Trane 4TTZ0024A, 4TWZ0024A, 4TTZ0036A, 4TWZ0036A, 4TTZ0048A Installer's Manual
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WARNING
!
WARNING
!
CAUTION
!
UNIT CONTAINS R-410A REFRIGERANT!
R-410A OPERATING PRESSURE EXCEEDS 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
APPROVED POE/AB COMPRESSOR OIL.
1’ Behind
From Service Panel
3’
5’ Above
Unrestricted
18-BC53D2-3
Installer’s Guide
Air Conditioner/Heat Pump
4TTZ0/4TWZ0 with ComfortLink™ 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 and illustrations do not cover all variations in systems nor provide for every possible contingency
to be met in connection with installation. All phases of this
installation must comply with NATIONAL, STATE AND
LOCAL CODES. 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.
A. GENERAL
Single Unit Installation
1
™
This information is intended for use by individuals pos ses s ing
adequate backgrounds of electrical and mechanical experience. Any
attempt to repair a central air condition ing product may result in
personal injury and or property damage. The manufacturer or seller
cannot be respon sible for the interpretation of this information, nor
can it assume any liability in connection with its use.
NOTICE:
Trane has always recommended installing Trane approved
matched indoor and outdoor systems.
The benefits of installing approved matched systems are maximum efficiency, optimum performance and best overall system
reliability.
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/AB
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/AB oil, reference Retrofit Bulletin TRN-APG02EN. Check for transportation damage after unit is uncrated. Re port
promptly, to the carrier, any damage found to the unit.
oil that readily absorbs moisture from the atmosphere.
Check for transportation damage after unit is uncrated. Report
promptly, to the carrier, any damage found to the unit.
To determine the electrical power requirements of the unit, refer
to the nameplate of the unit. The electrical power available must
agree with that listed on the nameplate.
B. LOCATION AND PREPARATION OF THE UNIT
(INFORMATION APPLICABLE TO HEAT PUMPS ONLY:)
The Heat Pump has been designed and manufactured to withstand
and operate in severe winter conditions. However, there are precautionary steps which should be taken at the time of installation
which will help assure the efficient operation of the unit. It is rec-
ommended that these precautions be taken for units being
installed in areas where snow accumulation and prolonged
below freezing temperatures occur.
1. Units should be elevated three (3) to twelve (12) inches above
the pad or roof top, depending on local weather. This additional
height will allow better drainage of snow and ice (melted during defrost cycle) prior to its refreezing. This should prevent a
build-up of ice around the unit which occurs when unit is not
elevated. Insure that drain holes in unit base pan are
not obstructed preventing draining of defrost water.
2. 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 and should be of sufficient distance from the unit
to prevent restriction of airflow to and from the unit. Also
allow for proper maintenance space. The barrier should be
constructed of materials which will blend in with the building
design.
3. Avoid locating the unit where condensation and freezing of defrost vapor may annoy the customer. For instance, installing
the unit under a bedroom, kitchen, or picture window may be
annoying to the customer since condensate and fog will occur
during the defrost cycle.
4. Avoid locating the unit under the eaves or other overhead
structures as sizeable icicles may form and the unit may be
damaged by these falling icicles.
Installer’s Guide
CAUTION
!
WARNING
!
BASEPAN
2
TAB REMOVAL
(INFORMATION APPLICABLE TO ALL UNITS:)
1. When removing unit from the pallet, notice the tabs on the
basepan. Remove tabs by cutting with a sharp tool as shown
in Figure 2 and slide unit off of pallet.
2. The unit should be set on a level support pad at least as
large as the unit base pan, such as a concrete slab. If this is
not the application used please refer to Application Guide
SSC-APG005-EN.
3. The support pad must NOT be in direct contact with any
structure. Unit must be positioned a minimum of 12" from
any wall or surrounding shrubbery to insure adequate airflow.
Clearance must be provided in front of control box (access
panels) and any other side requiring service access to meet
National Electrical Code. Also, the unit location must be far
enough away from any structure to prevent excess roof run-off
water from pouring directly on the unit. Do not locate unit(s)
close to bedroom(s).
4. The top discharge area must be unrestricted for at least five
(5) feet above the unit. See Figure 1.
5. When the outdoor unit is mounted on a roof, be sure the roof
will support the unit’s weight. Properly selected isolation is
recommended to prevent transmission to the building structure.
6. The maximum length of refrigerant lines from outdoor to
indoor unit should NOT exceed eighty (80) feet.
7. If outdoor unit is mounted above the air handler, maxi mum
lift should not exceed twenty-five (25) feet (suction line). If
air handler is mounted above condensing unit, maximum lift
should not exceed twenty-five (25) feet (liquid line).
