Trane 4TWV0024A1000A, 4TWV0036A1000A, 4TWV0048A1000A, 4TWV0060A1000A, 4TTV0024A1000A Installer's Manual

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Page 1
Scan to see help videos on this product
Installer’s Guide
Variable Speed ComfortLink™™ II Heat Pumps and Air Conditioners
4TWV0024A1000A 4TWV0036A1000A 4TWV0048A1000A 4TWV0060A1000A
4TTV0024A1000A 4TTV0036B1000A 4TTV0048A1000A 4TTV0060A1000A 4TTV0061A1000A
NNoottee:: “Graphics in this document are for representation
only. Actual model may differ in appearance.”
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.
October 2014
SSAAFFEETTYY WWAARRNNIINNGG
18-BC89D1-1D-EN
Page 2
SAFETY SECTION — OUTDOOR
IImmppoorrttaanntt — This document contains a wiring diagram and service information. This is customer property and is to remain with this unit. Please return to service information pack upon completion of work.
WWAARRNNIINNGG
HHAAZZAARRDDOOUUSS VVOOLLTTAAGGEE!!
FFaaiilluurree ttoo ffoollllooww tthhiiss WWaarrnniinngg ccoouulldd rreessuulltt iinn pprrooppeerrttyy ddaammaaggee,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr ddeeaatthh.. DDiissccoonnnneecctt aallll eelleeccttrriicc ppoowweerr,, iinncclluuddiinngg rreemmoottee ddiissccoonnnneeccttss bbeeffoorree sseerrvviicciinngg.. FFoollllooww pprrooppeerr lloocckkoouutt//ttaaggoouutt pprroocceedduurreess ttoo eennssuurree tthhee ppoowweerr ccaannnnoott bbee iinnaaddvveerrtteennttllyy eenneerrggiizzeedd..
WWAARRNNIINNGG
RREEFFRRIIGGEERRAANNTT OOIILL!!
AAnnyy aatttteemmpptt ttoo rreeppaaiirr aa cceennttrraall aaiirr ccoonnddiittiioonniinngg pprroodduucctt mmaayy rreessuulltt iinn pprrooppeerrttyy ddaammaaggee,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr ddeeaatthh.. TThheessee uunniittss uussee RR--441100AA rreeffrriiggeerraanntt wwhhiicchh ooppeerraatteess aatt 5500 ttoo 7700%% hhiigghheerr pprreessssuurreess tthhaann RR--2222.. UUssee oonnllyy RR--441100AA aapppprroovveedd sseerrvviiccee eeqquuiippmmeenntt.. RReeffrriiggeerraanntt ccyylliinnddeerrss aarree ppaaiinntteedd aa ““RRoossee”” ccoolloorr ttoo iinnddiiccaattee tthhee ttyyppee ooff rreeffrriiggeerraanntt aanndd mmaayy ccoonnttaaiinn aa ““ddiipp”” ttuubbee ttoo aallllooww ffoorr cchhaarrggiinngg ooff lliiqquuiidd rreeffrriiggeerraanntt iinnttoo tthhee ssyysstteemm.. AAllll RR--441100AA ssyysstteemmss wwiitthh vvaarriiaabbllee ssppeeeedd ccoommpprreessssoorrss uussee aa PPVVEE ooiill tthhaatt rreeaaddiillyy aabbssoorrbbss mmooiissttuurree ffrroomm tthhee aattmmoosspphheerree.. TToo lliimmiitt tthhiiss ““hhyyggrroossccooppiicc”” aaccttiioonn,, tthhee ssyysstteemm sshhoouulldd rreemmaaiinn sseeaalleedd wwhheenneevveerr ppoossssiibbllee.. IIff aa ssyysstteemm hhaass bbeeeenn ooppeenn ttoo tthhee aattmmoosspphheerree ffoorr mmoorree tthhaann 44 hhoouurrss,, tthhee ccoommpprreessssoorr ooiill mmuusstt bbee rreeppllaacceedd.. NNeevveerr bbrreeaakk aa vvaaccuuuumm wwiitthh aaiirr aanndd aallwwaayyss cchhaannggee tthhee ddrriieerrss wwhheenn ooppeenniinngg tthhee ssyysstteemm ffoorr ccoommppoonneenntt rreeppllaacceemmeenntt..
CCAAUUTTIIOONN
HHOOTT SSUURRFFAACCEE!!
MMaayy ccaauussee mmiinnoorr ttoo sseevveerree bbuurrnniinngg.. FFaaiilluurree ttoo ffoollllooww tthhiiss CCaauuttiioonn ccoouulldd rreessuulltt iinn pprrooppeerrttyy ddaammaaggee oorr ppeerrssoonnaall iinnjjuurryy.. DDoo nnoott ttoouucchh ttoopp ooff ccoommpprreessssoorr..
CCAAUUTTIIOONN
CCOONNTTAAIINNSS RREEFFRRIIGGEERRAANNTT!!
FFaaiilluurree ttoo ffoollllooww pprrooppeerr pprroocceedduurreess ccaann rreessuulltt iinn ppeerrssoonnaall iillllnneessss oorr iinnjjuurryy oorr sseevveerree eeqquuiippmmeenntt ddaammaaggee.. SSyysstteemm ccoonnttaaiinnss ooiill aanndd rreeffrriiggeerraanntt uunnddeerr hhiigghh pprreessssuurree.. RReeccoovveerr rreeffrriiggeerraanntt ttoo rreelliieevvee pprreessssuurree bbeeffoorree ooppeenniinngg ssyysstteemm..
CCAAUUTTIIOONN
GGRROOUUNNDDIINNGG RREEQQUUIIRREEDD!!
