Trane 5TWR5 User manual

18-BC118D1-1A-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.

Heat Pumps

5TWR5

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 AHRI rated only with TXV/EEV indoor systems. Some of the benefits of installing approved matched indoor and out-

door split systems are maximum efficiency, optimum performance and the best overall system reliability.

Installation and Operation Manual

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......................................... 5

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

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

Section 8. Refrigerant Line Leak Check ............................................... 9

Section 9. Evacuation and Servicing .................................................... 9

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

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

Section 12. Electrical - High Voltage .................................................. 13

Section 13. Start Up.............................................................................. 14

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

Section 15. Checkout Procedures....................................................... 18

Section 16. Defrost Control ................................................................. 19

Section 17. Troubleshooting ................................................................ 22

Section 18. Wiring Diagrams ............................................................... 24

Section 19. Pressure Curves ............................................................... 27

Section 20. Refrigerant Circuit (only for reference)........................... 31

2 18-BC118D1-1A-EN

Section 1. Safety

WARNING

HAZARDOUS VOLTAGE!

Failure to follow this Warning could result in property

damage, severe personal injury, or death.

Disconnect all electric power, including remote

disconnects before servicing. Follow proper lockout/

tagout procedures to ensure the power cannot be

inadvertently energized.

WARNING

REFRIGERANT OIL!

Any attempt to repair a central air conditioning product

may result in property damage, severe personal injury,

or death.

Use only R-454B approved service equipment. All

R-454B systems with variable speed compressors use

variable speed compressor 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 vaccum with air and

always change the driers when opening the system for

component replacement.

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

pressure. 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

WARNING

SERVICE VALVES!

Failure to follow this warning will result in abrupt re-

lease of system charge and may result in personal in-

jury and/or property damage. Extreme caution should

be exercised when opening the Suction and Liquid

Line Service Valve. Turn valve stem counterclockwise

only until the stem contacts the rolled edge. No torque

is required.

WARNING

BRAZING REQUIRED - IF USING MECHANICAL

CONNECTIONS, ENSURE LEAK TEST IS

NEGATIVE!

Failure to inspect lines or use proper service tools

may result in equipment damage or personal injury.

If using existing refrigerant lines make certain that all

joints are brazed, not soldered.

HIGH LEAKAGE CURRENT!

Failure to follow this Warning could result in property

damage, severe personal injury, or death.

Earth connection essential before connecting

electrical supply.

NOTE: R454B refrigerant is a blend and should only

be added to the system in liquid form.

Important: If using other than copper pipe, follow

manufacturer’s installation instructions. Joints must

be brazed or other UL/IMC/URMC approved joint that

meets pressure requirements.

WARNING

RISK OF FIRE!

Flammable refrigerant used. To be repaired only by

trained service personnel. Do not puncture refrigerant

tubing.

Dispose of properly in accordance with federal or local

regulations. Flammable refrigerant used.

VENTILATION

Ensure that the area is in the open or that it is ad-

equately ventilated before breaking into the system or

conducting any hot work.

WARNING

Mode Model Operating Range

Cooling 1.5 – 5 Ton 55°F – 120°F

Heating 1.5 – 5 Ton 0°F – 66°F

18-BC118D1-1A-EN 3

Table 2.2

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.

Unit Dimensions and Weight

Models H x D x W (in)

Weight* (lb)

5TWR5018A 33 x 30 x 33 174

5TWR5024A 33 x 30 x 33 174

5TWR5030A 33 x 30 x 33 174

5TWR5036A 37 x 34 x 37 199

5TWR5042A 45 x 34 x 37 250

5TWR5048A 45 x 34 x 37 250

5TWR5060A 45 x 34 x 37 251

* Weight values are estimated uncrated.

Section 2. Unit Location Considerations

2.1 Piping Guidelines

Piping material, pipe routing, and installation shall include protection from physical damage in operation and

service, and be in compliance with national and local codes and standards. All field joints shall be accessible for

inspection prior to being covered or enclosed. Install of pipe work shall be kept to a minimum.

That provisions shall be made for expansion and contraction of long runs of piping.

2.2 Unit Dimensions and Weight

Standard

Line Set

150’ Max

TOTAL Line Length

50’

Max

Vertical

Change

50’

Max

Vertical

Change

2.3 Refrigerant Piping Limits

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

(including lift).

2. The maximum vertical change should not exceed 50 feet.

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

Note: For other line lengths, refer to Refrigerant Piping Application Guide, SS-APG006F-EN, or Refrigerant

Piping Software Program.

4 18-BC118D1-1A-EN

2.5 Cold Climate Considerations

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 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.

2.6 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.

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.

Min. 12” to

Shrubbery

Avoid Install

Near Bedrooms

Min 5’ Unrestricted

Access Panel

Min 3’

Unrestricted

2.4 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.

It is not recommended to install in a location where noise

may distract the building occupants. Some examples of

these types of locations are sleeping quarters and by

windows of a living area. Please discuss location with the

building owner prior to installation.

Avoid locations such as near windows where condensa-

tion 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.

