Insulation for copper air conditioning pipes - technical specifications

To install an air conditioning system, you need to use copper pipelines. They are best suited for transporting freon. Two pipelines are being laid. Freon enters one in a gaseous state, and the other in a liquid.

Copper is considered the most ductile metal. It is resistant to corrosion processes. This metal is ideal for freon circulation. Soldering and flaring of copper pipes is quite simple.

Therefore, installing such a pipeline is not a technically difficult task. After completion of the installation, high-quality thermal insulation of the air conditioner route is required. This article will show you how to complete this task step by step.

Aluminum is the enemy of the split system

The use of an aluminum pipe in the installation of an air conditioner is the worst solution, since in terms of its physical characteristics, aluminum is much inferior to copper in the following factors:

• unlike copper, aluminum is susceptible to corrosion;
• The tensile strength of aluminum is three times less than that of copper.

Pros and cons of copper pipes

Advantages of copper pipes:

• long service life - copper pipelines can last more than 50 years;
• thanks to plasticity, it is possible to produce tubes with a small diameter - if it is necessary to use small tubes in compact products, there is no alternative to copper;
• frost resistance - when the liquid inside the pipe freezes, it will not burst;
• corrosion resistance;
• small dimensions - the tubes have very thin walls;
• resistance to temperature fluctuations;
• UV resistance;
• low permeability to gases - when installing various systems for transporting low-pressure gases, copper products are often chosen;
• when transporting water through copper communications, the concentration of copper in the water does not exceed standard values, the water does not become harmful to human health; copper can be used in medicine and in the food industry;
• chemical inertness;
• operating temperatures up to 100°C;
• the copper walls have a very smooth surface, the pipes are practically not overgrown with deposits of calcium and magnesium salts; have low hydraulic resistance;
• easy recycling - copper can be melted down and reused many times in production;
• pipes can be bent without loss of tightness;

The main disadvantages of using copper pipelines are:

• quite high price;
• restrictions on the working pressure of pipes with large diameters; tubes of small diameters withstand pressure on a par with steel ones;
• operating temperature limitation;
• installation is somewhat more complex than installation of plastic pipelines;
• lower mechanical strength than steel and plastic; the pipe can be crushed, it can be pierced (on purpose; it’s difficult to pierce it accidentally - but there are children with playful hands in every family).

Types of materials for thermal insulation of air conditioning pipes - pros and cons

Technical insulation for copper air conditioning pipes should extend their service life by controlling condensation and reducing energy loss, and be easy to install to save time.

To protect freon lines, highly elastic materials on different bases are used.

Foam rubber

Flexible insulation based on foamed elastomer with a closed cell structure and long service life. It has low thermal conductivity and high vapor permeation resistance, which provides good insulation performance to prevent condensation, reduce energy consumption.

resistance to building materials;

thermal conductivity coefficient - 0.036 W/m*K;

application temperature - from -400C to +850C (when gluing over the entire surface of the pipe); easy, quick installation due to high elasticity.

When installing insulation on copper pipes outdoors, it is necessary to cover it with protective paint in two or more layers.

Foamed polyethylene

A practical material with a closed-porous structure, low thermal conductivity and high resistance to water vapor diffusion to protect against condensation. Foamed polyethylene tubes are used in a wide temperature range, have stable technical characteristics, and are suitable for complex routes due to their increased flexibility.

Main factors against using aluminum

Replacing copper pipes in air conditioning systems with aluminum is not only undesirable, but not allowed, let’s figure out why:

• joining of aluminum and copper. Aluminum and copper have different coefficients of thermal expansion, as a result we get depressurization of the system, which leads to freon leakage and incorrect operation of the equipment, while corrosion of the metal forms at the junction of aluminum and copper due to the chemical interaction of these metals.
• freezing of the heat exchanger of the indoor unit, as well as the freon line;
• installation using an aluminum pipe is called “low-quality”; as a result, if the system fails, you will receive a non-warranty case and all costs of restoring the system will have to be compensated at your own expense.
• And if you meet installers who tell you about the huge advantages of an aluminum pipe, then feel free to stop further business with them, you will be the winner, and they will not hit another jackpot.

You should not underestimate the importance of installing a split system, from the most inexpensive to luxury brands; in both cases, 50% of the proper operation of the equipment will depend on how the installation and configuration were carried out, including what consumables were used.

The task of our company is to ensure that you purchase a reliable system that meets all the criteria specifically for you, and also that high-quality installation is carried out using those consumables and materials that are recommended by the manufacturers themselves, and only after that we will be confident that that you will be 100% satisfied after all the work done.

Air conditioner insulation procedure

The size of the thermal insulation layer for split systems depends on the diameter of the pipes. In apartments, pipes are usually insulated with a material 6 mm thick. For this purpose, non-porous synthetic rubber is chosen. The composition is not afraid of water, is fireproof and prevents the spread of flame in a fire. The pieces of insulation are connected to each other with vinyl tape.

Laying the air conditioner route

Thermal insulation of the copper pipes of a split system takes a lot of time, since it is necessary not only to wrap the route elements with the appropriate material, but also to place them in a pre-made hole in the wall. These actions are performed in a certain sequence:

• Calculations are being carried out. They are necessary to determine the location where the system will be placed. Also, thanks to preliminary measurements, you can take into account the location of the air conditioning units. Markings are made on the wall, and then grooves are made.
• After gating, the route structure is prepared. It is necessary to unwind the coil with tubes and put insulation material on them. It is better not to bend the pipes too much so that they do not break and the tightness of the route is not broken.
• After preparing the route, it is laid in the channels in the wall. The system is secured to mounting tape and dowel nails.
• After installing the entire system, the grooves are covered up, returning them to their previous appearance. Now you can install the air conditioning units and conduct a test run.

When insulating the route, it is better to carry out pressure testing. It is necessary so as not to damage the installed system during finishing work. Additionally, you can install a pressure gauge on the line to always know the pressure in the system. This measure reduces the risk of refrigerant leaks.

