Trane 5TWR4 - User Manual

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18-BC117D1-1B-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

5TWR4

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 ...................................................... 7

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

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

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

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

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

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This document is an Installation and Operation Manual for Trane 5TWR4 series Heat Pumps, identified as 18-BC117D1-1B-EN. It provides comprehensive instructions for the safe and proper installation, startup, and maintenance of these units.

Function Description

The Trane 5TWR4 Heat Pumps are designed to provide heating and cooling for residential and commercial applications. They are split systems, meaning they consist of an outdoor condensing unit and an indoor evaporative coil. The units utilize R-454B refrigerant, which is classified as a flammable (A2L) refrigerant, necessitating specific safety precautions during installation and servicing. The system is designed for maximum efficiency, optimum performance, and overall reliability when installed as an approved matched indoor and outdoor system, AHRI rated with TXV/EEV indoor systems.

Important Technical Specifications

The manual details various technical specifications crucial for installation and operation:

Refrigerant Type: R-454B (Flammable, A2L).
Operating Range:
- Cooling: 55°F - 120°F
- Heating: 0°F - 66°F
Unit Dimensions and Weight (H x D x W, Weight (lb)):*
- 5TWR4018A, 5TWR4024A, 5TWR4030A: 33 x 30 x 33 inches, 174 lbs
- 5TWR4036A: 37 x 34 x 37 inches, 199 lbs
- 5TWR4042A, 5TWR4048A, 5TWR4060A: 45 x 34 x 37 inches, 250-251 lbs
- (*Weight values are estimated uncrated.)
Refrigerant Piping Limits:
- Maximum TOTAL length: 150 feet (including lift).
- Maximum vertical change: 50 feet.
- Service valve connection sizes vary by model and line type (e.g., 5TWR4018A Vapor Line: 5/8 inch, Liquid Line: 5/16 inch; Vapor Line Connection: 3/4 inch, Liquid Line Connection: 5/16 inch). Alternate connection sizes are also provided.
Factory Charge: Units are factory charged for the outdoor condensing unit, 10 feet of tested connecting line, and the smallest rated indoor evaporative coil match.
Low Voltage Wiring:
- 18 AWG: 150 Ft. Max. Wire Length
- 16 AWG: 225 Ft. Max. Wire Length
- 14 AWG: 300 Ft. Max. Wire Length
Defrost Control: Selectable termination temperatures (47°F as shipped, 70°F with Jumper J2 cut for higher termination). Defrost initiation can be forced by shorting TEST_COMMON to FRC_DFT.
Charging Charts: Detailed R-454B refrigerant charging charts are provided for various models (018A-060A) based on liquid temperature, design subcooling, and liquid gage pressure. Subcooling correction tables are included for different line lengths and lifts.
Pressure Curves: Graphs illustrate liquid and suction pressure curves for different models (e.g., 5TWR4018A1, 5TWR4024A1, 5TWR4030A1, 5TWR4036A1, 5TWR4042A1, 5TWR4048A1, 5TWR4060A1) across a range of outdoor temperatures and indoor entering wet bulb curves, indicating expected pressures at specific CFM.

Usage Features

Installation Flexibility: The units can be mounted on a support pad or rooftop, with recommendations for proper isolation to prevent sound/vibration transmission.
Clearance Requirements: Minimum clearances are specified for optimal airflow and service access (5 feet above, 3 feet in front of control box/sides, 12 inches from walls/shrubbery).
Cold Climate Considerations: Recommendations include elevating units 3-12 inches above the pad/rooftop and avoiding snow drift locations to prevent obstruction of drain holes and ice accumulation.
Coastal Considerations: For installations within one mile of salt water, the addition of a Seacoast Kit (BAYSEAC001) is required for models without factory-supplied shields.
Refrigerant Line Insulation: The vapor line must always be insulated, and direct metal-to-metal contact between liquid and vapor lines should be avoided.
Low Voltage Hook-up Diagrams: Detailed wiring diagrams are provided for various thermostat and air handler configurations (5TEM6, 5TEM4, 5TAM5, and with furnace) to guide proper electrical connections.
Defrost Control Settings: The defrost termination temperature can be adjusted based on ambient conditions (e.g., 47°F or 70°F). Specific instructions are given for checking defrost control operation.
System Start-Up: A five-step process guides the initial startup, including ensuring completion of installation steps, setting the thermostat to OFF, applying power, waiting for the compressor crankcase heater (if applicable), and finally setting the thermostat to ON.
Charging Methods: Subcooling charging is recommended for outdoor temperatures above 55°F, while a weigh-in method is recommended for temperatures below 55°F (heating only).

Maintenance Features

Safety Warnings: Extensive safety warnings are provided throughout the manual, emphasizing the need for qualified personnel for installation and service, precautions against flammable refrigerant, electrical hazards, and proper handling of components.
Leak Check Procedures: After piping, the system must be pressure tested with dry nitrogen to 150 PSIG, and all brazed locations checked for leaks using a soapy solution. A system pressure test to the outdoor nameplate pressure for at least 60 minutes is required.
Evacuation Procedures: The refrigerant lines and indoor coil must be evacuated to no higher than 350 microns, with specific checks to ensure the vacuum holds.
Refrigerant Servicing: Detailed guidelines for safe refrigerant recovery, pressure testing, leak testing, and charging are provided, including the use of correctly marked recovery cylinders and calibrated weighing scales.
Service Valve Operation: Instructions for safely opening both gas and liquid service valves are provided, emphasizing caution with the liquid line service valve to prevent abrupt release of system charge.
Troubleshooting Guides: Flowcharts are included for diagnosing common issues such as "Compressor fails to start" and "Troubleshooting Outdoor TXV / Heating Mode," guiding technicians through diagnostic steps.
Defrost Control Checkout: Procedures for checking normal operation of the defrost control, including LED status, voltage checks, and forced defrost initiation, are outlined.
LED Fault Codes: A table lists LED fault codes (e.g., 1 FLASH for Ambient Temp Sensor out of range, 2 FLASH for Coil Temp Sensor out of range, 3 FLASH for Low Pressure Switch open) and their corresponding defrost control behavior, aiding in rapid diagnosis.
System Charge Adjustment: Instructions for determining and adjusting the system charge based on line length, lift, and outdoor temperature are provided, along with a form to record system information.
Checkout Procedures: A comprehensive checklist ensures all operational and checkout procedures are completed, including verifying refrigerant lines, insulation, electrical connections, fan operation, drain line drainage, and airflow.