FFaaiilluurree ttoo iinnssppeecctt oorr uussee pprrooppeerr sseerrvviiccee ttoooollss mmaayy rreessuulltt iinn eeqquuiippmmeenntt ddaammaaggee oorr ppeerrssoonnaall iinnjjuurryy.. RReeccoonnnneecctt aallll ggrroouunnddiinngg ddeevviicceess.. AAllll ppaarrttss ooff tthhiiss pprroodduucctt tthhaatt aarree ccaappaabbllee ooff ccoonndduuccttiinngg eelleeccttrriiccaall ccuurrrreenntt aarree ggrroouunnddeedd.. IIff ggrroouunnddiinngg wwiirreess,, ssccrreewwss,, ssttrraappss,, cclliippss,, nnuuttss,, oorr wwaasshheerrss uusseedd ttoo ccoommpplleettee aa ppaatthh ttoo ggrroouunndd aarree rreemmoovveedd ffoorr sseerrvviiccee,, tthheeyy mmuusstt bbee rreettuurrnneedd ttoo tthheeiirr oorriiggiinnaall ppoossiittiioonn aanndd pprrooppeerrllyy ffaasstteenneedd..
WWAARRNNIINNGG
SSEERRVVIICCEE VVAALLVVEESS!!
FFaaiilluurree ttoo ffoollllooww tthhiiss wwaarrnniinngg wwiillll rreessuulltt iinn aabbrruupptt rreelleeaassee ooff ssyysstteemm cchhaarrggee aanndd mmaayy rreessuulltt iinn ppeerrssoonnaall iinnjjuurryy aanndd//oorr pprrooppeerrttyy ddaammaaggee.. EExxttrreemmee ccaauuttiioonn sshhoouulldd bbee eexxeerrcciisseedd wwhheenn ooppeenniinngg tthhee LLiiqquuiidd LLiinnee SSeerrvviiccee VVaallvvee.. TTuurrnn vvaallvvee sstteemm ccoouunntteerrcclloocckkwwiissee oonnllyy uunnttiill tthhee sstteemm ccoonnttaaccttss tthhee rroolllleedd eeddggee.. NNoo ttoorrqquuee iiss rreeqquuiirreedd..
WWAARRNNIINNGG
BBRRAAZZIINNGG RREEQQUUIIRREEDD!!
FFaaiilluurree ttoo iinnssppeecctt lliinneess oorr uussee pprrooppeerr sseerrvviiccee ttoooollss mmaayy rreessuulltt iinn eeqquuiippmmeenntt ddaammaaggee oorr ppeerrssoonnaall iinnjjuurryy.. iiff uussiinngg eexxiissttiinngg rreeffrriiggeerraanntt lliinneess mmaakkee cceerrttaaiinn tthhaatt aallll jjooiinnttss aarree bbrraazzeedd,, nnoott ssoollddeerreedd..
WWAARRNNIINNGG
HHIIGGHH LLEEAAKKAAGGEE CCUURRRREENNTT!!
FFaaiilluurree ttoo ffoollllooww tthhiiss WWaarrnniinngg ccoouulldd rreessuulltt iinn pprrooppeerrttyy ddaammaaggee,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr ddeeaatthh.. EEaarrtthh ccoonnnneeccttiioonn eesssseennttiiaall bbeeffoorree ccoonnnneeccttiinngg eelleeccttrriiccaall ssuuppppllyy..
©2014 Trane
18-BC89D1-1D-EN
Page 3
+VDC -VDC
ELECTRICAL HAZARD
Failure to follow this warning coul d result in personal injury or death.
WAIT TWO (2) MINUTES after disconnecting power prior to touching electrical components as they may hol d a dangerous charge of 400VDC, then verify DC Voltage is less than 42 VDC at inverter test points labeled +VDC and -VDC befor e ser vicing board.
400 VOLTS
WARNING
+ VDC
and
- VDC
CAUTION - HOT SURFACE
Scan to see an overview video about the IVSC Board
SSAAFFEETTYY SSEECCTTIIOONN —— OOUUTTDDOOOORR
Approved Combinations for Variable Speed Units
TZONE 850 Comfort Control, or TZONE 950 with Software Version
3.0 or Higher
TAM8C or later models
XC80 Furnace
XC95m Furnace
Approved System Accessories
Note: See AHRI directory for approved indoor and outdoor model
combinations. Only Trane coils and air handlers are approved for use with variable speed outdoor units.
Table 1. Operating Range
Cooling 55° F to 120° F
Heating -10° F to 66° F
18-BC89D1-1D-EN
3
Page 4
Table of Contents
Unit Location Considerations. . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coastal Considerations . . . . . . . . . . . . . . . . 7
Unit Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Setting Up the Unit . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Line Considerations . . . .. . . . . . . . 9
Refrigerant Line Brazing . . . . . . . . . . . . . . .. . . . 12
Refrigerant Line Leak Check . .. . . . . . . . . . . . . 14
Refrigerant Line and Indoor Coil
Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Charging: Weigh-In Method . . . . . . . .. . . . . . . 15
Service Valves . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 16
Electrical — Low Voltage . . . . . . . . . . . . . . . . . . 17
Electrical — High Voltage . . . . . . . . . . . . . . . . . . 18
Integrated Variable Speed Control Board
LED Indicators . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 19
Start Up . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 20
System Charge Adjustment . . . . . . . . . . . . . . . 21
Subcool Charging Correction Charts. . . . . . . 22
Refrigerant Charging Chart . . . . . . . . . . . . . . . 22
Charging the Unit. . . . . . . . . . . . .. . . . . . . . . .. . . 23
Communicating Display Assembly
(CDA). . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 25
Defrost Control (Heat Pump only). . . . . . . . . . 26
Checkout Procedures . . . . . . . . . . . . . . . .. . . . . . 27
4
18-BC89D1-1D-EN
Page 5
Unit Location Considerations
D
H
W
50
Ma
x
Line
Lift
Sta n dard
Line Se t
150 Max
Line Length
50 Max Line
Lift
100
M
ax
Line
Length
100 Max
Line
Length
Refer to (a), (b), and (c) footnotes for
specific m odel details
Table 2. Unit Dimensions and Weight
Models
4TWV0024A 48 x 30 x 33 206
4TWV0036A 50 x 34 x 37 243
4TWV0048A 50 x 34 x 37 255
4TWV0060A 54 x 34 x 37 265
4TTV0024A 48 x 30 x 33 207
4TTV0036B 50 x 34 x 37 239
4TTV0048A 50 x 34 x 37 259
4TTV0060A 54 x 34 x 37 265
4TTV0061A 54 x 34 x 37 303
* Weight values are estimated (uncrated).
