Intertek GPG 16 SEER, M SERIES Installation Instructions Manual
INSTALLATION INSTRUCTIONS
GPG 16 SEER “M” SERIES
SINGLE PACKAGE GAS-ELECTRIC HEATING & COOLING UNITS
Affix this manual and Users Information
Manual adjacent to the unit.
ATTENTION INSTALLING PERSONNEL
Prior to installation, thoroughly familiarize yourself with this Installation Manual. Observe all safety warnings. During installation
or repair, caution is to be observed.
It is your responsibility to install the product safely and to educate the customer on its safe use.
RECOGNIZE THIS SYMBOL
AS A SAFETY PRECAUTION.
These installation instructions cover the outdoor installation of
self contained package air conditioner and heating units. See
the Specification Sheets applicable to your model for information
regarding accessories.
*NOTE: Please contact your distributor or our website for the
applicable Specifications Sheets referred to in this manual.
This Forced Air Central Unit Design Complies With Requirements
Embodied in The American National Standard / National Standard
of Canada Shown Below.
ANSI Z21.47•CSA-2.3 Central F urnaces
Goodman Manufacturing Company, L.P.
IOG-3012
3/15
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com
© 2015 Goodman Manufacturing Company, L.P.
INDEX
REPLACEMENT PARTS............................................ 3
O
RDERING PARTS ............................................ 3
SAFETY INSTRUCTIONS ......................................... 3
UNIT LOCATION ................................................... 4
A
LL INSTALLATIONS:.......................................... 4
G
ROUND LEVEL INSTALLATIONS ONLY:........................ 4
R
OOFTOP INSTALLATIONS ONLY:.............................. 5
R
OOF CURB INSTALLATIONS ONLY: ........................... 5
GENERAL INFORMATION ........................................ 5
TRANSPORTATION DAMAGE ................................... 5
RIGGING DETAILS ................................................. 6
GAS PIPING ........................................................ 6
H
IGH ALTITUDE DERATE (U.S. INSTALLATIONS ONLY) ....... 6
P
IPING ........................................................ 6
G
AS PIPING CHECKS.......................................... 7
PROPANE GAS INSTALLATIONS ................................ 7
T
ANKS AND PIPING ........................................... 8
ELECTRICAL WIRING ............................................. 8
T
HERMOSTAT LOCATION ...................................... 8
S
INGLE STAGE THERMOSTAT .................................. 9
UNIT VOLTAGE ............................................. 10
H
EAT ANTICIPATOR SETTING ................................ 10
CIRCULATING AIR AND FILTERS .............................. 1 1
A
IRFLOW CONVERSION...................................... 11
D
UCTWORK ................................................. 11
F
ILTERS .................................................... 11
VENTING.......................................................... 11
I
NSTALLATION - FLUE HOOD EXHAUST...................... 11
NSTALLATION - COMBUSTION AIR INTAKE HOOD ........... 12
I
CONDENSATE DRAIN ........................................... 12
C
ONDENSATE DRAIN CONNECTION........................... 12
NORMAL SEQUENCES OF OPERATION ...................... 12
H
EATING ................................................... 12
C
OOLING ................................................... 12
F
AN ONLY .................................................. 13
STARTUP, ADJUSTMENTS, AND CHECKS ................... 1 3
H
EATING STARTUP.......................................... 13
COOLING STARTUP ......................................... 16
TROUBLESHOOTING ........................................... 17
I
GNITION CONTROL ERROR CODES .......................... 17
F
AULT RECALL ............................................. 17
A
BNORMAL OPERATION - HEATING ......................... 17
INTERNAL CONTROL FAILURE ............................. 17
EXTERNAL LOCKOUT ..................................... 17
PRESSURE SWITCH STUCK OPEN ......................... 17
PRESSURE SWITCH STUCK CLOSED ....................... 18
PRIMARY LIMIT .......................................... 18
