Tube Size and Component Selection PDF
Tube Size and Component Selection PDF
Tube Size and Component Selection PDF
Guide
This application guide provides refrigerant piping guidelines for Trane® Model
RAUC air-cooled condensing units that range in size from 20 through 120 tons.
Use the information presented here to properly select interconnecting piping
and refrigerant components for these systems.
The Trane Company, in proposing these system design and application concepts,
assumes no responsibility for the performance or desirability of any resulting
system design. Design of the HVAC system is the prerogative and responsibility of
the engineering professional.
Overview ............................................................................................... 4
Background .............................................................................................. 4
Updated Guidelines ................................................................................. 5
Smaller liquid lines .......................................................................... 5
Suction-line dependencies .............................................................. 5
Component selection summary (table) .......................................... 6
Hot gas bypass in commercial comfort-cooling applications ...... 7
Equipment Proximity ............................................................................... 7
Equipment Placement ............................................................................. 7
SS-APG001-EN-0901 3
Overview
“Why did Trane change the rules for refrigerant piping in large split systems?
Didn’t the old rules work?” … “The Trane Reciprocating Refrigeration Manual
has been used for decades to size lines; are you saying it’s wrong?”
These questions and others have been posed by split-system designers about
the current piping practices for RAUC condensing units. But did we (Trane)
really change the rules, or simply refocus them?
These rules remain unchanged for today’s piping practices, but through
practical experience, we’ve identified one more:
Years of observation revealed that the lower the system refrigerant charge,
the more reliably the split system performed. Any amount in excess of the
minimum design charge made it more difficult to manage the refrigerant in the
system. Why? Excess refrigerant increases the likelihood that refrigerant will
end up in areas where it may cause operational problems over the life of the
system.
Background
The equivalent line lengths for refrigerant components, recommended pressure
drops for suction and liquid lines, and minimum and maximum refrigerant
velocities that were originally published in the 1940s edition of the Trane
Reciprocating Refrigeration Manual originated from long-forgotten research. At
least some of the supporting data was probably derived from measurements
and/or equations that involved water because the pictures found in likely
resources illustrate water components.
Through the years, analytical and empirical information for refrigerant piping
has been reviewed and updated based on equation-based modeling and on two
research papers: Pressure Losses in Tubing, Pipe, and Fittings by R.J.S. Pigott
and Refrigerant Piping Systems—Refrigerants 12, 22, 500 by the American
Society of Refrigeration Engineers (ASRE). In his paper, Mr. Pigott describes his
use of refrigerant as the fluid and his direct measurement of pressure drops. His
findings indicated that the pressure drop of many line components is small and
4 SS-APG001-EN-0901
Overview
Similarly, the conclusion of the ASRE research paper states that the minimum
velocity requirement (needed to maintain oil entrainment in vertical risers and
horizontal lines) varies with the diameter of the refrigerant tubing and the
saturated temperature of the suction gas.
Updated Guidelines
Smaller Liquid Lines
Historically, liquid lines were sized to minimize the pressure losses within the
piping circuit. Then, as now, movement of oil through the piping is not a
concern because oil is miscible in liquid refrigerant at normal liquid-line
temperatures. For the liquid line and its components, keeping the pressure drop
at or below the traditional 6 psid [41 kPa] requirement assures that a solid
column of liquid refrigerant will be available at the expansion valve.
Table 1. Expansion Valves If the objective is also to minimize the liquid-line charge, we would choose the
for RAUC 20–120-Ton Applications smallest liquid line that maintains subcooling at the thermal expansion valve
Evaporator Coil Expansion Valve b (TXV). Most likely, such an approach would increase the pressure drop well
Capacity a Trane Part No. beyond 6 psid [41 kPa]; it would also use more, but not all, of the subcooling.
2 to 4 tons VAL07364
As a safety factor, we recommend maintaining at least 5°F [2.7°C] of subcooling
at the TXV throughout the system operating envelope. The line sizes and
5 to 6 tons VAL07074
refrigeration components identified in Table 1 and Table 2 (page 6) were chosen
7 to 10 tons VAL07075 to minimize the refrigerant charge and to maintain the needed subcooling.
11 to 14 tons VAL07076
SS-APG001-EN-0901 5
Overview
Refrigerant ckts 1 1 1 2 2 2 2 2 2
Minimum step 9 tons 9 tons 14 tons 9 tons 14 tons 14 tons 15 tons 20 tons 30 tons
Suction Line
Tube diameter c
Horizontal 2-1/8 in. 2-1/8 in. 2-1/8 in. 2-1/8 in. 2-1/8 in. 2-1/8 in. 2-5/8 in. 2-5/8 in. 3-1/8 in.