When mounting the outdoor unit on a roof, be sure the roof will support the unit’s weight.
Properly selected isolation is recommended to alleviate sound or vibration transmission to the building structure.
Table 3. Refrigerant Line and Service Valve Connection Sizes
Model
4TWV0024A
4TWV0036A
4TWV0048A
4TWV0060A
4TTV0024A
4TTV0036B
4TTV0048A
4TTV0060A
4TTV0061A
1 — 1/8
1 — 1/8
1 — 1/8
H x D x W (in) Weight * (lb)
Rated Line Sizes
Vapor
Liquid
Line
(a)
5/8
(a)
3/4
(a)
7/8
(b)
(a)
5/8
(a)
3/4
(a)
7/8
(c)
(d)
Line
3/8 5/8 3/8
3/8 3/4 3/8
3/8 7/8 3/8
3/8 7/8 3/8
3/8 5/8 3/8
3/8 3/4 3/8
3/8 7/8 3/8
3/8 7/8 3/8
3/8 7/8 3/8
Service Valve
Connection Sizes
Vapor Line
Connection
Liquid Line
Connection
(a)
The max length of refrigerant lines from outdoor to indoor unit MUST NOT exceed 150 feet. The max vertical change MUST NOTexceed 50 feet.
(b)
The max length of refrigerant lines from the outdoor to indoor unit MUST NOTexceed 80 feet. The max vertical change MUST NOT exceed 10 feet.
(c)
the max length of refrigerant lines from outdoor to indoor unit MUST NOT exceed 80 feet. The max vertical change MUST NOTexceed 25 feet.
(d)
the max length of refrigerant lines from outdoor to indoor unit MUST NOT exceed 80 feet. The max vertical change MUST NOTexceed 25 feet.
18-BC89D1-1D-EN
5
Page 6
Min. 12” to Shrubbe ry
Avoid Install Nea r Bedrooms
Min 5 Unre stricte d
Access Pa nel
Min 3 Unrestricted
Min. 12 to Shrubbery
Min. 12 to Wall
UUnniitt LLooccaattiioonn CCoonnssiiddeerraattiioonnss
Table 4. Alternate Refrigerant Line and Service Valve Connection Sizes
Service Valve
Connection Sizes
Vapor Line
Connection
Liquid Line
Connection
Model
4TWV0024A
4TWV0036A
4TWV0048A
4TWV0060A
Alternate Line Sizes
3/4"
Vapor
Line
(a)
Liquid
Line
5/16" 5/8" 3/8"
5/8" 5/16" 3/4" 3/8"
(b)
7/8"
5/16" 3/4" 3/8"
3/4" 3/8" 7/8" 3/8"
3/4" 3/8" 7/8" 3/8"
7/8" 3/8" 7/8" 3/8"
Model
4TTV0024A
4TTV0036B
4TTV0048A
4TTV0060A
4TTV0061A
(a)
The max length of refrigerant lines from outdoor to indoor unit MUST NOT exceed 150 feet. The max vertical change MUST NOTexceed 50 feet.
(b)
The max length of refrigerant lines from outdoor to indoor unit MUST NOT exceed 80 feet. The max vertical change MUST NOTexceed 25 feet.
Vapor
Line
Liquid
Line
3/4" 5/16" 5/8" 3/8"
5/8" 5/16" 3/4" 3/8"
7/8" 5/16" 3/4" 3/8"
3/4" 3/8" 7/8" 3/8"
3/4" 3/8" 7/8" 3/8"
7/8" 3/8" 7/8" 3/8"
3/4" 3/8" 7/8" 3/8"
7/8" 3/8" 7/8" 3/8"
Alternate Line Sizes
Service Valve
Connection Sizes
Vapor Line
Connection
Liquid Line
Connection
Table 5. Suggested Locations for Best Reliability
Ensure the top discharge area is unrestricted for at least 5 feet above the unit.
Provide at least 3 feet clearance in front of the control box (access panels) and any other side requiring service.
Do not locate close to bedrooms as operational sounds may be objectionable.
Avoid locations near windows and similar areas where condensation and freezing defrost vapor can annoy a customer.
Position the outdoor unit a minimum of 12” from any wall or surrounding shrubbery to ensure adequate airflow.
Outdoor unit location must be far enough away from any structure to prevent excess roof runoff water or icicles from falling directly on the unit.
Position the outdoor unit a minimum of 12” from any wall or surrounding shrubbery to ensure adequate airflow.
Outdoor unit location must be far enough away from any structure to prevent excess roof runoff water or icicles from falling directly on the unit.
6
18-BC89D1-1D-EN
Page 7
Min. 12
Sn ow
Barrier
3-12” Elevation
Snow L egs
Pad
UUnniitt LLooccaattiioonn CCoonnssiiddeerraattiioonnss
Table 6. Cold Climate Considerations (Heat Pump Only)
Note: It is recommended that these precautions be taken for
units being installed in areas where snow accumulation and prolonged below-freezing temperatures occur.
Units should be elevated 3–12 inches above the pad or rooftop, depending on local weather. This additional height will allow drainage of snow and ice melted during defrost cycle prior to its refreezing. Ensure that drain holes in unit base pan are not obstructed, preventing drainage of defrost water.
If possible, avoid locations that are likely to accumulate snow drifts. If not possible, a snow drift barrier should be installed around the unit to prevent a build-up of snow on the sides of the unit.
Coastal Considerations
If installed within one mile of salt water, including seacoasts and inland waterways, models without factory supplied Seacoast Salt Shields require the addition of BAYSEAC001 (Seacoast Kit) at installation time.
18-BC89D1-1D-EN
7
Page 8
Unit Preparation
1. Check for damage and report promptly to the carrier any damage found to the unit.
2. To remove the unit from the pallet, remove tabs by cutting with a sharp tool.
Setting Up the Unit
Table 7. Pad Installation
When installing the unit on a support pad, such as a concrete slab, consider the following:
The pad should be at least 1” larger than the unit on all sides.