FLAME DETECTED WITH GAS VALVE CLOSED ............. 18
LOW FLAME SIGNAL ..................................... 18
A
BNORMAL OPERATION - COOLING ......................... 18
SHORT CYCLE COMPRESSOR DELA Y ....................... 18
HIGH PRESSURE SWITCH/LOSS OF CHARGE SWITCH ...... 18
MAINTENANCE................................................... 19
F
ILTER REPLACEMENT OR CLEANING ........................ 19
ABINET FINISH MAINTENANCE ............................. 19
C
C
LEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)........ 19
CONDENSER, EVAPORATOR, AND INDUCED DRAFT MOTORS .19
F
LAME SENSOR (QUALIFIED SERVICER ONLY) ............... 19
F
LUE PASSAGES (QUALIFIED SERVICER ONLY).............. 19
C
LEANING FLUE PASSAGES (QUALIFIED SERVICER ONLY) ... 19
M
AIN BURNER FLAME (QUALIFIED SERVICER ONLY) ........ 19
C
LEANING BURNERS ........................................ 20
ACCESSORIES AND FUNCTIONAL PARTS ................... 20
SHEET METAL ACCESSORIES ................................. 20
F
UNCTIONAL PARTS ........................................ 20
G
ENERAL INFORMATION..................................... 20
APPENDIX ........................................................ 21
GNITION CONTROL DIAGNOSTIC INDICATOR CHART ........ 21
I
H
EATING TIMING CHART ................................... 21
C
OOLING TIMING CHART ................................... 21
UNIT DIMENSIONS .......................................... 22
W
IRING DIAGRAM .......................................... 23
M
INIMUM CLEARANCES ..................................... 24
R
ECOMMENDED FILTER SIZES ............................... 24
B
LOWER PERFORMANCE .................................... 25
S
TART-UP CHECKLIST ................................ 27 - 28
2
REPLACEMENT PARTS
ORDERING PARTS
When reporting shortages or damages, or ordering repair parts,
give the complete unit model and serial numbers as stamped on
the unit’s nameplate.
Replacement parts for this appliance are available through your
contractor or local distributor. For the location of your nearest
distributor, consult the white business pages, the yellow page
section of the local telephone book or contact:
CONSUMER AFFAIRS
GOODMAN MANUFACTURING COMPANY, L.P.
7401 SECURITY WA Y
HOUSTON, TEXAS 77040
(713) 254-4729
SAFETY INSTRUCTIONS
TO THE INSTALLER
Before installing this unit, please read this manual to familiarize
yourself on the specific items which must be adhered to, including
maximum external static pressure to unit, air temperature rise,
minimum or maximum CFM and motor speed connections.
TO THE OWNER
A warranty certificate is provided with the unit. Read the warranty
carefully and note what is covered. Keep the warranty certificate
in a safe place so you can find it when necessary.
Keep this literature in a safe place for future reference.
3
Advertenci a e spe cia l p ara la insta l aci ón de calentad o res ó manejadoras
de aire en áreas cerradas como estacionamientos ó cuartos de servicio .
RISQUE D'E MPO ISO N NEM EN T AU
MONOXYDE DE CARBONE
Cett e v entilation est nécessaire pour éviter le danger d'in t oxication
au CO pouvant survenir si un appareil produisant du monoxyde
de carbon e continue de fonction ne r au sein de la zone confinée.
Le monoxyde de
des
dommages permanents au cerveau et meme la mort.
carbone peut causer des maladies graves telles que
CO can cause serious illness including perm anent brain
damag e or death.
B10259-216
Las emis ion es de monóxido de carbono pueden circ ula r a través
del aparat o c uando se opera en cualquier modo.
El monóx i do de carbono puede causar enfermedades seve ra s
como daño cerebral permanente ó muerte.
B10259-216
UNIT LOCATION
IMPORTANT NOTE: Remove wood shipping rails prior to installa-
tion of the unit.
ALL INSTALLATIONS:
• For proper flame pattern within the heat exchanger and
proper condensate drainage, the unit must be mounted level.
• The flue outlet hood must be at least 12 inches from any opening through which flue gases could enter a building, and at
least three feet above any forced air inlet located within ten feet. The economizer/manual fresh air intake/motorized fresh
air intake and combustion air inlet mounted on the unit are not affected by this restriction.
