Trane TTA240F Series, TTA240F3, TTA240F4, TTA240FK, TTA240FW Installation Operation & Maintenance

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TTA-SVN03A-EN

Installation Operation Maintenance

Split System Cooling Condensers 20-Ton

Model (60 Hz):

TTA240F***A

June 2006

Model (50 Hz):

TTA200FD**A

Preface and Cautions and Warnings

Literature Change History

TTA-SVN03A-EN (June 2006) Release of 20T, R410A product.

Note: One copy of this document

ships inside the control panel of each unit and is customer property. It must be retained by the unit’s maintenance personnel.

This booklet describes proper installation, operation, and maintenance procedures for air cooled systems. By carefully reviewing the information within this manual and following the instructions, the risk of improper operation and/or component damage will be minimized.

It is important that periodic maintenance be performed to help assure trouble free operation. A maintenance schedule is provided at the end of this manual. Should equipment failure occur, contact a qualified service organization with qualified, experienced HVAC technicians to properly diagnose and repair this equipment.

Warnings and Cautions

Notice that warnings and cautions appear at appropriate intervals throughout this manual. Warnings are provided to alert installing contractors to potential hazards that could result in personal injury or death, while cautions are designed to alert personnel to conditions that could result in equipment damage.

Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

NOTICE: Warnings and Cautions appear at appropriate sections

throughout this literature. Read these carefully.

WARNING: Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION: Indicates a situation that may result in equipment or property-

damage only accidents.

Note: All phases of this installation

must comply with the NATIONAL, STATE & LOCAL CODES. In addition to local codes, the installation must conform with National Electric Code -ANSI/NFPA NO. 70 LATEST REVISION.

Note: Do Not release refrigerant

to the atmosphere! If adding or removing refrigerant is required, the service technician must comply with all federal, state, and local laws.

Table of Contents

Preface and Cautions and Warnings......................................... 2

Model Number Description...................................................... 4

Electrical Data.............................................................................. 6

Installation.................................................................................... 7

System Prestart Procedure........................................................ 15

System Test Mode (ReliaTel)....................................................... 18

Troubleshooting (ReliaTel).......................................................... 19

Maintenance................................................................................ 22

Warranty....................................................................................... 24

TTA-SVN03A-EN 3

Model Number Description

All products are identified by a multiple-character model number that precisely identifies a particular type of unit. An explanation of the alphanumeric identification code is provided. Its use will enable the owner/operator, installing contractors, and service engineers to define the operation, specific components, and other options for any specific unit.

When ordering replacement parts or requesting service, be sure to refer to the specific model number, serial number, and DL number (if applicable) stamped on the unit nameplate.

TTA 090 A 3 00 B A

DIGITS 1-3: PRODUCT TYPE

TTA = Split System Cooling

DIGITS 4-6: NOMINAL GROSS COOLING CAPACITY (MBh)

200 = 200 MBh

240 = 240 MBh

DIGIT 7: REFRIGERATION CIRCUIT

A = 1 Refrigerant Circuit R22

B = 2 Refrigerant Circuit R22

C = Manifold Scroll Compressors R22

D = 1 Refrigerant Circuit R410A

E = 2 Refrigerant Circuit R410A

F = Manifold Scroll Compressors

R410A

DIGITS 8: ELECTRICAL CHARACTERISTICS

3 = 208-230/60/3

4 = 460/60/3

DIGITS 9, 10: FACTORY INSTALLED OPTIONS

00 = Packed Stock

0S = Black Epoxy Coated Coil

0R = ReliaTel™, no LCI Board

0T = ReliaTel™, no LCI Board with

Black Epoxy Coated Coil

0U = ReliaTel™, with LCI Board

0W = ReliaTel™, with LCI Board and

Black Epoxy Coated Coil

DIGITS 11: MINOR DESIGN SEQUENCE

CURRENT

DIGITS 12: Service Digit

A = First

W = 575/60/3

D = 380-415/50/3

K = 380/60/3

4 TTA-SVN03A-EN

Dimensional Data

Figure 1. TTA200F, TTA240F, Dimensional Data, Connection Location, Clearances, Corner Weights

TTA240F---A 292 lbs 181 lbs 222 lbs 140 lbs 835 lbs 920 lbs

TTA200FD--A 132 kg 82 kg 101 kg 64 kg 379 kg 418 kg

TTA-SVN03A-EN 5

APPROXIMATE CORNER WEIGHT (MASS)

TOTAL UNIT

WEIGHT

TOTAL SHIPPING

WEIGHTMODEL NO. #1#2#3#4

Electrical Data

Table 1. TTA Unit Electrical Data

Model Electrical Voltage Circuit Fuse Amps Amps

Number Characteristics Range Ampacity Size Qty. RLA LRA Qty. HP FLA LRA

TTA240F3 208-230/60/3 187-254 89.4 110 2 35.3 239.0 2 1 5.0 14.4

TTA240F4 460/60/3 414-506 46.6 60 2 18.5 125.0 2 1 2.5 5.8

TTA240FK 380/60/3 342-418 - - 2 - - 2 1 3.4 7.8

TTA240FW 575/60/3 578-632 36.0 50 2 14.2 80.0 2 1 2.0 5.1

TTA200FD 380-415/50/3 380-415 48.8 60 2 20.0 118.0 2 1 1.9 5.8

Basic Unit Characteristics Compressor Motor Outdoor Fan Motor

Allowable Minimum Maximum

6 TTA-SVN03A-EN

Installation

Installation procedures should be performed in the sequence that they appear in this manual. Do not destroy or remove the manual from the unit.