The pad must be separate from any structure.
The pad must be level.
The pad should be high enough above grade to allow for drainage.
The pad location must comply with National, State, and Local codes.
8
18-BC89D1-1D-EN
Page 9
Refrigerant Line Considerations
Line Length
Liquid Li ne
Vapor Line
Insulati on
Table 8. Required Refrigerant Line Length
Determine required line length and lift. You will need this to determine the subcooling charging corrections later in the installation process.
Total Line Length = ___________________________Ft.
Total Vertical Change (lift) = ____________________Ft.
Table 9. Refrigerant Line Insulation
Important: The Vapor Line must always be insulated. DO NOT allow
the Liquid Line and Vapor Line to come in direct (metal to metal) contact.
Note: The gas line must always be insulated. Insulating the liquid line
through attic spaces may benefit system performance by minimizing heat gain in the liquid line.
18-BC89D1-1D-EN
9
Page 10
8 Feet Maximum
Side View
8 Feet Maximum
Joist/Rafter
Isolator
Line Set
RReeffrriiggeerraanntt LLiinnee CCoonnssiiddeerraattiioonnss
Table 10. Reuse Existing Refrigerant Lines
CCAAUUTTIIOONN
RREEFFRRIIGGEERRAANNTT!!
FFaaiilluurree ttoo iinnssppeecctt oorr uussee pprrooppeerr sseerrvviiccee ttoooollss mmaayy rreessuulltt iinn eeqquuiippmmeenntt ddaammaaggee oorr ppeerrssoonnaall iinnjjuurryy.. IIff uussiinngg eexxiissttiinngg rreeffrriiggeerraanntt lliinneess mmaakkee cceerrttaaiinn tthhaatt aallll jjooiinnttss aarree bbrraazzeedd,, nnoott ssoollddeerreedd..
For retrofit applications, where the existing indoor evaporator coil and/or refrigerant lines will be used, the following precautions should be taken.
Ensure that the indoor evaporator coil and refrigerant lines are the correct size.
Ensure that the refrigerant lines are free of leaks, acid, and oil.
Important: For more information, see publication number SS-
APG006–EN
Table 11. Refrigerant Line Routing Precautions
Important: Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls, or other structural elements.
Important: Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines.
For Example:
When the refrigerant lines must be fastened to floor joists or other framing in a structure, use isolation type hangers.
Isolation hangers should also be used when refrigerant lines are run in stud spaces or enclosed ceilings.
Where the refrigerant lines run through a wall or sill, they should be insulated and isolated.
Isolate the lines from all duct work.
Minimize the number of 90° turns.
Table 12. Isolation From Joist/Rafter
Secure Vapor Line from joists using isolators every 8 ft. Secure Liquid Line directly to insulated Vapor Line using tape, wire, or other appropriate
10
method every 8 ft.
18-BC89D1-1D-EN
Page 11
Table 13. Isolation In Wall Spaces
Side View
Isolator
Line Set
8 Feet Maximum
Wall
8 Feet Maximum
Wall
Sealant Insulation
Vapor Line
Duct Work
Isolator
Line Set
DO NOT han g line sets from d uct work
RReeffrriiggeerraanntt LLiinnee CCoonnssiiddeerraattiioonnss
Secure Vapor Line from joists using isolators every 8 ft. Secure Liquid Line directly to insulated Vapor Line using tape, wire, or other appropriate
method every 8 ft.
Table 14. Isolation Through Wall
18-BC89D1-1D-EN
11
Page 12
Refrigerant Line Brazing
Table 15. Braze the Refrigerant Lines
1. Remove caps or plugs. Use a deburring tool to debur the pipe ends. Clean both internal and external surfaces of the tubing using an emery cloth.
2. Remove the pressure tap cap and valve core from each service valves.
3. Purge the refrigerant lines and indoor coil with dry nitrogen.
12
18-BC89D1-1D-EN
Page 13
Table 15. Braze the Refrigerant Lines (continued)
3-4” from valve
4. Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge.
5. Braze the refrigerant lines to the service valves.
a. For Units shipped with a field-installed external drier, check
liquid line filter drier’s directional flow arrow to confirm correct direction of refrigeration flow (away from outdoor unit and toward evaporator coil) as illustrated. Braze the filter drier to the Liquid Line.
6. Continue the dry nitrogen purge. Do not remove the wet rag until all brazing is completed.
Important: Remove the wet rag before stopping the dry nitrogen
purge.
Note: Precautions should be taken to avoid heat damage to base pan
during brazing. It is recommended to keep the flame directly off of the base pan.
7. Replace the pressure tap valve cores after the service valves have cooled.
RReeffrriiggeerraanntt LLiinnee BBrraazziinngg
18-BC89D1-1D-EN
13
Page 14
Refrigerant Line Leak Check
150 PSIG
0350
Microns
ON
OFF
1 MIN.
Table 16. Check for Leaks
1. Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry nitrogen.
2. Check for leaks by using a soapy solution at each brazed location.
Note: Remove nitrogen pressure and repair any leaks before
continuing.
Refrigerant Line and Indoor Coil Evacuation
IImmppoorrttaanntt:: Do not open the service valves until the
14
refrigerant lines and indoor coil leak check and evacuation are complete.
1. Evacuate until the micron gauge reads no higher than 350 microns, then close off the valve to the vacuum pump.
2. Observe the micron gauge. Evacuation is complete if the micron gauge does not rise above 500 microns in one (1) minute.
3. When evacuation is complete, blank off the vacuum pump and micron gauge, and close the valves on the manifold gauge set.
18-BC89D1-1D-EN
Page 15
Charging: Weigh-In Method
Weigh-In Method can be used for the initial installation, or anytime a system charge is being replaced. Weigh-In Method can also be used when power is not available to the equipment site or operating conditions (indoor/outdoor temperatures) are not in range to verify with the subcooling charging method.
Table 17. Heat Pumps
A
B C D
Table 18. Air Conditioners
A
Charge
multiplier for
interconnecting
refrigerant
Model
Model
Factory
Charge
Charge
adder for
Indoor Coil
tube length
024 7 lb. 6 oz. 6 oz.