• To avoid possible corrosion of the heat exchanger, do not locate the unit in an area where the outdoor air (i.e. combustion
air for the unit) will be frequently contaminated by compounds containing chlorine or fluorine. Common sources of such
compounds include swimming pool chemicals and chlorine bleaches, paint stripper, adhesives, paints, varnishes, sealers,
waxes (which are not yet dried) and solvents used during construction and remodeling. Various commercial and industrial
processes may also be sources of chlorine/fluorine compounds.
• To avoid possible illness or death of the building occupants, do NOT locate outside air intake device (economizer, manual
fresh air intake, motorized fresh air intake) too close to an exhaust outlet, gas vent termination, or plumbing vent outlet.
For specific distances required, consult local codes.
• Allow minimum clearances from the enclosure for fire
protection, proper operation, and service access (see
appendix). These clearances must be permanently maintained.
• The combustion air inlet and flue outlet hoods on the unit
must never be obstructed. If used, do not allow the
economizer/manual fresh air damper/ motorized fresh air
damper to become blocked by snow or debris. In some
climates or locations, it may be necessary to elevate the unit
to avoid these problems.
• When the unit is heating, the temperature of the return air
entering the unit must be between 50° F and 100° F.
B10259-216
GROUND LEVEL INSTALLATIONS ONLY:
• When the unit is installed on the ground adjacent to the
building, a level concrete (or equal) base is recommended.
Prepare a base that is 3” larger than the package unit
footprint and a minimum of 3” thick.
• The base should also be located where no runoff of water
from higher ground can collect in the unit.
Outside Slab Installation
4
ROOFTOP INSTALLATIONS ONLY:
NOTE: To ensure proper condensate drainage, unit must be installed in
a level position.
• To avoid possible property damage or personal injury, the roof must
have sufficient structural strength to carry the weight of the unit(s)
and snow or water loads as required by local codes. Consult a
structural engineer to determine the weight capabilities of the
roof.
• The unit may be installed directly on wood floors or on Class A,
Class B, or Class C roof covering material.
• To avoid possible personal injury, a safe, flat surface for service
personnel should be provided.
ROOF CURB INSTALLATIONS ONLY:
• Sufficient structural support must be determined prior to locating
and mounting the curb and package unit.
Rooftop Installation
• Ductwork must be constructed using industry guidelines. The duct
work must be placed into the roof curb before mounting the package
unit.
• Curb insulation, cant strips, flashing and general roofing material are furnished by the
contractor.
GENERAL INFORMATION
This unit is approved for outdoor installation ONLY. Rated performance is achieved after
72 hours of operation.
unit specification sheet for split system models or product specification sheet for packaged
and light commercial models. Specification sheets can be found at www.goodmanmfg.com
for Goodman® brand products. Within the website, please select the residential or
commercial products menu and then select the submenu for the type of product to be
installed, such as air conditioners or heat pumps, to access a list of product pages that
each contain links to that model’s specification sheet.
To assure that your unit operates safely and efficiently, it must be installed, operated, and
maintained in accordance with these installation and operating instructions, all local building
codes and ordinances, or in their absence, with the latest edition of the National Fuel Gas
Code NFPA 54/ANSI Z223.1 and National Standard of Canada CAN/CSA B149 Installation
Codes.
The heating and cooling capacities of the unit should be greater than or equal to the
design heating and cooling loads of the area to be conditioned. The loads should be
calculated by an approved method or in accordance with A.S.H.R.A.E. Guide or Manual J - Load Calculations published by the Air
Conditioning Contractors of America.
Rated performance is delivered at the specified airflow. See outdoor
Roof Curb Installation
Obtain from:
American National Standards Institute
1430 Broadway
New York, NY 10018
TRANSPORTATION DAMAGE
Check the carton upon arrival for external damage. If damage is found, a request for inspection by carrier agent should be made in
writing immediately .
Carefully inspect the unit for damage including damage to the cabinetry. Any bolts or screws which may have loosened in transit
must be re-tightened. In the event of damage, the receiver should:
1. Make notation on delivery receipt of any visible damage to shipment or container.
2. Notify carrier promptly and request an inspection.
5
3. In case of concealed damage, carrier should be notified as soon as possible-preferably within 5 days.
4. File the claim with the following supporting documents:
a. Original Bill of Lading, certified copy, or indemnity bond.
b. Original paid freight bill or indemnity in lieu thereof.
c. Original invoice or certified copy thereof, showing trade and other discounts or reductions.
d. Copy of the inspection report issued by carrier representative at the time damage is reported to the carrier. The carrier
is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or
manufacturer will not accept claims from dealers for transportation damage.
