Trane Foundation GCC180-300 Installation Operation & Maintenance
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Trane Foundation GCC180-300 Installation Operation & Maintenance

Trane Foundation GCC180-300 Installation Operation & Maintenance

Packaged rooftop air conditioners
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Installation, Operation, and Maintenance
Packaged Rooftop Air
Conditioners Foundation™
Cooling and Gas/Electric
15 to 25 Tons, 60 Hz
Model Numbers: GCC180-300
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment
can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or
serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.
December 2022
SAFETY WARNING
RT-SVX51L-EN

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Summary of Contents for Trane Foundation GCC180-300

  • Page 1 Installation, Operation, and Maintenance Packaged Rooftop Air Conditioners Foundation™ Cooling and Gas/Electric 15 to 25 Tons, 60 Hz Model Numbers: GCC180-300 SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.
  • Page 2 (HCFCs). Not all refrigerants containing these compounds bump cap, fall protection, electrical PPE and arc have the same potential impact to the environment. Trane flash clothing). ALWAYS refer to appropriate advocates the responsible handling of all refrigerants-...
  • Page 3 Follow EHS Policies! This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in Failure to follow instructions below could result in part without written permission. Trane reserves the right to death or serious injury.

  • Page 4: Table Of Contents

    Table of Contents Model Number Description ....6 Unit Disconnect (FIYUDC) ... . . 28 Through the Base Gas Utility Option.
  • Page 5 Table of Contents Phase Monitor ......37 Standard Troubleshooting ....44 Low Pressure Cutout .

  • Page 6: Model Number Description

    Model Number Description Digit 1 — Unit Type Digit 11— Minor Design Sequence Digit 17 — Condenser Coil Protection G = Packaged Gas/Electric 0 = Standard Coil 4 = CompleteCoat™ Condenser Coil Digit 2 — Efficiency Digit 12,13 — Service Sequence Digit 18 —...

  • Page 7: General Information

    General Information WARNING • Inspect the complete exterior for signs of shipping damages to unit or packing material. Fiberglass Wool! • Verify that the nameplate data matches the sales order Exposure to glass wool fibers without all necessary and bill of lading. PPE equipment could result in cancer, respiratory, •...

  • Page 8: Economizer Control Actuator Electromechanical Control

    General Information Economizer Control Actuator safety input of the LSD. The compressor contactor coil is connected to the ‘CC’ terminal of the LSD. If the high Electromechanical Control pressure control switch or the discharge line thermostat is The ECA monitors the mixed air temperature, return air open, the 24 Vac signal to the SI input of the LSD is temperature, minimum position setpoint (local or remote), interrupted and the compressor contactor coil supply is...

  • Page 9: Initiation Of Operating Modes - Jade

    General Information Thermostat (TCONT402AN32DA) Low Leak Economizer Units This thermostat is a multi-stage 3 heat/2 cool, auto To configure the JADE controller, set: changeover digital display thermostat. It is a SYSTEM SETUP menu: OCC = INPUT nonprogrammable, wall-mounted thermostat, and it can be Attach the occupancy sensor to the OCC SENSOR wire used for economizer operation.

