INSTALLATION INSTRUCTIONS GPG 16 SEER "M" SERIES

Document Information

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 Furnaces

IOG-3012 3/15

Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com

© 2015 Goodman Manufacturing Company, L.P.

INDEX

• REPLACEMENT PARTS ............................................ 3
• ORDERING PARTS ............................................ 3
• SAFETY INSTRUCTIONS ......................................... 3
• UNIT LOCATION ................................................... 4
• ALL INSTALLATIONS: .......................................... 4
• GROUND LEVEL INSTALLATIONS ONLY: ........................ 4
• ROOFTOP INSTALLATIONS ONLY: .............................. 5
• ROOF CURB INSTALLATIONS ONLY: ........................... 5
• GENERAL INFORMATION ........................................ 5
• TRANSPORTATION DAMAGE ................................... 5
• RIGGING DETAILS ................................................. 6
• GAS PIPING ........................................................ 6
• HIGH ALTITUDE DERATE (U.S. INSTALLATIONS ONLY) ....... 6
• PIPING ........................................................ 6
• GAS PIPING CHECKS .......................................... 7
• PROPANE GAS INSTALLATIONS ................................ 7
• TANKS AND PIPING ........................................... 8
• ELECTRICAL WIRING ............................................. 8
• THERMOSTAT LOCATION ...................................... 8
• SINGLE STAGE THERMOSTAT .................................. 9
• UNIT VOLTAGE ............................................. 10
• HEAT ANTICIPATOR SETTING ................................ 10
• CIRCULATING AIR AND FILTERS .............................. 11
• AIRFLOW CONVERSION ...................................... 11
• DUCTWORK ................................................. 11
• FILTERS .................................................... 11
• VENTING .......................................................... 11
• INSTALLATION - FLUE HOOD EXHAUST ...................... 11
• INSTALLATION - COMBUSTION AIR INTAKE HOOD ........... 12
• CONDENSATE DRAIN ........................................... 12
• CONDENSATE DRAIN CONNECTION ........................... 12
• NORMAL SEQUENCES OF OPERATION ...................... 12
• HEATING ................................................... 12
• COOLING ................................................... 12
• FAN ONLY .................................................. 13
• STARTUP, ADJUSTMENTS, AND CHECKS ................... 13
• HEATING STARTUP .......................................... 13
• COOLING STARTUP ......................................... 16
• TROUBLESHOOTING ........................................... 17
• IGNITION CONTROL ERROR CODES .......................... 17
• FAULT RECALL ............................................. 17
• ABNORMAL 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
• ABNORMAL OPERATION - COOLING ......................... 18
• SHORT CYCLE COMPRESSOR DELAY ....................... 18
• HIGH PRESSURE SWITCH/LOSS OF CHARGE SWITCH ...... 18
• MAINTENANCE ................................................... 19
• FILTER REPLACEMENT OR CLEANING ........................ 19
• CABINET FINISH MAINTENANCE ............................. 19
• CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY) ........ 19
• CONDENSER, EVAPORATOR, AND INDUCED DRAFT MOTORS . 19
• FLAME SENSOR (QUALIFIED SERVICER ONLY) ............... 19
• FLUE PASSAGES (QUALIFIED SERVICER ONLY) .............. 19
• CLEANING FLUE PASSAGES (QUALIFIED SERVICER ONLY) ... 19
• MAIN BURNER FLAME (QUALIFIED SERVICER ONLY) ........ 19
• CLEANING BURNERS ........................................ 20
• ACCESSORIES AND FUNCTIONAL PARTS ................... 20
• SHEET METAL ACCESSORIES ................................. 20
• FUNCTIONAL PARTS ........................................ 20
• GENERAL INFORMATION ..................................... 20
• APPENDIX ........................................................ 21
• IGNITION CONTROL DIAGNOSTIC INDICATOR CHART ........ 21
• HEATING TIMING CHART ................................... 21
• COOLING TIMING CHART ................................... 21
• UNIT DIMENSIONS .......................................... 22
• WIRING DIAGRAM .......................................... 23
• MINIMUM CLEARANCES ..................................... 24
• RECOMMENDED FILTER SIZES ............................... 24
• BLOWER PERFORMANCE .................................... 25
• START-UP CHECKLIST ................................ 27 - 28

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 WAY
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.

