Trane A4HP5 User manual

88-A4HP5001-1D-EN

Heat Pumps

A4HP5

Installation and Operation Manual

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.............................................. 4

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 ............................................... 9

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

Section 10. Service Valves..................................................................... 9

Section 11. Electrical - Low Voltage ................................................... 10

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

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

Section 14. System Charge Adjustment............................................. 13

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

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

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

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

Section 19. Pressure Curves ............................................................... 28

Section 20. Refrigerant Circuit (only for reference)........................... 32

2 88-A4HP5001-1D-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

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 sys-

tem. 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

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

APP-APG012-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 AP-

PROVED 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

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.

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

WARNING

BRAZING REQUIRED - IF USING MECHANICAL

CONNECTIONS, ENSURE LEAK TEST IS NEGA-

TIVE!

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.

88-A4HP5001-1D-EN 3 D

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

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

Warning!

This product can expose you to chemicals including

lead which are known to the State of California to

cause cancer and birth defects or other reproductive

harm.

For more information go to www.P65Warnings.ca.gov

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.

4 88-A4HP5001-1D-EN

Section 2. Unit Location Considerations

2.1 Unit Dimensions and Weight

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.

Unit Dimensions and Weight

Models H x W x D (in)

Weight* (lb)

A4HP5018D

32.6 X 29.8 X 29.8 162

A4HP5024D

32.6 X 29.8 X 29.8 162

A4HP5030D

28.6 X 29.8 X 29.8 159

A4HP5036D

36.6 X 34.3 X 34.3 199

A4HP5042D

44.6 X 34.3 X 34.3 227

A4HP5048D

44.6 X 34.3 X 34.3 250

A4HP5060D

44.6 X 34.3 X 34.3 250

* Weight values are estimated uncrated.

2.2 Service Valves Locations

1. The locations of the below listed valves in

the unit are shown in the figure.

a) Liquid line connection

b) Access valve for compressor suction

pressure measurement

c) Suction line connection

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.

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.

Liquid Line Connection Access valve for compressor

suction pressure measurement

Suction Line

Connection

50’

Max

Vertical

Change

50’

Max

Vertical

Change

Standard

Line Set

150’ Max

TOTAL Line Length

88-A4HP5001-1D-EN 5 D

Min. 12” to

Shrubbery

Avoid Install

Near Bedrooms

Min 5’ Unrestricted

Access Panel

Min 3’

Unrestricted

2.4 Suggested Locations for Best Reliability

2.5 Cold Climate Considerations

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

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.

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.

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.

6 88-A4HP5001-1D-EN

Line Length

Section 5. Refrigerant Line Considerations

5.1 Refrigerant Line and Service Valve Connection Sizes

Table 5.1

5.3 Required Refrigerant Line Length

5.2 Factory Charge

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

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.

Line Sizes Service Valve Connection Sizes

Model Vapor

Line

Liquid

Line

Vapor Line

Connection

Liquid Line

Connection

A4HP5018D

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

A4HP5024D

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

A4HP5030D

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

A4HP5036D

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

A4HP5042D

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

A4HP5048D

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

A4HP5060D

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

88-A4HP5001-1D-EN 7 D

5.5 Reuse Existing Refrigerant Lines

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.

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

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.

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 88-A4HP5001-1D-EN

Isolation Through Wall DO NOT hang line sets from ductwork

Sealant

Insulation

Vapor Line

Wall

Ductwork

Isolator

Line Set

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.

NOTE:

OTE:

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

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

88-A4HP5001-1D-EN 9 D

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.

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 mi-

crons 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 SIDE

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

10 88-A4HP5001-1D-EN

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.

11.2 Low Voltage Hook-up Diagrams

With Furnace With Variable Speed Furnace

• Units with pigtails require wirenuts for

connections. Cap all unused wires.

•

In AC systems for multiple stages of heat,

jumper W1 and W2 together if comfort

control has only one stage of heat.

* If equipped with second stage heat

** When using a BK enabled comfort control,

cut BK jumper and bypass Y and YLo at the

furnace. Connect BK from comfort control to

BK of the furnace

Thermostat Furnace Furnace

Outdoor

Unit

B/C

24 VAC HOT

FAN

24 VAC

Common

COOL

HEATING

YY1 YY

YLO

Thermostat Outdoor

Unit

B/C

24 VAC HOT

FAN

24 VAC

Common

COOL

HEATING

BK **

B/C

HEAT PUMP SYSTEMS

Blue

24 VAC HOT

FAN

24 VAC

Common

SOV

COOL/HEAT

1st STAGE

HEATING

2nd STAGE

EMERGENCY

HEAT

Thermostat Air Handler Outdoor

Unit

Pink Black W2

Pink

White White

AC SYSTEMS

B/C

Blue

24 VAC HOT

FAN

24 VAC

Common

COOLING

HEAT

Thermostat Air Handler Outdoor

Unit

In AC systems for multiple stages

of electric heat, jumper W1 and W2

together if comfort control has only

one stage of heat.

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