NOTE: When inspecting the unit for transportation damage, remove all packaging materials. Recycle or dispose of the packaging
material according to local codes.
RIGGING DETAILS
IMPORTANT NOTE: If using bottom discharge with roof curb,
ductwork should be attached to the curb prior to installing the
unit. Ductwork dimensions are shown in roof curb installation
instructions.
Refer to the Roof Curb Installation Instructions for proper curb
installation. Curbing must be installed in compliance with the National
Roofing Contractors Association Manual.
Lower unit carefully onto roof mounting curb. While rigging unit, center
of gravity will cause condenser end to be lower than supply air end.
GAS PIPING
IMPORTANT NOTE: This unit is factory set to operate on natural gas at
the altitudes shown on the rating plate.
The rating plate is stamped with the model number, type of gas and gas
input rating. Make sure the unit is equipped to operate on the type of
gas available. Conversion to LP gas is permitted with the use of a factory
authorized conversion kit. Contact your distributor or refer to the
specification sheet for your model for a listing of approved LP gas
conversion kit(s). Refer to the Installation Manual provided with the
LP kit for conversion from natural gas to propane gas.
The minimum supply pressure should not vary from that shown in the
Inlet Gas Pressure table because this could prevent the unit from
having dependable ignition. In addition, gas input to the burners
must not exceed the rated input shown on the rating plate. Overfiring
of the unit could result in premature heat exchanger failure.
INLET GAS PRESSURE
Natural Min. 5.0" W.C., Max. 10.0" W.C.
Propane Min. 11.0" W.C., Max. 13.0" W.C.
Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in
T able Above.
Rigging
HIGH ALTITUDE DERATE (U.S. INSTALLATIONS ONLY)
IMPORTANT NOTE: The gas/electric units naturally derate with altitude. Do not attempt to increase the firing rate by changing
orifices or increasing the manifold pressure. This can cause poor combustion and equipment failure. At all altitudes, the manifold
pressure must be within 0.3 inches W.C. of that listed on the nameplate for the fuel used. At all altitudes and with either fuel, the
air temperature rise must be within the range listed on the unit nameplate. Contact your distributor or refer to the specification
sheet for your model for listing of approved high altitude conversion kit(s). Refer to the Installation Manual provided with the high
altitude kit for altitude adjustments.
NOTE: No changes are required up to 2,000 feet. Use the appropriate high altitude kit above 2,000 feet.
PIPING
IMPORTANT NOTE: To avoid possible unsatisfactory operation or equipment damage due to under firing of equipment, do not
undersize the natural/propane gas piping from the meter/tank to the unit. When sizing a trunk line, include all appliances on that
line that could be operated simultaneously.
6
The rating plate is stamped with the model number, type of gas and gas
g
)
input rating. Make sure the unit is equipped to operate on the type of
gas available. The gas line installation must comply with local codes, or in
the absence of local codes, with the latest edition of the National Fuel
Gas Code NFPA 54/ANSI Z223.1.
Natural Gas Connection
Refer to the Proper Piping Practice drawing for the general layout at the
unit. The following rules apply:
1. Use black iron pipe and fittings for the supply piping. The use of a
flex connector and/or copper piping is permitted as long as it is in
agreement with local codes.
2. Use pipe joint compound on male threads only. Pipe joint compound
must be resistant to the action of the fuel used.
3. Use ground joint unions.
4. Install a drip leg to trap dirt and moisture before it can enter the
gas valve. The drip leg must be a minimum of three inches long.
5. Use two pipe wrenches when making connection to the gas
valve to keep it from turning.
6. Install a manual shut-off valve in a convenient location (within
six feet of unit) between the meter and the unit.
7. Tighten all joints securely.
8. The unit must be connected to the building piping by one
of the following methods:
• Rigid metallic pipe and fittings
• Semirigid metallic tubing and metallic fittings (Aluminum
alloy tubing must not be used in exterior locations)
• Listed gas appliance connectors used in accordance with
the terms of their listing that are completely in the same
room as the equipment
• In the prior two methods above the connector or tubing
must be protected from physical and thermal damage.