Isolation of the interblock route reduces energy costs. If you do not insulate the freon line, the climate control equipment will operate at reduced performance. In addition, condensation formed on the tubes can damage the connecting elements.

It is better to insulate the route before all connecting elements are installed. The main thing is to choose the right size of material, taking into account the diameter of the tubes. The copper element is inserted into the heat insulator up to the boundaries of the joints with the nuts. The heat insulator protects the route from damage in the groove during thermal expansion.

Features of drainage hose placement:

• The hose is laid in the same groove with freon tubes. In this case, the route is carried out at a natural slope towards draining the accumulated condensate.
• Drainage is carried out separately from the main route - for this case, a clear slope is created only for the drainage hose. Freon pipes can be laid out of level. They are often carried along the ceiling.
• If it is impossible to drain the drainage from the split system due to gravity, a special pump is used that removes the condensing liquid under pressure.

When marking the groove for the route, it is necessary to avoid sharp turns with a negative angle.

Insulation for copper air conditioning pipes - technical specifications

To install an air conditioning system, you need to use copper pipelines. They are best suited for transporting freon. Two pipelines are being laid. Freon enters one in a gaseous state, and the other in a liquid.

Copper is considered the most ductile metal. It is resistant to corrosion processes. This metal is ideal for freon circulation. Soldering and flaring of copper pipes is quite simple.

Therefore, installing such a pipeline is not a technically difficult task. After completion of the installation, high-quality thermal insulation of the air conditioner route is required. This article will show you how to complete this task step by step.

Insulation materials

Copper air conditioner pipes are insulated with the following materials:

• L'Isolante K-FLEX. The material is elastic and flexible. It is made from closed-cell foam rubber. Its performance characteristics allow it to be classified as a high-quality product. Low vapor permeability and thermal conductivity ensure ease of use of the material. It is characterized by high corrosion and fire safety.
• Energoflex. Often used to insulate air conditioning routes. The range of products of this brand is quite wide. The presented material has a closed-cell surface.
• Thermaflex. Has many similarities with L'Isolante K-FLEX products.

When insulating the copper lines of the split system, it is necessary to ensure the tightness of the joints of the material.

For external insulation, it is important to choose a material that is not afraid of ultraviolet radiation and is also capable of maintaining its properties at sub-zero and high temperatures. These properties help protect copper tubes from external factors.

Criteria for choosing thermal insulation for copper lines:

• Reliability of insulation. You should not skimp on consumables when installing the device, as this may affect its service life.
• Insulating surface area. The tubes are completely insulated. The fittings are also securely closed - this way you can avoid the appearance of wet places.
• The presence of seams - their number should be minimal. The joints are carefully sealed.

Chrome plated copper pipe

For convenience, cables, drainage and insulated copper lines are placed in a corrugated pipe.

Replacing an air conditioner drain pipe is no different than installing new copper pipes. The main condition that needs to be taken into account is the timely shutdown of the pipes and draining of the refrigerant. It is important to be careful when working with freon as it can be harmful to your skin. Replacing a copper line is similar to laying a main line when installing a split system.

For modern air conditioning systems, a new type of material is used - chrome-plated furniture pipe. It is highly durable and efficient. The main disadvantage of the material is that if there is minor mechanical damage, it will have to be re-chromed.

Why is expensive copper used and not cheaper plastic?

Pipes are used when installing split system routes. Copper is a metal that is practically not susceptible to corrosion processes and is not afraid of temperature changes and direct sunlight. Particularly important is the fact that it does not react with refrigerants, only with the chlorine they contain. As a result of this reaction, a protective layer is formed on the inside of the pipe. Copper tubes for installing air conditioners look very aesthetically pleasing, do not spoil the overall appearance, and last for more than 100 years.

The pipes are highly durable, and cutting, if necessary, is very easy using a pipe cutter. In a word, copper has a lot of advantages over cheap analogues, which is why craftsmen use this particular material in their work.

How to cut copper pipes correctly

How to replace a tube if it leaks? First of all, you need to correctly measure the dimensions of the pipe. The thread of the tubes must be very fine

It is important to consider that a professional approach to threading can create a tight seal for the laid route of the air conditioning system

A special pipe cutter is used to cut pipes. To cut a pipe, you need to install a tool at the very end of it and slowly rotate it in the direction opposite to the direction of the clock hand, cutting the pipe. At the same time, the use of this tool allows you to avoid obtaining a bevel, the formation of uneven cuts or blockage of the extreme part of the pipe. The tube must be cut evenly. The shear angle should not be less than or more than 90°C.

After cutting, the pipe must be cleaned of any small nicks and sawdust that have formed. When working with a pipe, you should prevent any metal filings, dust particles or other small particles from entering the pipe. It is very difficult to blow through a pipe, so you need to handle its edges very carefully.

Replacing air conditioner pipes with hoses will not be as reliable and durable. All the advantages of the hose lie in its flexibility. The choice of material for the pipes of the structure is determined by the design itself and the installation conditions of the air conditioner.

Price difference

The cost of copper is constantly growing and depends on the exchange rate. The decrease in the quantity and quality of the mined metal, its increasing shortage, contribute to the constant rise in prices for copper products. Therefore, the issue of finding an alternative that can replace copper in the production of air conditioning systems is one of the most pressing.

Aluminum has only recently begun to be used in cryogenic equipment (refrigerators, car air conditioners). The cost is stable and almost three times cheaper than copper; there are large reserves in nature. This opens up great prospects for the industrial production of products from this metal.

Installation of a condensate drainage system

This process is very simple.

