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Installation, Operation,
and Maintenance
Packaged Rooftop Air Conditioners
Foundation™ Gas/Electric
3 to 5 Tons, 60Hz
Model Numbers:
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.
January 2019
GBC036-060
SAFETY WARNING
RT-SVX058C-EN
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Troubleshooting
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Summary of Contents for Ingersoll-Rand GBC036 Series
- Page 1 Installation, Operation, and Maintenance Packaged Rooftop Air Conditioners Foundation™ Gas/Electric 3 to 5 Tons, 60Hz Model Numbers: GBC036-060 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 Introduction Read this manual thoroughly before operating or servicing this unit. WARNING Warnings, Cautions, and Notices Proper Field Wiring and Grounding Required! Safety advisories appear throughout this manual as Failure to follow code could result in death or serious required. Your personal safety and the proper operation of injury.
- Page 3 Introduction WARNING Follow EHS Policies! Failure to follow instructions below could result in death or serious injury. • All Ingersoll Rand personnel must follow Ingersoll Rand Environmental, Health and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc.
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Page 4: Table Of Contents
Table of Contents Model Number Description Resetting Cooling and Heating Lockouts . .32 ....5 Unit Economizer Control (ECA) ..33 General Information . -
Page 5: Model Number Description
Model Number Description Model Number Description Digit 1 — Unit Type Downflow Low Leak Economizer, Model Number Notes Comparative Enthalpy, W/ Packaged Cooling, Gas heat Barometric Relief 1. Some field set up required. Digit 2 — Efficiency Digit 15 — Supply Fan/Drive 2. -
Page 6: General Information
General Information Overview of Manual Precautionary Measures Note: One copy of this document ships inside the control panel of each unit and is customer property. It must WARNING be retained by the unit’s maintenance personnel. Fiberglass Wool! This booklet describes proper installation, operation, and Product contains fiberglass wool. -
Page 7: Unit Description
General Information Unit Description Phase Monitor The Phase Monitor is a three-phase line monitor module Before shipment, each unit is leak tested, dehydrated, that protects against phase loss, phase reversal and phase charged with refrigerant and compressor oil, and run unbalance. -
Page 8: Initiation Of Operating Modes - Jade Control
General Information designed to mount directly to the sheet metal duct. Each kit Attach the occupancy sensor to the OCC SENSOR wire and contains two sensors. The return air duct sensor "R" terminal (at customer connections). The occupancy (X1310004001) is set to open at 135°F. sensor must utilize a normally open contact for proper operation. -
Page 9: Dimensional Data
Dimensional Data Figure 1, p. 9 illustrates the minimum operating and service clearances for either a single or multiple unit installation. These clearances are the minimum distances necessary to assure adequate serviceability, cataloged unit capacity, and peak operating efficiency. Providing less than the recommended clearances may result in condenser coil starvation, “short-circuiting”... - Page 10 Dimensional Data Figure 2. Gas/electric units — overview DISCONNECT SWITCH ACCESS GAS CONNECTION CONDENSATE DRAIN CONNECTION Figure 3. Gas/electric units — front & side views — 3–5 tons 42.558 42.004 20.735 15.860 7.860 42.175 29.671 43.675 44.675 76.814 47.934 NOTES: 1.
- Page 11 Dimensional Data Figure 4. Gas/electric units — bottom view — 3–5 tons Figure 5. Foundation units — back view (horizontal configuration) — 3–5 tons RETURN SUPPLY RT-SVX058C-EN...
- Page 12 Dimensional Data Figure 6. Roof curb —3–5 tons SUPPLY RETURN Figure 7. Downflow unit clearance — 3–5 tons standard efficiency CLEARANCE CLEARANCE UNIT OUTLINE CLEARANCE CLEARANCE RT-SVX058C-EN...