036 9 lb. 8 oz. 12 oz.
048 10 lb. 12 oz. 15 oz.
060 11 lb. 14 oz.
1 lb., 2 oz. 0.6 oz/ft
0.6 oz/ft
0.6 oz/ft
0.6 oz/ft
024 7 lb. 6 oz. 6 oz.
036 9 lb. 6 oz. 12 oz.
048 11 lb. 1 oz.
060 11 lb. 14 oz.
061 12 lb. 7 oz.
Table 19. New Installations — Calculating Charge using the Weigh-In method
1. Measure in feet the distance between the outdoor unit and the indoor
unit and record on Line 1. Include the entire length of the line from the service valve to the IDU.
2. Enter the charge multiplier from Column D.
3. Multiply the total length of refrigerant tubing (Line 1) times the value on
Step 2. Record the result on Line 3 of the Worksheet.
4. Locate the outdoor equipment size in Column A. Record the value shown
in Column C of Table 16 for Heat Pumps or Table 17 for Air Conditioners.
5. Add the values from Step 3 and Step 4 and record the resulting value.
This is the amount of refrigerant to weigh-in prior to opening the service valves.
New Installation Weigh-In Method Worksheet
1. Line Length (ft) ________________________
2. Value from Column D x ________________________
3. Step 1 x Step 2 = ________________________
4. Charge Adder (column C) + ________________________
5. Refrigerant (Steps 3+4) = ________________________
B C D
Factory
Charge
Charge
adder for
Indoor Coil
1 lb., 0 oz. 0.6 oz/ft
1 lb., 2 oz. 0.6 oz/ft
1 lb., 4 oz. 0.6 oz/ft
Charge
multiplier for
interconnect-
ing refrigerant
tube length
0.6 oz/ft
0.6 oz/ft
Table 20. Sealed-System Repairs — Calculating Charge using the Weigh-In method.
1. Measure in feet the distance between the outdoor unit and the indoor
unit and record on Line 1. Include the entire length of the line from the service valve to the IDU.
2. Enter the charge multiplier from Column D.
3. Multiply the total length of refrigerant tubing (Line 1) times the value on
Line 2. Record the result on Line 3 of the Worksheet.
4. Locate the outdoor equipment size in Column A. Record the value shown
in Column C of Table 16 for Heat Pumps or Table 17 for Air Conditioners.
5. Record the value in Column B to Line 5 of the Worksheet.
6. Add the values from Step 3, Step 4, and Step 5 and record the resulting
value on Line 6. This is the amount of refrigerant to weigh-in.
Note: The only mode approved for setting or validating system charge is using Charging Mode-Cooling. Charging Mode-Cooling is a variable
speed test mode found in the 850/950 comfort control Technician Menu. Outdoor Temperature must be between 55°F and 120°F with Indoor Temperature kept between 70°F and 80°F.
18-BC89D1-1D-EN
New Installation Weigh-In Method Worksheet
1. Line Length (ft) ________________________
2. Value from Column D x ________________________
3. Step 1 x Step 2 = ________________________
4. Charge Adder (column C) + ________________________
5. Factory Charge (column B) + ________________________
6. Refrigerant (Steps 3+4+5) = ________________________
15
Page 16
Service Valves
Cap
1/4 Turn Only Counterclockwise for Full Open Position
Valve Stem
Unit Side of Valve
Pressure Tap Port
Gas Line Connection
Cap
3/16 Hex Wrench
Rolled Edge to Captivate Stem
Hex Headed Valve System
Service Port
Unit Side of Service Valve
Table 21. Open the Gas Service Valve
Important: Leak check and evacuation must be completed before
Note: Do not vent refrigerant gases into the atmosphere.
1. Remove valve stem cap.
2. Using a wrench, turn valve stem 1/4 turn counterclockwise to
3. Replace the valve stem cap to prevent leaks. Tighten finger
Table 22. Open the Liquid Service Valve
opening the service valves.
the fully open position.
tight plus an additional 1/6 turn.
WWAARRNNIINNGG
SSEERRVVIICCEE VVAALLVVEESS!!
FFaaiilluurree ttoo ffoollllooww tthhiiss wwaarrnniinngg wwiillll rreessuulltt iinn aabbrruupptt rreelleeaassee ooff ssyysstteemm cchhaarrggee aanndd mmaayy rreessuulltt iinn ppeerrssoonnaall iinnjjuurryy aanndd//oorr pprrooppeerrttyy ddaammaaggee.. EExxttrreemmee ccaauuttiioonn sshhoouulldd bbee eexxeerrcciisseedd wwhheenn ooppeenniinngg tthhee LLiiqquuiidd LLiinnee SSeerrvviiccee VVaallvvee.. TTuurrnn vvaallvvee sstteemm ccoouunntteerrcclloocckkwwiissee oonnllyy uunnttiill tthhee sstteemm ccoonnttaaccttss tthhee rroolllleedd eeddggee.. NNoo ttoorrqquuee iiss rreeqquuiirreedd..
Important: Leak check and evacuation must be completed before
4. Remove service valve cap.
5. Fully insert 3/16” hex wrench into the stem and back out
6. Replace the valve cap to prevent leaks. Tighten finger tight
opening the service valves.
counterclockwise until valve stem just touches the rolled edge (approximately five (5) turns).
plus an additional 1/6 turn.
16
18-BC89D1-1D-EN
Page 17
Electrical — Low Voltage
Neatl y bundle all low voltag e wire s as sh ow n.
Com m unicating Com fort Cont rol
W1 W2 W3
G
Y2
B
O
BK D Y1
R
Field wiring
Brown
Blue
Brown Blue
Red
B - Blue
D - Note 3
D R B
Note 1 & Note 2
Red
Only used for Load Shed (Cap off if not us ed)
Com m unicating Indoo r Unit
Note 4
Note 5
Comm unicating Outdoor Unit
Table 23, p. 17defines the size and combined total maximum length of low voltage wiring from the outdoor unit, to the indoor unit, and to the
thermostat.
