Trane 4TTZ0, 4TWZ0 Installer's Manual

Download

Page 1

18-BC53D2-6

Installer’s Guide

Air Conditioner/Heat Pumps

4TTZ0/4TWZ0 with ComfortLinkTM II and Charge Assist

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of work.

These instructions do not cover all variations in systems or provide for every possible contingency to be met in connection with the installation. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to your installing dealer or local distributor.

NOTE: The manufacturer recommends installing only approved matched indoor and outdoor systems. All of the manufacture’s split systems are A.H.R.I. rated only with TXV/EEV indoor systems. Some of the benefits of installing approved matched indoor and outdoor split systems are maximum efficiency, optimum performance and the best overall system reliability.

Table of Contents

Section 1. Safety ..................................................................................... 2

Section 2. Unit Location Considerations..............................................3

Section 3. Unit Preparation .................................................................... 5

Section 4. Setting the Unit ..................................................................... 5

Section 5. Refrigerant Line Considerations ......................................... 6

Section 6. Refrigerant Line Routing ..................................................... 7

Section 7. Refrigerant Line Brazing ...................................................... 8

Section 8. Refrigerant Line Leak Check .............................................10

Section 9. Evacuation ...........................................................................11

Section 10. Service Valves ................................................................... 11

Section 11. Electrical - Low Voltage .................................................... 12

Section 12. Electrical - High Voltage ................................................... 17

Section 13. Start Up .............................................................................. 18

Section 14. System Charge Adjustment ............................................. 19

Section 15. Checkout Procedures and Troubleshooting ................... 30

Page 2

Section 1. Safety

▲

WARNING

▲

WARNING

▲

WARNING

▲

WARNING

▲

CAUTION

▲

CAUTION

▲

WARNING

This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. The manufacture or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

These units use R-410A refrigerant which operates at 50 to 70% higher pressures than R-22. Use only R-410A approved service equipment. Refrigerant cylinders are painted a “Rose” color to indicate the type of refrigerant and may contain a “dip” tube to allow for charging of liquid refrigerant into the system. All R-410A systems use a POE oil that readily absorbs moisture from the atmosphere. To limit this “hygroscopic” action, the system should remain sealed whenever possible. If a system has been open to the atmosphere for more than 4 hours, the compressor oil must be replaced. Never break a vacuum with air and always change the driers when opening the system for component replacement. For specific handling concerns with R-410A and POE oil, reference Retrofit Bulletin SS-APG006-EN and APP-APG011-EN or APP-APG012-EN.

LIVE ELECTRICAL COMPONENTS! During installation, testing, servicing, and troubleshooting of this product, it may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

If using existing refrigerant lines make certain that all joints are brazed, not soldered.

Scroll compressor dome temperatures may be hot. Do not touch the top of compressor; it may cause minor to severe burning.

NOTE: It is recommended to install manufacturer approved matched indoor and outdoor systems. NOTE: All approved split systems are AHRI rated with only

TXV indoor systems.

NOTE: The beneﬁts of installing approved indoor and outdoor split systems are maxi mum efﬁciency, optimum performance and the best overall system reliability.

UNIT CONTAINS R-410A REFRIGERANT! R-410A operating pressures exceed the limit of R-22. Proper service equipment is required. Failure to use proper service tools may result in equipment damage or personal injury.

SERVICE

USE ONLY R-410A REFRIGERANT AND AP-

PROVED POE COMPRESSOR OIL.

Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclockwise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and /or property damage.

2 18-BC53D2-6

Page 3

Section 2. Unit Location Considerations

2.1 Unit Dimensions and Weight

Table 2.1

Unit Dimensions and Weight

Models H x D x W (in)

4TTZ0024A

4TTZ0036B

4TTZ0048A/B

4TTZ0060A

4TWZ0024A

4TWZ0036B

4TWZ0048A/B

4TWZ0060A

* Weight values are estimated (uncrated).

54 x 34 x 37 335

54 x 34 x 37 420

54 x 34 x 37 340

54 x 34 x 37 345

54 x 34 x 37 430

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.

Weight* (lb)

2.2 Refrigerant Piping Limits

1. The maximum length of refrigerant lines from outdoor to indoor unit should NOT exceed sixty (60) feet.

2. The maximum vertical change should not exceed twenty five (25) feet*.

3. Service valve connection diameters are shown in Table 5.1.

NOTE: For line lengths greater than sixty (60) feet, Refer to Refrigerant Piping Application Guide, SS-APG006-EN or Refrigerant Piping Software Program, 32-3312-03 (or latest revision).

Standard Line Set

60’ Max

Line Length

25’ Max Line

Lift

35’ Max

Line

Length

Restricted to maximum vertical change of 25 ft.

18-BC53D2-6 3

25’ Max Line

Lift

35’ Max

Line

Length

Page 4

Avoid Install

2.3 Suggested Locations for Best Reliability

Ensure the top discharge area is unrestricted for at least five (5) feet above the unit.

Three (3) feet clearance must be provided 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 such as near windows 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.

Near Bedrooms

Min. 12” to Shrubbery

Min 5’ Unrestricted

Min 3’ Unrestricted

Access Panel

Min. 12” to Wall

2.4 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 roof top, 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 draining 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.

Min. 12”

Snow

Barrier

Snow Legs

3-12” Elevation

Pad

4 18-BC53D2-6

Page 5

2.5 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.

Section 3. Unit Preparation

3.1 Prepare The Unit For Installation

STEP 1 - Check for damage and report prompt-

ly to the carrier any damage found to the unit.

