Ingersoll-Rand GBC036-060 Installation, Operation And Maintenance Manual Download Page 4

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RT-SVX058B-EN

Table of Contents

Model Number Description

. . . . . . . . . . . . . . . 5

General Information

. . . . . . . . . . . . . . . . . . . . . 6

Unit Inspection

. . . . . . . . . . . . . . . . . . . . . . . . 6

Precautionary Measures

. . . . . . . . . . . . . . . . 6

Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Unit Description

. . . . . . . . . . . . . . . . . . . . . . . 6

System Input Devices & Functions

. . . . . . . 7

Sensors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Initiation of Operating Modes - JADE Control-
ler

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Dimensional Data

. . . . . . . . . . . . . . . . . . . . . . . . 9

Unit Weights

. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Rigging

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Unit Foundation

. . . . . . . . . . . . . . . . . . . . . . 15

General Unit Requirements

. . . . . . . . . . . . 15

Main Unit Power

. . . . . . . . . . . . . . . . . . . . . 17

Factory-Mounted Unit Options

. . . . . . . . . . . 23

Unit Disconnect (FIYUDC)

. . . . . . . . . . . . . . 23

Through the Base Gas Utility Option

. . . . 24

Pre Start

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Verifying Proper Air Flow (Units with Belt
Drive Indoor Fan)

. . . . . . . . . . . . . . . . . . . . . 25

Electromechanical Controls
Test Procedure

. . . . . . . . . . . . . . . . . . . . . . . 25

Start Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Standard Economizer Start-Up

. . . . . . . . . 26

LLE Controls Test Procedure

. . . . . . . . . . . 26

Compressor Start-Up

. . . . . . . . . . . . . . . . . 26

Heating Start-Up

. . . . . . . . . . . . . . . . . . . . . 27

Final System Set Up

. . . . . . . . . . . . . . . . . . 27

Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fan Belt Adjustment—Belt Drive Units

. . 28

Monthly Maintenance

. . . . . . . . . . . . . . . . . 28

Final Process

. . . . . . . . . . . . . . . . . . . . . . . . . 30

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . 31

Standard Troubleshooting

. . . . . . . . . . . . . 31

Low Leak Economizer
(LLE) Troubleshooting

. . . . . . . . . . . . . . . . . 32

Resetting Cooling and Heating Lockouts

. .32

Unit Economizer Control (ECA)

. . . . . . . . . .32

Wiring Diagrams

. . . . . . . . . . . . . . . . . . . . . . . .34

Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Central Air Conditioner

. . . . . . . . . . . . . . . . .35

Summary of Contents for GBC036-060

Page 1: ...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 Packaged Rooftop Air Conditioners Foundation Gas Electric 3 to 5 Tons 60Hz Installation Operation and Maintenance RT SVX058B EN Augu...

Page 2: ...ult in minor or moderate injury It could also be used to alert against unsafe practices NOTICE Indicates a situation that could result in equipment or property damage only accidents WARNING Proper Field Wiring and Grounding Required Failure to follow code could result in death or serious injury All field wiring MUST be performed by qualified personnel Improperly installed and grounded field wiring...

Page 3: ...in Configuration section 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 All policies can be found on the BOS site Where local regulation...

Page 4: ...FIYUDC 23 Through the Base Gas Utility Option 24 Pre Start 25 Verifying Proper Air Flow Units with Belt Drive Indoor Fan 25 Electromechanical Controls Test Procedure 25 Start Up 26 Standard Economizer Start Up 26 LLE Controls Test Procedure 26 Compressor Start Up 26 Heating Start Up 27 Final System Set Up 27 Maintenance 28 Fan Belt Adjustment Belt Drive Units 28 Monthly Maintenance 28 Final Proces...

Page 5: ...izer Dry Bulb W Barometric Relief M Downflow Low Leak Economizer Reference Enthalpy W Barometric Relief P Downflow Low Leak Economizer Comparative Enthalpy W Barometric Relief Digit 15 Supply Fan Drive Type Motor 0 Standard Motor 1 Oversized Motor Digit 16 Not Used Digit 17 Condenser Coil Protection 0 Standard Coil 4 CompleteCoat Condenser Coil Digit 18 Through The Base Provisions 0 No Through The...

