Air conditioner system installation

The most important function of a filter drier is to absorb moisture. The second is to provide physical filtration. When installing a new air conditioner condenser, you must always install a liquid line filter drier into the refrigeration system.

Most new air conditioner condensers come with a liquid line filter drier for you to install. Manufacturers recommend the filter drier be installed close to the expansion valve TXV at the indoor coil, as often as possible. This keeps the TXV protected and keeps the filter drier from being exposed to weather where it could rust. There is also an arrow for flow direction.

This arrow must always be in the direction that is going into the indoor coil. Moisture enters the system in different ways. If a system is not evacuated properly, moisture will exist in it.

Moisture can also come from leaks or motor windings. The water can cause corrosion and create failure in metallic parts. Water or moisture can also react with the oil in the refrigerant system. This is called hydrolysis, which forms acids in the system. Acids, moisture, or any other contamination in the lines will be extremely dangerous to the integrity of your new air conditioning system.

All good HVAC companies have strict processes in place for their install teams to prevent failure as much as possible. Any time a refrigerant line is open to the atmosphere, it is vital to install a new filter drier.

This is true of installations as well as service repairs. This brazing process is the same for connection to the indoor evaporator coil.

This, again, involves open flames and should only be performed by a trained professional. The gases used in the process are explosive. There is an open flame outside and inside the home.

It can be dangerous to the installer, the homeowner, and the home, causing permanent damage without proper training. Following manufacturer and safety guidelines is key. Preparing the line set for refrigerant in this way is the most important step in ensuring the safety and efficiency of your air conditioner. Sadly, this process is unknown or not followed to most install teams. Not all companies are equal in training or processes, and many contractors lack the proper equipment.

A good HVAC company will have all the tools and processes needed to install the air conditioner professionally and thoroughly. After the line set is fitted properly into the service valves and indoor coil, heat protection needs to be applied.

Heat protection can be a heat-absorbing paste, wet towels, or rags. Anything that would keep the heat spreading into either of the coils is acceptable. If the valves are overheated and the O-rings are damaged, the refrigerant will leak past the valve into the line set, losing the factory charge. From the factory, the air conditioner condenser is prepared, cleaned, and the refrigerant is added. If the refrigerant is exposed before the process is completed, it becomes contaminated, along with the condenser coil.

If this step is performed improperly, all the refrigerant would need to be recovered and the condenser coil would need cleaned and prepared again before any refrigerant could be added. Most indoor coils have a metering device called an expansion valve that will be damaged if not protected from the heat during brazing. If these get too hot, or any contaminants are introduced, the expansion valve will be compromised and fail to operate.

Once the heat protection is completed, a tank containing a gas called dry nitrogen is hooked up to a regulator and possibly a manifold gauge set. This allows the nitrogen to be purged while brazing. The nitrogen protects the inside of the copper tubing from oxidizing during brazing. The damage will not always be present immediately. Brazing with nitrogen, when done properly, will give the system maximum opportunity for performance, reliability, and dependability.

After the system is brazed in both the indoor and the outdoor components, it must be checked for leaks using the same dry nitrogen, up to a specific amount of pressure. Using the dry nitrogen to pressure test the system achieves three things:. It is very important to verify with the installation manual provided by the manufacturer what they recommend for pressure.

Most systems are designed for PSI when testing. If there is too much pressure added, problems can occur. If the pressure is too high for the O-ring seal, for instance, the nitrogen will bleed into the refrigerant, contaminating it. In this scenario, all the refrigerant contained in the condenser from the factory will be compromised and will have to be recovered, then the coil cleaned and prepped for more refrigerant.

Typically a system is vacuumed to a minimum of microns. The manufacturer's recommended vacuum is found in the installation manual. Refrigeration systems are designed to operate with only oil and refrigerant flowing through them.

Our atmosphere is made up of oxygen, nitrogen, and moisture. These are enemies to the system's operation and may enter the system during installation or servicing. Removal of these, along with air or other non-condensable products, is required. This is achieved through the vacuum process when installing the air conditioner. The vacuum process can take no less than 30 minutes and up to an hour or more depending on the size of equipment coils and length of line set.

Failure to provide a dry, moisture-free atmosphere before introducing the refrigerant into the rest of the system will in all cases promote an inconsistent operation, and eventually permanent failure of the system. To achieve a successful vacuum on an air conditioning system there are several key tools and equipment that must be used:.

The vacuum must achieve microns or less in the system and hold the vacuum for this to be successful. This is also the second and final leak test. If a system does not hold a vacuum, then there is a leak somewhere. Once a proper vacuum is achieved and has proven to hold, the system is ready to have refrigerant introduced to it. If hoses are disconnected from the system before the refrigerant has been released into the system, the atmosphere will break the vacuum.

If this happens, the vacuum process must be redone before refrigerant can be introduced. With the hoses still connected to the service valves of the air conditioner, the refrigerant is released into the system, breaking the vacuum by opening the suction-side service valve first followed by the liquid side second. For the air conditioning system to operate, the high- and low-voltage wiring must be reconnected. Using the existing power supply from the electrical panel inside the home, the installer will mount a new service disconnect box.

The disconnect is mounted securely to the side of the house using appropriate fasteners, based on the type of surface it is being mounted to.

There are two main types of disconnect boxes. One is fused and the other is non-fused. They are both appropriate to use outdoors. A fused disconnect allows the proper overcurrent protection required by the manufacturer. This type is most common and required when the main circuit from the panel exceeds the maximum required overcurrent protection. It also allows for additional safety to the air conditioner condenser. A non-fused disconnect may be used only in cases where the breaker matches identically to the manufactures listed maximum overcurrent protection.