STEP 2 - To remove the unit from the pallet, remove tabs by cutting with a sharp tool.

Section 4. Setting the Unit

4.1 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.

18-BC53D2-6 5

Page 6

Section 5. Refrigerant Line Considerations

5.1 Refrigerant Line and Service Valve Connection Sizes

Table 5.1

Line Sizes Service Valve Connection Sizes

Model

4TTZ0024A

4TTZ0036B

4TTZ0048A/B

4TTZ0060A

4TWZ0024A

4TWZ0036B

4TWZ0048A/B

4TWZ0060A

Vapor

Line

3/4 3/8 5/8 3/8

3/4 3/8 3/4 3/8

7/8 3/8 3/4 3/8

5/8 3/8 5/8 3/8

3/4 3/8 3/4 3/8

5.2 Factory Charge

Trane outdoor condensing units are factory charged with the system charge required for the outdoor condensing unit, ﬁfteen (15) feet of tested connecting line, and the smallest indoor evaporative coil match. See unit nameplate. If connecting line length exceeds ﬁfteen (15) feet and/or a larger indoor evaporative coil is installed, then ﬁnal refrigerant charge adjustment is necessary. Use Charge Assist™ or the Manual Charging procedure found in the outdoor unit Service Facts. Charge level can always be veriﬁed with the Refrigerant Charging Chart found in the Service Facts.

Liquid

Line

Vapor Line

Connection

Liquid Line

Connection

5.3 Required Refrigerant Line Length

Determine required line length and lift. You will need this later in STEP 2 of Section 14.

Total Line Length = __________ Ft.

Total Vertical Change (lift) = __________ Ft.

5.4 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.

Liquid Line

Line Length

Vapor Line

Insulation

6 18-BC53D2-6

Page 7

5.5 Reuse Existing Refrigerant Lines

▲

CAUTION

If using existing refrigerant lines make certain that all joints are brazed, not soldered.

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.

Section 6. Refrigerant Line Routing

6.1 Precautions

Important: Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines.

Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls, or other structural elements.

For Example:

• When the refrigerant lines have to 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 ductwork.

• Minimize the number of 90º turns.

8 Feet Maximum

Joist/Rafter

Isolator

Side View

8 Feet Maximum

Secure Vapor line from joists using isolators every 8 ft. Secure Liquid Line directly to Vapor line using tape, wire, or other appropriate method every 8 ft.

Line Set

18-BC53D2-6 7

Isolation From Joist/Rafter

Page 8

8 Feet Maximum

Wall

Isolator

Wall

Side View

8 Feet Maximum

Line Set

Secure Vapor Line using isolators every 8 ft. Secure Liquid Line directly to Vapor Line using tape, wire, or other appropriate method every 8 ft.

Isolation In Wall Spaces

Sealant

Ductwork

Insulation

Vapor Line

Isolator

Line Set

Isolation Through Wall

Section 7. Refrigerant Line Brazing

7.1 Braze The Refrigerant Lines

STEP 1 - Remove caps or plugs. Use a deburr-

ing tool to debur the pipe ends. Clean both internal and external surfaces of the tubing using an emery cloth.

DO NOT hang line sets from ductwork

8 18-BC53D2-6

Page 9

STEP 2 - Remove the pressure tap cap and valve cores from both service valves.

STEP 3 - Purge the refrigerant lines and indoor coil with dry nitrogen.

STEP 4 - Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge.

Braze the refrigerant lines to the service valves.

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 basepan during brazing. It is recommended to keep the flame directly off of the basepan.

18-BC53D2-6 9

Page 10

STEP 5 - Replace the pressure tap valve cores

150 PSIG

after the service valves have cooled.

Section 8. Refrigerant Line Leak Check

8.1 Check For Leaks

STEP 1 - Pressurize the refrigerant lines and

evaporator coil to 150 PSIG using dry nitrogen.

STEP 2 - Check for leaks by using a soapy solution or bubbles at each brazed location.

Remove nitrogen pressure and repair any leaks before continuing.

10 18-BC53D2-6

Page 11

Section 9. Evacuation

1/4 TURN ONLY

9.1 Evacuate the Refrigerant Lines and Indoor Coil

Important: Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete.

STEP 1 - Evacuate until the micron gauge reads no higher than 350 microns, then close off the valve to the vacuum pump.

STEP 2 - Observe the micron gauge. Evacuation is complete if the micron gauge does not rise above 500 microns in one (1) minute.

Once evacuation is complete blank off the vacuum pump and micron gauge, and close the valves on the manifold gauge set.

0350

Microns

OFF

1 MIN.

Section 10. Service Valves

10.1 Open the Gas Service Valve

Important: Leak check and evacuation must be completed before opening the service valves.

NOTE: Do not vent refrigerant gases into the atmosphere

STEP 1 - Remove valve stem cap.

STEP 2 - Using an adjustable wrench, turn valve

stem 1/4 turn counterclockwise to the fully open position.

STEP 3 - Replace the valve stem cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn.

CAP

UNIT SIDE OF VALVE

PRESSURE TAP PORT

COUNTERCLOCKWISE FOR FULL OPEN POSITION

VALVE STEM

GAS LINE CONNECTION

18-BC53D2-6 11

Page 12

10.1 Open the Liquid Service Valve

▲

WARNING

Important: Leak check and evacuation must be completed before opening the service valves.

STEP 1 - Remove service valve cap.

STEP 2 - Fully insert 3/16” hex wrench into the

stem and back out counterclockwise until valve stem just touches the rolled edge (approximately five (5) turns.)