Note: The use of color coded low voltage wire is recommended to simplify connections between the outdoor unit, the control, and the indoor
unit.
Note: The maximum total cable length for the entire comfort control communicating system is 500 ft. 18 AWG.
Table 23. Low Voltage Maximum Wire Length
CONTROL WIRING
WIRE SIZE MAX. WIRE LENGTH
18 AWG 500 Ft. Combined
Table 24. Low Voltage Hook-up Diagrams
Figure 1. Fully Communicating System
1. In communicating mode, unused terminals are non-functional. Do not use.
2. Terminals present will vary by indoor model.
3. “D” is the data line. Installer to select a wire color.
4. If a 3rd party condensate overflow switch is installed, it should be wired in series with R to the thermostat or connected to the External Switch terminals on the AFC. See External Switch wiring section in the air handler Installer’s Guide.
5. Wire present only on Variable Speed Outdoor Units.
Note: Anti-oxidizing grease is supplied in the documentation package for use when making low voltage field wiring connections at the outdoor
unit. Apply grease to field wiring before installing wire caps to protect these connections from corrosion.
18-BC89D1-1D-EN
17
Page 18
Electrical — High Voltage
Table 25. High Voltage Power Supply
WWAARRNNIINNGG
LLIIVVEE EELLEECCTTRRIICCAALL CCOOMMPPOONNEENNTTSS!!
FFaaiilluurree ttoo ffoollllooww tthhiiss WWaarrnniinngg ccoouulldd rreessuulltt iinn pprrooppeerrttyy ddaammaaggee,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr ddeeaatthh.. FFoollllooww aallll eelleeccttrriiccaall ssaaffeettyy pprreeccaauuttiioonnss wwhheenn eexxppoosseedd ttoo lliivvee eelleeccttrriiccaall ccoommppoonneennttss.. IItt mmaayy bbee nneecceessssaarryy ttoo wwoorrkk wwiitthh lliivvee eelleeccttrriiccaall ccoommppoonneennttss dduurriinngg iinnssttaallllaattiioonn,, tteessttiinngg,, sseerrvviicciinngg,, aanndd ttrroouubblleesshhoooottiinngg ooff tthhiiss pprroodduucctt..
The high voltage power supply must agree with the equipment nameplate.
Power wiring must comply with national, state, and local codes.
Follow instructions on unit wiring diagram located on the inside of the control box cover and in the Service Facts document included with the unit.
Table 26. High Voltage Disconnect Switch
WWAARRNNIINNGG
HHIIGGHH LLEEAAKKAAGGEE CCUURRRREENNTT!!
FFaaiilluurree ttoo ffoollllooww tthhiiss WWaarrnniinngg ccoouulldd rreessuulltt iinn pprrooppeerrttyy ddaammaaggee,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr ddeeaatthh.. EEaarrtthh ccoonnnneeccttiioonn eesssseennttiiaall bbeeffoorree ccoonnnneeccttiinngg eelleeccttrriiccaall ssuuppppllyy..
Install a separate disconnect switch at the outdoor unit.
For high voltage connections, flexible electrical conduit is recommended whenever vibration transmission may create a noise problem within the structure.
Table 27. High Voltage Disconnect Switch
Ground the outdoor unit per national, state, and local code requirements.
18
18-BC89D1-1D-EN
Page 19
Integrated Variable Speed Control Board
FAN
ALUMINUM COVER PLATE
LSOV
EEV
LOAD
MONITOR
TOOL
SHED
CDA
EXT.ODT
PERSONALITY MODULE
STATUS
COMM
T4
T3
T1
T2
HPCO
DATA
CHARGE
SOLENOID
(N/A Phase I)
10
1
18
9
J1
J6
J4
DRB
J8
J9
J3
J10
J2
J5
J20
PSC
(no t u se d)
PWM
STATUS
COMM
High Voltage to Con de ns or
The Status (Green) and COMM (Am ber) LEDs are located in t he upper right region of the Control Board.
Fau lt m es sages are displayed on the CDA
LED Indicators
LLEEDD’’SS
LED RATE
MEDIUM
STATUS
(GREEN)
SOLID ON TEST MODE
INTERMITTENT
SLOW
FAST
DESCRIP-
TION
1 TIME PER SECOND
2 TIMES PER SECOND
5 TIMES PER SECOND
1 FLASH EVERY 4 SECONDS
INDICA-
TION
STANDBY/ IDLE
CALL FOR CAPACITY
POWER UP DELAY
HARD LOCKOUT
LED RATE DESCRIPTION INDICATION
COMM
(AMBER)
SLOW
FAST
1 TIME PER DEVICE
5 TIME PER SECOND
DEVICE COUNT
LOSS OF COMMUNICATION
18-BC89D1-1D-EN
19
Page 20
Start Up
ON
OFF
3 HRS.
1. Ensure you have completed the following sections. ”Refrigerant Line Brazing,” p. 12 through ”Electrical — High Voltage,” p. 18
2. Set System Thermostat to OFF.
3. Turn on disconnect(s) to apply power to the indoor and outdoor units.
20
4. Wait 3 hours before starting the unit if the outdoor ambient temperature is below 85° F.
5. Run the system using the “Charging Mode-Cooling” test mode found in the 850/950 comfort control. This is the only approved method for setting the system charge level by subcooling.
Follow the on-screen prompts.
18-BC89D1-1D-EN
Page 21
System Charge Adjustment
120° F
55° F
80° F 70° F
Table 28. Temperature Measurements
Check the outdoor temperatures.
Subcooling using “Charging Mode-Cooling” is the only recommended method of charging between 55 ° F and 120° F ambient outdoor temperature.
For best results the indoor temperature should be kept between 70° F to 80° F.
Table 29. Subcooling Charging Corrections
Determine the final subcooling value using total Line Length and Lift measured in Table 8, p. 9— (Required Refrigerant Line Length) and the Subcooling Charging Corrections Charts.