Aluminum alloy tubing and connectors must be coated
to protect against external corrosion when in contact
GROMMET
with masonry, plaster or insulation or are subject to
repeated wettings by liquids (water - not rain water,
detergents or sewage)
NOTE: The unit gas supply entrance is factory sealed with
plugs. Keep plugs in place until gas supply is ready to be
installed. Once ready, replace the plugs with the supplied
grommets and install gas supply line.
Natural Gas Capacity of Pipe
in Cubic Feet of Gas Per Hour (CFH)
Length of
Pipe in Feet
10 132 278 520 1050 1600
20 92 190 350 730 1100
30 73 152 285 590 980
40 63 130 245 500 760
50 56 115 215 440 670
60 50 105 195 400 610
70 46 96 180 370 560
80 43 90 170 350 530
90 40 84 160 320 490
100 38 79 150 305 460
Pressure = .50 PSIG or less and Pressure Drop of 0.3" W.C. (Based
CFH =
Heatin
Nominal Black Pipe Size (inches)
1/2 3/4
on 0.60 Specific Gravity Gas)
1
1 1/4 1 1/2
BTUH Furnace Input
Va lu e o f Gas (BTU/Cubic Foot
GROUND JO INT UNION
(INSTALLED AHEAD OF GAS VALVE)
DRIP LEG
Proper Piping Practice
MANUAL
SHUT-OFF
VALVE
GAS PIPING CHECKS
There will be air in the gas supply line after testing for leaks on
a new installation. Therefore, the air must be bled from the
line by loosening the ground joint union until pure gas is
expelled. Tighten union and wait for five minutes until all gas
has been dissipated in the air. Be certain there is no open
flame in the vicinity during air bleeding procedure. The unit is
placed in operation by closing the main electrical disconnect
switch for the unit.
PROPANE GAS INSTALLATIONS
IMPORTANT NOTE: Propane gas conversion kits must be installed
to convert units to propane gas. Contact the distributor or
refer to the specification sheet for your model for the correct
LP conversion kit(s).
7
All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters (See NBFU Manual 58).
For satisfactory operation, propane gas supply pressure must be within 9.7 - 10.3 inches W.C. at the manifold with all gas appl iances
in operation. Maintaining proper gas pressure depends on three main factors:
1. Vaporization rate, which depends on (a) temperature of the liquid, and (b) wetted surface area of the container or
containers.
2. Proper pressure regulation.
3. Pressure drop in lines between regulators, and between second
stage regulator and the appliance. Pipe size required will depend
on length of pipe run and total load of all appliances.
First Stage
Regulator
5 to 15 P SIG
(20 PSIG Max.)
Continuous
11" W.C.
TANKS AND PIPING
Complete information regarding tank sizing for vaporization,
recommended regulator settings and pipe sizing is available from most
regulator manufacturers and propane gas suppliers.
Since propane gas will quickly dissolve white lead or most standard
commercial compounds, special pipe dope must be used. Shellac base
compounds resistant to the actions of liquefied petroleum gases such
as Gasolac®, Stalactic®, Clyde’s® or John Crane® are satisfactory.
See Typical Propane Gas Piping figure for typical piping arrangement.
