent Ft.*)BTU/Hr 50’ 100’ 150’Capacity or less or less or less12,000 3/8 3/8 3/818,000 3/8 3/8 1/224,000 3/8 1/2 1/236,000 1/2 1/2 1/242,000 1/2 5/8 5/848,000 1/2 5/8 5/860,000 1/2 5/8 5/872,000 1/2 5/8 5/896,000 5/8 7/8 7/8Recommended Discharge Line Sizes(For R22 or R407C Refrigerant)NOTEEquivalent Length Ft*BTU/Hr 50’ 100’ 150’Capacity or less or less or less12,000 1/2 1/2 5/818,000 5/8 5/8 5/824,000 5/8 7/8 7/836,000 7/8 7/8 7/842,000 7/8 7/8 7/848,000 7/8 7/8 7/860,000 7/8 1-1/8 1-1/872,000 7/8 1-1/8 1-1/896,000 1-1/8 1-1/8 1-3/8Vertical runs are based on a total rise of 30equivalent feet. For longer sizes, individualcalculations must be made. Sizes assumethe use of single risers; double risers may benecessary.Consult the Copeland applications data guide formore detailed information regarding refrigerant linetraps and line sizing.2.7.2 Water/Glycol, Chilled Water and HotWater Reheat PipingThe piping connections for water/glycol, chilled watersystems and systems with optional hot water reheatare sweat connections. Pipe sizes may not necessarilybe the same size as the unit connection. Pipingshould be sized to match the required system pressuredrop and pump capacity (if applicable) and mayrequire reducing fi ttings to match the connection sizeon the air conditioner.Water/glycol/chilled water-cooled systems with lowentering fl uid temperatures should have insulatedpiping. The recommended ethylene glycol solutionratio is 40% glycol to 60% water. (SATS recommendsDowtherm SR1 manufactured by Dow Chemical Co.)Use only ethylene glycol with inhibitors for corrosionprotection.WARNINGGlycol is hazardous. Consult the manufacturer’sMSDS for detailed safety information.CAUTIONWhen installing and fi lling the water/glycol/chilled water loop and optional hot water reheatloop, all air must be bled from the pipingsystem.CAUTIONThe piping system must be fl ushed prior to operatingthe system. Failure to do so will resultin equipment problems.A strainer should be included in the water/glycol/chilled water line and optional hot water reheat line.Once the system is operational, the fl uid runs throughthe strainer where any foreign objects are removed.The strainer screen should be cleaned periodically.2.7.3 Pump PackageInstall a concentric reducer at the pump suction anddischarge openings and make all piping at least one-(1) size larger than the diameter of the openings. Ifa suction strainer necessary, install one with a netarea 2-3 times larger than the suction piping. Thepiping leaving the drycooler should enter the pumpsuction port. Install a check valve in the dischargeline to prevent back fl ow that may damage the pumpon shut down. Install a ball valve in the suction anddischarge lines for maintenance purposes.2-8Air Technology Systems, Inc.
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