- Page 13 Dimensional Data Figure 8. Barometric relief and economizer— 3–5 tons ECONOMIZER BAROMETRIC RELIEF BAROMETRIC RELIEF RIGHT VIEW OF UNIT BACK VIEW OF UNIT Figure 9. Manual damper — 3–5 tons MANUAL DAMPER HOOD RIGHT VIEW OF UNIT BACK VIEW OF UNIT NOTE: VERIFY WEIGHT, CONNECTION, AND ALL DIMENSIONS WIT INSTALLER DOCUMENTS BEFORE...
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Page 14: Unit Weights
Unit Weights Table 1. Maximum unit & corner weights (lb) and center of gravity dimensions (in.) cooling with optional electric heat units only (a), (b) Weights (lb) Corner Weights Center of Gravity (in.) Unit Tons Model No. Shipping Length Width GBC036* GBC048* GBC060*... -
Page 15: Installation
Installation Unit Foundation Note: For sound consideration, cut only the holes in the roof deck for the ductwork penetrations. Do not cut out the entire roof deck within the curb perimeter. WARNING If a Curb Accessory Kit is not used: a. - Page 16 Installation Factory Installed Economizer External Vent Hood Installation • Ensure the economizer has been pulled out into the operating position. Refer to the standard or low leak WARNING economizer Installation Instructions for proper Hazardous Voltage! position and setup. Disconnect all electric power, including remote •...
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Page 17: Main Unit Power
Installation trap condition which could result in condensate backup Figure 13. Vent hood shipping location due to “air lock”. Filter Installation Each unit ships with 2-inch filters installed. The quantity of filters is determined by unit size. Access to the filters is obtained by removing the filter access panel. - Page 18 Installation Optional TBUE Wiring (Through the Base Protection devices must be sized according to the electrical data on the nameplate. Electrical Option) • If the unit is not equipped with an optional factory • Location of the applicable electrical service is installed nonfused disconnect switch, a field supplied illustrated below.
- Page 19 Installation The transformer is located in the control panel. The circuit Figure 16. Conventional thermostat field wiring breaker is located on the left side of the transformer and diagram can be reset by pressing in on the black reset button. Controls using 24 Vac Before installing any connecting wiring, refer to “Dimensional Data,”...
- Page 20 Installation Gas Heat Data Figure 17. Schematic diagram for field gas piping to units Table 3. Gas heater operating data Heating Input Rate— Btu/h 115,000 100,000 72,000 Minimum Supply Gas 4/11 4/11 4/11 Pressure Natural/LP Manifold Gas Pressure Combustion Blower Suction -0.50 to - -0.50 to - -0.50 to -...
- Page 21 Installation • V1, V2, V3 = Line Voltage Readings WARNING • VD = Line Voltage reading that deviates the farthest from the average voltage. Live Electrical Components! Example: If the voltage readings of the supply power During installation, testing, servicing and measured 221, 230, and 227, the average volts would be: troubleshooting of this product, it may be necessary to work with live electrical components.
- Page 22 Installation Checklist Use the following checklist in conjunction with the general checklist (“General Unit Requirements,” p. 15) to ensure that the unit is properly installed and ready for operation. WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized.