STEP 3 - Replace the valve cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn.

Cap

Unit Side

of Service

Valve

Service Port

3/16” Hex Wrench

Rolled Edge to

Captivate Stem

Hex Headed

Valve System

Section 11. Electrical - Low Voltage

11.1 Low Voltage Maximum Wire Length

Table 11.1 defines the maximum total 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 11.1

ComfortLinkTM II Control Wiring

WIRE SIZE MAX. WIRE LENGTH

18 AWG 250 Ft.

24 VOLTS

WIRE SIZE MAX. WIRE LENGTH

18 AWG 150 Ft.

16 AWG 225 Ft.

14 AWG 300 Ft.

12 18-BC53D2-6

Page 13

11.2 Low Voltage Hook-up Diagrams

Fully Communicating System

TAM8 Communicating

Air Handler

Communicating Comfort Control

Brown Red Blue

Field wiring

Y2 Y1

D R B

Note 1

Communicating Outdoor Unit

Neatly bundle all low voltage wires behind the service valve cover as shown.

D - Note 2

B - Blue

Notes:

1. In communicating mode, unused terminals are non-functional. Do not use.

2. “D” is the data line. Installer to select a wire color.

3. 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.

4. For 24 VAC Outdoor equipment, accessory BAYCC24VK01A must be ordered separately.

Brown

Blue

Fully Communicating System

Communicating Comfort Control

Note 3

Brown Red Blue

Comm. Variable Speed

Furnace or Air Handler

R BK

D Y1 Y2 G

Note 1 W1 W2

Communicating Outdoor Unit

Neatly bundle all low voltage wires behind the service valve cover as shown.

D - Note 2

Brown

Blue

B - Blue

Notes:

1. In communicating mode, unused terminals are non-functional. Do not use.

2. “D” is the data line. Installer to select a wire color.

3. To connect optional devices (such as a float switch), wire in series from indoor unit “R” to Comfort Control “R”.

18-BC53D2-6 13

Page 14

TAM7 Air Handler

12345

2(Compressor)

2(Stag es)

AC (Sys tem)

}

OUTDOOR

Capacity (Tons)

OUTDOOR

}

Torque

CFM/Ton

Cool OffDelay

}

INDOOR

CFM

+12V

R13

R14

RNET 1

RNET 2

C22

C19

C15C

C10

with 24 Volt Control Hook-up Diagram

24 Volt

Comfort Control

W G Y1

O R B Y2

Note:

1. * For multiple stages of electric heat, jumper W1, W2, and W3 together if comfort control has only one stage of heat.

2. YI and YO connections must be made as shown for freeze protection and internally mounted condensate overflow circuits to work properly.

3. If a 3rd party condensate overflow switch is installed, it should be wired in ser ies between YO and Y to the outdoor unit.

4. Air conditioner models do not use the Black (X2) or Orange wires from the outdoor unit.

5. For non-communicating applications, use 24 volt harness accessor y BAYACHP024A.

Field wiring

White Green Yellow Orange Red Blue Brown

TAM7 Air Handler

W3 * W2 W1

(In)

YI O R B

(Out)

Neatly bundle all low voltage wires behind the service valve cover as shown.

W1 - White

Y2 - Brown

O - Orange R - Red B - Blue Y1 - Yellow

Air Conditioner or Heat Pump -

Black

(X2)

Yellow/Red

Orange

Note 4

Red

Note 5

Yellow

Blue

TAM7 Air Handler with 24 Volt Control Hook-up Diagram (Continued)

Control Board

14 18-BC53D2-6

Must configure to “OFF” for heat pump.

Must configure to “ON” for 20 SEER (2 stages)

Must configure to “ON” for 20 SEER (2 compressors)

Page 15

Communicating Indoor Unit with 24 Volt Control Hook-up Diagram

Air Conditioner or Heat Pump -

Neatly bundle all low voltage wires behind the service valve cover as shown.

Note 6

Comm. Variable Speed

Furnace or Air Handler -

Comfort Control

R Y1 Y2

Notes:

1. See User Interface setup menu for 24 VAC control mode and cooling CFM options.

2. First stage CFM for 4TTZ0 and 4TWZ0 equals 50%.

3. For furnace+heat pump applications, comfort control must be dual fuel capable or use accessory TAYPLUS103A.

4. W3 terminal may not be present on indoor unit.

5. Comfort Control may not have W2 or W3 terminals.

6. Air conditioner models do not use Black (X2) or Orange wires from the outdoor unit.

7. For non-communicating applications, use 24 volt harness accessory BAYACHP024A.

Red Yellow Brown Green White

Blue Orange

Y1 Y2

G W1 W2 W3

BK D

Note 1

Red

Yellow

Brown

Black

Yellow

Red

Yellow/Red

Black

(X2)

Note 7

Orange

Blue

Orange

18-BC53D2-6 15

Page 16

11.3 Defrost Control (Heat Pump only)

FRC_DFT

TEST_COMMON

TST

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.

FAULT IDENTIFICATION A fault condition is indicated by the fault LED on the control board inside the heat pump control box.

In normal operation, the status LED will ﬂash once each second. If the light is ﬂashing more than once per second or not at all, refer to the Service Facts for that unit.

PIN IDENTIFICATION

1. TEST_COMMON (Shorting any of the other pins to this pin causes the function of the other pin to be executed. Leaving this pin open results in the normal mode of operation.)