There is a minimum and a maximum required overcurrent protection. You must be within these guidelines. The system will not pass the code requirements if they are not. For example, if you have an existing amp circuit that supplies the disconnect, but the listed overcurrent protection is only 30 amps, you must use the fused disconnect and install amp fuses with it to properly protect the air conditioning condenser.

If the amperage from the breaker matches the maximum or the minimum overcurrent protection, a non-fused disconnect is acceptable. The service disconnect has specific locations for the high voltage circuit from the panel to be connected and specific locations for the power to get to the air conditioner itself through the electrical whip.

This allows the pull inside the service disconnect to break or disconnect the power supply to the air conditioner without having to shut the breaker off from the main panel. Because the air conditioner is outside, it would be cumbersome to run in and out of the house to turn the power on or off in case of emergency or servicing.

The service disconnect is required by state and local code requirements. There are also requirements for placement of the air conditioning condenser. It boils down to making sure there is proper accessibility. The low-voltage control wire is connected directly into the air conditioning condenser at the proper locations according to the air conditioning condenser installation instructions. The low-voltage control wire is what allows the air conditioner to cycle according to the parameters set regarding temperature and humidity inside the home.

The low voltage wiring is connected to the control board inside the furnace on designated terminals. The moisture removed from the home during the cooling process travels down a plastic PVC pipe. It must be connected to the primary side of the evaporator coil. The evaporator coil has a primary and a secondary drain location.

The primary condensate drain line will travel from the indoor evaporator coil to an appropriate floor drain or condensation pump.

A condensation pump is used where a proper floor drain does not exist in the home. There are also other reasons where a condensate pump is required or is beneficial to install. The important thing to remember if a condensate pump is used is that it must be serviced a minimum of twice a year to maintain proper performance. Any condensate tubing or piping should be secured and glued with the proper cement.

A trap and an overflow safety switch must also be installed in the condensate system. This is to protect the equipment and the area from flooding due to a restriction. The safety overflow switch is connected to the secondary port on the indoor evaporator coil and wired into the furnace control to shut down the system when it is tripped.

The startup and commissioning testing process is done after the system is completely installed and ready to operate. The system is turned on and must run for minutes. This will allow the refrigerant to flow through the system and start the air conditioning process. A temperature above 75 degrees Fahrenheit is recommended in most cases. This allows the components in the air conditioning system to be in full operation to allow maximum cooling potential during charging.

Sometimes running the furnace to heat the house is a common practice to provide the necessary load on the home. After minutes of operation, the system can now be commissioned. A good installer will check the thermostat operation, system sequence of operation, and multiple other areas.

While the system is operating, the following data is important to collect to ensure proper operation within manufacturers' specifications:.

This is the basic list of the proper data that should be known and recorded. This is the only way to know for sure how the system is operating and if it is within manufacturing specifications.

If any of these do not fall within manufacturer specifications, your system may not be warrantied by the manufacturer. Commissioning is important for several reasons. For you, the peace of mind that you are receiving a properly set up and adjusted system for maximum comfort, efficiency, and dependability.

It also ensures the manufacturer's warranty will be in full effect. The benefit to the company installing the system is that it gives a baseline of operational performance in case any issues arise later. It also gives the installing team confidence that before they leave, your system is in perfect operation.

It is very common for systems to be installed and started up without much consideration for proper commissioning. Unfortunately, many companies turn it on and walk away the moment cold air is coming through the vents.

Proper commissioning is a specific process that requires training and special equipment to perform the process correctly.

It also requires additional time and labor on a job site. Commissioning is the only way to know for sure exactly how well your system is operating. Why would a company skip this step, then? In a word: cost. Skipping this process costs a company less, which in turn might lower your initial investment slightly. This is a long-term gamble, though, with your money, your safety, and your comfort. A good HVAC contractor will have trained installation teams that will properly commission your air conditioner before they leave the job.

The cleanup process is comparatively simple. All material and old equipment should be loaded up and taken away from the home. The floor protection should be rolled up last, keeping all debris from the installation inside the drop cloth and out of your home.

All areas should be swept and free of any materials or debris. You should expect to see the area in the same condition in which it was found. A walkthrough of what was done during the installation should be completed with you. Going over safety, maintenance, warranty, and all special instructions are expected. As a final mechanical step, a locking cap should be placed on the outdoor portion of the unit.

This cap can only be unlocked with the correct key. This is to prevent tampering with your equipment, and also to prevent theft of the refrigerant. This cap is often a specific color, which will let a technician know which type of refrigerant your system uses.

A visual inspection of the work completed should also be offered. Finally, a review of the commissioning and thermostat operation. After the final walkthrough, final signatures and payments are collected. The process may seem long and complicated, but in the hands of a skilled installation team, the entire process should be second nature.

Your money and comfort are at risk if any of these steps are skipped. Knowing the full process will allow you to hold companies accountable when you decide to invest in a new air conditioning system.

The result will be a comfortable, efficient, long-lasting product. Are you looking for a good HVAC company to install your new air conditioner system? We hope this article has given you some tools to assist in selecting one that meets your needs. We believe in doing something right the first time. Are you in the Columbus area and ready to take the next step with one of our experienced professionals? Call us today or schedule an estimate. We proudly serve the Dublin, Ohio, community.

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