  • Page 10: Dimensional Data

    Dimensional Data Below figure illustrates the minimum operating and service Providing less than the recommended clearances may clearances for either a single or multiple unit installation. result in condenser coil starvation, “short-circuiting” of These clearances are the minimum distances necessary to exhaust and economizer airflows, or recirculation of hot assure adequate serviceability, cataloged unit capacity, and condenser air.
  • Page 11 Dimensional Data Figure 2. Cooling with optional electrical heat — overview (gas/electric) CONDENSATE DRAIN REFRIGERANT GAUGE CONNECTION ACCESS GAS CONNECTION(G*C UNIT ONLY) CUSTOMER POWER CONDUIT CONNECTION(ALTERNATE) GAS CONNECTION (G*C UNIT-TBU GAS ONLY) DISCONNECT SWITCH ACCESS Figure 3. Cooling with optional electrical heat — front and side views (gas/electric) 58 5/8”...
  • Page 12 Dimensional Data Figure 4. Cooling with optional electrical heat units— plain view (gas/electric) SUPPLY RETURN 64 9/16” 71 15/16” 68 9/16” 14 15/16” 7 7/16” 6 13/16” 6 15/16” 36 1/16” 82 1/4" THROUGH THE BASE ELECTRICAL (THRU-THE-BASE GAS-G*C UNIT ONLY) 7 3/8”...
  • Page 13 Dimensional Data Figure 6. Cooling with optional electrical heat — roof crub 116 7/8” 1” 2969 MM 25 MM 1 13/16” 1” 46 MM 25 MM 1 1/2” (38 MM) PERIMETER 22 1/4” CURB FLANGE 565 MM 23 1/4” 1” 591 MM 25 MM 28 9/16”...
  • Page 14 Dimensional Data Figure 8. Cooling with optional electric heat — downflow unit clearance CLEARANCE 36” 914 MM UNIT OUTLINE CLEARANCE 68” 1727 MM CLEARANCE FORM TOP OF UNIT 72” MM (1829 MM) ROOF 76 1/2” OPENING 1943 MM CLEARANCE 48” 1219 MM 81”...
  • Page 15 Dimensional Data Figure 10. Cooling with optional electric heat — manual damper MANUAL DAMPER HOOD 26 7/8” 12 13/16” 24 7/8” 123 1/8” 18 1/4” 86 15/16” BACK VIEW OF UNIT LEFT VIEW OF UNIT NOTE: VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WITH INSTALLER DOCUMENTS BEFORE INSTALLATION. RT-SVX51L-EN...

  • Page 16: Weights

    Weights Table 1. Maximum unit and corner weights (lb) and center of gravity dimensions (in.) Weights (lb) Corner Weights Center of Gravity (in.) Unit Model Tons Shipping Length Width GCC180A 2339 2013 17.5 GCC210A 2353 2028 GCC240A 2350 2025 GCC300A 2386 2061 Weights are approximate.

  • Page 17: Rigging

    Weights Rigging in the unit base rail. Do not use cables, chains, or slings except as shown. WARNING 3. Install a lifting bar, as shown in Figure 12, p. 17, to Heavy Object! protect the unit and to facilitate a uniform lift. The minimum distance between the lifting hook and the top Failure to follow instructions below could result in of the unit should be 7 feet.

  • Page 18: Installation

    Installation Unit Foundation Check with a roofing contractor for proper waterproofing procedures. WARNING Ductwork Risk of Roof Collapsing! Failure to ensure proper structural roof support could Elbows with turning vanes or splitters are recommended to cause the roof to collapse, which could result in death minimize air noise due to turbulence and to reduce static or serious injury and property damage.

  • Page 19: Factory Installed Economizer

    Installation ☐ Assemble and install the roof curb (if applicable). Refer Important: to the latest edition of the curb installers guide that • Make sure you read the label located ships with each curb kit. on the cover plate before you discard ☐...

  • Page 20: Tco1 Instructions

    Installation Figure 15. Vent hood installation Figure 17. Factory installed down flow TCO1 limit location Gas Heater Conversion Instructions Important: Conversion should be made prior to installation of equipment at job site. Note: Only Applicable for GCC210A*E (H, Z) If the unit is installed in a horizontal configuration, the factory-installed gas orifice spuds, air orifice plate, and TCO1 limit must be replaced with the gas orifice spuds, air orifice plate, and TCO1 limit for horizontal applications...
  • Page 21 Installation Figure 19. Remove screws from manifold assembly Figure 21. Remove screws from inducer blower assembly and air orifice plate 4. Remove the natural gas orifice spuds from the manifold. See the following figure. Figure 22. Remove screws from inducer blower 5.
  • Page 22 Installation Figure 23. TCO1 limit ship-with location 17. Once the conversion is complete, scratch off the ink square (to the right-hand side). SCRATCH INK OFF SQUARE WHEN USING SUPPLEMENTAL HEATING DATA on both English and French nameplate. 18. Paste the ship-with supplemental heating data label over the existing heating data on both English and French nameplate.

  • Page 23: Condensate Drain Configuration

    Installation Figure 25. Location for pasting supplemental heating data label Paste supplemental heating data label over the dotted area Condensate Drain Configuration Field Installed MERV13 Filters An evaporator condensate drain connection is provided on Optional MERV13 filters are available for purchase. each unit.