Sizing Between First and Second Stage Regulator
Maximum Propane Capacities listed are based on 1 PSIG Pressure Drop at 10
PSIG Setting. Capacities in 1,000 BTU/HR
PIPE OR
TUBING
LENGTH,
FEET
30 309 700 1,303 2,205 3,394 1,843 3,854
40 265 599 1,115 1,887 2,904 1,577 3,298
50 235 531 988 1,672 2,574 1,398 2,923
60 213 481 896 1,515 2,332 1,267 2,649
70 196 446 824 1,394 2,146 1,165 2,437
80 182 412 767 1,297 1,996 1,084 2,267
90 171 386 719 1,217 1,873 1,017 2,127
100 161 365 679 1,149 1,769 961 2,009
150 130 293 546 923 1,421 772 1,613
200 111 251 467 790 1,216 660 1,381
250 90 222 414 700 1,078 585 1,224
300 89 201 378 634 976 530 1,109
350 82 185 345 584 898 488 1,020
400 76 172 321 543 836 454 949
To convert to Capacities at 15 PSIG Settings -- Multiply by 1.130
To convert to Capacities at 5 PSIG Settings -- Multiply by 0.879
TUBING SIZE, O.D., TYPE L
3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"
NOMINAL PIPE SIZE,
SCHEDULE 4 0
Sizing Between Single or Second Stage Regulator and Appliance*
Maximum Propane Capacities Listed are Based on 1/2" W.C. Pressure Dr op at
11" W.C. Setting. Capacities in 1,000 BTU/HR
PIPE OR
TUBING
LENGTH,
FEET
10 49 110 206 348 539 291 608 1,146 2,353 3,525
20 34 76 141 239 368 200 418 788 1,617 2,423
30 27 61 114 192 296 161 336 632 1,299 1,946
40 23 52 97 164 253 137 284 541 1,111 1,665
50 20 46 86 146 224 122 255 480 985 1,476
60 19 42 78 132 203 110 231 436 892 1,337
80 16 36 67 113 174 94 198 372 764 1,144
100 14 32 59 100 154 84 175 330 677 1,014
125 12 28 52 89 137 74 155 292 600 899
150 11 26 48 80 124 67 141 265 544 815
200 10 22 41 69 106 58 120 227 465 697
250 9 19 36 61 94 51 107 201 412 618
300 8 18 33 55 85 46 97 182 374 560
350 7 16 30 51 78 43 89 167 344 515
400 7 15 28 47 73 40 83 156 320 479
*DATA IN ACCORDANCE WITH NFPA PAMPHLET NO. 54
TUBING SIZE, O.D., TYPE L
3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 1" 1- 1/4" 1-1/2"
200 PSIG
Maximum
Second Stage
Regulator
Typical Propane Gas Piping
NOMINAL PIPE SIZE,
SCHEDULE 40
ELECTRICAL WIRING
THERMOSTAT LOCATION
Mount the thermostat approximately five feet above the floor, in an area that has an inside, vibration-free wall and has good air
circulation.
Movement of air must not be obstructed by furniture, door, draperies, etc. The thermostat must not be mounted where it will be
affected by drafts, hot or cold water pipes or air ducts in walls, radiant heat from fireplace, lamps, the sun, television, etc. Consult
the Instruction Sheet packaged with thermostat for mounting instructions.
Propane Gas Pipe Sizing
8
All units have two stages of heating and two stages of mechanical
cooling. Units which will have economizers may use thermostats
with two or three stages of cooling. All units can use single stage
or multi-stage thermostats. Refer to figures later in this section for
wiring.
Thermostat
R
CY1
Y2
Two-Stage Heating
with
Two-Stage Cooling
The units are designed for operation on 60 hertz current and at
voltages as shown on the rating plate. All internal wiring in the unit
is complete. It is necessary to bring in the power supply to the
contactor as shown on the unit wiring diagram which is supplied
with each unit. The low voltage wiring must be connected between
the unit control panel and the room thermostat.
SINGLE STAGE THERMOSTAT
To use a single stage thermostat, move jumper located to the
left of the terminal strip labeled “Stage Delay” from NONE to “5”
or “10” minutes. This selection will cause the control to run on
low stage for the selected time (5 or 10 minutes) then shift to
HIGH ST AGE. This option controls both cooling and heating modes.
If the jumper is not moved, only low-stage cool and low-stage
heat will operate.
W1
W2
R C W1W2
Two-Stage Heating with Two-Stage Cooling
G
I
ntegrated
GY1Y2
Thermostat Diagram
Control Module
5 MINUTE DELAY
PERIOD WI TH
JUMPER IN THIS
POSITION
10 MINUTE DELAY
PERIO D WITH
JUMPER IN THIS
POSITION
Refer to the unit wiring diagram for electrical connections. When
installed, the unit must be electrically grounded in accordance
with local codes or in the absence of local codes, with the
National Electrical Code, ANSI/NFPA No. 70, and/or the CSA C22.1 Electrical Code. Ensure low voltage connections are waterproof.
Two-Stage Heating (timed) and Two-Stage Cooling (timed)
with Single Stage Thermostat Diagram
9
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