It is necessary to remove the lower fasteners from the air conditioner body so that it can rise. In the lower part, under the fan that blows the evaporator, there is a tray for collecting condensate. There is a pipe on its side, and it is to it that you need to attach the drainage pipe for removing condensate from the air conditioner using a clamp. The indoor unit housing is lowered and installed in place

In this case, it is very important that the corrugation passes through it through a special hole made in the side wall. The fasteners are screwed into place. Now all that remains is to take the attached corrugated hose either into the sewer or onto the street

If the withdrawal process is associated with the installation of a drainage route, then you must first decide how easier and more convenient it is to carry out the entire process. As mentioned above, the best option is to make grooves into which to lay the hose. The most important thing is to maintain an inclination angle of at least 3%.

Now all that remains is to remove the attached corrugated hose either to the sewer or to the street. If the withdrawal process is associated with the installation of a drainage route, then you must first decide how easier and more convenient it is to carry out the entire process. As mentioned above, the best option is to make grooves into which to lay the hose. The most important thing is to maintain an inclination angle of at least 3%.

Basic drainage problems

The most common malfunction of the condensate drainage system from the air conditioner is a clogged hole in the bath. Dust and dirt with condensation settle to the bottom of the pan, where sludge forms. It grows and covers the pipe. The consequence is the flow of water over the edges of the bath. The liquid begins to drip onto the floor and leak down the walls.

And other malfunctions:

1. If the air conditioner works for heating in winter, then often the drainage pipe on the street simply freezes.
2. The slope of the drainage route was set incorrectly.
3. If the pump fails.
4. If the amount of refrigerant in the system has decreased, which leads to icing of the evaporator and supply pipes, so the ice begins to melt along the entire length of the route, pouring water onto the floor.
5. The evaporator may become covered with ice if the pressure regulator stops working. If the temperature outside the window begins to decrease, this can lead to a decrease in the freon temperature due to a drop in its pressure.

Cleaning the drainage system

You can clean the condensate drainage system from the air conditioner with your own hands only if the bathtub pipe is clogged. To do this you need:

Remove the filters located on the device body in front of the evaporator. They must be washed thoroughly. The air conditioner housing is raised. The drainage tube is disconnected from the pan. The latter is removed and washed

Pay special attention to the hole. If the tube is clogged in the same way as the drain hole, then it must be blown out. If that doesn't work, you'll have to replace it with a new one. All other steps for assembling the condensate drain system are performed in the reverse order.

Experts recommend using a chlorhexidine solution to disinfect drains and the condensate drain pan. Although any household detergent that contains chlorine will easily cope with the task.

For other malfunctions associated with the failure of one or another device or part, it is better to call a specialist. Independent actions can lead to irreparable consequences.

https://youtube.com/watch?v=L-4-BgJKNoo

Benefits of use

• The aluminum pipe for installing air conditioners bends well, without creases, and requires less effort. The same tools are used as when working with copper.
• low melting point. This makes soldering of elements faster (4 times), significantly saving time, gas, and soldering rods. There is no need for additional equipment, turning seams, etc. The welding seams are much stronger than the metal itself. The blowtorch and gas are the same as for copper.
• due to greater softness, less effort is spent on pipe flaring, the set of tools is the same. The strength of the pipes is ensured by their greater thickness.
• expansion up to 30%.
• thermal conductivity characteristics are almost two times lower than those of copper. This contributes to lower condensation of pipes in the system.
• corrosion resistance is higher, the oxidation reaction rate is lower. This will keep the inside of the cryogenic system pipes clean for a longer time.
• wide temperature range from -80⁰ C to 120⁰ C.
• aluminum pipe for installing air conditioners is lighter, so it can be delivered in 50- and 100-meter coils. This reduces the amount of waste, welding seams and reduces the likelihood of leaks.

Application in water supply systems

Thermal insulation is mainly made in the form of a flexible tube with a cut on the side. The length of the material is usually 2 m. The cut serves for ease of installation of the insulator on rolled pipes. If the length of the heat insulator is greater than the size of the system section, then the material is simply cut using a sharp tool.

Thermal insulation of copper water pipes.

After installation, the insulation is sealed with a special adhesive or tape reinforced with a reinforcing layer. Most often, glue or adhesive tape is sold along with the heat insulator. Using these materials you can perfectly insulate plumbing and other systems. As a result, it is possible to minimize heat loss and condensation formation.

The use of insulation in the form of a flexible tube may become impossible in areas of the system with a complex configuration. In this case, thermal paint is used. This material is called liquid insulation. It allows you to insulate pipelines of any size and shape.

Thermal paint should also be used on open areas of utility lines that are exposed to sunlight. The liquid insulating material is resistant to UV radiation. This property is absent in rubber and foamed polyethylene.

Kinds

Pipes for air conditioners are classified according to several parameters.

Main types depending on:

Technologies for their production:

• cold-deformed pipe products;
• pipes for air conditioners made by welding with further hot tempering;
• pressed.

Technological processing:

• hardened;
• hardened;
• semi-hardened;
• anodized;
• artificially aged;
• naturally aged.

Section shapes:

• square;
• rectangular;
• round;
• shaped.

Wall thickness:

• thin-walled (up to 5 mm);
• thick-walled.

Round aluminum pipes

Reasons why a thin air conditioner pipe freezes

Ice or a “fur coat” on the thin tube (and its nut) of the external unit of the split system indicates that the cooling process begins even before the internal unit. This is due to the fact that freon begins to boil before entering the evaporator.

Freezing may occur if your air conditioner is installed, serviced, or repaired by unqualified personnel. Here are the “handicraft” mistakes that RemBytTech craftsmen most often encounter:

• Moisture in the cooling circuit. This could happen if unprofessional repairs were carried out to eliminate a leak or refill the air conditioner with refrigerant.
• The route is too long. Longer than provided by the split system manufacturer.
• Partial shut-off of the tap-valve on a thin tube. This leads to it boiling before the evaporator and freezing of the liquid tube.

If the air conditioner has not been touched, it was working properly before, but the high-pressure pipe freezes over, most likely some kind of breakdown has occurred. The most common ones are the following.