  • Page 24: Main Unit Power

    Installation Note: If the unit is not equipped with an optional factory Figure 26. Through the base electrical option installed nonfused disconnect switch or circuit breaker, a field supplied disconnect switch must be installed at or near the unit in accordance with the National Electrical Code (NEC latest edition).

  • Page 25: Requirements Of Gas Heat

    Installation conduit with the high voltage power wiring. 5. Route low voltage wiring as per Figure 27, p. Table 2. Electromechanical thermostat 24V AC conductors with electromechanical unit Distance from Unit to Control Recommended Wire Size 22 gauge 0 - 30 feet 0 - 9.1 m 0.33 mm^2 20 gauge...

  • Page 26: Gas Heat Data

    Installation Gas Heat Data • Flue Exhaust clear of any obstruction Table 3. Gas heater operating data Heating Input Rate—Btu/h 240,000 320,000 350,000 380,000 Minimum Supply Gas Pressure Natural/LP 5.0/11.0 5.0/11.0 4.5/11.0 5.5/11.0 Manifold Gas Pressure 3.2-3.5 3.2-3.5 3.2-3.5 3.2-3.5 Combustion Blower Suction Pressure (1 Stage) -0.6 to -0.8...

  • Page 27: Voltage Imbalance

    Installation Figure 29. Typical unit gas train configuration percent current imbalance with a resulting increase in motor winding temperatures that will decrease motor life. If the voltage imbalance is over 2 percent, notify the proper agencies to correct the voltage problem before operating this equipment.

  • Page 28: Compressor Crankcase Heaters

    Installation 5. Restore the main electrical power and recheck the ☐ Verify that the condenser fan and indoor blower turn phasing. If the phasing is correct, open the disconnect freely without rubbing and are properly tightened on the switch or circuit protection switch and remove the shafts.

  • Page 29: Through The Base Gas Utility Option

    Installation Field Installed Connections the base or through the front corner post where the disconnect enclosure is mounted. The hole is sized for WARNING 1 1/2–in. conduit. Hazardous Voltage w/Capacitors! 2. If the conduit required for your application is larger than 1 1/2–in., remove the termination plate and connect to Failure to disconnect power and discharge capacitors the larger hole using field supplied reducing washers.
  • Page 30 Installation Figure 31. Through the base gas piping installation RT-SVX51L-EN...

  • Page 31: Pre Start

    Pre Start Verifying Proper Air Flow (Units Fan Test and Minimum Ventilation. Connect red thermostat wire (R) to black thermostat wire (G). with Belt Drive Indoor Fan) Economizer Cooling. Connect a jumper wire across OAT Much of the systems performance and reliability is closely on Economizer Control (ECA).

  • Page 32: Start Up

    Start Up Electromechanical Controls - When the thermostat fan selection switch is set to the "On" position, the thermostat keeps the indoor fan relay coil (F) Sequence Of Operation energized for continuous fan motor operation. These units are offered with electromechanical controls. Economizer Set-Up - Standard Note: The Condensate Overflow Switch (COF) (optional) Economizer...

  • Page 33: Heating Operation (For Gas Units) - Standard Economizer

    Start Up When the W2 contacts close, the second stage electric Table 8. Ignition module diagnostics (continued) heat contactor (BH or BH and DH) is energized, if Pressure switch (no vent air flow, bad CBM, applicable. The thermostat cycles both the first and second Three blinks closed at initial call for heat).

  • Page 34: Economizer Minimum Position Handling For 2-Speed Fan

    Start Up When there is a call for Cool 2, the second compressor is are no field adjustments and the module will automatically energized and the Supply Fan will switch to High Speed. reset from a fault condition. The unit will stage down compressors for cooling in reverse Low Pressure Cutout order that they were staged and the supply fan will follow the unit mode transitions.

  • Page 35: Jade Controls - Low Leak Economizer

    Start Up JADE Controls - Low Leak Economizer Sequence of Operation Table 9. Dry bulb operation no DCV (CO sensor) - 2 speed fan OA Good to Occupied Unoccupied Y1-I Y2-I FAN SPD Y1-O Y2-O economize? 0-v/Off 0-v/Off MIN POS L Closed None 24-v/On...