2. TST = Test (Shorting TEST_COMMON to this pin speeds up all defrost board timings.)

3. FRC_DFT = Forced Defrost (Short TEST_COMMON to this pin for two [2] seconds to initiate a forced defrost. Remove the short after defrost initiates.)

OUTDOOR CONTROL BOARD – PIN IDENTIFICATION

DEFROST CONTROL CHECKOUT Normal operation requires:

a. Status LED on board ﬂashing 1 time/sec-

ond.

b. 12 VDC between D & B in communicating

mode.

c. 24 VAC between R & B in 24V mode.

d. Defrost initiation when FRC_DFT pin is

shorted to TEST_COMMON pin.

If a defrost control problem is suspected, refer to the service information in control box.

16 18-BC53D2-6

Page 17

Section 12. Electrical - High Voltage

▲

WARNING

12.1 High Voltage Power Supply

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.

12.2 High Voltage Disconnect Switch

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.

12.3 High Voltage Ground

Ground the outdoor unit per national, state, and local code requirements.

18-BC53D2-6 17

Page 18

Section 13. Start Up

OFF

DON

CANCEL

OFF

13.1 System Start Up

STEP 1 - Ensure Sections 7 through 12 have

been completed.

STEP 2 - Set System Thermostat to OFF.

STEP 3 - Turn on disconnect(s) to apply power

to the indoor and outdoor units.

STEP 4 - Wait one (1) hour before starting the unit if compressor crankcase heater accessory is used and the Outdoor Ambient is below 70ºF.

STEP 5 - Set system thermostat to ON.

60 MIN.

DON

CANCEL

18 18-BC53D2-6

Page 19

Section 14. System Charge Adjustment

14.1 Temperature Measurements

STEP 1 - Check the outdoor temperatures.

Subcooling (in cooling mode) is the only recommended method of charging above 55º F ambient outdoor temperature. See Section 14.2.

For outdoor temperatures below 55º F, follow the Superheat charging instructions (in heating mode). See Section 14.6.

NOTE: It is important to return in the spring or summer to accurately charge the system in the cooling mode with outdoor ambient temperature below 55ºF.

See Section 14.2 for

Outdoor

Temperatures

Above 55º F

See Section 14.6 for

Outdoor

Temperatures

Below 55º F

120º F

55º F

Outdoor Temp 1

55º F

Outdoor Temp 2

For best results the indoor temperature should be kept between 70º F to 80º F.

14.2 Subcooling Charging in Cooling (Above 55º F Outdoor Temp.)

STEP 1 - Use the refrigerant line total length

and lift measurements from Section 5.3.

Total Line Length = __________ Ft.

Vertical Change (Lift) = __________ Ft.

80º F

70º F

Indoor Temp

LIFT

18-BC53D2-6 19

Page 20

STEP 2 - U

sing the total Line Length and Lift measured in STEP 1 and the subcool charging table corrections below,

determine the Dip Switch position for your model.

SUBCOOL CHARGING TABLE CORRECTIONS

SUBCOOL CHARGING TABLE CORRECTIONS FOR LINE LENGTH AND RISE

TABLE A TABLE B

All other approved, matched systems.

Dip Switch 1- ON

REFRIGERANT LINE LIFT (FEET)

2-TON HP MODEL ONLY

10 20 25 30 40 60 80

TOTAL REFRIGERANT LINE LENGTH (FEET)

SUBCOOL CHARGING TABLE CORRECTIONS FOR LINE LENGTH AND RISE

Max Lift

Dip Switch 2-ON

TABLE A TABLE B

4TEE3_03 Air Handler Downflow & Horizontal Left Only

4TXCB003 Coil Downflow & Horizontal Right Only 4TXCC006 Coil Downflow & Horizontal Right Only

REFRIGERANT LINE LIFT (FEET)

10 20 25 30 40 60 80

TOTAL REFRIGERANT LINE LENGTH (FEET)

Max Lift

Dip Switch 3-ON

These matches ONLY

Dip Switch 2-ON

REFRIGERANT LINE LIFT (FEET)

4-TON HP MODEL ONLY

10 20 25 30 40 60 80

TOTAL REFRIGERANT LINE LENGTH (FEET)

SUBCOOL CHARGING TABLE CORRECTIONS FOR LINE LENGTH AND RISE

LOWER Dip Switch 1- ON

REFRIGERANT LINE LIFT (FEET)

10 20 25 30 40 60 80

5-TON HP MODELS ONLY

TOTAL REFRIGERANT LINE LENGTH (FEET)

All other approved, matched systems.

Max Lift

Dip Switch 3-ON

All other approved, matched systems.

Max Lift

UPPER

MIDDLE Dip Switch 2-ON

Dip Switch 3-ON

4TEE3_06 Air Handler 4TXCC008 Coil 4TXCD010 Coil

REFRIGERANT LINE LIFT (FEET)

10 20 25 30 40 60 80

TOTAL REFRIGERANT LINE LENGTH (FEET)

4TEE3_10 Downflow & Horizontal Left Only

REFRIGERANT LINE LIFT (FEET)

10 20 25 30 40 60 80

TOTAL REFRIGERANT LINE LENGTH (FEET)

These matches ONLY

Max Lift

Dip Switch 1-ON

Max Lift

Dip Switch 3-ON

SUBCOOL CHARGING TABLE CORRECTIONS FOR LINE LENGTH AND RISE

AND

ALL AC MODELS

3-TON HP MODELS

20 15

REFRIGERANT

LINE LIFT (FEET)

LOWER

Dip Switch 1- ON

10 20 25 30 40 60 80

Dip Switch setting from Subcool Charging Table Corrections = __________

Set Dip Switch on the Charge AssistTM control board.