Note! An electric valve or expansion valve regulates the refrigerant pressure depending on changes in ambient temperature. The only difference between the valves is that in the electric valve the adjustment is electronic, while in the expansion valve it is mechanical. Basically, they are installed in complex split systems. In simple air conditioners, they are usually replaced by a capillary tube, “tuned” to a constant pressure drop.

Galvanic corrosion

Previously, the combined use of copper and aluminum was not possible. They form a “galvanic couple” of metals. If they are not connected tightly enough, an electrochemical reaction occurs. Copper oxidizes and corrosion of aluminum occurs. Therefore, when securing with a nut, you cannot use a regular aluminum pipe instead of a copper one. In this case, the connection will not be monolithic, since there is a possibility of destruction of the rolled aluminum pipe, which will inevitably lead to corrosion.

Modern technologies make it possible to solve this problem by producing aluminum pipes with copper tips. Using high-tech equipment, copper is welded to an aluminum tube using intermolecular welding. The result is high-quality material for transferring refrigerant between the external and internal units of the air conditioner at an affordable price.

Sheathed Copper Pipe Rods

Freon R-407С

Freon R-407C also acts as a replacement for the prohibited freon R-22. Consists of R-32 (23%), R-125 (25%), R-134A (52%).

• The boiling point is -50.5°C.
• has no smell
• has no color
• non-flammable
• non-toxic (high fluorine content)
• non-isotropic
• Requires the use of polyester oil
• has a high cost

Due to the non-isotropy, refueling in the event of a leak is not possible. In this case, it is necessary to completely remove any remaining freon and refill the system.

The content of hydrogen molecules in R-407C freon is less than R-22 and R-410A, which makes it less flammable and explosive.

How to insulate an air conditioner route?

Thermal insulation helps reduce equipment power losses. Some of it may escape through the heat transfer of the pipeline. Thermal insulation helps prevent condensation. The thickness of the insulation depends on the diameter of the air conditioning pipes.

The isolation procedure takes quite a long time. Because it is necessary not only to wrap the pipeline with insulating material, but also to place it in the hole made in the wall.

Completion of the work includes the following stages:

1. Calculation of the location of the system. It is necessary to correctly position the copper pipes and air conditioning units. Next, markings are made on the wall to make the task easier. Then the walls are chipped.
2. After creating the grooves, they proceed to preparing the route. The pipe coil is unwound to a certain length. Insulation is put on the tubes. It must be purchased in advance in the required volume. To solve the problem more effectively, you need to wrap the air conditioner route with a special Teflon winding tape.
3. To equip a long pipeline, soldering of a copper structure is used. It is recommended to avoid breaking the pipeline. This may damage it. As a result, coolant will leak from the system. You need to install the system very carefully.
4. The finished route is laid in the channels prepared for it. The pipes are secured using dowel nails and mounting tape. The system must be installed flush.
5. After laying the pipeline, the grooves are covered, giving the walls a beautiful appearance. After completing this stage, the air conditioner units are installed, adjusted, and a test run of the equipment is carried out.

After completion of the work, it is necessary to perform pressure testing of the pipeline. To do this, use nitrogen, which is prepared in advance. This stage allows you to avoid accidental breakdown of the structure in the wall. Its implementation makes it possible to avoid possible dismantling work to troubleshoot problems. It is recommended to equip the system with a pressure gauge. Based on its indicators, it is possible to determine the presence and number of existing leaks or their absence.

As an alternative to winding tape, you can use a corrugated pipe of a suitable diameter. It is perfect for laying pipes in grooves. If we are talking about installing a pipeline in a decorative box, there is no point in using a corrugated pipe. It will be more convenient to use winding tape.

How to install thermal insulation?

Typically, insulating copper air conditioning pipes takes some time, since you not only need to put the appropriate material on the pipes, but also place it all in a pre-made hole in the wall. All these actions can be divided into several stages.

First, the necessary calculations are carried out in order to accurately determine the location where the system will be located, and also take into account the location of not only the pipes, but also the air conditioner units. It will be necessary to mark the wall to facilitate further work. After this, you can start gating. When all the necessary grooves have been made, you can proceed directly to preparing the route design. You need to unwind the coil with copper tubes to a certain length and put pre-purchased insulation on them. For convenience, you can wrap the route in some places with special reinforced tape. It is worth noting that if the route turns out to be too long, additional soldering of copper pipes may be required. In addition, it is better to try not to bend the structure too much, since the pipes may break, resulting in a leak of refrigerant when the air conditioner is started, which will have to be repaired. Therefore, it is better to handle the system carefully during the installation stage. When the route is ready, it is necessary to lay it directly into the channels prepared for it in the wall. Fastening can be done using mounting tape and dowel nails

It is important to ensure that the structure does not protrude any further than the plane of the wall. After the entire system is installed in its place, you can cover up the grooves to return the wall to its original appearance. When the surface work is completed, you can begin installing the air conditioning units, as well as setting up their operation and test running.

How to isolate the route?

To solve the problem, you can use materials from different manufacturers. The most relevant is the following thermal insulation:

K-FLEX insulation is a flexible elastic material. It is made from special raw materials - closed-cell foam rubber. The thermophysical and operational characteristics of this thermal insulation are of high quality. Low thermal conductivity and vapor permeability make the use of this material very convenient. The insulation is durable. It has a high level of sanitary, fire and corrosion safety.

The products are considered one of the best on the market. Its manufacturer has an impeccable reputation among consumers. K-FLEX thermal insulation is one of the most reliable and effective. It is ideal for insulating air conditioner pipes.

Energoflex insulation can also be used to solve the problem under consideration. The range of products of this brand is very wide. The company produces thermal insulation from foamed polymers, especially for air conditioning systems. The material is characterized by a closed-cell surface. It provides a decent level of moisture protection and vapor permeability.

