Foundations BAYLPKT300 LP Conversion Kit Foundation Packaged Rooftop Units Instruction Manual

Foundations BAYLPKT300 LP Conversion Kit Foundation Packaged Rooftop

Units

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. 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.

Warnings, Cautions, and Notices
Read this manual thoroughly before operating or servicing this unit. Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, could result 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.

Important Environmental Concerns
Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs such as HCFCs and HFCs.

Important Responsible Refrigerant Practices
Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified according to local rules. For the USA, the Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

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 poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/national electrical codes.

WARNING Personal Protective Equipment (PPE) Required!
Failure to wear proper PPE for the job being undertaken could result in death or serious injury. Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:

• Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.
• When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS and OSHA/GHS (Global Harmonized System of Classification and Labeling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.
• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.

WARNING Follow EHS Policies!
Failure to follow instructions below could result in death or serious injury.

• All Trane personnel must follow the company’s Environmental, Health and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc. Where local regulations are more stringent than these policies, those regulations supersede these policies.
• Non-Trane personnel should always follow local regulations.

Copyright
This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks
All trademarks referenced in this document are the trademarks of their respective owners.

Revision History

• Model number updates in Used With information.
• Updated Parts List.
• Updated Table 1 and Table 2 with new data.

General Information

These instructions describe converting gas package unit models from natural gas to LP gas. Conversion from natural gas to LP gas is a critical procedure, therefore, these instructions must be followed closely.

Inspection

1. Unpack all components of the LP Conversion Kit.
2. Check carefully for shipping damage. If any damage is found, report it immediately, and file a claim against the transportation company.
3. This kit contains the correct parts required for LP conversion. Refer to Table 2 to determine proper orifice selection. The kit contains the following items.

**Table 1.     BAYLPKT300***

Table 2.         Orifice size selection

Unit

| Gas heat input rating (MBh)| LP Orifice size| Air Orifice Plate (Part No. Last 4 Digits)| Air Orifice Diameter (inches)
---|---|---|---|---
GCC180A(3,4,W)E(L or X)| 240| #49| –| –
GCC180A(3,4,W)E(M or Y)| 320| #49| 0010| 1.54
GCC180A(3,4,W)E(H or Z)| 350| #48| –| –
GCC210A(3,4,W)E(L or X)| 240| #49| –| –
GCC210A(3,4,W)E(M or Y)| 320| #49| 0010| 1.54
GCC210A(3,4,W)E(H or Z) – DF| 380| #47| –| –
GCC210A(3,4,W)E(H or Z) – HZ| 350| #48| –| –
GCC240A(3,4,W)E(L or X)| 240| #49| –| –
GCC240A(3,4,W)E(M or Y)| 320| #49| 0010| 1.54
GCC240A(3,4,W)E(H or Z)| 380| #47| –| –
GCC300A(3,4,W)E(L or X)| 240| #49| –| –

Unit

| Gas heat input rating (MBh)| LP Orifice size| Air Orifice Plate (Part No. Last 4 Digits)| Air Orifice Diameter (inches)
---|---|---|---|---
GCC300A(3,4,W)E(M or Y)| 320| #49| 0010| 1.54
GCC300A(3,4,W)E(H or Z)| 380| #47| –| –
GBC180A(3,4,W)E(L or X)| 240| #49| NA|
GBC180A(3,4,W)E(M or Y)| 320| #49| NA|
GBC180A(3,4,W)E(H or Z)| 350| #48| NA|
GBC210A(3,4,W)E(L or X)| 240| #49| NA|
GBC210A(3,4,W)E(M or Y)| 320| #49| NA|
GBC210A(3,4,W)E(H or Z)| 400| #46| NA|
GBC240A(3,4,W)E(L or X)| 240| #49| NA|
GBC240A(3,4,W)E(M or Y)| 320| #49| NA|
GBC240A(3,4,W)E(H or Z)| 400| #46| NA|
GBC300A(3,4,W)E(L or X)| 240| #49| NA|
GBC300A(3,4,W)E(M or Y)| 320| #49| NA|
GBC300A(3,4,W)E(H or Z)| 400| #46| NA|

Installation

Conversion Procedure
Note: Conversion should be made prior to installation of equipment at the job site.

1. Place the thermostat selector switch to the OFF position.
   WARNING Hazardous Voltage w/Capacitors and Gas!
   Failure to turn off gas or disconnect power before servicing could result in an explosion or electrocution which could result in death or serious injury. Turn off the gas supply and disconnect all electric power, including remote
   disconnects before servicing unit. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors. Verify with an appropriate voltmeter that all capacitors have discharged.

2. Open the unit electrical disconnect switch.

3. Shut off gas supply to the unit.

4. Remove gas valve access panel.

5. Break pipe union.

6. Remove pipe from street elbow.

7. Remove six screws from manifold bracket. See Figure 1.

8. Remove natural gas orifices from manifold. See Figure 2.

9. Install LP orifices specified in Table 2. Engage threads of manifold and tighten orifice three and one half turns.

10. If the unit model listed in Table 2 (for BAYLPKT300*) requires a change to the air orifice plate, perform steps 11 through 16, otherwise proceed to step 17

11. Disconnect the inducer motor wiring harness.

12. Remove six screws securing the inducer blower assembly. See Figure 3 and Figure 4.

13. Remove three screws securing air orifice plate. See Figure 3.

14. Using three screws, install the ship-with, air orifice plate.

15. Install the inducer blower assembly using six screws.

16. Connect inducer blower wire harness.

17. Install the LP gas valve spring. Follow instructions provided with the conversion spring kit.

18. Reverse the disassembly procedure and secure all components in their respective position.

19. Attach the nameplate and label supplied with the conversion kit below the unit nameplate.

20. Check all piping joints and electrical connections for tightness.

21. Turn on the gas supply to unit.

22. Measure the gas pressure. If the pressure exceeds 14 inches water column (34.8 mbar), reset the regulator at the gas supply.

23. Restore unit power.

24. Place the thermostat selector switch to the HEAT position and adjust the setpoint indicator to its highest setting. The burners should light.

25. Adjust the unit manifold pressure to 10 inches water column (24.9 mbar) per the rating plate.

26. Install the access panel.

Trane and American Standard create comfortable, energy efficient indoor environments for commercial and residential applications. 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.

References

• American Standard® | Air Conditioning and Heating | HVAC Systems
• Trane Heating & Air Conditioning

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