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Split system (MRCOOL Universal) lineset routing constraints?

cagey

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May 16, 2023
Messages
12
Location
on the 5000' contour line in SE AZ
I'm evaluating ideas for replacing the two 23 year old 4 ton 12 SEER R22 package heat pumps sitting on my roof. They're still working okay, but will need to be replaced eventually. When that happens, I would rather not replace them with rooftop package units (mainly because of maintenance access issues, impeding roof replacement, but also because commodity replacement RTUs (e.g. Goodman GPH16 below) don't seem to offer substantial performance improvement), so I've been seeking to understand what alternatives might be available.

A new-to-me class of solution I've just stumbled across is exemplified by the MRCOOL Universal Series of split systems, which offer a mini-split-like (variable-speed) outdoor condenser coupled with precharged "no vacuum" DIY lineset to a single-speed indoor air handler, offered at 2-5 Ton capacity points w/18-20 SEER performance, at what I consider appealing prices). The heating specs of these units are particularly impressive, offering 100% of rated heat capacity down to 17F (vs my existing units providing 47%, and a current-market 16 SEER Goodman GPH16 providing 52%, at the same temp) which would remove the need to deploy efficiency-killing heat strips (our location might hit 17F one or two days per year). These units have been available for 3+ years, and reviews seem to confirm the mfgr performance specs and good reliability.

To my question: my house is a 1-story ranch (garage is a separate building, so not involved). I would prefer not to locate the air handlers in the attic (not much headspace, difficulty in moving the new air handlers up there (due to both size and weight), future maintenance access difficulty, more challenging duct rework). I was thinking an alternative way to retrofit a system like this for long-term maintainability while reusing most of the existing ductwork would be to create (per system/RTU) a new "air handler room" in the house (first floor) itself, in which the air handler would be deployed in vertical-upflow orientation. However, the new air handler room(s) would be located in the middle of the house (beneath where the existing RTUs tie into the duct system) away from exterior walls, resulting in the need for the lineset to rise 9 ft from the condenser up the exterior wall into the attic, run 20+ ft horizontally across the attic and down 6 ft to the air handler, creating an "up, across, down" (inverted U) lineset topo. I've studied the MRCOOL Universal (and look-alike Gree Flexx) installation manuals, and they have surprisingly little to say about lineset routing constraints/rules of thumb: their diagrams show both condenser below air handler, and air handler below condenser configurations, but with the lineset running steadily upward/downward between the two endpoints:
Capture.PNG

Can anyone confirm/refute whether the "inverted U" lineset topo I described in boldface above would would result in a reliable and fully performing system?

Thanks in advance!
 
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pcmeiners

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Aug 13, 2009
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In the only town in Pennsylvania, Bloomsburg.
""This is directly from LG's installation manual (page 39)

"Components such as oil traps, solenoid valves, filter-dryers, sight glasses, tee fittings, and other after-market accessories are not permitted on the refrigerant piping system between the outdoor unit and the indoor unit. Duct Free Single Zone systems are provided with redundant systems that assure oil is properly returned to the compressor. Sight-glasses and solenoid valves may cause vapor to form in the liquid stream.""

The gas/liquid lineset velocity in most split systems is very high, oil is pushed along. The smaller the lineset tube diameter, the higher the velocity. The only time I can see a non return bend might be necessary is if the indoor unit is greatly lower than the outside unit with a long length lineset. Your lineset is relatively short, you should have no issues.

Just to give a relative gas velocity.....

1702914485763.png

"Returning to the system schematic, droplets of oil are pumped out of the
compressor along with the hot, high-pressure refrigerant vapor. The velocity of
the refrigerant inside the discharge line must be high enough to carry the small
oil droplets through the pipe to the condenser."
 
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cagey

Member
Joined
May 16, 2023
Messages
12
Location
on the 5000' contour line in SE AZ
The gas/liquid lineset velocity in most split systems is very high, oil is pushed along. The smaller the lineset tube diameter, the higher the velocity. The only time I can see a non return bend might be necessary is if the indoor unit is greatly lower than the outside unit with a long length lineset. Your lineset is relatively short, you should have no issues.
Thanks for your reply. From the installation manual, for all capacities of the MRCOOL Universal System, the refrigerant line diameters are 3/4 in. (Vapor), 3/8 in. (Liquid). Cross referencing with the "Determine Refrigerant Velocity" chart you provided, it predicts vapor velocity 2500 fpm (3 ton) to 4000 fpm (5 ton), with liquid velocities "off the top of the chart", all of which I assume meets your "very high [velocity]" expectation.

The max lineset length I expect to need is 50 ft (MRCOOL precharged "no vacuum" DIY linesets come in 15 ft, 25 ft, 35 ft, and 50 ft lengths, and 35 ft might not be quite enough given bend allowances etc.) which I assume is still "relatively short" (the LG manual I found for comparable units, IM_MultiV_S_OutdoorUnits.pdf specifies (pg 38) "Longest distance from ODU to IDU" of "492 feet (Actual)" which makes 50 ft. seem short)?

To be clear, I wasn't asking about the need for oil return bends (since the max rise in my application is < 6 m, I concluded none would be necessary); I just included the related diagram to illustrate that the system is capable of "condenser above air handler" configurations.
 

pcmeiners

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Messages
7,878
Location
In the only town in Pennsylvania, Bloomsburg.
"Longest distance from ODU to IDU" of "492 feet (Actual)" which makes 50 ft. seem short)?"

In my lookup (5 ton Mr cool), they state 98ft is maximum lineset, still your needed length is still well under the maximum. Did pull up a Mitsubishi unit stating 492 feet (???), guess that for running in the Royal castle. .. due to the fact it would be an install for royalty, I guess a minor issue such as pipe friction losses would have no effect, for their special home, for some people who are more equal than others :thumbup:

"These units have been available for 3+ years, and reviews seem to confirm the mfgr performance specs and good reliability."

Personally I hate 1st year "new and improved versions" of anything. always seems to turn out to be an under engineered release. 3 years is a plus mark.
 
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cagey

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May 16, 2023
Messages
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Location
on the 5000' contour line in SE AZ
Contact their tech department that's what there for.
For closure: I did this, switched from voice call to email due to a long wait queue, and over a number of days and one back-and-forth, was assured that my proposed lineset routing would result in a reliable and fully performing system.

As an aside, this r/DIYHeatPumps Mr.Cool.Universal-Gree.Flexx.Tips thread was quite helpful, in particular because it linked to an enlightening Gree Flexx (MRCOOL Universal OEM) Training session video.
 

fitter30

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Peace Valley,mo
For closure: I did this, switched from voice call to email due to a long wait queue, and over a number of days and one back-and-forth, was assured that my proposed lineset routing would result in a reliable and fully performing system.

As an aside, this r/DIYHeatPumps Mr.Cool.Universal-Gree.Flexx.Tips thread was quite helpful, in particular because it linked to an enlightening Gree Flexx (MRCOOL Universal OEM) Training session video.
For a diy company they want u to succeed with a good install. Piped wrong system could eat a compressor from oil return either starving the compressor or bringing back the oil in a slug within a matter of hours.
 
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