Manufacturers of thermal insulation

The Energoflex company produces various tubes for thermal insulation; the range allows you to select the material of the required diameter in order to equip the system in accordance with all the necessary requirements. Tubes are produced from foamed polymers, the composition of which was specially developed for use in various air conditioning systems. It has a closed-cell surface, thereby providing a high level of resistance to moisture permeability and vapor permeability, which is important when insulating cold surfaces.

The insulation materials are produced by Thermaflex, a company that produces closed-cell synthetic rubber tubing. This provides flexibility to the material as well as excellent insulating properties. In addition, it is resistant to microorganisms.

There are other manufacturers that produce similar products that have similar properties and are used in thermal insulation.

Consumables for installing air conditioners

L-shaped brackets are attached to the outside wall and the outdoor unit of the split system is installed on them. All bracket mounting holes must be engaged. The more powerful and heavier the mounted block, the larger the brackets themselves, and they have a larger number of holes for fasteners. A variety of fasteners can be used for brackets. In standard installation of small household air conditioners, 4 10x100 mm anchors are used. If the facade wall is a complex sandwich structure, for example, brick-insulation-foam blocks, then other types of fasteners can be used.

Copper pipes through which freon will flow connect the outdoor and indoor units of the air conditioner, forming a closed circuit. This circuit must be as tight as possible, since unwanted freon leaks reduce the efficiency of the air conditioner and require frequent refilling of freon. Copper pipes are connected to the air conditioner units using threaded flare fittings. Such connections can become weakened when the street temperature fluctuates throughout the year, as a result of which small freon leaks are possible at the flared pipe joints. In order to avoid the unpleasant consequences of leaks, and not to find yourself in the midst of a heat wave with a non-working air conditioner, it is recommended to carry out annual maintenance.

Air conditioner maintenance is the diagnosis, identification, elimination and prevention of problems in the operation of the system.

Maintenance includes the following types of work:

• Cleaning the indoor unit, including air intake grilles, filters and heat exchanger, antibacterial treatment with a disinfectant compound.
• Check the functioning and, if necessary, clean the drainage system.
• Cleaning the housing and heat exchanger of the external unit of the air conditioner.
• Checking the integrity of the refrigerant flow system, measuring the discharge and suction pressure in the circuit. Elimination of minor leaks in the system and refilling with freon.
• Testing the operation of the air conditioner in all modes, checking the indication of modes.
• Checking the operation of the compressor and fan: identifying extraneous noise, measuring starting and operating currents.
• Control measurements of air temperature at the inlet and outlet of the air conditioner.

The maximum and minimum permissible length of the copper pipeline for interunit communication is indicated by air conditioner manufacturers in the operating manual.

In any case, the length of the freon pipe should not be less than three meters for household models of air conditioners; you definitely need to pay attention to this. There is also such a term as an oil lifting loop. A loop is required when the height difference between the indoor and outdoor units is more than 5-7 meters. For household series, such a case is rare, but sometimes it does occur. For semi-industrial and industrial air conditioners, large height differences are more common.

The correct oil lifting loop should be made with a small radius and have a small depth, that is, it should create a plug of oil, but not accumulate a large amount of it. Copper pipes should only be cut with a special tool - a pipe cutter. After cutting, the end of the copper pipe must be processed with a rimmer. This is a device for removing burrs and smoothing pipe surfaces after cutting. A smooth end surface of the pipe is necessary for high-quality rolling and ensuring high tightness of the joints.

In order for the air conditioner to work properly, copper pipes along the entire length must be thermally insulated, including where they pass through the wall.

The thermal insulation of the air conditioner is made of synthetic rubber and is supplied in two-meter tubes. It comes in black and gray, but the color does not affect the thermal insulation properties. It is used to prevent heat loss and the formation of condensation on the surface of air conditioner tubes.

Attention! Make sure that the freon pipes passing into the hole in the outer wall are also thermally insulated! A common mistake is when thermal insulation is stretched over external and internal copper pipes only up to the hole in the wall. This method of thermal insulation of freon communications is allowed only as a last resort: when it is impossible to drill a hole of the required diameter with a large concentration of reinforcement in the facade wall (usually happens in the lower floors of multi-apartment high-rises). In this case, the freon tubes in the wall itself remain without thermal insulation, and the hole in the wall is foamed with polyurethane foam. When air enters a hole in the wall, condensation will begin to form on the tubes over time, which will flow into the wall. And since walls always have microcracks and pores, whether they are brick or concrete structures, sooner or later, streaks or dark spots of mold may appear on your walls.

The nuts connecting copper pipes to the indoor unit of the air conditioner are also subject to thermal insulation to prevent the formation of condensation. It happens that in order to facilitate fixation of the indoor unit on the mounting plate, unqualified installers violate the integrity of the thermal insulation in the indoor unit. The thermal insulation in the indoor unit is made of foam plastic and its damage can also lead to the formation of condensation and stains on the walls.

Copper pipes, insulation, drainage hose and electrical cable together form a freon pipe, or “trace”.

Before the assembled freon pipe is passed into the hole in the outer wall, the copper pipes must be closed with plugs at the ends. This prevents construction dust, sand, dirt, etc. from entering the pipes. Otherwise, when you first start the air conditioner, dirt will inevitably get into the compressor, and the consequences will be about the same as if you pour coarse sand into a car engine: the air conditioning compressor will very quickly fail.

• Copper tubes must be completely insulated along their entire length, without breaks. Proposals from installers to pass bare copper pipes and foam the hole with mounting foam and thereby “thermally insulate” the copper pipes are categorically not accepted!
• To create a single thermal insulation cover, the joints of the thermal insulation sections must be wrapped with hydrous tape.
• Fastening external communications. Communications (tubes, cables) passing along the street wall must be securely fastened. The installer must secure the communications to the outer wall at least at one point, since in strong winds the unsecured communications sway and the copper tubes in the rolling areas on the external unit may burst. This will cause freon to leak from the air conditioner.
• Communications laid on an external wall in an open way must be wrapped with reinforced tape or Teflon tape so that the thermal insulation of copper pipes does not deteriorate under the influence of the environment. If the street part of the communications is placed in a decorative box, then continuous wrapping with adhesive tape or Teflon tape is not necessary.