Vertical (up) 1-5/8 in. 1-5/8 in. 2-1/8 in. 1-5/8 in. 2-1/8 in. 2-1/8 in. 2-1/8 in. 2-5/8 in. 2-5/8 in.
Filter shell DHY00345 DHY00339 DHY00339 DHY00345 DHY00339 DHY00339 DHY00341 DHY00341 DHY00342
(1 per ckt)
Filter core COR00067 COR00067 COR00067 COR00067 COR00067 COR00067 COR00067 COR00067 COR00067
(1 per ckt) (1 per ckt) (1 per ckt) (1 per ckt) (1 per ckt) (1 per ckt) (2 per ckt) (2 per ckt) (2 per ckt)
Access port Schraeder Schraeder Schraeder Schraeder Schraeder Schraeder Schraeder Schraeder Schraeder
(3 per ckt) valve w/core valve w/core valve w/core valve w/core valve w/core valve w/core valve w/core valve w/core valve w/core
Frostat™ control KIT01387 KIT01387 KIT01387 KIT01387 KIT01387 KIT01387 KIT01387 KIT01387 KIT01387
Ball valve VAL06645 VAL06645 VAL06645 VAL06645 VAL06645 VAL06645 VAL06647 VAL06647 VAL06649
(2 per ckt)
Liquid Line
Tube diameter c 5/8 in. 7/8 in. 7/8 in. 5/8 in. 7/8 in. 7/8 in. 7/8 in. 1-1/8 in. 1-1/8 in.
Filter shell DHY00110 DHY00111 DHY00111 DHY00110 DHY00111 DHY00111 DHY00115 DHY00116 DHY00116
(1 per ckt)
Filter core COR00019 COR00019 COR00019 COR00019 COR00019 COR00019 COR00019 COR00019 COR00019
(1 per ckt) (1 per ckt) (1 per ckt) (1 per ckt) (1 per ckt) (1 per ckt) (2 per ckt) (2 per ckt) (2 per ckt)
Solenoid valve, VAL07010 VAL01829 VAL01829 VAL07010 VAL01829 VAL01829 VAL01831 VAL02150 VAL02133
coil (1 per ckt) COI01004 COI01004 COI01004 COI01004 COI01004 COI01004 COI01004 COI01004 COI01004
Sight glass d GLS00830 GLS00831 GLS00831 GLS00830 GLS00831 GLS00831 GLS00831 GLS00832 GLS00832
(1 per ckt)
Access port Schraeder Schraeder Schraeder Schraeder Schraeder Schraeder Schraeder Schraeder Schraeder
(2 per ckt) valve w/core valve w/core valve w/core valve w/core valve w/core valve w/core valve w/core valve w/core valve w/core
Ball valve VAL06655 VAL06657 VAL06657 VAL06655 VAL06657 VAL06657 VAL06657 VAL06659 VAL06659
(2 per ckt)
6 SS-APG001-EN-0901
Overview
Hot gas bypass increases the minimum refrigerant charge; it also inflates the
first cost of the system. Besides adding more paths for potential refrigerant
leaks, hot gas bypass increases the likelihood of refrigerant distribution
problems. Finally, hot gas bypass uses excessive amounts of energy by
preventing compressors from cycling with fluctuating loads.
Trane now has more than ten years of experience in the successful use of
packaged rooftop equipment without hot gas bypass in commercial comfort-
cooling applications. To prevent evaporator freeze-up, our equipment typically
includes Trane® Frostat™ coil frost protection.
Like hot gas bypass, the Frostat system protects the coil from freezing, but it
does so by turning off compressors when a sensor detects the formation of
frost on the evaporator coil. The compressor is released to operate when the
coil temperature rises a few degrees above the frost threshold. The Frostat
control strategy reduces the overall energy consumption of the system while
reliably maintaining system control.
Note: If the needs of a particular installation warrant the addition of hot gas
bypass, consult Hot Gas Bypass Control (Trane applications engineering
manual AM-CON 10) for piping recommendations.
Equipment Proximity
In split-system applications, minimizing the refrigerant charge is critical to
reliable, cost-effective operation. This design goal can be accomplished, in part,
by routing the refrigerant lines as directly as possible to shorten the distance
between components. Line lengths and riser heights should be no longer than
absolutely necessary.
