Trane ODYSSEY TTA Series Owner's manual

ODYSSEY
TTA-IOM-EN0110
January 2010
Installation
Operation
Maintenance
Light Commercial
Split System 5-20 Tons
TTA Model 50 Hz
Single Circuit;
TTA 075 RD
TTA 100 RD
TTA 120 RD
Dual Circuit;
TTA 150 RD
TTA 180 RD
TTA 200 RD
TTA 240 RD
Manifolded Compr.;
TTA 150 RD0G
TTA 180 RD0G
TTA 200 RD0G
TTA 240 RD0G
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Model Nomenclature
TTA-IOM-EN0110
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TTA-IOM-EN0110 3
Contents
2erutalcnemoNledoM
4noitamrofnIlareneG
5
6
8
noitallatsnI
Refrigerant Piping Guidelines
Refrigerant Charging and Evacuation
10ataDlareneG
12gniriWlacirtcelE
17Dimensional Data
21noitarepO
22ec
nanetniaM
Maintenance Log 122
23gnitoohSelbuorT
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4
General Information
This manual covers the installation of
the TTA075, TTA100 and TTA120
(Single Circuit), TTA150, TTA180,
TTA200 and TTA240 (Dual Circuit
and Manifolded Compressor) system
outdoor units. 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 weather-protected 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 con
sealed 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.
Warning: open and lock unit disconnect to prevent injury or death from
electric shock or contact with moving parts before attempting any installation
or maintenance.
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5
Installation
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 1.
Warning: 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 severe personal
injury or death and can seriously
damage the unit.
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.
Clearances
Provide enough space around the
unit to allow unrestricted access
to all service points. Refer to unit
dimensional data for minimum
required service and free air
clearances. Observe the following
points to insure proper unit operation.
A. Do not install the unit under a low
overhang. Condenser discharge
clearance is not less than 2.5 mm.
Important: Do not obstruct condenser
discharge air. This can result in warm
air recirculation through the coil.
B. Do not locate the unit in a position
where runoff water can fall into the
fan discharge openings.
C. Condenser intake air is supplied
from three sides of the unit. Adhere
to the minimum required clearances
given in dimensional data.
Unit 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 dimensional data.
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6
Refrigerant Piping Guidelines
Figure 1
Refrigerant Piping
To ensure the return of oil in the
refrigerant lines, it is necessary to
follow these recommendations:
1. Select the tube lengths with care
and try to avoid having a final few
meters of tube to use up. Refer to
table 2 for tube sizes.
2. Pitch all horizontal suction lines
down towards the unit to assist
gravity oil drainage back to the
compressor.
3. Avoid creating large oil traps in
horizontal suction lines as this will
reduce oil circulating in the system
and may eventually lead to failure
of the compressor.
4. A small oil trap at the end of a
horizontal suction line before a long
vertical riser (of more that 2.5
metres) has the advantage of
assisting the high velocity gas to
carry the oil up the vertical pipe.
5. Liquid lines require no special
installation techniques as the liquid
refrigerant R-22 and the oil mix.
The densities of the refrigerant and
oil are near enough the same so
any movement of liquid refrigerant
will carry oil with it.
6. The installation of a liquid line
sight is recommended. It is very
useful during the maintenance
procedures.
Refrigerant Piping Guidelines
A. Maximum recommended line
lengths: (per circuit)
Maximum linear length 200 Ft.
(W/o accumulator)
Maximum suction line lift 60 Ft.
Maximum liquid line lift 60 Ft.
B. Maximum allowable pressure
drops (R-22):
Suction line 6 psi.
Liquid line 35 psi.
(without subcooler)
Route refrigerant piping for
minimum linear length,
minimum number of bends and
fittings (no reducers) and minimum
amount of line exposed to outdoor
ambients.
C. Recommended line sizes:
TTA075RD (Single Circuit)
TTA150RD (Dual Circuit)
Suction line
1 1/8 inch sealed type L
refrigerant tubing.
Liquid line
1/2 inch sealed type L
refrigerant tubing.
D. Recommended line sizes:
TTA100RD and TTA120RD
(Single Circuit)
TTA180RD, TTA200RD and
TTA240RD
(Dual Circuit)
Suction line
1 3/8 inch sealed type L
refrigerant tubing.
Liquid line
1/2 inch sealed type L
refrigerant tubing.
Stub
Connection
Valve Stem
Valve Cap
Service Valve
Seal Cap
Gauge
Port
Cap
E. Recommended line sizes:
TTA150RD0G, TTA180RD0G,
TTA200RD0G and TTA240RD0G
(Manifolded Compressor)
Suction line
1 5/8 inch sealed type L
refrigerant tubing.
Liquid line
5/8 inch sealed type L
refrigerant tubing.
Note: Insulate all refrigerant piping
and connections.
TTA 150 RD 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8
TTA 180 RD0G 5/8 1 5/8 5/8 1 5/8 5/8 1 5/8 5/8 1 5/8
TTA 200 RD0G 5/8 1 5/8 5/8 1 5/8 5/8 1 5/8 5/8 1 5/8
TTA 240 RD0G 5/8 1 5/8 5/8 1 5/8 5/8 1 5/8 5/8 1 5/8
Table 2 - Recommended Interconnecting Lines
Length of Interconnecting Line (feet)
0-20 21-40 41-60 61-80
Liq. Suct. Liq. Suct. Liq. Suct. Liq. Suct.
TTA 075 RD 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8
TTA 100 RD 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 3/8
TTA 120 RD 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 3/8
Notes: 1. Two line sets are required for dual circuits units.
2. For line lengths over 80 linear feet and 15 feet liquid line riser,
consult your local Trane representative.
TTA 180 RD 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 3/8
TTA 200 RD 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 3/8
TTA 240 RD 1/2 1 1/8 1/2 1 1/8 1/2 1 1/8 1/2 1 3/8
TTA 150 RD0G 5/8 1 5/8 5/8 1 5/8 5/8 1 5/8 5/8 1 5/8
Model
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TTA-IOM-EN0110 7
Refrigerant Piping Guidelines
Figure 2
Refrigerant Piping Procedures
(Outdoor units)
Each TTA unit ships with a R-22
holding charge. Due to this minimal
amount, we recommend that it 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 1) line up properly
with the holes in the unit cabinet.
3.Front-seat (close) both of the
service valves must be closed
before the system is opened.
Caution: Fully close the liquid and
suction line service valves before
puncturing the seal caps on the
connection stubs. If the seal caps are
punctured with the valves open, the
refrigerant contained in each circuit
will be lost.
Warning: Do not heat the seal caps
unless they have been punctured. If
caps are intact, application of heat
may generate excessive pressure in
the connection stub, causing personal
injury or death due to rupturing of
components and damage to the
service valve.
4.Heat and remove the seal caps.
Caution: Do not remove the seal
caps from refrigerant connections
unit prepared to braze refrigerant
lines to the connections. Excessive
exposure to atmosphere may allow
moisture or dirt to contaminate the
system, damaging valve seats and
causing ice formation in system
components.
5.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 2
to 8 psig dry nitrogen purge flowing
through the pipe being brazed 9
(Figure 2).
Caution: Install a regulating valve
between the nitrogen source and
the gauge manifold (Figure 2).
Unregulated pressures 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.
6.Shut off nitrogen supply.
7.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 value.
Refrigerant Piping Procedure
(Indoor Unit)
Once liquid and suction lines are
complete to the refrigerant
connections on the indoor unit, heat
and remove the seal caps on the
indoor unit connection stubs to
release the dry nitrogen charge.
1.Remove both seal caps from the
indoor unit connection stubs.
Caution: Do not remove seal caps until
prepared to braze refrigerant lines to
the connections. Extended exposure to
atmosphere may allow moisture or dirt
to contaminate the system, damaging
system components.
2.Turn nitrogen supply on. Nitrogen
enters through the liquid line
gauge port.
3.Braze the liquid line connections.
4.Open the gauge port on the suction
line and then braze 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.
Manifold
Gauge Pressure
Regulating
Valve
Dry
Supply
Nitrogen
Liquid Line
Gauge Port
Liquid Line Service Valve
Suction Line Service Valve
Suction Line Gauge Port
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8TTA-IOM-EN0110
Refrigerant Charging
and Evacuation
System Evacuation
1. After completion of leak check,
evacuate the system.
2. Attach appropriate hoses from
manifold gauge to gas and liquid
line pressure taps.
Note: Unnecessary switching of
hoses can be avoided and complete
evacuation of all lines leading to
sealed system can be accomplished
with manifold center hose and
connecting branch hose to a cylinder
of R-22 and vacuum pump.
3. Attach center hose of manifold
gauges to vacuum pump.
4. Evacuate the system to hold a
350 micron vacuum.
5. Close off valve to vacuum pump
and observe the micron gauge.
If gauge pressure rised above
500 microns in one (1) minute,
then evacuation is incomplete or
the system has a leak.
6. If vacuum gauge does not rise
above 500 microns in one (1)
minute, the evacuation should be
complete.