Subcooling Charging Correction Worksheet
Total Line Length (ft) ________________________
Total Vertical Charge (lift) ________________________
(Values from — Required Refrigerant Line Length)
Design Subcooling Value ________________________
(from nameplate or Service Facts)
Final Subcooling Value ________________________
18-BC89D1-1D-EN
21
Page 22
Subcool Charging Correction Charts
2.0 TON S UBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE)
TOTAL REFRIGERANT LINE LENGTH (FEET)
Add 1°
Add 1°
Use Design Subcoo ling
Add 2°
70 80 90 100 110 120 130 140 1506050403020
50 40 30 25 15 10
0
REFRIGERANT LINE LIFT (FEET)
3.0 TON S UBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE)
TOTAL REFRIGERANT LINE LENGTH (FEET)
Add 1°
Add 1°
Use Design Subcoo ling
Add 2°
70 80 90 100 110 120 130 140 1506050403020
50 40 30 25 15 10
0
REFRIGERANT LINE LIFT (FEET)
4.0 TON S UBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE)
TOTAL REFRIGERANT LINE LENGTH (FEET)
Add 1°
Add 1°
Use Design Subcoo ling
Add 2°
70 80 90 100 110 120 130 140 1506050403020
50 40 30 25 15 10
0
REFRIGERANT LINE LIFT (FEET)
5.0 TON S UBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE)
NOTE: 15 0 ft. le ngth is approv ed ONLY with 7/8 vap or lines .
1°
1°
TOTAL REFRIGERANT LINE LENGTH (FEET)
Add 1°
Add 1°
Add 1°
Use Desig n Subcooling
Add
Add 4°
70 80 90 100 11 0 120 130 140 15060
50
40
3020
50 40 30 25 15 10
0
REFRIGERANT LINE LIFT (FEET)
HP: 1-1 /8 Vapor Line Lim it
AC: 1-1/8 Vap or Line Limit
Figure 2. Subcool Charging Corrections — 2.0 Ton
Figure 3. Subcool Charging Corrections — 3.0 Ton
Refrigerant Charging Chart
R-410A REFRIGERANT CHARGING CHART
DESIGN SUBCOOLING (°F)
LIQUID
TEMP
(°F)
8 9 10 11 12 13 14
LIQUID GAGE PRESSURE (PSI)
Figure 4. Subcool Charging Corrections — 4.0 Ton
Figure 5. Subcool Charging Corrections — 5.0 Ton
55 179 182 185 188 191 195 198
60 195 198 201 204 208 211 215
65 211 215 218 222 225 229 232
70 229 232 236 240 243 247 251
75 247 251 255 259 263 267 271
80 267 271 275 279 283 287 291
85 287 291 296 300 304 309 313
90 309 313 318 322 327 331 336
95 331 336 341 346 351 355 360
100 355 360 365 370 376 381 386
105 381 386 391 396 402 407 413
110 407 413 418 424 429 435 441
115 435 441 446 452 458 464 470
120 464 470 476 482 488 495 501
125 495 501 507 514 520 527 533
Refer to Service Facts or Installer’s Guide for charging method
22
18-BC89D1-1D-EN
Page 23
Charging the Unit
20 MIN.
PRESSURE CURVE SAMPLE
Cooling @ 1450 SCFM Heating @ 1350 SCFM
DISCHARGE PRESSURE (PSIG)
OUTDOOR TEMPERATURE (Degree F)
SUCTION PRESSURE (PSIG)
110
115
120
125
130
135
140
145
150
155
160
165
170
40 60 80 100 120
200
250
300
350
400
450
500
550
40 60 80 100 120
(1)
(1)
(3)
(3)
(5)
(4)
(2)
(2)
INDOOR ENTERING WET BULB CURVES TOP TO BOTTOM 71, 67, 63 AND 59 DEG F.
INDOOR ENTERING WET BULB CURVES TOP TO BOTTOM 71, 67, 63 AND 59 DEG F.
30
40
50
60
70
80
90
100
110
120
130
140
-5 5 15 25 35 45 55 65
200
250
300
350
400
450
500
-5 5 15 25 35 45 55 65
INDOOR ENTERING DRY BULB CURVES TOP TO BOTTOM 80, 70, AND 60 DEG F.
INDOOR ENTERING DRY BULB CURVES TOP TO BOTTOM 80, 70, AND 60 DEG F.
Table 30. Proper Gage Pressure
Using the ”Refrigerant Charging Chart”, p. 22adjust refrigerant level to attain proper gage pressure.
Add refrigerant if the Liquid Gage Pressure is lower than the chart value.
1. Connect gauges to refrigerant bottle and unit as illustrated.
2. Purge all hoses.
3. Open bottle.
4. Stop adding refrigerant when liquid line temperature and Liquid Gage Pressure match the charging chart.
Note: Recover refrigerant if the Liquid Gage Pressure is higher than
the chart value.
Table 31. Stabilize the system
5. Wait 20 minutes for the system condition to stabilize between adjustments.
Note: When the Liquid Line Temperature and Gage Pressure
approximately match the chart, the system is properly charged.
6. Remove gauges.
7. Replace service port caps to prevent leaks. Tighten finger tight plus an additional 1/6 turn.
Table 32. Verify Performance
8. Refer to System Pressure Curves in the Service Facts document to verify typical performance.
18-BC89D1-1D-EN
23
Page 24
CChhaarrggiinngg tthhee UUnniitt
Table 33. System Information
9. Record system pressures and temperatures after charging is complete.
Outdoor model number = ________________________
Measured Outdoor Ambient = ________________________°F
Measured Indoor Ambient = ________________________°F
Measured Liquid Line Temp = ________________________°F
Measured Suction Line Temp = ________________________°F
Indoor Wet Bulb = ________________________°F
Liquid Gage Pressure = ________________________ PSIG
Suction Gage Pressure = ________________________ PSIG
24
18-BC89D1-1D-EN
Page 25
Communicating Display Assembly (CDA)
1. External shut d own (Loa d Sh ed)
2. Min. Airflow
3. Blower on/off delays
4. Custom Airflow
5. PFC (Powe r Factor Correction)
1. FRC DFT (Force d Defrost)
2. EEV Test
3. Evacua tio n
4. Drive Diagn ostic Tes t
5. OD Fan Tes t
TECHNICIAN MENUS
SYSTEM STATUS
XXXXXXXXXXXXXXXX
NAVIGATION
To enter and exit Technician Menus, pres s the Up/Do wn buttons s im ultaneou sly for 5 se co nds.