20 18-BC53D2-6

All approved, matched systems.

Max Lift

MIDDLE

Dip Switch 2-ON

TOTAL REFRIGERANT LINE LENGTH (FEET)

UPPER

Dip Switch 3-ON

Page 21

14.3 Determine the charge adjustment procedure

Final refrigerant charge adjustment is necessary. Choose the appropriate method below.

• Charge AssistTM procedure in Section 14.4

• Manual charging procedure in Section 14.5

14.4 Charge AssistTM Procedure

NOTE: Outdoor Temperature (ODT) must be between 55°F and 120°F. See Section 14.1

IMPORTANT: Be sure to set Dip Switches on the Outdoor Control Board for Line Length and Lift before entering Charge Assist™ Mode. See Section 14.2

STEP 1 - To enter Charge Assist™ Mode, press the MODE button for at least one (1) second. The on-board LEDs will indicate if the system is capable of continuing. For a detailed description of on-board LEDs and their function, see the Service Facts.

The system will take approximately 12-20 minutes to stabilize before the charge can be checked by Charge Assist™. Once the system is stabilized, watch to see which LED turns on next. If the system charge is correct, the “CHARGED” LED will turn on and remain on for one (1) hour. Once charged, the system will exit Charge Assist™ and control will return to the Comfort Control.

STEP 2 - If the system charge is low, the “ADD” LED will turn on and stay on up to one (1) hour or until enough refrigerant is added to reach the required system charge level and turn on the “CHARGED” LED.

When the “ADD” LED is on, the charging solenoid output will be active. This feature works to automatically control refrigerant ﬂow with BAYCAKT001.

OUTDOOR CONTROL BOARD –

CHARGE ASSIST™

CHARGE ASSIST™ PORT

STEP 3 - If the system charge is high, the “REC”

LED will turn on and the unit will exit Charge Assist™. You must recover refrigerant from the system before re-entering Charge Assist™.

For instructions on the Charge Assist™ tool BAYCAKT001, see the Installer’s Guide 18-HH15D1-* (the position of the * denotes the latest revision number).

18-BC53D2-6 21

NOTE: Charge Assist™ port is designed for liquid refrigerant charging.

Page 22

14.5 Manual Charging Procedure in Cooling between 55°F and 120°F OD Ambient

NOTE: Outdoor Temperature (ODT) must be between 55°F and 120°F. See Section 14.1

IMPORTANT: Be sure to set Dip Switches on the Outdoor Control Board for Line Length and Lift. Use the corresponding charge chart and dip switch column in Section 14.2 to determine desired liquid pressure when using the manual charging procedure.

STEP 1 - Stabilize the system by operating for a minimum of 20 minutes.

At startup, or whenever charge is removed or added, the system must be operated for a minimum of 20 minutes to stabilize before accurate measurements can be made.

20 MIN.

STEP 2 - Measure the liquid line temperature and pressure at the outdoor unit’s service valve.

Measured Liquid Line Temp = __________ º F

Liquid Gage Pressure = __________ PSIG

Dip Switch setting from 14.2 Step 2 __________

107 °F

22 18-BC53D2-6

Page 23

Use the liquid line temperature and liquid line

p (°F)

gage pressure from Step 2, along with the Dip Switch setting column, to determine the proper Liquid Gage Pressure.

STEP 3 - Find the appropriate refrigerant charging chart on the following page for your system type and tonnage.

STEP 4 - Locate your liquid line temperature in the left column of the table and the intersecting liquid line gage pressure under the DIPSWITCH selection column.

Example:

• A 3 ton AC is installed with line length of 30

feet and a line lift of 15 feet.

• The Dip Switch setting is 2-ON.

• The measured liquid line temperature is

85°F and the Liquid Gage Pressure is 299 PSIG.

299 PSIG is shown as the intersection of the

Dip Switch ON column and the 85°F Liquid Temperature row.

3 TON AC R410A REFRIGERANT CHARGING CHART

ONLY DIPSWITCH

Liquid

Tem

55 186 186 190 60 202 202 206 65 219 219 222 70 237 237 240 75 256 256 260 80 277 277 280 85 299 299 302 90 322 322 325

95 346 346 350 100 371 371 375 105 397 397 402 110 425 425 430 115 454 454 460 120 484 484 491 125 515 515 523

LIQUID GAGE PRESSURE (PSIG)

1 ON

LOWER * MIDDLE UPPER

* Data is based on 10.5° of subcooling at a 95° ambient

ONLY DIPSWITCH

2 ON

PRINTED FROM D155861P02 REV 2

ONLY DIPSWITCH

3 ON

Example

18-BC53D2-6 23

Page 24

p (°F)

2 TON AC R410A REFRIGERANT CHARGING CHART

PRINTED FROM D155861P02 REV 2

p (°F)

PRINTED FROM D155859P02 REV 4

p (°F)

ONLY DIPSWITCH

2 Ton AC

Liquid

Tem

55 191 196 197 60 205 210 212 65 221 226 227 70 237 243 244 75 255 261 263 80 274 281 283 85 295 302 305 90 316 325 328

95 339 349 352 100 364 374 378 105 390 401 406 110 417 430 435 115 445 460 465 120 475 491 497 125 505 524 530

3 TON AC R410A REFRIGERANT CHARGING CHART

ONLY DIPSWITCH

3 Ton AC

Liquid

Temp (°F)

