Trane 4TWR6 User manual

18-AC104D1-1G-EN

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 informa-

tion 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.................................................................... 4

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

Section 5. Refrigerant Line Considerations......................................... 4

Section 6. Refrigerant Line Routing ..................................................... 5

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

Section 8. Refrigerant Line Leak Check............................................... 7

Section 9. Evacuation ............................................................................ 8

Section 10. Service Valves .................................................................... 8

Section 11. Electrical - Low Voltage ..................................................... 9

Section 12. Electrical - High Voltage .................................................. 10

Section 13. Start Up.............................................................................. 10

Section 14. System Charge Adjustment............................................. 10

Section 15. Checkout Procedures ...................................................... 14

Section 16. Defrost Control ................................................................. 15

Section 17. Troubleshooting ............................................................... 20

Section 18. Wiring Diagrams............................................................... 22

Section 19. Pressure Curves............................................................... 25

Section 20. Refrigerant Circuit (only for reference) .......................... 28

Heat Pumps

4TWR6

Installation and Operation Manual

2 18-AC104D1-1G-EN

Section 1. Safety

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 connec-

tion 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 cyl-

inders 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 “hygro-

scopic” 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

Bulletins SS-APG006-EN and APP-APG011-EN.

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.

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

APPROVED POE COMPRESSOR OIL.

LIVE ELECTRICAL COMPONENTS!

During installation, testing, servicing, and trouble-

shooting 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.

WARNING

CAUTION

HOT SURFACE!

May cause minor to severe burning. Failure to follow

this Caution could result in property damage or per-

sonal injury. Do not touch top of compressor.

CAUTION

CONTAINS REFRIGERANT!

Failure to follow proper procedures can result in

personal illness or injury or severe equipment

damage.

System contains oil and refrigerant under high pres-

sure. Recover refrigerant to relieve pressure before

opening system.

CAUTION

GROUNDING REQUIRED!

Failure to inspect or use proper service tools may

result in equipment damage or personal injury.

Reconnect all grounding devices. All parts of this

product that are capable of conducting electrical

current are grounded. If grounding wires, screws,

straps, clips, nuts, or washers used to complete a

path to ground are removed for service, they must be

returned to their original position and properly

fastened.

CAUTION

HAZARDOUS VOLTAGE!

Disconnect power and discharge capacitors before

servicing.

WARNING

18-AC104D1-1G-EN 3

Unit Dimensions and Weight

Models H x D x W (in) Weight* (lb)

4TWR6024N 41 x 34 x 37 236

4TWR6036N 45 x 34 x 37 257

4TWR6048N 45 x 34 x 37 292

4TWR6060N 45 x 34 x 37 293

* Weight values are estimated.

Section 2. Unit Location Considerations

2.1 Unit Dimensions and Weight

2.2 Refrigerant Piping Limits

Table 2.1

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.

Standard

Line Set

150” Max

Line Length

50’’

Max

Vertical

Change

50’’

Max

Vertical

Change

Min. 12” to

Shrubber

Avoid Install

Near Bedrooms

Min 5’ Unrestricted

Access Panel

Min 3’

Unrestricted

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.

1. The maximum length of refrigerant lines from outdoor to indoor unit should NOT exceed 150 feet.

2. The maximum vertical change should not exceed fifty (50) feet.

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

Note: For line lengths greater than fifty (50) feet, Refer to Refrigerant Piping Application Guide,

SS-APG006F-EN, or Refrigerant Piping Software Program.

4 18-AC104D1-1G-EN

2.4 Cold Climate Considerations

NOTE: It is recommended that these precautions be taken for units being installed in areas where snow accumula-

tion 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 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.

2.5 Coastal Considerations

If installed within one mile of salt water, including seacoasts and inland waterways, models without factory sup-

plied Seacoast Salt Shields require the addition of BAYSEAC001 (Seacoast Kit) at installation time.

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

Section 3. Unit Preparation

3.1 Prepare The Unit For Installation

STEP 1 - Check for damage and report promptly to the carrier any damage found to the unit.

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.

Line Sizes Service Valve Connection Sizes

Model Vapor

Line

Liquid

Line

Vapor Line

Connection

Liquid Line

Connection

4TWR6024N 5/8 3/8 3/4 3/8

4TWR6036N 3/4 3/8 3/4 3/8

4TWR6048N 7/8 3/8 7/8 3/8

4TWR6060N 1-1/8 3/8 7/8 3/8

Section 5. Refrigerant Line Considerations

5.1 Refrigerant Line and Service Valve Connection Sizes

Table 5.1

Alternate Line Sizes Line Sizes Service Valve Connection Sizes

Model Vapor

Line

Liquid

Line

Vapor Line

Connection

Liquid Line

Connection

4TWR6024N 3/4 3/8 3/4 3/8

4TWR6036N 5/8 3/8 3/4 3/8

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

4TWR6048N 3/4 3/8 7/8 3/8

4TWR6060N 3/4 3/8 7/8 3/8

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

18-AC104D1-1G-EN 5

Line Length

5.3 Required Refrigerant Line Length

5.2 Factory Charge

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.

The outdoor condensing units are factory charged with the system charge required for the outdoor condensing

unit, ten (10) feet of tested connecting line, and the smallest rated indoor evaporative coil match. Always verify

proper system charge via subcooling (TXV/EEV) or superheat (fixed orifice) per the unit nameplate.

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.