18-BC118D1-1A-EN 5

Section 5. Refrigerant Line Considerations

5.1 Refrigerant Line and Service Valve Connection Sizes

Table 5.1

Line Sizes Service Valve Connection Sizes

Model Vapor

Line

Liquid

Line

Vapor Line

Connection

Liquid Line

Connection

5TWR5018A 5/8 5/16 3/4 5/16

5TWR5024A 3/4 5/16 3/4 5/16

5TWR5030A 3/4 5/16 3/4 5/16

5TWR5036A 3/4 5/16 3/4 5/16

5TWR5042A 7/8 5/16 7/8 5/16

5TWR5048A 7/8 5/16 7/8 5/16

5TWR5060A 7/8 3/8 7/8 3/8

Alternate Refrigerant Line and Service Valve Connection Sizes

Line Sizes Service Valve Connection Sizes

Model Vapor

Line

Liquid

Line

Vapor Line

Connection

Liquid Line

Connection

5TWR5018A 5/8 3/8 3/4 5/16

5TWR5024A 3/4 3/8 3/4 5/16

5TWR5030A 3/4 3/8 3/4 5/16

5TWR5036A 3/4 3/8 3/4 5/16

5TWR5042A 7/8 3/8 7/8 5/16

5TWR5048A 7/8 3/8V 7/8 5/16

5TWR5060A 7/8 3/8 7/8 3/8

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

Line Length

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.

5.2 Factory Charge

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.

6 18-BC118D1-1A-EN

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.

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

18-BC118D1-1A-EN 7

Isolation Through Wall DO NOT hang line sets from ductwork

Sealant

Insulation

Vapor Line

Wall

Ductwork

Isolator

Line Set

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

8 18-BC118D1-1A-EN

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.

Purge the refrigerant lines and indoor coil with dry nitrogen.

Note: A2L equipment shall have red marked service ports and pipes through which refrigerant is serviced.

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.

NOTE:

Precautions should be taken to avoid heat damage to basepan during brazing. It is recommended to

keep the flame directly off of the basep

an.

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

3-4” from valve

STEP 1 STEP 2 STEP 3

STEP 4 STEP 5

Section 7. Refrigerant Line Brazing

7.1 Braze The Refrigerant Lines

18-BC118D1-1A-EN 9

Section 8. Refrigerant Line Leak Check

8.1 Check For Leaks

STEP 2 - Check for leaks by using a soapy

solution or bubbles at each brazed location.

Note: Remove nitrogen pressure and repair any

leaks before continuing.

After completion of field piping for split systems, the field pipework shall be pressure tested with nitrogen and then

vacuum tested prior to refrigerant charging, according to the following requirements:

1. The minimum leak test pressure of the lineset and indoor coil shall be the high side design pressure, unless the

high side of the system, cannot be isolated from the low side of the system in which case the entire system

shall be pressure tested to the low side design pressure.

2. The test pressure after removal of pressure source shall be maintained for at least 1 hour with no decrease of

pressure indicated by the test gauge, with test gauge resolution not exceeding 5% of the test pressure.

Important: Under no circumstances shall potential sources of ignition be used in the searching for or detection of

refrigerant leaks.

Important: The following leak detection methods are deemed acceptable for all refrigerant systems:

• Electronic leak detectors calibrated for R454B

• Bubble method

STEP 2 - Observe the micron gauge. Evacuation

is complete, if the micron gauge does not rise

above 500 microns in one (1) minute and 1500

microns in ten (10) minutes.

STEP 3 - Once evacuation is complete, blank off

the vacuum pump and micron gauge, and close

the valve on the manifold gauge set.

1 MIN.

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.

0350

Microns

ON OFF

Section 9. Evacuation and Servicing

9.1 Evacuate the Refrigerant Lines and Indoor Coil

STEP 1 - Pressurize the refrigerant lines and

evaporator coil to 600 PSIG using dry nitrogen. 600 PSIG

10 18-BC118D1-1A-EN

9.2 Servicing

Under no circumstances shall potential sources of ignotion be used in the searching for or detection of refrigerant

leaks.

The following leak detection methods are deemed acceptable for all refrigerant systems:

• Electronic leak detectors calibrated for R454B

• Bubble method

• Fluorscent method agents

If a leakage of refirgerant is found which requires brazing, all of the refrigerant shall be recovered from the system,

or isolated (by means of shut off valves) in a part of the system remote from the leak.

• If repairs must be made after system is charged, properly and safely remove or isolate refrigerant and purge

the section of the system needing repair with Nitrogen gas or oxygen free nitrogen prior to opening the circuit.

• The REFRIGERANT CHARGE shall be recovered into the correctly marked recovery cylinders.

• Ensure that the outlet for the vaccum pump is not close to any potential ignition sources and the ventilation is

available.

• Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall

be leak-tested on completion of charging but prior to commissioning. A follow up leak test shall be carried out

prior to leaving the site.

• Ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of

cylinders for holding the total system charge is available. Only use cylinders designated for the recovered

refrigerant and labelled for the refrigerant. Cylinders shall be complete with pressure-relief valve and

associated shut-off valves in good working order.

• A set of caliberated weighing scales shall be available and in good working order. Hoses shall be complete

with leak-free disconnect couplings and in good condition. Ensure any associated electrical components are

sealed.

• The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder. Do not

mix refrigerants.

• If compressors or compressor oils are to be removed, ensure that they have been evacuated to an

acceptable level to make certain that FLAMMABLE REFRIGERANT does not remain within the lubricant.

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

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