55 186 186 190

60 202 202 206

65 219 219 222

70 237 237 240

75 256 256 260

80 277 277 280

85 299 299 302

90 322 322 325

95 346 346 350 100 371 371 375 105 397 397 402 110 425 425 430 115 454 454 460 120 484 484 491 125 515 515 523

** With AM7 or AM8: Dip switch 1 = 11° of subcooling at 95° ambient

4 TON AC R410A REFRIGERANT CHARGING CHART

ONLY DIPSWITCH

4 Ton AC

Liquid

Tem

55 200 203 208

60 217 221 225

65 235 239 243

70 254 258 263

75 274 279 284

80 295 301 306

85 318 323 329

90 341 347 354

95 366 372 379 100 392 398 406 105 418 426 434 110 446 454 464 115 475 483 495 120 506 514 526 125 537 545 560

** With AM7 or AM8: Dip Switch 1 = 13° subcooling at a 95° ambient

5 TON AC R410A REFRIGERANT CHARGING CHART

ONLY DIPSWITCH

5 Ton AC 5 Ton HP

Liquid

Tem

55 191 197 201

60 207 213 218

65 224 231 236

70 242 249 255

75 261 268 275

80 281 289 296

85 302 310 318

90 324 333 342

95 347 356 366 100 372 381 392 105 397 407 418 110 423 434 446 115 451 462 474 120 479 491 504 125 509 521 535

LIQUID GAGE PRESSURE (PSIG)

1 ON

LOWER * MIDDLE UPPER

* Data is based on 10.1° of subcooling at a 95° ambient

1 ON **

LOWER * MIDDLE UPPER

1 ON **

LOWER * MIDDLE UPPER

* Data is based on 15.0° of subcooling at a 95° ambient

1 ON

LOWER * MIDDLE UPPER

* Data is based on 11.2° of subcooling at a 95° ambient

ONLY DIPSWITCH

2 ON

PRINTED FROM D155861P01 REV 2

LIQUID GAGE PRESSURE (PSIG)

ONLY DIPSWITCH

2 ON

* Data is based on 10.5° of subcooling at a 95° ambient

LIQUID GAGE PRESSURE (PSIG)

ONLY DIPSWITCH

2 ON

PRINTED FROM D155861P03 REV 2

LIQUID GAGE PRESSURE (PSIG)

ONLY DIPSWITCH

2 ON

PRINTED FROM D155861P04 REV 2

ONLY DIPSWITCH

3 ON

ONLY DIPSWITCH

3 ON

ONLY DIPSWITCH

3 ON

ONLY DIPSWITCH

3 ON

2 Ton HP

3 Ton HP

4 Ton HP

Note: See page 20 for subcool charging correction tables A and B

2 TON HP R410A REFRIGERANT CHARGING CHART

ONLY DIPSWITCH

Liquid

Temp (°F)

55 192 199 210 60 206 213 227 65 221 229 245 70 238 246 264 75 256 264 284 80 275 284 306 85 295 305 329 90 316 327 354

95 339 350 380 100 363 374 407 105 388 400 435 110 415 427 465 115 443 456 497 120 471 485 529 125 502 516 563

3 TON HP R410A REFRIGERANT CHARGING CHART

ONLY DIPSWITCH

Liquid

Temp (°F)

55 194 195 199

60 208 210 215

65 224 227 232

70 242 246 250

75 260 265 270

80 280 286 291

85 301 308 313

90 324 331 337

95 348 356 362 100 373 382 388 105 399 409 416 110 427 438 445 115 456 467 475 120 486 498 507 125 517 531 540

** With AM7 or AM8: Dip switch 1 = 10° of subcooling at 95° ambient

4 TON HP R410A REFRIGERANT CHARGING CHART

ONLY DIPSWITCH

Liquid

Temp (°F)

SEE TABLE B ** SEE TABLE A * SEE TABLE A

55 202 204 206

60 217 220 223

65 234 238 240

70 251 256 259

75 270 277 280

80 290 298 301

85 312 321 325

90 334 345 349

95 358 370 375 100 383 397 403 105 409 425 432 110 436 454 462 115 465 485 494 120 494 516 527 125 525 550 562

** With AM7 or AM8: Dip switch 1 = 13° of subcooling at 95° ambient

5 TON HP R410A REFRIGERANT CHARGING CHART

ONLY DIPSWITCH

Liquid

Tem

55 208 208 210

60 225 225 227

65 242 242 245

70 260 260 264

75 280 280 284

80 300 300 305

85 322 322 327

90 345 345 350

95 369 369 374 100 394 394 400 105 420 420 426 110 447 447 454 115 476 476 483 120 505 505 513 125 536 536 544

LIQUID GAGE PRESSURE (PSIG)

1 ON

SEE TABLE A * SEE TABLE A SEE TABLE B

1 ON **

LOWER * MIDDLE UPPER

1 ON

LOWER * MIDDLE

* Data is based on 14.8° of subcooling at a 95° ambient

** Data is based on 16.7° of subcooling at a 95° ambient

ONLY DIPSWITCH

2 ON

* Data is based on 9.5° of subcooling at a 95° ambient

** Data is based on 18.0° of subcooling at a 95° ambient

* Data is based on 11.5° of subcooling at a 95° ambient

* Data is based on 15.9° of subcooling at a 95° ambient

** Data is based on 13.5° of subcooling at a 95° ambient

PRINTED FROM D155859P01 REV 4

LIQUID GAGE PRESSURE (PSIG)

ONLY DIPSWITCH

2 ON

LIQUID GAGE PRESSURE (PSIG)

ONLY DIPSWITCH

2 ON

PRINTED FROM D155859P03 REV 4

LIQUID GAGE PRESSURE (PSIG)

ONLY DIPSWITCH

2 ON

PRINTED FROM D155859P04 REV 4

ONLY DIPSWITCH

UPPER & 4TEE3_10

DOWNFLOW & HORIZ.