Equipment Placement
Position the RAUC condensing unit as close to the evaporator as possible to
maximize reliability and to minimize both the length of the interconnecting lines
and the system refrigerant charge. Route the refrigerant lines by the shortest
direct path using only horizontal and vertical piping configurations. The
SS-APG001-EN-0901 7
Overview
permissible separation between the evaporator and the RAUC condensing unit
depends on the total line length and the elevation difference between these
devices.
Note: Elevation differences between the evaporator and the RAUC unit are
critical. Interconnecting lines of 150 ft [45.7 m] are permissible without Trane
review, but only a limited length can be in a riser.
8 SS-APG001-EN-0901
Line Sizing, Routing,
and Component Selection
access port
manual
discharge
ball valve access filter
line
port
condenser and
subcooler coil
manual
angle valves
compressors manual
ball valve
moisture- solenoid
filter drier
indicating valve access
with
sight glass port
access port
manual
distributor
ball valve
access port manual ball valve
SS-APG001-EN-0901 9
Line Sizing, Routing,
and Component Selection
Figure 2. Liquid-Line Riser Limitations for RAUC 20- through 120-Condensing Units
Routing. Install the liquid line with a slight slope in the direction of flow so
that it can be routed with the suction line.
A height limitation exists for liquid lines that include a liquid riser because of
the loss of subcooling that accompanies the pressure loss in the height of the
liquid column. Figure 2 depicts the permissible rise in the liquid line (that is,
without excessive loss of subcooling). Again, system designs outside the
application envelope of the RAUC unit require Trane review.
Note: Beginning in May 2000, 20- through 120-ton RAUC units include a
check/relief valve to prevent liquid refrigerant from being drawn back to the
compressor during the off cycle. The relief valve discharges to the condenser to
prevent excessive pressures from developing in the liquid line during off cycles.
Insulation. The liquid line is generally warmer than the surrounding air, so
it does not require insulation. In fact, heat loss from the liquid line improves
system capacity because it provides additional subcooling.
10 SS-APG001-EN-0901
Line Sizing, Routing,
and Component Selection
■ Access port. The access port allows the unit to be charged with liquid
refrigerant and is used to determine subcooling. This port is usually a
Schraeder valve with a core.
■ Expansion valve. The expansion valve is the throttling device that meters
the refrigerant into the evaporator coil. Metering too much refrigerant floods
the compressor; metering too little elevates the compressor temperature.
Choosing the correct size and type of expansion valve is critical to assure
that it will correctly meter refrigerant into the evaporator coil throughout the
entire operating envelope of the system. Correct refrigerant distribution into
the coil requires an expansion valve for each distributor.
For improved modulation, choose expansion valves with balanced port
construction and external equalization. Table 1 (page 5) identifies the part
numbers of the valves recommended for commercial RAUC systems.
■ Ball shutoff valves. Adding manual, ball-type shutoff valves upstream and
downstream of the filter simplifies replacement of the filter core.
As a matter of practicality, Table 2 (page 6) lists only one of the numerous
manufacturers of these values. If you choose a valve by another
SS-APG001-EN-0901 11
Line Sizing, Routing,
and Component Selection
When the application includes a suction riser, oil must be forced to travel the
height of the riser. Riser traps and double risers are unnecessary in the suction
line. All 20- through 120-ton RAUC units unload such that a single line size,
preselected in Table 2, provides sufficient lift to push entrained oil up the
permissible riser height. To assure proper oil movement, the permissible unit
separation is 150 ft [45.7 m], including a maximum vertical rise of 50 ft [15 m].
System designs outside this application envelope require Trane review.
Note: If a suction riser is properly sized, oil will return to the compressor
regardless of whether a trap is present. If a suction riser is oversized, adding a
trap will not restore proper oil movement.
Insulation. Any heat that transfers from the surrounding air to the cooler
suction lines increases the load on the condenser (reducing the system’s air-
conditioning capacity) and promotes condensate formation (adversely affecting
indoor air quality). After operating the system and testing all fittings and joints
to verify that the system is leak-free, insulate the suction lines to prevent heat
gain and unwanted condensation.
12 SS-APG001-EN-0901
Line Sizing, Routing,
and Component Selection
ball shutoff valve. Position them as close to the compressor as possible. Table 2
(page 6) identifies suitable components, by part number, for each RAUC model.
■ Access port. The access port is used to determine suction pressure. This
port is usually a Schraeder valve with a core.
■ Frostat™ coil frost protection. The Frostat control is the preferred method
for protecting evaporator coils from freezing. It senses the suction-line
temperature and temporarily disables mechanical cooling if it detects frost
conditions. The control is mechanically attached to the outside of the
refrigerant line, near the evaporator, and wired to the unit control panel.