  • Page 36: Economizer Set-Up

    Start Up Table 12. Enthalpy operation with DCV (CO sensor) - 2 speed fan OA Good to Occupied Unoccupied Y1-I Y2-I FAN SPD Y1-O Y2-O economize? 0-v/Off 0-v/Off VENTMIN L Closed 24-v/On 0-v/Off VENTMIN L Closed High 24-v/On 24-v/On VENTMIN H Closed Below set 0-v/Off...

  • Page 37: Phase Monitor

    Start Up Initiation of Operating Modes The W (heating mode) is not controlled by the controller but it requires the status to know where to position the OA The JADE controller is able to initiate the following modes: damper for minimum position for the fan speed. Compressor, Economizer, Fans, Heating System, and The 2–speed fan delay is available when FAN SPEED is Cooling System.

  • Page 38: Compressor Start-Up

    Start Up buttons. Note: Copeland ZP scroll compressors for R410A units use Trane OIL00094. Compressor 2. Press the button to select the item. types and appropriate oil charge is listed in 3. “RUN?” is displayed. the following tables. 4. Press to start the test.

  • Page 39: Maintenance

    Maintenance Make sure all personnel are standing clear of the unit deflection value determined in Step before proceeding. The system components will start when 3. Set the small O-ring at zero on the force scale of the the power is applied. gauge plunger.

  • Page 40: Monthly Maintenance

    Maintenance Table 17. Belt tension measurement and deflection ranges (mm/kg) Deflection Force (kg) Small P.D Range Belts Cross Super Gripbelts (mm) Gripnotch (mm) Steel Cable Gripbelts (mm) (mm) Section Min. Max. Min. Max. Min. 13.3–16.0 13.3 20.0 17.2 24.5 14.5 17.8 16.9–21.4 15.6...

  • Page 41: Heating Season

    Maintenance WARNING – ambient temperature – compressor oil level (each circuit) Hazardous Chemicals! – compressor suction and discharge pressures (each Failure to follow this safety precaution could result in circuit) death or serious injury. Coil cleaning agents can be either acidic or highly alkaline and can burn severely –...
  • Page 42 Maintenance Table 18. Unit data log (continued) -schematic(s) -connections Network ID RT-SVX51L-EN...
  • Page 43 Maintenance RT-SVX51L-EN...

  • Page 44: Troubleshooting

    Troubleshooting WARNING the main power disconnect switch and removing the test mode connections. Hazardous Service Procedures! 7. Refer to the individual component test procedures if Failure to follow all precautions in this manual and on other components are suspect. the tags, stickers, and labels could result in death or serious injury.

  • Page 45: Resetting Cooling And Heating

    Troubleshooting Note: If an alarm still exists after you clear it, it re- • SYS Alarm displays within 5 seconds. • Actuator Undervoltage To Clear an Alarm • Actuator Overvoltage Once the alarm has been identified and the cause has •...

  • Page 46: Error Code

    Troubleshooting • Pulse Flash: 1/30 Second On / 1/4 Second Off: (2 • 4 Flashes: RA Temp Sensor Seconds between pulse sequences) • 6 Flashes: OA Humidity Sensor Error Code • 7 Flashes: OA Temp Sensor • 8 Flashes: MA Temp Sensor •...

  • Page 47: Wiring Diagrams

    Wiring Diagrams Note: Wiring diagrams can be accessed via e-Library by number search field or by contacting technical entering the diagram number in the literature order support. Table 21. Wiring diagrams Type of Diagram Schematic Type Voltage Description Airflow Number Schematic, PWR-EM, 208V-230V, 2-Stage GH with VFD - 15T-25T 208-230 12134575...

  • Page 48: Warranty

    Products Covered — This warranty is extended by Trane, and which have been returned to the warrantor. and applies to the following products: The warrantor’s warranty is conditional on the Customer...
  • Page 49 Notes RT-SVX51L-EN...
  • Page 50 Notes RT-SVX51L-EN...
  • Page 51 Notes RT-SVX51L-EN...
  • Page 52 For more information, please visit trane.com or americanstandardair.com. Trane and American Standard have a policy of continuous product and product data improvement and reserve the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

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