Page 6: ...Avoid contact with the skin or eyes Wear long sleeved loose fitting clothing gloves and eye protection Wash clothes separately from other clothing rinse washer thoroughly Operations such as sawing blowing tear out and spraying may generate fiber concentrations requiring additional respiratory protection Use the appropriate NIOSH approved respiration in these situations First Aid Measures Eye Conta...

Page 7: ...unit A delay timer prevents the unit from starting for 3 minutes Phase Monitor The Phase Monitor is a three phase line monitor module that protects against phase loss phase reversal and phase unbalance It is intended to protect compressors from reverse rotation It has an operating input voltage range of 190 600 Vac and LED indicators for ON and FAULT There are no field adjustments and the module w...

Page 8: ...de damper control based on occupied unoccupied conditions Low Leak Economizer Units To configure the JADE controller set SYSTEM SETUP menu OCC INPUT Attach the occupancy sensor to the OCC SENSOR wire and R terminal at customer connections The occupancy sensor must utilize a normally open contact for proper operation If an occupancy sensor is not used another option to controlling occupied and unoc...

Page 9: ...onomizer airflows or recirculation of hot condenser air Figure 1 Typical installation clearance for single and multiple unit applications END TO END NOTE 2 3 SIDE BY SIDE NOTE 2 NOTE 1 3 0 4 0 5 0 3 0 WITHOUT ECONOMIZER 5 8 WITH ECONOMIZER NOTES 1 FOR HORIZONTAL DISCHARGE UNIT THIS MEASUREMENT IS REDUCED TO 1 6 TO MINIMIZE DUCT EXTENSION 2 WHEN EQUIPPED WITH ECONOMIZER OR BAROMETRIC RELIEF DAMPER ...

Page 10: ...TCH ACCESS GAS CONNECTION Figure 3 Gas electric units front side views 3 5 tons NOTES 1 THRU THE BASE GAS AND ELECTRICAL IS NOT STANDARD ON ALL UNITS 2 VERIFY WEIGHT CONNECTION AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION 47 934 42 175 43 675 44 675 20 735 15 860 7 860 29 671 76 814 42 004 42 558 ...

Page 11: ...Dimensional Data RT SVX058B EN 11 Figure 4 Gas electric units bottom view 3 5 tons Figure 5 Foundation units back view horizontal configuration 3 5 tons SUPPLY RETURN ...

Page 12: ...Dimensional Data 12 RT SVX058B EN Figure 6 Roof curb 3 5 tons SUPPLY RETURN Figure 7 Downflow unit clearance 3 5 tons standard efficiency CLEARANCE CLEARANCE CLEARANCE CLEARANCE UNIT OUTLINE ...

Page 13: ...5 tons BACK VIEW OF UNIT RIGHT VIEW OF UNIT ECONOMIZER FAN BAROMETRIC RELIEF BAROMETRIC RELIEF Figure 9 Manual damper 3 5 tons MANUAL DAMPER HOOD BACK VIEW OF UNIT RIGHT VIEW OF UNIT FAN NOTE VERIFY WEIGHT CONNECTION AND ALL DIMENSIONS WIT INSTALLER DOCUMENTS BEFORE INSTALLATION ...

Page 14: ...A B C D Length Width 3 GBC036 574 524 95 111 172 146 42 29 4 GBC048 616 566 110 119 175 162 40 29 5 GBC060 636 586 120 125 174 168 39 28 a Weights are approximate b Weights do not include additional factory or field installed options accessories c Corner weights are given for information only Figure 10 Corner weights WARNING Heavy Objects Ensure that all the lifting equipment used is properly rate...

Page 15: ... checklist listed below is a summary of the steps required to successfully install a commercial unit This checklist is intended to acquaint the installing personnel with what is required in the installation process It does not replace the detailed instructions called out in the applicable sections of this manual Check the unit for shipping damage and material shortage file a freight claim and noti...