The manual should remain weatherprotected with the unit until all installation procedures are complete.

Note: It is not the intention of this

manual to cover all possible variations in systems that may occur or to provide comprehensive information concerning every possible contingency that may be encountered during an installation. If additional information is required or if specific problems arise that are not fully discussed in this manual, contact your local sales office.

Note: “Warnings” and “Cautions”

appear at appropriate places in this manual. Your personal safety and the proper operation of this machine require that you follow them carefully. The Company assumes no liability for installations or servicing performed by unqualified personnel.

Installation Checklist

An “Installation Checklist” is provided at the end of the installation section of this manual. Use the checklist to verify that all necessary installation procedures have been completed. Do not use the checklist as a substitute for reading the information contained in the manual. Read the entire manual before beginning installation procedures.

Unit Inspection

Inspect material carefully for any shipping damage. If damaged, it must be reported to, and claims made against the transportation company. Compare the information that appears on the unit nameplate with ordering and submittal data to insure the proper unit was shipped. Available

power supply must be compatible with electrical characteristics specified on component nameplates. Replace damaged parts with authorized parts only.

Inspection Checklist

To protect against loss due to damage incurred in transit, complete the following checklist upon receipt of the unit.

[ ] Inspect individual pieces of the shipment before accepting the unit. Check for obvious damage to the unit or packing material.

[ ] Inspect the unit for concealed damage before it is stored and as soon as possible after delivery. Concealed damage must be reported within 15 days. If concealed damage is discovered, stop unpacking the shipment. Do not remove damaged material from the receiving location. Take photos of the damage if possible. The owner must provide reasonable evidence that the damage did not occur after delivery.

[ ] Notify the carrier’s terminal of damage immediately by phone and by mail. Request an immediate joint inspection of the damage by the carrier and the consignee.

[ ] Notify the sales representative and arrange for repair. Do not repair the unit until the damage is inspected by the carrier’s representative.

Initial Leak Test

All TTA units are shipped with a holding charge of nitrogen in each circuit. Remove the compressor access panel(s) shown in Figure 1. Locate the liquid line or suction line service valve for each circuit. Install gauges to determine if the circuits are still pressurized. If not, the charge has escaped. Repair as required to obtain a leak-free circuit.

Lifting Recommendations

Before preparing the unit for lifting, estimate the approximate center of gravity for lifting safety. Because of placement of internal components, the unit weight may be unevenly distributed. Approximate unit weights are given in Table 2.

Table 2. Total Unit and Corner Weight

TTA240F---A 292

TTA200FD--A 132 kg82 kg101 kg64 kg379 kg

WARN ING

APPROXIMATE

CORNER WEIGHT

(MASS)

181

222

lbs

140

lbs

TOTAL

UNIT

WEIGHTMODEL NO.#1#2#3#4

835 lbs

Improper Unit Lift!

On-sight lifting equipment must be capable of lifting the unit weight with an adequate safety factor. The use of under-capacity lifting devices may result in death or serious injury or possible equipment or property-only damage.

The crated unit can be moved using a forklift of suitable capacity. For lifting the unit, attach lifting straps or slings securely to the lifting holes at each corner. Use spreader bars to protect the unit casing from damage. Test lift the unit to determine proper balance and stability.

CAUTION

Use spreader bars to prevent lifting straps from damaging the unit. Install bars between lifting straps. This will prevent the straps from crushing the unit cabinet or damaging the unit finish.

TTA-SVN03A-EN 7

Installation

Clearances

Provide enough space around the unit to allow unrestricted access to all service points. Refer to Figure 1 for unit dimensions and minimum required service and free air clearances. Observe the following points to insure proper unit operation.

1. Do not install the unit under a low overhang. Condenser discharge must not be restricted. See Note in Figure 1.

Note: Important! Do not obstruct

condenser discharge air. This can result in warm air recirculation through the coil.

2. Do not locate the unit in a position where runoff water can fall into the fan discharge openings.

3. Condenser intake air is supplied from three sides of the unit. Adhere to the minimum required clearances given in Figure 1.

Unit Mounting

Rooftop Mounting

If the unit will be roof mounted, determine for certain that the structure is strong enough to support the unit and any required accessories. Unit weights are given in Table 2. The unit should be elevated on a level, field fabricated four-inch steel or wood 4" x 4" mounting frame. Complete the frame and secure it into position before lifting the unit to the roof. The mounting frame must support a minimum of three of the unit’s four sides and should span roof supports to distribute the load on the roof.