LEFT **

3 ON

Page 25

STEP 5 - Adjust refrigerant level to attain

PRESSURE CURVES FOR 4TWX5049E1000B

proper gage pressure.

Add refrigerant if the Liquid Gage Pressure is lower than the chart value.

1. Connect gages 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 matches the charging chart.

Recover refrigerant if the Liquid Gage Pressure is higher than the chart value.

STEP 6 - Stabilize the system.

1. 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.

2. Remove gages.

3. Replace service port caps to prevent leaks. Tighten ﬁnger tight plus an additional 1/6 turn.

STEP 7 - Verify typical performance.

Refer to System Pressure Curves in the Service Facts to verify typical performance.

20 MIN.

(Example only - see Service Facts)

4TEE3F49C1 4TEE3F49C1

Cooling @ 1450 SCFM Heating @ 1350 SCFM

550

INDOOR ENTERING WET BULB CURVES TOP TO BOTTOM

500

71, 67, 63 AND 59 DEG F.

450

400

350

(4)

INDOOR ENTERING WET BULB CURVES TOP TO BOTTOM 71, 67, 63 AND 59 DEG F.

(5)

(3)

(1)

OUTDOOR TEMPERATURE (Degree F)

(3)

(1)

300

250

200

DISCHARGE PRESSURE (PSIG)

40 60 80 100 120

170

165

160

155

150

145

140

135

130

125

120

115

SUCTION PRESSURE (PSIG)

110

40 60 80 100 120

500

INDOOR ENTERING DRY BULB CURVES

(2)

TOP TO BOTTOM

450

80, 70, AND 60 DEG F.

400

350

300

250

200

-5 5 15 25 35 45 55 65

140

INDOOR ENTERING DRY BULB CURVES

130

TOP TO BOTTOM

120

80, 70, AND 60 DEG F.

(2)

110

100

-5 5 15 25 35 45 55 65

18-BC53D2-6 25

Page 26

STEP 8 - Record System Information for reference.

Record system pressures and temperatures after charging is complete.

Outdoor model number = _________________

Measured Outdoor Ambient = __________ º F

Measured Indoor Ambient = __________ º F

Measured Liquid Line Temp = __________ º F

14.6 Subcooling Charging Below 55º F Outdoor Temp. (In Heating Only)

STEP 1 - Check the outdoor temperature. If

the ODT is less than 55º F, follow these charging instructions for the heating mode of operation. For temperatures above 55º F, see Section 14.1.

NOTE: It is important to return in the spring or summer to accurately charge the system in the cooling mode with outdoor ambient above 55ºF.

Measured Suction Line Temp = __________ º F

Liquid Gage Pressure = __________ PSIG

Suction Gage Pressure = __________ PSIG

Dip Switch Selection = _____________

55º F

Outdoor Temp

80º F

70º F

Indoor Temp

For best results the indoor temperature should be kept between 70º F and 80º F. See the Indoor Temp illustration. Add system heat if needed.

STEP 2 - Stabilize the system by operating in the heating mode for a minimum of 20 minutes.

Important: Whenever charge is added or removed, the system must run for a minimum of 20 minutes before accurate measurements can be made.

20 MIN.

26 18-BC53D2-6

Page 27

STEP 3 - Measure the suction line pressure and temperature at the “true” suction line and record the values below.

NOTE: the side service panel will need to be removed to gain access to this area.

Attach temperature probe and the gage as shown. Ensure the probe is securely attached and well insulated.

Measured Suction Line Temperature = __________º F

36 °F

Measured Suction Line Pressure = __________º F

Compare these values to the 15 degree superheat chart in Table 13.2.

18-BC53D2-6 27

Page 28

STEP 4 - Use the measured values from Step 3 to determine a target superheat of 15 degrees.

Table 13.2

15 degree Superheat Chart

Example: Assume a suction pressure of 81 PSIG and a suction temperature of 36º F.

When the suction temperature is in line with the suction gage pressure, the target superheat value will be 15 degrees. (Example values highlighted in Table 13.2)

Suction Line

Temp

10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 70

Suction Gage

Pressure

42 44 47 50 52 55 58 61 64 67 70 74 77 81 84 88 92

96 100 104 108 112 117 121 126 131 136 141 157

STEP 5 - Adjust refrigerant level to attain 15 degrees of superheat.

Add refrigerant if the suction line temperature is above the value that is in line with the measured suction gage pressure.

1. Connect gages as shown in Step 3.

2. Purge all hoses.

3. Open bottle.

4. Stop adding refrigerant when the suction line temperature is in line with the measured suction line pressure in Table

13.2.

Recover refrigerant if the suction line temperature is lower than the temperature that is in line with the system’s suction pressure.

28 18-BC53D2-6

Page 29

STEP 6 - Stabilization and completion.

PRESSURE CURVES FOR 4TWX5049E1000B

1. Wait 20 minutes for the system condi-

tion to stabilize between adjustments.

NOTE: When the suction temperature is in line with the suction gage pressure, the target superheat value will be 15 degrees.

2. Remove gages.

3. Replace service port caps to prevent

leaks. Tighten ﬁnger tight plus an additional 1/6 turn.