A decorative box is used when installing the indoor unit of an air conditioner in order to hide the route indoors. A box of standard size 60x60 mm is usually used. If communications will take place in a decorative box, then the gaps between the box and the indoor unit are sealed with white silicone sealant or closed with special plastic covers.

It is advisable to use a drainage hose that is corrugated, solid (without breaks), with a rigid plastic spiral. The attachment point of the outdoor drainage hose with the drainage hose from the indoor unit must be secured with electrical tape and a metal clamp. The slope of the drainage pipe must be at least 1 centimeter per 1 meter of length (more is better, less is unacceptable!). The drainage hose must be securely attached. It is advisable to firmly fix the drainage hose every meter of length to prevent sagging and the formation of all kinds of loops in which condensate can stagnate. When sagging appears in the drainage system, water plugs form and condensation from the internal unit of the air conditioner has nowhere to drain except into the room - along the wall, wallpaper, onto the floor or upholstered furniture.

Important! After installing the air conditioner, installers must test the drainage system. To do this, water is poured into the drainage pipe from the side of the indoor unit, and the free flow of water to the street is checked. If this is not done, you should ask the installer to demonstrate the permeability of the drainage system. This will require no more than 2 minutes and 0.5 liters of plain clean water. And in the future it will help save you time and nerves.

When choosing a location for installing the air conditioner, it is necessary to take into account that the section of the wall on which you plan to mount the indoor unit must be strong and capable of supporting the weight of the split system units. There must be unhindered air circulation around the indoor unit. The gap between the top panel of the indoor unit and the ceiling must be at least 170 - 200 mm. The indoor unit is mounted using the mounting plate included in the delivery kit. The mounting plate is attached to the wall using screws and is fixed to the wall strictly level. In this case, normal removal of condensate formed during operation of the air conditioner is ensured. The indoor unit must not be placed near sources of heat and humidity, and the unit must not be installed near a doorway. There should be no obstruction to the air blown out of the indoor unit. It is advisable to leave free space near and below the indoor unit for servicing.

There must be enough free space around the outdoor unit of the air conditioner for effective heat exchange. Warm air must be discharged in such a direction as not to cause inconvenience to neighbors. The outdoor unit must be mounted on a flat, solid base. The distance to the nearest obstacle should be at least 500 mm from the front side and at least 400 mm from the sides of the outdoor unit.

Vacuuming is the final and one of the most important stages in the installation of air conditioners! The name of the operation speaks for itself - a vacuum is created in the air conditioning system by pumping air from the freon pipes and the indoor unit.

What does ignoring this operation entail?

The freon (refrigerant) contained in each outdoor unit also contains oil to lubricate the compressor. This oil is extremely hygroscopic, that is, it can absorb moisture, including from the air. If evacuation is not performed, then in the sealed system (outdoor unit - freon tubes - indoor unit) air saturated with moisture will remain, and over time the compressor oil will lose its technological properties. The oil will no longer lubricate the moving parts of the compressor, which may cause premature failure of the compressor.

Since a vacuum pump is not a cheap piece of equipment, careless installation crews find a way out of the situation - they blow the system with freon contained in the outdoor unit.

Diameter table

The small cross-section allows you to avoid making large holes in the wall of the building when pulling. Depending on the power of the unit, the diameter varies. The list of diameters produced is given below:

The higher the power of the air conditioner declared by the manufacturer, the greater the amount of refrigerant the tubes must pass through. And the distance between external and internal blocks varies. Therefore, the sizes of copper pipes for air conditioners also differ. This refers to their length. Typically, copper tubes are supplied in coils of 15 meters; 25 and 50 meters.

But some manufacturers cut them at the factory into rods 2 meters long, installing plastic plugs at their ends to prevent debris and moisture from getting inside. If the person who bought the air conditioner wants to install it himself, he will not need a whole coil of pipe. Coves are used by specialists who install air conditioners on a large scale.

As with any external engineering systems, thermal insulation is required. This is necessary to avoid condensation accumulation, overheating or freezing of the transported liquid or gas. Typically, special protection made of foamed, non-porous rubber or polyethylene is used for these purposes. It is produced in the form of two-meter black tubes.

Their thermal conductivity is l (0°C) = 0.036 W/mK. Insulation for copper air conditioning pipes can protect them at temperatures ranging from -150°C to +150°C. In addition, the very thin walls of the copper pipeline can lose temperature, which sharply increases the consumption of electricity and refrigerant during operation of the split system. Typically, thermal insulation is sold as a kit. If not, you need to purchase it separately and be sure to install it.

During installation, metal cutting tools are usually not used. This prevents chips generated during cutting from entering the cooling system. The shavings may well clog the hole in the tube and damage the air conditioner. That is why two main methods of fastening are used: connection using fittings and soldering the copper pipes of the air conditioner to each other. Solder has a low melting point, which makes it possible to use a conventional gas torch when joining tubes.

Copper is by no means a cheap metal; it is used only where such costs are justified. This is not only the installation of refrigeration and air conditioning systems. This metal, classified as non-ferrous, practically does not oxidize. It is not afraid of contact with other metals, and therefore is widely used in the chemical and food industries, as well as in mechanical engineering.

When designating products, for example, a copper pipe with a diameter of 8 mm, we mean one of the main parameters of pipes - the outer diameter. Many properties of the future pipeline (working pressure, length, etc.) depend on this indicator. It is necessary to be able to operate with quantities such as inches and millimeters, since according to GOST, they are the main measures of this parameter. The digital equivalent of the values ​​of parameters such as length and diameter is often used in formulas for various calculations.

Today, we can distinguish the following diameters of copper pipes, which, one way or another, appear in the tables:

• External;
• Interior;
• Nominal.