Figure 2. Roof Mounted Unit

WARNIN G

Mounting Integrity!

Ensure that the roof structure supports are strong enough to support the weight of the unit and any accessories. Failure to do so could result in death or serious injury or possible equipment or property-only damage.

The following warning complies with State of California law, Proposition 65.

WARNIN G

Fiberglass Wool!

Product contains fiberglass wool. Disturbing the insulation in this product during installation, maintenance or repair will expose you to airborne particles of glass wool fibers and ceramic fibers known to the state of California to cause cancer through inhalation. Glass wool fibers may also cause respiratory, skin or eye irritation.

Ground Level Mounting

For ground level installation, the unit base should be adequately supported and hold the unit near level. The installation must meet the guidelines set forth in local codes. The support should extend two inches beyond the unit base channels at all points. The unit and support must be isolated from any adjacent structure to prevent

possible noise or vibration problems. Any ground level location must comply with required clearances given in Figure 1.

Refrigerant Piping

Structural Preparation

Holes must be made in the structure to run refrigerant lines. For the majority of ground-level installations, the holes can be made in the header that rests on top of the foundation. Alternatively, these holes may also be made in the foundation itself. On roofmounted units, refrigerant lines should enter the building as close to the unit as possible; preferably within three to four inches of the refrigerant connection on the unit, plus a six-inch (long radius) 90 degree ell entering the building, Figure 2.

Refrigerant Piping Guidelines

1. Maximum recommended line lengths (per circuit):

Maximum linear length..........

(w/o accumulator)

Maximum suction line lift......

Maximum liquid line lift ........

2. Maximum allowable pressure drops (R410A):

Suction Line............................

Liquid Line...............................

Note: Route refrigerant piping for

minimum linear length, minimum number of bends and fittings (no reducers) and minimum amount of line exposed to outdoor ambients.

3. Recommended line sizes TTA200 and 240F (two speed):

Suction Line

Liquid Line

Note: Insulate all refrigerant piping

and connections.

1 5/8" sealed type L refrigerant tubing

5/8" sealed type L refrigerant tubing

150 Ft.

50 Ft.

5 psi

50 psi

8 TTA-SVN03A-EN

Installation

Refrigerant Piping Procedures (Outdoor Units)

Each TTA unit ships with a holding charge of dry nitrogen. The nitrogen should be removed and the entire system evacuated (at the proper time) to avoid possible contamination.

1. Remove the compressor service access panel.

2. Locate the liquid and suction line service valves. Check that the piping connection stubs on the valves (Figure 3) line up properly with the holes in the unit cabinet.

Figure 3.

3. Remove the refrigerant connection seal caps and open the service valve slowly to release the nitrogen from the unit.

CAUTION

Do not remove the seal caps from refrigerant connections, or open the service valves until prepared to braze refrigerant lines to the connections. Excessive exposure to atmosphere (> 5 min.) may allow moisture or dirt to contaminate the system, damaging valve seals and causing ice formation in system components.

4. Cut, fit and braze tubing, starting at the outdoor unit and work toward the indoor unit.

Note: Use long radius ells for all 90

degree bends.

All brazing should be done using a 2 to 3 psig dry nitrogen purge flowing through the pipe being brazed, Figure 3.

CAUTION

Install a regulating valve between the nitrogen source and the gauge manifold (Figure 3). Unregulated pressure can damage system components.

CAUTION

Wet-wrap all valves and protect painted surfaces from excessive heat. Heat can damage system components and the unit finish.

5. Shut off nitrogen supply.

6. Shut off the manifold valve for the line that is connected to the suction line service valve. Disconnect the line from the gauge port on the valve.

Figure 4.

Refrigerant Piping Procedure (Indoor Unit)

Once liquid and suction lines are complete to the refrigerant connections on the indoor unit, puncture the seal caps on the indoor unit connection stubs to release the dry nitrogen charge.

CAUTION

Do not apply heat to remove seal caps until they have been punctured. If seal caps are intact, application of heat may generate excessive pressure in the unit and result in damage to the coil or expansion valve.

1. Remove both seal caps from the indoor unit connection stubs.

CAUTION

2. Turn nitrogen supply on. Nitrogen enters thorough liquid line gauge port.

3. Braze the liquid line connections.

4. Open the gauge port on the suction line and then braze the suction line to the connection stub. Nitrogen will bleed out the open gauge port on the suction line.

5. Shut off nitrogen supply.

Leak Check

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 the system through the service valve with dry nitrogen to 200 psi. Use soap bubbles or other leak-checking methods to ensure that all field joints are leak free. If not, release pressure, repair and repeat leak test.

TTA-SVN03A-EN 9

+ 19 hidden pages

Trane TTA240F Series, TTA240F3, TTA240F4, TTA240FK, TTA240FW Installation Operation & Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual