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Refrigerant Line Sizes for 5 Ton AC

Jimt1000

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D'Hanis, Texas
I am replacing a 3 ton and a 2 ton split AC system serving two zones with a single 5 ton AC with motorized supply dampers to serve the two zones. All good. I have a two story home and the furnaces are located in the upper attic and the condensing units are located at the ground level (21 feet of rise from ground to the attic). The new AC is going to be a Trane 5 ton model 4TTV8060A. The existing vapor line sizes running up into the attic are 3/4" and they run inside my exterior brick wall (behind the sheetrock in a 2x6 stud space) from the ground level to the attic space. The existing old AC condensers being removed are not next to each other (i.e., they are on opposite sides of the house). So, unless I am willing to have 21' of insulated refrigerant line exposed on the exterior brick of my home, which I'm not willing to do else I fear a divorce forthcoming, I must make use of the existing 3/4" vapor line inside the exterior brick wall as described. My AC technician has recommended brazing a 7/8" line where immediately accessible to the 3/4" line running in the brick wall in both the attic and at the ground level where the condenser will be. So, I would have a 7/8" line transitioning immediately off the condenser to a 3/4" line which would then run 21' up in the exterior brick wall into the attic where it would then transition back to a 7/8" line to the furnace.

As a civil engineer who knows enough mechanical engineering to get myself into trouble, this makes sense (i.e., bigger line less friction loss albeit with less velocity). Looking at the Trane installation manual seems to verify this is OK, but it also adds confusion. See below insert picture from the Trane installation manual. Table 3 calls for the vapor line size to be 1-1/8" and as footnoted, a max. length of 80' and a max. length of vertical rise of 25'. Yet, in Table 4, "Alternate Line Sizes" are provided whereby for the 4TTV8060A it is stated that the vapor line can be 3/4" or 7/8" and as footnoted, a max. length of 150' and a max. length of vertical rise of 50'. The footnoting as stated above seems counterintuitive given the line sizes provided; however, regardless, I am OK in my application no matter what the line size configuration (i.e., I only have 21' of vertical rise and I'm less than 80' in total length).

So, my questions are herewith:
1. Given the "Alternate Line Sizes" in Table 4, I'm assuming the usage of a short reach of 3/4" vapor line is OK and the idea of transitioning to 7/8" where possible is a good idea to improve efficiency (i.e., reduce losses in the line). Does this sound reasonable?
2. If Table 3 says 1-1/8" is the "Rated Size" and Table 4 says 3/4" and 7/8" are "Alternate Sizes", then are we dealing with just the degradation of efficiency in the system in terms of reductions in line size? In other words, would it be proper to interpret these tables to say, "... 1-1/8" is preferred, but 7/8" and 3/4" are acceptable"? And the difference would be the slight loss of efficiency which probably wouldn't be noticeable?

Any answers and insight would be appreciated. Regards, jft

Trane Refrigerant Line Sizes.jpg
 
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mike93lx

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Maybe the size will work fine, but if not, drywall repairs are easy. I'd open the walls before thinking about something external.

I have the same setup with my 3rd floor system. Not looking forward to replacing it, but I'll definitely open the walls if needed
 

karoc

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If units has a high efficiency rating then to get that rating you need 1 1/8. 7/8 would be minimum. Problem that I see in future is with your acknowledgment to run lines 7/8 to 3/4 to 7/8 could possibly void warranty, drop efficiency rating( I don’t think could really tell) even engineer.
They do make covers for line sets don’t look to bad if done right. I’ve ran line sets on outside walls on nice homes, plum cover then homeowners paint them match brick. Not bad at all
 
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Jimt1000

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D'Hanis, Texas
Thanks for the replies. On the drywall work, yes, it's not the end of the world but on one interior room downstairs we have a special finish which would require refinishing the entire wall, perhaps the room. So, not so simple to just cut the sheetrock. And any type of exterior run, even under a cover, wouldn't be acceptable.

Regarding the line sizing, I don't think a 7/8 to 3/4 to 7/8 vapor line install would void the warranty. I think the question is one of the impact to efficiency. I'm still perplexed why Trane would list the 3/4" line under "Alternate Line Sizes" for this model at 5 tons if it were not OK. And if the 3/4" line size is OK, then certainly a 7/8 - 3/4 - 7/8" line would be better since we're reducing the friction loss in the overall line. That's my thinking anyway.
 

mike93lx

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Thanks for the replies. On the drywall work, yes, it's not the end of the world but on one interior room downstairs we have a special finish which would require refinishing the entire wall, perhaps the room. So, not so simple to just cut the sheetrock. And any type of exterior run, even under a cover, wouldn't be acceptable.

Regarding the line sizing, I don't think a 7/8 to 3/4 to 7/8 vapor line install would void the warranty. I think the question is one of the impact to efficiency. I'm still perplexed why Trane would list the 3/4" line under "Alternate Line Sizes" for this model at 5 tons if it were not OK. And if the 3/4" line size is OK, then certainly a 7/8 - 3/4 - 7/8" line would be better since we're reducing the friction loss in the overall line. That's my thinking anyway.
I'd call them to ask.

I am on the same page for the exterior lineset. Last time I posted something similar, I got a lot of the same responses to just do it outside and it can be made to look fine. Works for many/most and that's completely fine. I'm not doing it
 
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karoc

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One of my War stories doing HVAC work:

Setting a condenser for engineer, sweat copper fittings using long radius elbows squaring it making it look good, pulled vacuum on system then getting ready open valves. Here comes engineer around corner. Started telling me how much those elbows restrict refrigerent 😩 I had cut out those expensive fittings, take piece of tubing, bend it using my knee and fit to unit (Engineers) Unit I took out had more fittings plus what was in attic. Oh well he was customer.
 
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fitter30

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PoorUB

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In my experience 7/8" is the minimum I would run. If the total run is over 25 feet I would run 1-1/8".

I worked with a guy that half assed line sizes all the time. I would go back and install the proper lines when the units didn't run properly, every time.

There is absolutely no way on earth I would run 3/4" on a 5 ton. Even if it was 5 feet. Nope, I wouldn't do it.
 

karoc

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You think engineers are tough, do HVAC work for Shell Oil chemist. That guy was tough
Edit; I corrected my spelling
 

fitter30

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You think engineers are tough, do HVAC work for Shell Oil chemist. That guy was tough
Edit; I corrected my spelling
Try McDonnell Douglas or worked on F18 line or mechanical engineers fresh out of ivy college. Either way i agree especially in my 20s and 30s after 20 years you know how the the game is played.
 
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