The very need for comparative tables with diameters arose due to different standards in Russia and Europe (All products related to copper pipes: https://rdmetall.ru/cvetmet/mednyj-prokat/mednye-truby/). Since most pipe manufacturers are foreign, the characteristics use inches, while in our territory they operate with mm values, see.

Copper pipe size chart for air conditioners

Main stages

After all preparatory work has been completed, the route is laid. It consists of two pipes covered with braiding and performing the functions of insulation and a cable that connects the indoor and outdoor units.

The manufacturer will help you choose the diameter of the pipes. Recommended sizes are indicated in the instructions for the split system. At low capacities, 1/4 and 3/8 pipes are used. The pipe is twisted and needs to be unrolled. You can't step on it with your feet because it will create a dent. If it is not corrected, then leaks and stagnation of water are possible in this place. All joints must be sealed with insulation. The next step is to place the cable in a corrugated pipe. The most commonly used cable is PVS 4x1.5. We place the corrugation together with the tubes, securing everything with ties

It is important here not to overdo it and not to overtighten the structure. We lay the finished route in the previously made grooves and fasten it using special ties into the drilled holes. All actions are carried out carefully, in compliance with all the above standards.

Exiting the highway to the street must be done with reserve. This is necessary so that in case of incorrect connection or changing the location of the outdoor unit, you do not have to add tubes or cables, because different connectors reduce the reliability of the system.

Russian aluminum pipes

Today, Russian manufacturers offer high-quality aluminum pipes for the installation of cryogenic equipment. They are cast from AD0 metal. This alloy consists of 99% aluminum, weldable, and is characterized by high corrosion resistance and sufficient strength. Manufacturers give it a several-year warranty and specify a service life of 15 years.

Reviews indicate that Russian-made aluminum pipes differ from their Chinese counterparts in the higher quality of raw materials, which affects their resistance to corrosion during operation.

Video description

The following video shows how mineral wool cylinders are mounted on a pipeline:

Insulation made of polystyrene foam and polystyrene foam

Insulating pipes with foam plastic is the simplest and most inexpensive way to insulate them. This material has all the necessary properties: it does not burn, withstands stress well, does not emit toxic substances, almost does not absorb water, is very easy to install and can be used repeatedly. Its only drawback is its attractiveness to mice and other rodents. Which, however, is unimportant when insulating underground pipelines, for which it is most often used.

Extruded polystyrene foam has even better technical characteristics - it is denser and more moisture-resistant, and better resists the destructive effects of ultraviolet rays.

Both materials are produced in the form of so-called shells - sections that are halves of a cylinder with a tongue-and-groove connection. They can be covered with a protective foil shell. This design allows the insulation to be used repeatedly, removing it for inspection or repair of communications.

The high density and compressive strength that such thermal insulation of pipelines has allows it to be used both for external pipes and for underground pipelines without installing rigid trays. For various nodes and turns, corresponding shaped shells are produced.

To lay several pipes or large-diameter pipes, special multi-profile segments or slabs of polystyrene foam or expanded polystyrene can be used, from which strips are cut and the box is assembled. Its walls are fastened with polyurethane foam.

Polyurethane foam insulation

Polyurethane foam is one of the most modern insulation materials, which is a cellular polymer material whose closed cavities are filled with carbon dioxide. It makes very effective thermal insulation for heating and water supply pipes.

On sale you can find pipes already insulated with polyurethane foam and covered with a protective sheath: polyethylene for underground installation and galvanized steel for surface installation.

The pipelines themselves can be insulated with this material in two ways: by spraying polyurethane foam or by enclosing them in a heat-insulating shell.

• Shells made of polyurethane foam do not differ in appearance from their analogues made of foam plastic and other similar materials. They come in different diameters and thicknesses, with or without a protective sheath, with or without a groove for laying a heating electric cable. The shell can be removed and put on again. The shell halves are placed on a section of the pipe and tightened with clamps, wire or a special polypropylene tape with a tension buckle.

Copper pipes according to GOST 32598-2013 for water supply and heating systems

The GOST 32598-2013 standard establishes the range (dimensions), technical requirements, control methods, and acceptance testing of copper pipes intended for water supply systems for water and steam heating.

Dimensions of copper pipes according to GOST 32598-2013

The table shows the recommended values ​​for the diameter and thickness of copper pipes for heating.

Designation of pipes according to GOST 32598-2013

The pipe designation according to GOST 32598-2013 indicates the same data as according to the EN 12735-1 standard, in addition there is additional information. The pipe marking should indicate:

• Manufacturing method (D - drawn);
• Shape (KR - round);
• Condition (M - soft, for an annealed pipe; P - semi-hard; T - hard, for an unannealed pipe);
• Dimensions (Outer diameter x wall thickness x length);
• Delivery form (piece, coil, BT - free winding coil, BU - ordered winding coil, BS - spiral winding coil - BS);
• Brand of copper;
• Standard.

The designation diagram is shown in the figure.

Example notation

To designate an annealed copper drawn pipe, round cross-section with a diameter of 10 mm, a wall thickness of 0.8 mm, made of M1r grade copper, the marking is used:

Flaring pipe ends

When installing an air conditioner and laying a line, return nuts and fittings are used to connect copper pipes. As a rule, each split system is equipped with shutters. They are located at the connection points of the tubes.

To screw a nut onto a pipe made of copper, the ends of the pipes must be flared. To do this, you will need a tool - a rolling tool and a small vice, which should be included with the rolling tool. Principle of operation:

1. The return nut fits onto the end of the pipe;
2. Leave a small indent from the edge and pipe and clamp it with a vice;
3. Then we bead the pipe;
4. After this, you need to compare the obtained data with the indicators in the table, which indicates the necessary parameters of the tube to be beveled.

The beading process must be carried out very carefully to avoid damage to the pipe. But, if it was not possible to avoid damage, you need to cut off the damaged end of the pipe and repeat all the work.