■ Ball shutoff valve. Adding manual, ball-type shutoff valves upstream and
downstream of the filter simplifies replacement of the filter core.
As a matter of practicality, Table 2 (page 6) lists only one of the numerous
manufacturers of these valves. If you choose a valve by another
manufacturer, ensure that its specifications are equivalent to the valve
identified in this guide.
SS-APG001-EN-0901 13
Single-Circuit Examples of Field-Installed
RAUCs Evaporator Piping
14 SS-APG001-EN-0901
Single-Circuit Examples of Field-Installed
RAUCs Evaporator Piping
1 Pitch the liquid line slightly—1 in./10 ft suction line Evaporator Coil
[1 cm/3 m]—so that the refrigerant drains with Horizontal-Split
toward the evaporator. “trim” (Standard) Circuiting
solenoid valve
2 Provide one expansion valve per distributor. liquid
3 Slightly pitch the outlet line from the suction line
header toward the suction riser—that is, sight
1 in./10 ft [1 cm/3 m] in the direction of flow. thermal
glass
Use the tube diameter that matches the expansion
suction-header connection. valve (TXV)
SS-APG001-EN-0901 15
Single-Circuit Examples of Field-Installed
RAUCs Evaporator Piping
“pumpdown”
solenoid valve
distributor
16 SS-APG001-EN-0901
Dual-Circuit Examples of Field-Installed
RAUCs Evaporator Piping
1 Pitch the liquid lines slightly—1 in./10 ft suction line Evaporator Coil
[1 cm/3 m]—so that the refrigerant drains (circuit 2) with Horizontal-Split
toward the evaporator. (Standard) Circuiting
liquid line
2 Provide one expansion valve per distributor. (circuit 2)
3 Slightly pitch the outlet line from the suction sight
header toward the suction riser—that is, glass
1 in./10 ft [1 cm/3 m] in the direction of flow.
Use the tube diameter that matches the
solenoid
suction-header connection. distributor
suction line valve
4 The top of the Circuit 1 suction riser must be (circuit 1)
higher than the bottom evaporator coil. Use
liquid line
the tube diameter recommended for a
(circuit 1)
vertical rise in Table 2 (page 6).
5 Arrange the suction line so that the
refrigerant gas leaving the coil flows
downward, past the lowest suction-header
outlet, before turning upward. thermal filter drier
6 The top of the Circuit 2 suction riser must be expansion
higher than the top evaporator coil. Use the valve (TXV)
tube diameter recommended for a vertical
rise in Table 2 (page 6).
7 Pitch the suction lines slightly—1 in./10 ft
[1 cm/3 m]—so that the refrigerant drains
toward the evaporator.
8 Insulate the suction lines.
SS-APG001-EN-0901 17
Dual-Circuit Examples of Field-Installed
RAUCs Evaporator Piping
(circuit 1)
filter drier
distributor
18 SS-APG001-EN-0901
Dual-Circuit Examples of Field-Installed
RAUCs Evaporator Piping
1 Pitch the liquid line slightly—1 in./10 ft suction line Evaporator Coil
[1 cm/3 m]—so that the refrigerant drains thermal expansion with Horizontal-Split
toward the evaporator. valves (TXV) (Standard) Circuiting
(circuit 2)
2 Provide one expansion valve per distributor.
sight liquid line
3 Slightly pitch the outlet line from the suction
glass (circuit 2)
header toward the suction riser—that is,
1 in./10 ft [1 cm/3 m] in the direction of flow.
Use the tube diameter that matches the filter drier
suction-header connection.
4 Arrange the suction line so that the suction line
refrigerant gas leaving the coil flows
downward, past the lowest suction-header
“trim”
outlet, before turning upward. Use a double-
solenoid valve
elbow configuration to isolate the TXV bulb
(circuit 1)
thermal expansion
higher than the bottom evaporator coil. Use
(circuit 2)
valves (TXV)
the tube diameter recommended for a
vertical rise in Table 2 (page 6).
10 The top of the Circuit 2 suction riser must be
higher than the top evaporator coil. Use the “trim”
tube diameter recommended for a vertical solenoid valve
rise in Table 2 (page 6).
11 Only use a “trim” solenoid valve for
constant-volume, humidity-sensitive liquid line
applications. For all other applications, (circuit 2)
install a single solenoid valve (the “pump-
down” solenoid valve) between the liquid-
line filter drier and the sight glass. sight
glass
liquid line
(circuit 1)
filter drier
“pump-down”
solenoid valve
distributor
‘
SS-APG001-EN-0901 19
Literature Order Number SS-APG001-EN-0901