8. Locate and install indoor coil or air handler in accordance
with instruction included with that unit.
C. INSTALLING REFRIGERANT LINES
If using existing refrigerant lines make certain that all joints are
brazed, not soldered.
Condensing units have provisions for braze connections.
Pressure taps are provided on the service valves of outdoor unit for
compressor suction and liquid pressures.
The indoor end of the recommended refrigerant line sets may
be straight or with a ninety (90) degree bend, depending upon
situation requirements. This should be thoroughly checked out
before ordering refrigerant line sets.
NOTE:
The gas line must always be insulated. Liquid lines that run
through attic space must also be insulated.
The units are factory charged with the system charge required
when using fifteen (15) feet of rated connecting line. See unit
nameplate.
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.
NOTE:
Large diameter tubing will be very difficult to rebend once it has
been shaped.
3. Determine the best starting point for routing the refrigerant
tubing — INSIDE OR OUTSIDE THE STRUCTURE.
4. Provide a pull-thru hole of sufficient size to allow both liquid
and gas lines.
5. Be sure the tubing is of sufficient length.
6. Uncoil the tubing — do not kink or dent.
7. Route the tubing making all required bends and properly
secure the tubing before making connections.
8. To prevent a noise within the building structure due to vibration transmission from the refrigerant lines, the following
precautions should be taken:
a. When the refrigerant lines have to be fastened to floor
joists or other framing in a structure, use isolation type
hangers.
b. Isolation hangers should also be used when refrigerant
lines are run in stud spaces or enclosed ceilings.
c. Where the refrigerant lines run through a wall or sill, they
should be insulated and isolated.
d. Isolate the lines from all ductwork.
D. SERVICE VALVE OPERATION
BRASS LIQUID LINE SERVICE VALVE
The Brass Liquid Line Service Valve is factory shipped in the
seated position to hold factory charge. The pressure tap service
port (when depressed) opens only to the field brazing side of the
valve when the valve is in the seated position. The liquid line valve
is not a back seating valve (see WARNING below).
Extreme caution should be exercised when opening the Liquid
Line Service Valve. Turn valve stem counterclockwise only until
the stem contacts the rolled edge. (See Figure 3). 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.
BRASS GAS LINE BALL SERVICE VALVE
The Brass Gas Line Service Valve is shipped in the closed position
to hold the factory refrigerant charge. The pressure tap service
port (when depressed) opens only to the field brazing side when the
valve is in the closed position.
The Gas Line Ball Service Valve is full open with a 1/4 turn. See
Figure 4.
BRAZING REFRIGERANT LINES
1. Remove lower access cover to access service valves.
2. Before brazing, remove plugs from external copper stub tubes.
Clean internal and external surfaces of stub tubes prior to
brazing.
3. Cut and fit tubing, minimizing the use of sharp 90° bends.
4. Insulate the entire gas line and its fittings.
5. Do NOT allow uninsulated liquid line to come in direct contact with bare gas line.
3
LIQUID LINE SERVICE VALVE
1. Determine the most practical way to run the lines.
2. Consider types of bends to be made and space limitations.
© 2009 Trane 18-BC53D2-3
Installer’s Guide
WARNING
!
CAP
1/4 TURN ONLY
COUNTERCLOCKWISE
FOR FULL OPEN
POSITION
VALVE STEM
GAS LINE CONNECTION
UNIT SIDE
OF VALVE
PRESSURE TAP PORT
4
6. Precautions should be taken to avoid heat damage
NOTE:
Use care to make sure that no moisture enters pressure tap port,
while wet rag is being used.
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.
7. Use a Dry Nitrogen Purge and Brazing Alloy without flux
8. Braze using accepted good brazing techniques.
LEAK CHECK
IMPORTANT:
Replace pressure tap port valve core before attaching hoses for evacuation.
GAS LINE BALL SERVICE VALVE
to the pressure tap valve core during brazing. It is
recommended that the pressure tap port valve core be
removed and a wet rag wrapped around the valve body.
when brazing the field line to the copper factory connection.
Flow dry nitrogen into either valve pressure tap port, thru the
tubing and out the other port while brazing.
NOTE:
DO NOT VENT REFRIGERANT INTO THE ATMOSPHERE.
NOTE:
A 3/16" Allen wrench is required to open liquid line service valve.
A 1/4" Open End or Adjustable wrench is required to open gas
line valve. A 3/4" Open End wrench is required to take off the
valve stem cap.
9. The liquid line shut-off valve can now be opened. Remove
shut-off valve cap. Fully insert hex wrench into the stem and
backout counterclockwise until valve stem just touches rolled
edge (approximately five [5] turns) observing WARNING
statement on page 2. See Figure 3.