Vapor Line

Liquid Line

Insulation

5.5 Reuse Existing Refrigerant Lines

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.

CAUTION

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

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.

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.

Comply with National, State, and Local Codes when

isolating line sets from joists, rafters, walls, or other

structural elements.

6 18-AC104D1-1G-EN

Isolation From Joist/Rafter

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 appro-

priate method every 8 ft.

Joist/Rafter

Isolator

Line Set

8 Feet Maximum

Isolation In Wall Spaces

Side View

Wall

Isolator

Line Set

8 Feet Maximum

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.

8 Feet Maximum

Isolation Through Wall DO NOT hang line sets from ductwork

Sealant

Insulation

Vapor Line

Wall

Ductwork

Isolator

Line Set

18-AC104D1-1G-EN 7

Section 7. Refrigerant Line Brazing

7.1 Braze The Refrigerant Lines

STEP 1 - Remove caps or plugs. Use a deburing tool to debur the pipe ends. Clean both internal and external

surfaces of the tubing using an emery cloth.

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.

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.

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: Install drier in Liquid Line.

NNOTE:OTE: Precautions should be taken to avoid heat damage to basepan during brazing. It is recommended to keepPrecautions should be taken to avoid heat damage to basepan during brazing. It is recommended to keep

the flame directly off of the basepan.the flame directly off of the basepan.

STEP 5 - Replace the pressure tap valve cores after the service valves have cooled.

3-4” from valve

STEP 1 STEP 2 STEP 3

STEP 4 STEP 5

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 nitrogren pressure

and repair any leaks before continuing.

8 18-AC104D1-1G-EN

Section 9. Evacuation

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.

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.

10.2 Open the Liquid Service Valve

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.

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.

WARNING

CAP

1/4 TURN ONLY

COUNTERCLOCKWISE

FOR FULL OPEN

POSITION

VALVE STEM

GAS LINE CONNECTION

UNIT SID

OF VALVE

PRESSURE TAP PORT

Cap

Rolled Edge to

Captivate Stem

Hex Headed

Valve System

Service Port

3/16” Hex Wrench

Unit Side

of Service

Valve

Gas Service Valve Liquid Service Valve

18-AC104D1-1G-EN 9

11.2 Low Voltage Hook-up Diagrams

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.

Table 11.1

24 VOLTS

WIRE SIZE MAX. WIRE LENGTH

18 AWG 150 Ft.

16 AWG 225 Ft.

14 AWG 300 Ft.

With TEM 6/8

Thermostat Air Handler Outdoor

Unit

B/C B/C

Blue

24 VAC HOT

FAN

24 VAC

Common

SOV

COOL/HEAT

1st STAGE

HEATING

2nd STAGE

EMERGENCY

HEAT Pink Black

White

COOL/HEAT

2nd STAGE Y2

With TAM 7/9

Thermostat Air Handler Outdoor

Unit

Blue

24 VAC HOT

FAN

24 VAC

Common

SOV

COOL/HEAT

1st STAGE

Y2 Y2

COOL/HEAT

2nd STAGE

HEATING

2nd STAGE

EMERGENCY

HEAT Pink Black

White

•

Units with pigtails require wirenuts for connections.

•

In systems with multiple stages of electric heat, jumper W1 and W2 together if comfort control has only one stage of heat.

** TEM6 only - When using a BK enabled comfort control, cut BK jumper and bypass Y1 and Y2 at the air handle

r. Connect BK from

comfort control to BK of the air handle

•

TAM7 only - When using a BK enabled comfort control, cut BK jumper on the AFC and connect BK from comfort control to BK of

the air handler

AM7 DIP switches must be configured for “HP: 2-Stage/1 Compressor”.

Note: Refer to Indoor Unit Literature for proper configuration.

WH/BLK

11.3 Defrost Control

Defrost controls have a selectable termination tem-

perature. As shipped, defrost will terminate at 47°F.

For a higher termination temperature, cut Jumper

J2 to achieve 70°F. Refer to the Defrost Control

section in this document for more information.

Pin Identification on J5 (See Illustration)

1. TEST_COMMON (Shorting to FRC_DFT

causes the control to initiate Forced Defrost.

Leaving this pin open results in the normal

mode of operation.)

2. 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:

• Status LED on board flashing 1 time/second

in standby or 2 times/second with a call for

heating or cooling.

• 24V AC between R & B

• 24V AC between Y, Y0 & B with unit operating

• 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.

Defrost Board Detail

Jumper J2 J5 Test Pins

10 18-AC104D1-1G-EN

Section 12. Electrical - High Voltage

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 this

document included with the unit.

LIVE ELECTRICAL COMPONENTS!

During installation, testing, servicing, and

troubleshooting of this product, it may be nec-

essary to work with live electrical components.

Failure to follow all electrical safety precau-

tions when exposed to live electrical compo-

nents could result in death or serious injury.

WARNING

12.2 High Voltage Disconnect Switch

12.3 High Voltage Ground

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

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.

Section 13. Start Up

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.

STEP 1 - Check the outdoor temperatures.

Subcooling (in cooling mode) is the only recommended method of charging above 55º F ambient outdoor tem-

perature. See Section 14.2.

For outdoor temperatures below 55º F, see Section 14.3.

Note: It is important to return in the spring or summer to accurately charge the system in the cooling mode when

outdoor ambient temperature is above 55º F.

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

Section 14. System Charge Adjustment

14.1 Temperature Measurements

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