Installation of copper pipes for air conditioners

Installation of pipelines between the external and external units of the air conditioner is completely doable with your own hands. If you purchased annealed pipes of the required length, then installation is carried out without welding.

Required tools and materials

To install copper pipes you will need:

• pipe cutter for copper pipes or hacksaw;

• flaring;

• file, sandpaper;
• FUM tape;
• spanners and gas wrench;
• rags.
• A pipe bender will come in handy - it will allow you to carefully bend pipes without wrinkles or deformations.

Precautionary measures

Be sure to wear safety glasses when cutting and stripping copper products.

Before filling the air conditioner with freon, be sure to check the operation of the system filled with air. Coat the joints with soap foam, turn on the air conditioner and let it run for a few minutes - the leak will be visible.

Work progress

The work is carried out after installing the air conditioner. First, carefully measure the distance from the external to the internal unit. The pipe is cut to a large margin in length. Thermally insulated products are cleaned of insulation at the ends. Insulation is put on uninsulated pipes.

Then carefully clean the ends of the pipes from burrs. Place union nuts with threads so that the threads are flush with the end of the workpiece. They are flared using a special device - flaring. This work must be done carefully - it is impossible for cracks, waves and folds to form on the tubes. The result is a reliable sealed connection between the nut and the tube.

Secure the pipeline to the fitting of the outdoor unit using a nut. Do not clamp the connection too hard - you can damage the tube.

Then the pipelines are placed inside the room and hung on brackets. Tubes for air conditioners are flexible, they can be bent if necessary simply by hand. With the help of a pipe bender, turns will be more accurate.

Then it is necessary to repeat all operations (cutting, deburring, flaring) and secure the pipeline to the indoor unit.

Installation features

The tubes must be insulated - for this there are all kinds of ready-made covers made of foamed polyurethane or polyethylene, sometimes coated with a layer of foil. Condensation will settle on an uninsulated pipe and drip onto the furniture. If the length of the communication is more than half a meter, then it is necessary to install special fastenings.

Manufacturing Features

The production of copper pipes for air conditioners is carried out using two technologies, on the basis of which they are divided into annealed and unannealed.

Annealed pipes undergo heat treatment in a special furnace, heating up to a temperature of 700°C. As a result of this process, the pipes become soft and plastic, although their strength is reduced to 210-220 thousand kPa

But in return, the products acquire an important property for installation in air conditioners - high elongation at break (up to 60%). This means that when bent, twisted and other deformations, the metal retains its molecular structure without breaks or cracks. Unannealed pipes are harder and stronger (up to 300 kPa), but they cannot be bent due to their low elongation at break, which is only 15%.

We recommend that you familiarize yourself with: Rules and methods for installing cross-linked polyethylene pipes with your own hands

General recommendations for installation of air conditioning system routes

The routes of air conditioning systems should be laid hidden in furrows, channels and shafts, trays and on hangers, while when laying hidden, access to detachable connections and fittings should be provided by installing doors and removable panels, on the surface of which there should be no sharp protrusions. Also, when laying pipelines hidden, service hatches or removable shields should be provided at the locations of dismountable connections and fittings.

Vertical sections should be cemented only in exceptional cases. Basically, it is advisable to place them in channels, niches, furrows, as well as behind decorative panels.

In any case, the hidden installation of copper pipelines must be carried out in a casing (for example, in corrugated polyethylene pipes). The use of corrugated PVC pipes is not permitted. Before sealing the pipeline laying areas, it is necessary to complete the as-built installation diagram for this section and conduct hydraulic tests.

Open laying of copper pipes is allowed in places that prevent their mechanical damage. Open areas can be covered with decorative elements.

It must be said that the laying of pipelines through walls without sleeves is almost never observed. However, we recall that for passage through building structures it is necessary to provide sleeves (cases), for example, made of polyethylene pipes. The inner diameter of the sleeve should be 5–10 mm larger than the outer diameter of the pipe being laid. The gap between the pipe and the case must be sealed with a soft, waterproof material that allows the pipe to move along the longitudinal axis.

When installing copper pipes, you should use a tool specially designed for this purpose - rolling, pipe bending, press.

Advice from experienced installers

A lot of useful information about the installation of freon pipes can be obtained from experienced installers of air conditioning systems

It is especially important to convey this information to designers, since one of the problems of the design industry is its isolation from installation. As a result, projects include solutions that are difficult to implement in practice.

As they say, paper will endure anything. Easy to draw, difficult to execute.

By the way, this is why all advanced training courses at the APIK Training and Consulting Center are conducted by teachers with experience in the field of construction and installation work. Even for management and design specialties, teachers from the field of implementation are invited to provide students with a comprehensive perception of the industry.

So, one of the basic rules is to ensure at the design level a height for laying freon routes that is convenient for installation. It is recommended to keep the distance to the ceiling and to the false ceiling at least 200 mm. When hanging pipes on studs, the most comfortable lengths of the latter are from 200 to 600 mm. Shorter length pins are difficult to work with. Longer studs are also inconvenient to install and may wobble.

When installing pipelines in a tray, do not hang the tray closer to the ceiling than 200 mm. Moreover, it is recommended to leave about 400 mm from the tray to the ceiling for comfortable soldering of pipes.

It is most convenient to lay external routes in trays. If the slope allows, then in trays with a lid. If not, the pipes are protected in a different way.

A recurring problem for many objects is the lack of markings. One of the most common comments when working in the field of architectural or technical supervision is to mark the cables and pipelines of the air conditioning system. For ease of operation and subsequent maintenance of the system, it is recommended to mark cables and pipes every 5 meters in length, as well as before and after building structures. The marking should use the system number and pipeline type.

When installing different pipelines above each other on the same plane (wall), it is necessary to install lower the one that is most likely to form condensate during operation. In the case of parallel laying of two gas lines of different systems above each other, the one in which the heavier gas flows should be installed below.