Page 16: ...sconnect switch and to the main power terminal block HTB1 in the unit control panel Install proper grounding wires to an earth ground Note All field installed wiring must comply with NEC and applicable local codes External Vent Hood Installation 1 Remove and discard the cover plate located on the gas heat panel Important Make sure you read the label located on the cover plate before you discard it...

Page 17: ...wiring is properly sized and installed follow the guidelines outlined below Note All field installed wiring must conform to NEC guidelines as well as state and Local codes Verify that the power supply available is compatible with the unit s nameplate ratings The available supply power must be within 10 percent of the rated voltage stamped on the nameplate Use only copper conductors to connect the ...

Page 18: ...ts Provide proper grounding for the unit in accordance with local and national codes Optional TBUE Wiring Through the Base Electrical Option Location of the applicable electrical service is illustrated below Refer to the customer connection diagram that is shipped with the unit for specific termination points The termination points depending on the customer option selected would be a factory mount...

Page 19: ...nductor for the length of the run Note Resistance in excess of 3 ohms per conductor could cause component failure due to insufficient AC voltage supply 3 Be sure to check all loads and conductors for grounds shorts and mis wiring 4 Do not run the AC low voltage wiring in the same conduit with the high voltage power wiring 5 Route low voltage wiring per illustrations on the next page NOTICE Use Cop...

Page 20: ... the staged gas pressure valve to a negative pressure 3 5 3 5 3 5 Combustion Blower Suction Pressure 1st Stage 0 50 to 0 55 0 50 to 0 55 0 50 to 0 55 Combustion Blower Suction Pressure 2nd Stage 0 65 to 0 70 0 65 to 0 70 Minimum Flame Sensing Current b b A voltage reading across pens V V is equatable to the flame sensing current One volt equals one micro amp 5 0 Micro Amps DC Normal Sensing Curren...

Page 21: ...tch or circuit protection switch and remove the phase sequence indicator Compressor Crankcase Heaters Each compressor can be equipped with a crankcase heater The proper operation of the crankcase heater is important to maintain an elevated compressor oil temperature during the Off cycle to reduce oil foaming during compressor starts Oil foaming occurs when refrigerant condenses in the compressor a...

Page 22: ... bearings for sufficient lubrication If the belts require adjustment or if the bearings need lubricating refer to the maintenance section of this manual for instructions Verify that a condensate trap is installed and the piping is properly sized and pitched Verify that the correct size and number of filters are in place Inspect the interior of the unit for tools and debris and install all panels i...

Page 23: ... low voltage class II control wiring through hole in base of unit but not through high voltage conduit refer to Figure 15 p 18 for high and low volt conduits location Feed control wiring through bushing provided on side panel Route wires through loose wire ties provided 5 Tighten the wire ties Secure the excess wire bundle under the wire ties in the outdoor section Do not leave excess wire in the ...

Page 24: ...edures to ensure the power cannot be inadvertently energized Verify with an appropriate voltmeter that all capacitors have discharged Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury For additional information regarding the safe discharge of capacitors see PROD SVB06 EN WARNING Proper Field Wiring and Grounding Required All field wiring ...

Page 25: ... 0 using the setpoint potentiometer located on the Economizer Control ECA if applicable Electromechanical Controls Test Procedure See unit schematic for correct wire numbers Fan Test and Minimum Ventilation Connect red thermostat wire R to black thermostat wire G Economizer Cooling Connect a jumper wire across OAT on Economizer Control ECA Connect red thermostat R wire to yellow thermostat wire Y1...

Page 26: ...r is a system critical sensor if the MA sensor is removed during the set up mode the JADE will alarm After 60 minutes the JADE controller will change to operation mode and all components removed or failed will alarm in the operation mode Upon power up or after a power outage or brownout the JADE controller module begins a 5 minute power up delay before enabling mechanical cooling Compressor Start ...

Page 27: ... checked open the main power disconnect switch to reset the unit Final System Set Up After completing all of the pre start and start up procedures outlined in the previous sections i e operating the unit in each of its modes through all available stages of cooling and heating perform these final checks before leaving the unit Program the Night Setback NSB panel if applicable for proper unoccupied ...

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