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Page 23: Factory-Mounted Unit Options
Factory-Mounted Unit Options Unit Disconnect (FIYUDC) Note: Wire size for the length of run should be determined using the circuit ampacity found on the unit nameplate and the N.E.C. WARNING 4. Route low voltage (class II), control wiring through hole in base of unit but not through high voltage Hazardous Voltage w/Capacitors! conduit (refer to Figure 15, p. -
Page 24: Through The Base Gas Utility Option
Factory-Mounted Unit Options Through the Base Gas Utility Important: All phases of this installation must comply with NATIONAL, STATE, and LOCAL Option CODES. In absence of local codes, the installation must conform with American This section contains the instructions for making field National Standard-Z223.1a- National Fuel connections to the Through the Base Gas Utility Option. -
Page 25: Pre Start
Pre Start Verifying Proper Air Flow (Units with Belt Drive Indoor Fan) Much of the systems performance and reliability is closely associated with, and dependent upon having the proper airflow supplied both to the space that is being conditioned and across the evaporator coil. The indoor fan speed is changed by opening or closing the adjustable motor sheave. -
Page 26: Start Up
Start Up Standard Economizer Start-Up mode and all components removed or failed will alarm in the operation mode. 1. Set the minimum position setpoint for the economizer • Upon power up (or after a power outage or brownout), to the required percentage of minimum ventilation the JADE controller module begins a 5 minute power using the setpoint potentiometer located on the up delay before enabling mechanical cooling. -
Page 27: Heating Start-Up
Start Up pressures to the operating pressure curve in the Service Facts. 3. Check system subcooling. Follow the instruction listed on the subcooling charging curve in the Service Facts. 4. Repeat Step 1 through Step 3 for each refrigerant circuit. 5. -
Page 28: Maintenance
Maintenance Make sure all personnel are standing clear of the unit 6. Compare the “force” scale reading (Step 5) with the before proceeding. The system components will start appropriate “force” value listed in Table 9, p. 28. If the when the power is applied. “force”... - Page 29 Maintenance • Make sure that all retaining screws are reinstalled in the unit access panels once these checks are complete. WARNING • With the unit running, check and record the: ambient Hazardous Voltage! temperature; compressor suction and discharge Disconnect all electric power, including remote pressures (each circuit);...
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Page 30: Final Process
Maintenance Moreover, chemical cleaners are a risk factor to MCHE due (3) Wiring Diagram Numbers (from unit control panel) to the material of the coil. The manufacturer does not — schematic(s) recommend the use of chemical cleaners to clean _____________________________________________________ microchannel coils. -
Page 31: Troubleshooting
Troubleshooting 7. Refer to the individual component test procedures if other components are suspect. WARNING Hazardous Service Procedures! Failures The maintenance and troubleshooting procedures Heating Failure - Low Heat Models recommended in this section of the manual could result in exposure to electrical, mechanical or other potential Verify heat failure by ignition module. -
Page 32: Low Leak Economizer (Lle) Troubleshooting
Troubleshooting b. Compressor lockout is indicated by a solid (non- • Excess outdoor air flashing) red LED. The JADE controller is a certified FDD product (HJW10) by To reset LSD - Cycle power on "R" input. California Title 24, Part 6. The FDD system is required for meeting California Energy Commission's Title 24 Simultaneous Heat and Cool Failure regulations. -
Page 33: Unit Economizer Control (Eca)
Troubleshooting Unit Economizer Control (ECA) Verify Economizer Status by Economizer Actuator (ECA) LED indicator: • OFF: No Power or Failure • ON: Normal, OK to Economize • Slow Flash: Normal, Not OK to Economize • Fast Flash - 1/4 Second On / 2 Seconds Off: –... -
Page 34: Wiring Diagrams
Wiring Diagrams Note: Wiring diagrams can be accessed via e-Library by entering the diagram number in the literature order number search field or by contacting technical support. Table 12. Wiring diagrams Type of Schematic Diagram Airflow Type Voltage Number Description 12132102 GBC 036-060, 60Hz, 1 STAGE Gas Heat 208-230... -
Page 35: Warranty
Warranty Central Air Conditioner Trane 2701 Wilma Rudolph Blvd. Clarksville, TN 37040-1008 GBC Units (Parts Only) Attention: Manager, Product Service Models Less than 20 Tons for Commercial GW-602-4800 Use* * This warranty is for commercial usage of said equipment and not applicable when the equipment is used for a This warranty is extended by Trane, to the original residential application. - Page 36 Ingersoll Rand (NYSE:IR) advances the quality of life by creating comfortable, sustainable and efficient environments. Our people and our family of brands—including Club Car®, Ingersoll Rand®, Thermo King® and Trane®—work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables;...
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