Section 7: Air Conditioning

(Cooling)
Unit 38: Installation
 Introduction to Equipment
Installation
• Installations require ductwork, electrical,
and mechanical work
• Some contractors use separate crews
• The three disciplines are licensed at
state and/or local levels
• Local codes must be followed while
performing all work
 Installing Square and
Rectangular Duct
• Duct sections are assembled in the field
• Sections must be measured accurately
• Sections connected with “S” fasteners
and drive cleats
• Duct systems must be fastened securely
• Flexible duct connections reduce
vibration noise
Square and Rectangular Duct
(cont’d.)

Figure 38–1 A duct system

 Square and Rectangular Duct
(cont’d.)

Figure 38–3A Figure 38–4 A round flexible duct connector

A flexible duct connector
 Installing Round Metal Duct
Systems
• Duct sections are available from supply
houses
• Sections are connected with self-
tapping sheet metal screws
• Occupy more clearance space than
square or rectangular duct
Source: HARDI
14x8 duct
 Insulation and Acoustical
Lining For Metal Duct
• Can be applied to the inside or outside of
the duct
• Interior duct lining
– Usually applied during fabrication in the shop
– Secured with tabs and washers or glue
– Must be secured to prevent blocking airflow
– Usually coated fiberglass
 Insulation and Acoustical
Lining For Metal Duct (cont’d.)

Figure 38-8 A tab that holds the fiberglass

duct liner to the inside of the duct
 Insulation and Acoustical
Lining For Metal Duct (cont’d.)

Figure 38-9 Acoustical lining reduces the cross-sectional area of the duct
 Installing Flexible Duct
• Has a flexible liner and may be insulated
• Low initial cost (materials and labor)
• Used as supply or return duct
• Proper support prevents collapsing
• Should be stretched to prevent duct from
collapsing
• Does not transmit noise well
 Electrical Installation
• Care should be taken whenever working
on or around electrical circuits
– Power supply must provide correct voltage
and wire size
– Split systems require two power supplies
– There should be a service disconnect close
to each piece of equipment
– Control voltage is obtained through a step-
down transformer
Figure 38–13 Wiring connecting indoor and outdoor units to the main power service
 Electrical Installation (cont’d.)

Figure 38–14 This pictorial diagram shows the relative position of the wiring as it is
routed to the room thermostat, the air handler, and the condensing unit
 Installing Split System Air
Conditioners
• The evaporator is normally located
close to the blower section
• Must be located on a solid base or
suspended from a strong support
• Access to the unit must be considered
before installing
 Installing Split System Air
Conditioners (cont’d.)
• Condensate drain piping
– About three pints (pt) of condensate per
hour of operation for each ton of air
conditioning
– A trap in the drain line will hold some water
and keep air from pulling into the unit
– Auxiliary drain pans
• Used when the evaporator is above the
conditioned space
 Installing Split System Air
Conditioners (cont’d.)

Figure 38–36 Condensate

piped to a drain below the
evaporator drain pan
The Split System Condensing
Unit
• Air circulation and installation
– Must have adequate air circulation and
discharged air must not circulate back
through the condenser
• Electrical and piping considerations
– Routed between the evaporator and the
condenser
– As short as practical, leaving adequate
room for service
The Split System Condensing
Unit (cont’d.)
• Service accessibility
• Water drainage from natural sources
– Drainage of the ground water and roof
water must be considered
• Solar influence
– Shade helps cool the unit
• Placing a condensing unit for best
appearance
The Split System Condensing
Unit (cont’d.)

Figure 38–43 This unit

is located improperly
and allows the roof
drain to pour down into
the top of the unit
 Installing Refrigerant Piping
• Always be kept as short as practical
• The refrigerant charge
– Shipped in the condensing unit with
enough charge to operate the unit with a
predetermined line length
• The line set
– When the manufacturer furnishes the
tubing, it is called a line set
 Installing Refrigerant Piping
(cont’d.)
• Tubing leak test and evacuation
– Commonly used to make the final
connections
• Altered line-set lengths
– May be treated as a self-contained system
of their own
• Precharged line sets (quick-connect line
sets)
Source: Lennox
 Installing Refrigerant Piping
(cont’d.)
• Altered precharged line sets
– When the lengths of quick-connect line
sets are altered, the charge will have to be
altered
• Piping advice
– The manufacturer’s recommendation
should always be followed
 Equipment Startup
• Allow crankcase heater to run overnight
before starting system
– Check fan rotation
– Check fan amperage
– Check airflow at registers
– Check the amperage of the compressor
– Check operating pressures and
temperatures
 Summary
• Installations require ductwork, electrical,
and mechanical work
• Rectangular galvanized duct sections
must be measured and fabricated
accurately, properly supported, and
installed with canvas collars to reduce
noise transmission
 Summary (cont’d.)
• Galvanized duct sections are often
joined with slips and drives
• Round metal duct sections are
connected with self-tapping sheet metal
screws
• Metal duct systems must be insulated
 Summary (cont’d.)
• Always exercise caution when installing
electric circuits
• Power supplies must match the system
requirements
• Split systems require two power
supplies
• Package systems require only one
power supply
 Summary (cont’d.)
• Low voltage control wiring is obtained
through a control transformer
• Package systems have all system
components contained in a single
cabinet
• Condensate from the system must be
properly removed: gravity or pump
 Summary (cont’d.)
• Auxiliary drain pans catch condensate
overflow and protect living space below
the unit
• Condenser discharge air must not
recirculate back through the coil
• Condensing units should be positioned
so that noise factor is low and service
panels are accessible
 Summary (cont’d.)
• Refrigerant piping runs should be as
short as possible
• The suction line should be insulated
• Piping circuit should be leak checked
and evacuated before introducing
refrigerant to the system
 Summary (cont’d.)
• When starting up an air conditioning
system, be sure to check operating
amperages, voltages and system
operating pressures