10. Replace liquid service pressure tap port cap and valve stem
cap. These caps MUST BE REPLACED to prevent leaks.
Replace valve stem and pressure tap cap finger tight, then
tighten an additional 1/6 turn.
11. The gas valve can now be opened. For a ball type gas valve,
open the gas valve by removing the shut-off valve cap and turning the valve stem 1/4 turn counterclockwise, using 1/4" Open
End or Adjustable wrench. See Figure 4 and refer to Step 8
prior to opening gas valve.
12. The gas valve is now open for refrigerant flow. Replace valve
stem cap to prevent leaks. Again, these caps MUST BE RE-
PLACED to prevent leaks. Replace valve stem and pressure
tap cap finger tight, then tighten an additional 1/6 turn. See
Figure 4.
If refrigerant lines are longer than fifteen (15) feet and/or a
different size than recommended, it will be necessary to adjust
system refrigerant charge upon completion of installation. See
unit Service Facts.
E. ELECTRICAL CONNECTIONS
After the brazing operation of refrigerant lines to both the outdoor
and indoor unit is completed, the field brazed connections must be
checked for leaks. Pressurize through the service valve ports, the indoor unit and field refrigerant lines with dry nitrogen to 350-400 psi.
Use soap bubbles or other leak-checking methods to see that all
field joints are leak-free! If not, release pressure; then repair!
SYSTEM EVACUATION
NOTE:
Since the outdoor unit has a refrigerant charge, the gas and
liquid line valves must remain closed.
1. Upon completion of leak check, evacuate the refrigerant lines
and indoor coil before opening the gas and liquid line valves.
2. Attach appropriate hoses from manifold gauge to gas and
liquid line pressure taps.
NOTE:
Unnecessary switching of hoses can be avoided and com plete
evacuation of all lines leading to sealed system can be accomplished with manifold center hose and connecting branch hose to
a cylinder of R-410A and vacuum pump.
3. Attach center hose of manifold gauges to vacuum pump.
4. Evacuate until the micron gauge reads no higher than 350 microns.
5. Close off valve to vacuum pump and observe the micron
gauge. If gauge pressure rises above 500 microns in one (1)
minute, then evacuation is incomplete or system has a leak.
6. If vacuum gauge does not rise above 500 microns in one (1)
minute, the evacuation should be complete.
7. With vacuum pump and micron gauge blanked off, open valve
on R-410A cylinder and charge refrigerant lines and indoor
coil with vapor to tank pressure of R-410A supply.
8. Close valve on R-410A supply cylinder. Close valves on manifold gauge set and remove refrigerant charging hoses from
liquid and gas pressure tap ports.
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.
1. Power wiring and grounding of equipment must comply with
national, state and/or local codes.
2. Power supply must agree with equipment nameplate.
3. Install a separate disconnect switch at the outdoor unit.
4. Ground the outdoor unit per code requirements.
5. Provide flexible electrical conduit whenever vibration transmission may create a noise problem within the structure.
6. The use of color coded low voltage wire is recommended to
simplify connections between the outdoor unit, the ComfortLink™ II control and the indoor unit
Table 1 – NEC Class II Control Wiring
ComfortLink™ II Control Wiring
WIRE SIZE MAX. WIRE LENGTH
18 AWG 250 FT
NOTE:
The maximum total cable length for the entire Comfort Control
communicating system is 500 ft. 18 AWG.
7. Mount the ComfortLink™ II control in accordance with instruction included with the ComfortLink™ II control.
Wire per appropriate hook-up diagram (included in these
instructions).
18-BC53D2-3 3
Installer’s Guide
FRC_DFT
TEST_COMMON
TST
F. DEFROST CONTROL (HEAT PUMPS ONLY)
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.
OUTDOOR CONTROL
6
BOARD – PIN
IDENTIFICATION
G. COMPRESSOR START UP
After all electrical wiring is complete, SET THE COMFORTLINK™ II CONTROL SWITCH IN THE OFF POSITION SO
COMPRESSOR WILL NOT RUN, and apply power by closing the
system main disconnect switch. This will activate the compressor
sump heat (where used). Do not change the ComfortLink™ II control Switch until power has been applied for one (1) hour. Following
this procedure will prevent potential compressor overload trip at
the initial start-up.
PIN IDENTIFICATION (SEE FIGURE 6.)
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.)
DEFROST CONTROL CHECKOUT
Normal operation requires:
a. Status LED on board flashing 1 time/second.
b. 12VDC between D & B.
c. 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.
4 18-BC53D2-3
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