Brazing; System Evacuation; Refrigerant Charging - Maytag FS4BG024K Installation Instructions Manual

The maximum vertical elevation between the air conditioner
and indoor coil is 50 ft. Systems that require more elevation
will need to have an oil trap installed in the vapor line. Refer to
the Application Guideline for Refrigerant Lines Over 75 Feet
(document 044B-0600) for piping details.
A filter drier is supplied with the air conditioner. It is required
and recommended that it be installed near the indoor coil.
It is recommended to replace existing refrigerant lines that
were previously used for an R-22 system. If the lines are not
replaced, they must be properly flushed by a licensed EPA
certified technician in accordance with the manufacturer's
instructions and established procedures.
MODEL
UP TO 25 TO
24 FT. 39 FT.
3/4 in.
-024K Units
(19 mm)
7/8 in.
-036K Units
(22 mm)
7/8 in.
-048K Units
(22 mm)
7/8 in.
-060K Units
(22 mm)
Table 3. Permissible Refrigerant Line Sizes

Brazing

Use the appropriate safety equipment while brazing. Items
such as gloves, safety glasses, proper ventilation, and a fire
extinguisher should be used.
1. Route the refrigerant lines from the indoor coil to the service
valves on the air conditioner. Avoid sharp radius bends and
turns. See Figure 5 (page 12)
2. Make sure that the vapor line is properly insulated for the
entire length of the run for maximum system efficiency.
Improper insulation may also create condensation and result
in water damage to the equipment and building structure.
3. Remove the valve cores from the air conditioner service
valves. Wrap the valves completely with wet rags to protect
them from overheating during the brazing operation.
4. Connect both the vapor and liquid lines. Tubes should be
round, de-burred and free of debris. Use a phosphorous
and copper or silver brazing alloy for the joints. Do not use
soft solder with a low melting point.
5. Connect the indoor lines according to the indoor unit
instructions. The indoor coil will require the same alloys and
wet rags to protect the sensors from excessive heat on the
refrigerant lines.
6. Allow the service valves to cool and replace the valve cores.
7. Leak test the connections using low pressure dry nitrogen.

System Evacuation

1. Connect the refrigerant gauge manifold to both the vapor
and liquid service valves.
to the vacuum pump.
2. Open both manifold valves and start the vacuum pump.
After a short time, it is recommended to close the manifold
valves and stop the vacuum pump to look for a rapid loss
LINE SET LENGTHS
VAPOR lInE
40 TO 75 TO
75 FT. 100 FT.
7/8 in. 1 1/8 in.
(22 mm) (29 mm) (10 mm)
1 1/8 in.
(29 mm) (10 mm)
1 1/8 in.
(29 mm) (10 mm)
1 1/8 in.
(29 mm) (10 mm)
Figure 5. Connect the center port
of vacuum. Loss of vacuum indicates that there is a leak in
the system. Repeat the leak test if required.
3. Evacuate the system to at least 500 microns to remove
non-condensables and water vapor. Close the manifold
valves and remove the vacuum pump.
4. Connect the refrigerant tank to the center manifold port of
the gauge set. Pressurize the system enough to break the
vacuum.
5. Open both service valves by turning the valve stems ¼ turn
counterclockwise. The stem will be in line with the tubes.
Replace the stem caps and tighten. Proceed with Refrigerant
Charging section.
The air conditioning system contains liquid and
LIQUID
gaseous refrigerant under pressure. Adjustment of
LINE
refrigerant charge should only be done by a qualified,
UP TO
100 FT. EPA certified technician thoroughly familiar with this
type of equipment. Under no circumstances should
3/8 in.
the homeowner attempt to install and/or service this
equipment. Failure to comply with this warning could
3/8 in.
result in equipment damage, personal injury, or death.
3/8 in.

Refrigerant Charging

3/8 in.
• The unit must be charged at a fixed speed setting. For this
purpose the thermostat needs to be wired and powered
prior to charging.
• The air conditioner is factory charged for field installed
lines 15 ft. in length with the matching indoor equipment.
Adjustments to the refrigerant charge will be required for
other length and tube sizes. For lines longer than 15 ft with
a 3/8" OD liquid line, add 0.52 oz. per ft. See
5).
• Small variations in the temperatures and pressures are
normal due to differences in the installation.
• Large variations in the temperatures and pressures
could indicate incorrect charge or another problem with a
component in the system.
The preferred method of charging is by weighing in the
additional refrigerant required. If a charging scale is not
available, the next preferred charging method would be to
use the sub-cooling method. After weighing in extra charge,
the subcooling values should be measured to confirm proper
charge.
MODEL
Factory Charge
for 15 ft. line set
Additional Charge
for 40 ft. line set
Additional Charge
for 75 ft. line set
Additional Charge
for 100 ft. line set
Table 4. Refrigerant Charge Quantities
WARNING:
NOTES:
2 TON 3 TON 4 TON
(-024K) (-036K) (-048K)
78 oz 93 oz 110 oz
16 oz 16 oz 18 oz
39 oz 43 oz 44 oz
57 oz 62 oz 63 oz
Table 4 (page
5 TON
(-060K)
123 oz
18 oz
44 oz
63 oz
5