STEP 7 - Target 10–15 degrees of subcooling using Section 14.1 as a guide.

NOTE: It is important to return in the spring or summer to accurately charge the system in the cooling mode with outdoor ambient above 55ºF.

20 MIN.

STEP 8 - Verify typical performance.

Refer to System Pressure Curves in the Service Facts to verify typical performance.

(Example only - see Service Facts)

4TEE3F49C1 4TEE3F49C1

Cooling @ 1450 SCFM Heating @ 1350 SCFM

550

INDOOR ENTERING WET BULB CURVES TOP TO BOTTOM

500

71, 67, 63 AND 59 DEG F.

450

400

350

(4)

300

250

200

DISCHARGE PRESSURE (PSIG)

40 60 80 100 120

170

INDOOR ENTERING WET BULB CURVES

165

TOP TO BOTTOM

160

71, 67, 63 AND 59 DEG F.

155

150

145

140

135

130

125

120

115

SUCTION PRESSURE (PSIG)

110

40 60 80 100 120

(3)

(1)

(5)

(3)

(1)

OUTDOOR TEMPERATURE (Degree F)

500

INDOOR ENTERING DRY BULB CURVES

(2)

TOP TO BOTTOM

450

80, 70, AND 60 DEG F.

400

350

300

250

200

-5 5 15 25 35 45 55 65

140

INDOOR ENTERING DRY BULB CURVES

130

TOP TO BOTTOM

120

80, 70, AND 60 DEG F.

(2)

110

100

-5 5 15 25 35 45 55 65

18-BC53D2-6 29

Page 30

Section 15. Checkout Procedures and Troubleshooting

15.1 Operational And Checkout Procedures

Final phases of this installation are the unit Operational and Checkout Procedures. To obtain proper performance, all units must be operated and charge adjustments made.

Important: Perform a final unit inspection to be sure that factory tubing has not shifted during shipment. Adjust tubing if necessary so tubes do not rub against each other when the unit runs. Also be sure that wiring connections are tight and properly secured.

Electric heaters, if used, are to be installed in the air handling device according to the instructions accompanying the air handler and the heaters.

IMPORTANT: See Limited Warranty information in Use and Care Manual.

CHECKOUT PROCEDURE

After installation has been completed, it is recommended that the entire system be checked against the following list:

1. Leak check refrigerant lines. ........................................ [ ]

2. Properly insulate suction lines and ﬁttings. ................... [ ]

3. Properly secure and isolate all refrigerant lines. ........... [ ]

4. Seal passages through masonry. If mortar is used, prevent mortar from coming

into direct contact with copper tubing. .......................... [ ]

5. Verify that all electrical connections are tight. ............... [ ]

6. Observe outdoor fan during on cycle for clearance

and smooth operation. .................................................. [ ]

7. Be sure that indoor coil drain line drains freely. Pour water

into drain pan. ............................................................... [ ]

8. Be sure that supply registers and return grilles are open

and unobstructed. ......................................................... [ ]

9. Be sure that a return air ﬁlter is installed. ..................... [ ]

10. Be sure that the correct airﬂow setting is used.

(Indoor blower motor) ................................................... [ ]

11. Operate complete system in each mode to

ensure safe operation. .................................................. [ ]

30 18-BC53D2-6

Page 31

15.2 Troubleshooting

WHAT TO CHEC K MOD E

SYSTEM FAULTS

REFRIGERANT CIRCUIT

Head Pressure Too High

Head Pressure Too Low

Suction Pressure Too High

Suction Pressure Too Low

Liquid Refrig. Floodback (TXV/EEV)

Liquid Refrig. Floodback (Cap. Tube)

I.D. Coil Frosting

Compressor Runs Inadequate or No Cooling/Htg

ELECTRICAL

Compressor & O.D. Fan Won’t Start

Compressor Will Not Start But O.D. Fan Runs

O.D. Fan Won’t Start

Compressor Hums But Won’t Start

Compressor Cycles on IOL

I.D. Blower Won’t Star t

DEFROST

Unit Won’t Initiate Defrost

Defrost Te rminates on Time

Unit Icing Up

HIG H VOLTAGE WIRI NG

COM PRES SOR IOL

POWE R SUP PLY

START CA PAC ITOR

RUN C APACITOR

CON TROL TRAN SFOR MER

CON TAC TOR CO NTACTS

LOW VOLTAGE WIRIN G

START RE LAY

REF. UNDER CHARGE

INE FFIC IEN T COM P.

EXC ESSI VE EVAP. LOAD

REF. OVERCH ARGE

STU CK CO MPRE SSO R

LOW VOLTAGE FUSE

CON TAC TOR CO IL

THE RMOS TAT

PPP

NON COND ENS ABLE S

O.D. AIR R ECIR CULATION

TXV /EEV STUC K OPE N

RES. O.D. A IRFL OW

C - Cooling H - Heating P - Primary Causes S - Secondary Causes * - 3 Phase Only

REF. CIR. RES TRICTIO NS

RES. I.D. AIRFL OW

SUP ERHE AT

CHE CK VALVE LEAKING

SOV CO IL DE FEC TIVE

SOV LE AKI NG

DEF ROST CONT ROL DE F.

DEF ROST RELAY DE F.

18-BC53D2-6 31

Page 32

32 18-BC53D2-6

The manufacturer has a policy of continuous product and product data improvement and it reserves the right to change design and specifications without notice.

Representative-only illustrations included in this document.

Trane 4TTZ0, 4TWZ0 Installer's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual