Trane 4TTM3060 - User Manual

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18-AC78D1-6

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 information

pack upon completion of work.

Condensing Units

These instructions do not cover all variations in systems or provide for every possible contingency to be met in connection with the in-

stallation. 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 manufac-

turer’s split systems are A.H.R.I. rated only with TXV 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.

4TTM3018 through 4TTM3060

Installer’s Guide

Table of Contents

Section 1. Safety .................................................................................................... 2

Section 2. Unit Location Considerations .................................................. 3

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 .................................................. 10

Section 9. Evacuation ....................................................................................... 11

Section 10. Service Valves .............................................................................. 11

Section 11. Electrical - Low Voltage ........................................................... 12

Section 12. Electrical - High Voltage .......................................................... 14

Section 13. Start Up ........................................................................................... 15

Section 14. System Charge Adjustment.................................................. 16

Section 15. Checkout Procedures and Troubleshooting ................ 24

Section 16. Independent Charge Verification ....................................... 26

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Summary

Safety Precautions

Handling R-410 A Refrigerant and POE Oil

Electrical Safety During Operation

Warning about live electrical components and potential for serious injury or death.

Liquid Line Service Valve Caution

Refrigerant Line Leak Detection

Performing a Refrigerant Line Leak Check

High Voltage Electrical Requirements

High Voltage Power Supply Considerations

Warning about live components and ensuring power supply matches equipment nameplate.

System Charge Adjustment

New Charging Procedure Overview

Introduction to the subcooling-based charging method to prevent overcharging.

Example of Charge Adjustment Calculation

Measuring System Pressures and Temperatures

Steps for measuring outdoor ambient, suction line, and liquid line pressures and temperatures.

Determining Target Liquid Temperature

Using charging tables to find the target liquid temperature based on measured conditions.

Adjusting System Refrigerant Charge

Procedure for determining and making adjustments to the refrigerant charge.

Adding or Removing Refrigerant

Detailed steps for adding or removing refrigerant using the manual charge assist port.

Verifying Refrigerant Charge Adjustment

Post-Installation Checkout

Operational and Checkout Procedure Checklist

System Fault Diagnosis Guide

A table correlating system faults with primary and secondary causes.

Independent Charge Verification

Initial Measurements for Verification

Steps to measure outdoor ambient, suction line pressure, and liquid line pressure.

Calculating Subcooling for Verification

Steps to find target liquid temperature, calculate actual and target subcooling.

Subcooling Difference Analysis

Calculating the subcooling difference and determining if it's within tolerance.

This document outlines the installation, operation, and maintenance procedures for Trane/American Standard Condensing Units, specifically models 4TTM3018 through 4TTM3060. It serves as an essential guide for individuals with adequate electrical and mechanical experience, emphasizing compliance with national, state, and local codes throughout all installation phases. The manual is intended to remain with the unit as customer property and should be returned to the service information pack upon completion of work.

Function Description

These condensing units are designed to be a core component of a central air conditioning system, working in conjunction with an indoor unit (air handler or gas furnace) to provide cooling. The system operates by circulating R-410A refrigerant, which absorbs heat from the indoor environment and releases it outdoors. The units are designed for optimal performance and efficiency when installed as part of an approved matched indoor and outdoor system, particularly with TXV (Thermostatic Expansion Valve) indoor systems, which are AHRI rated.

Usage Features

The installation process is broken down into several sections to ensure a systematic and safe setup.

Unit Location Considerations: This section provides guidelines for selecting an appropriate location for the outdoor unit. It includes details on unit dimensions and weight, refrigerant piping limits (maximum line length of 100 feet and vertical length of 60 feet), and specific restrictions to ensure proper airflow and minimize noise. For instance, the top discharge area must be unrestricted for at least five feet, and the unit should be positioned a minimum of 12 inches from any wall or shrubbery. It also advises against locating the unit near bedrooms due to operational sounds and ensuring it's far enough from structures to prevent roof runoff water from pouring directly on it.
Unit Preparation and Setting: Before installation, the unit should be checked for shipping damage. The manual details how to remove the unit from its pallet. For pad installation, it specifies that the pad should be 1-2 inches larger than the unit on all sides, separate from any structure, level, and high enough for drainage, all while complying with local codes.
Refrigerant Line Considerations and Routing: The document provides a table for refrigerant line and service valve connection sizes, ensuring the correct line diameters are used. It emphasizes the importance of insulating the vapor line and preventing direct metal-to-metal contact between the liquid and vapor lines. For existing refrigerant lines, precautions include ensuring correct sizing, and freedom from leaks, acid, and oil. Routing guidelines focus on preventing noise and vibration transmission to the building structure by using isolation-type hangers when fastening lines to joists, rafters, or walls, and insulating lines that run through walls or sills. Minimizing 90-degree turns is also recommended.
Refrigerant Line Brazing and Leak Check: A detailed, step-by-step process for brazing refrigerant lines is provided. This includes deburring pipe ends, cleaning surfaces, purging lines and the indoor coil with dry nitrogen, and wrapping a wet rag around valve bodies to prevent heat damage during brazing. The filter drier's directional flow arrow must be checked for correct refrigeration flow. After brazing, the system must be pressurized to 150 PSIG with dry nitrogen and checked for leaks using a soapy solution.
Evacuation and Service Valve Operation: The system must be evacuated until a micron gauge reads no higher than 350 microns, and then observed to ensure it doesn't rise above 500 microns in one minute. This ensures all non-condensables and moisture are removed. The manual provides a critical warning regarding the careful opening of the liquid line service valve to prevent abrupt release of system charge. The vapor service valve must be opened first.
Electrical Connections: Low voltage wiring guidelines specify maximum wire lengths based on wire gauge (18 AWG for 150 ft, 16 AWG for 225 ft, 14 AWG for 300 ft) and require field-provided bushing or strain relief at the entry point. Hook-up diagrams for air handlers and gas furnaces (both standard and variable speed) are included. High voltage wiring requires a separate disconnect switch at the outdoor unit and field-provided flexible electrical conduit, with strict adherence to national, state, and local codes for power supply and grounding.
System Start-Up: A sequence for system start-up is provided, including setting the thermostat to OFF, applying power, and waiting periods (five minutes if no crankcase heater, one hour if a crankcase heater is used and ambient temperature is below 70°F) before setting the thermostat to ON.

Maintenance Features

The manual includes sections dedicated to system charge adjustment, checkout procedures, and troubleshooting, which are crucial for maintaining optimal performance.

System Charge Adjustment: This section outlines a new charging procedure that helps prevent overcharging, as subcooling alone is not sufficient for these units. It requires measuring outdoor ambient temperature, suction line pressure (PSIG), liquid temperature, and liquid pressure. The system is charged to the minimum liquid temperature or maximum liquid line pressure, whichever is reached first. Detailed steps are provided for checking indoor and outdoor ambient temperatures (outdoor ambient should be above 60°F for accurate charging), stabilizing the system in cooling mode for a minimum of ten minutes, and determining the target (minimum) liquid temperature and maximum allowable liquid pressure using provided charging tables. Instructions for adding or removing system charge using the manual charge assist port are given, emphasizing liquid charging and stabilization periods after adjustments. Finally, it details how to verify the refrigerant adjustment and record system information.
Independent Charge Verification: This section provides a method to verify the subcooling difference is within the tolerance range after the system has been charged. It involves measuring outdoor ambient temperature (between 60°F and 105°F), stabilizing the system, measuring suction line pressure, liquid line pressure, and liquid line temperature. These measurements are then used with the charging tables and a provided worksheet to calculate actual subcooling, target subcooling, and the subcooling difference. This verification ensures accurate charging and system performance.
Checkout Procedures and Troubleshooting: The final phases of installation include operational and checkout procedures to ensure proper performance. A comprehensive checklist covers leak checking refrigerant lines, insulating suction lines, securing and isolating refrigerant lines, sealing passages through masonry, verifying electrical connections, observing outdoor fan operation, ensuring indoor coil drain line drains freely, checking supply registers and return grilles, verifying return air filter installation, and confirming correct airflow settings. The troubleshooting section provides a detailed table of system faults, categorizing them by refrigerant circuit, electrical, and defrost issues. For each fault, it lists primary causes and secondary causes, indicating whether the issue is related to cooling or heating, and if it applies to 3-phase systems. This allows technicians to systematically diagnose and resolve problems, ensuring the unit operates safely and efficiently.