7. Remove vacuum pump. Attach
center hose of manifold gauge to
R-22 cylinder, purge the charging
line, open valve on R-22 cylinder
and allow refrigerant pressure to
build up to about 40 psig.
8. Close valve on the R-22 supply
cylinder and close valves on
manifold gauge.
9. Leak test the entire system. Using
proper procedures and caution,
repair any leaks found and repeat
the leak test.
Caution: Do not connect a
dual-circuit outdoor unit to a single
circuit evaporating unit. (blower)
Tubing Sizes Additional Additional See
Suction Liquid Tubing Length Refrigerant Note
1 1/8" 3/8" 15 ft. 0 lb. 11.5 oz. (1)
1 1/8" 3/8" 25 ft. 1 lb. 3.0 oz. (1)
1 1/8" 3/8" 32 ft. 1 lb. 8.0 oz. (1)
1 1/8" 3/8" 40 ft. 1 lb. 14.0 oz. (1)
1 3/8" 1/2" 15 ft. 1 lb. 4.0 oz. (2)
1 3/8" 1/2" 25 ft. 2 lb. 1.0 oz. (2)
1 3/8" 1/2" 32 ft. 2 lb. 11.0 oz. (2)
1 3/8" 1/2" 40 ft. 3 lb. 5.0 oz. (2)
1 5/8" 5/8" 15 ft. 1 lb. 15.5 oz. (3)
1 5/8" 5/8" 25 ft. 3 lb. 5.5 oz. (3)
1 5/8" 5/8" 32 ft. 4 lb. 3.2 oz. (3)
1 5/8" 5/8" 40 ft. 5 lb. 4.0 oz. (3)
1Amounts shown are based on .75 ounces of refrigerant per foot
of 1 1/8" and 3/8" lines.
2Amounts shown are based on 1.33 ounces of refrigerant per foot
of 1 3/8" and 1/2" lines.
3Amounts shown are based on 2.1 ounces of refrigerant per foot
of 1 5/8" and 5/8" lines.
Note: for tubing over 40 ft. calculate the additional refrigerant needed,
based on notes above.
Note: Each TTA unit ships with R-22 holding charge.
Table 4 - Additional Required Refrigerant
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9
Refrigerant Charging
and Evacuation
Caution
• Freon Gas “R22” only.
• Always evacuate air from the tubing
before adding refrigerant.
• Add refrigerant through the
charging port of liquid line valve
after the completion of evacuation.
• The refrigerant provided by the
manufacturer meets all the
requirements of our units. When
using recycled or reprocessed
refrigerant, it is advisable to ensure
its quality is equivalent to that of a
new refrigerant. For this, it is
necessary to have a precise
analysis made by a specialized
laboratory. If this condition is not
respected, the manufacturer’s
warranty could be cancelled.
Liquid Charging
After the refrigerant pipework system
has been pressure tested and
evacuated, the refrigerant may be
charged as follows.
1. Weigh the refrigerant cylinder on
weighing scale.
2. Attach the charging line from the
center hose of manifold gauge to
R-22 cylinder.
3. Open valve on R-22 cylinder and
purge the charging line.
4. Invert the refrigerant cylinder, open
the liquid line service valve. Open
manifold valve so that only liquid
will enter the system. The sufficient
operating charge is recommended
in Table 3.
Gaseous Charging
This procedure is accomplished
with the unit operating. Electrical
connections must be complete.
Do not proceed until the system is
ready to operate.
Procedure
1. Open liquid valve that refrigerant
go through air handler unit and
open suction valve.
2. Turn on power to the unit. Allow the
system to run for five to ten
minutes to stabilize operating
conditions.
3. Measure airflow across the indoor
coil. Compare the measurements
with the fan performance data
in the Data/Submittal or Service
Facts. Once proper airflow is
established, observe the suction
and head pressure gauges on the
gauge manifold.
Suction Line Service Valve
Suction Line Gauge Port
Liquid Line Service Valve
Liquid Line
Gauge Port
Manifold
Gauges
Figure 3
Pressure reading should fall
approximately at the points shown
by the pressure curves in Service
Facts. Add or remove refrigerant
(gas only) as required to obtain
correct head and suction pressure.
Check suction line superheat and
condenser sub-cooling to ensure
the unit is operating properly.
4. Disconnect all power to the unit.
5. Remove the charging system from
the unit and close the opening in
the bottom of the control box with
the pivotal cover before attempting
to replace access panel.
6. Replace all panels.
Additional Charge
Refrigerant suitable for a tube length
of 12 to 25 feet is recommended in
Table 3. When the tube is longer than
25 feet, additional charging is
necessary. For the additional amount,
using the table 4 for recommended
amounts:
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