To return to the Ho me Screen, press th e Up/Dow n bu ttons s im ultaneou sly for 5 se co nds.
To return to the top level of any m enu , p re ss the Left/Right buttons s im ultaneou sly for 5 se co nds.
After five min utes o f inactivity in th e Technician Menu sectio n, the Ho m e Screen will be disp layed. Press ing the Enter button fo r 5 seco nds will increas e this time to 20 minutes.
ALERT HISTORY
MENU
ALERT MENU
CONFIG MENU
CONTROL MENU
MONITOR MENU
The Monitor Me nu displays in formation on System statu s, Drive s tats and the System Tach omete r.
The Alert His tory menu displays alerts sto red over time. Note that clearing Alert History will also cle ar Active Alerts.
The Alert Menu displays active alerts.
The Co nfiguration Menu is whe re System p arameters and options are s et and reported.
The Co ntrol Me nu contain s a selection of unit function tests that are used to verify operation.
Scan to see an overview video about the CDA
NNoottee:: See the Service Facts found in the control box of
the outdoor unit for more information.
18-BC89D1-1D-EN
25
Page 26
Defrost Control (Heat Pump only)
65ºF
60ºF
55ºF
50ºF
45ºF
40ºF
35ºF
30ºF
-40ºF -20ºF 0ºF 20ºF 40ºF 60ºF
FACTORY TERMINATION TEMP
AMBIENT TEMPERATURE
TERMINATION TEMPERATURE
MEDIUM TERMINATION TEMP
HIGH TERMINATION TEMP
DEFROST TERMINATION PROFILES
FRC DFT
PRESS ENTER
TEST IN PROGRESS
CTS <value>
TEST COMPLETE
CONTROL MENU
CONFIG
MENU
MONITOR
MENU
DDeemmaanndd DDeeffrroosstt
The demand defrost control measures heat pump outdoor ambient temperature with a sensor located outside the outdoor coil. A second sensor located on the outdoor coil is used to measure the coil temperature. The difference between the ambient and the colder coil temperature is the difference or delta-T measurement. This delta-T measurement is representative of the operating state and relative capacity of the heat pump system. By measuring the change in delta-T, we can determine the need for defrost. The coil sensor also serves to sense outdoor coil temperature for termination of the defrost cycle.
FFaauulltt IIddeennttiiffiiccaattiioonn
A fault condition is indicated by the CDA connected to the control board inside the heat pump control box.
DDeeffrroosstt EEnnaabblleedd
Demand Defrost is enabled with the following inputs to the Integrated Variable Speed Control (IVSC):
Outdoor ambient temperature sensor (ODS-B) reporting an outdoor temperature at or below 52° F.
Coil temperature sensor (CBS) reporting a coil temperature at or below 35° F.
Heat/Cool Demand (HCD) from the communicating comfort control for at least two minutes or more.
DDeeffrroosstt IInniittiiaattiioonn
The calculated temperature difference between the outdoor temperature sensor and the coil temperature sensor is called Delta T. Defrost can occur once the current Delta T exceeds the Delta T initiate value. The Defrost initiate value is calculated using a clean-coil Delta T x 2.0, plus a temperature bin correction factor. Initiation Delta Twill automatically adjust based on the outdoor temperature. This adaptive logic assures a complete defrost for a range of outdoor temperatures.
CCDDAA NNaavviiggaattiioonn ttoo FFoorrcceedd DDeeffrroosstt
Figure 6. CDA Mini Menu
NNOOTTEESS:: FFoorrcceedd DDeeffrroosstt
1. System must be running with demand from the thermostat.
2. FRC DFT TEST can be initiated in heat mode only.
3. Press ENTER to begin forced defrost.
4. Execute Forced Defrost following Forced Defrost (Defrost terminates on Coil Temperature or maximum time override of 15 minutes).
5. When test begins, TEST IN PROGRESS displays on line 1 and Coil Temperature value on line 2.
NNoottee:: Home Screen, under System Status will display
DEFROST.
6. When test is complete, TEST COMPLETE displays for 10 seconds.
7. If there is a defrost fault condition, test terminates and sends alert to the alert menu.
8. For more information, refer to the Alert Code Tables in Service Facts and Technical Service Manual (Pub. No. 34–4301–01) documents.
NNoottee:: Screens will update as the test proceeds.
26
18-BC89D1-1D-EN
Page 27
Checkout Procedures
The final phase of the installation is the system Checkout Procedures. The following list represents the most common items covered in a Checkout Procedure. Confirm all requirements in this document have been met.
All wiring connections are tight and properly secured.
Voltage and running current are within limits.
All refrigerant lines (internal and external to equipment) are isolated, secure, and not in direct contact with each other or structure.
All braze connections have been checked for leaks. A vacuum of 350 microns provides confirmation that the refrigeration system is leak free and dry.
Final unit inspection to confirm factory tubing has not shifted during shipment. Adjust tubing if necessary so tubes do not rub against each other or any component when unit runs.
Ductwork is sealed and insulated.
All drain lines are clear with joints properly sealed. Pour water into drain pan to confirm proper drainage.
Supply registers and return grilles are open, unobstructed, and air filter is installed.
Indoor blower and outdoor fan are operating smoothly and without obstruction.
Indoor blower motor set on correct speed setting to deliver required CFM.
Cover panels are in place and properly tightened.
For gas heating systems, manifold pressure has been checked and all gas line connections are tight and leak free.
For gas heating systems, flue gas is properly vented.
System functions safely and properly in all modes.
Owner has been instructed on use of system and given manual.
18-BC89D1-1D-EN
27
Page 28
NNootteess
Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the leader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad portfolio of advanced controls and HVAC systems, comprehensive building services, and parts. For more information, visit www.Trane.com.
Trane has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice.
©2014 Trane
18-BC89D1-1D-EN
Supersedes 18-BC89D1-1C-EN (January 2014)
13 Oct 2014
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