WARNING
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WHAT TO DO IF YOU SMELL GAS:

• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR BUILDING.
• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR'S PHONE. FOLLOW THE GAS SUPPLIER'S INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.

INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

WARNING
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

WARNING
HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE, INSPECTION, MAINTENANCE AND SUPERVISION. IF THE BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED.

WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT USE THIS UNIT IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE UNIT AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL HAVING BEEN UNDER WATER.

WARNING
THIS UNIT MUST NOT BE USED AS A "CONSTRUCTION HEATER" DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE. THIS TYPE OF USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TEMPERATURES AND EXPOSURE TO CORROSIVE OR VERY DIRTY ATMOSPHERES.

HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING
TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH, DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE UNIT BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

WARNING
DO NOT CONNECT TO OR USE ANY DEVICE THAT IS NOT DESIGN CERTIFIED BY GOODMAN FOR USE WITH THIS UNIT. SERIOUS PROPERTY DAMAGE, PERSONAL INJURY, REDUCED UNIT PERFORMANCE AND/OR HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF SUCH NON-APPROVED DEVICES.

WARNING
INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED ONLY BY INDIVIDUALS MEETING THE REQUIREMENTS OF AN "ENTRY LEVEL TECHNICIAN" AS SPECIFIED BY THE AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI). ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH A BACKGROUND MAY RESULT IN PRODUCT DAMAGE, PERSONAL INJURY OR DEATH.

CARBON MONOXIDE POISONING HAZARD

DANGER

CARBON MONOXIDE POISONING HAZARD

Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas

Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode.

CO can cause serious illness including permanent brain damage or death.

PELIGRO

RIESGO DE INTOXICACIÓN POR MONÓXIDO DE CARBONO

Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio.

Los equipos ó aparatos que producen monóxido de carbono (tal como automóvil, calentador de gas, calentador de agua por medio de gas, etc) no deben ser operados en áreas cerradas debido al riesgo de envenenamiento por monóxido de carbono (CO) que resulta de las emisiones de gases de combustión. Si el equipo ó aparato se opera en dichas áreas, debe existir una adecuada ventilación directa al exterior.

Esta ventilación es necesaria para evitar el peligro de envenenamiento por CO, que puede ocurrir si un dispositivo que produce monóxido de carbono sigue operando en el lugar cerrado. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo.

El monóxido de carbono puede causar enfermedades severas como daño cerebral permanente ó muerte.

RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE

Avertissement special au sujet de l'installation d'appareils de hauffage ou de traitement d'air dans des endroits clos, tets les garages, les locaux d'entretien et les stationnements. Evitez de mettre en marche les appareils produisant du monoxyde de carbone (tels que les automobile, les appareils de chauffage autonome, etc.) dans des endroits non ventilés tels que les d'empoisonnement au monoxyde de carbone. Si vous devez faire fonctionner ces appareils dans un endroit clos, assures-vous qu'il y ait une ventilation directe provenant de l'exterier.

Cette ventilation est nécessaire pour éviter le danger d'intoxication au CO pouvant survenir si un appareil produisant du monoxyde de carbone continue de fonctionner au sein de la zone confinée. Les émissions de monoxyde de carbone peuvent etre recircules dans les endroits clos, si l'appareil de chauffage ou de traitement d'air sont en marche. Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort.

UNIT LOCATION

IMPORTANT NOTE: Remove wood shipping rails prior to installation 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.

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.

Diagram: Outside Slab Installation - Illustrates a unit placed on a concrete slab adjacent to a building, showing clearances.

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.

Diagram: Rooftop Installation - Shows a unit mounted on a roof, indicating clearances and structural considerations.

ROOF CURB INSTALLATIONS ONLY:

• Sufficient structural support must be determined prior to locating and mounting the curb and package unit.
• 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.

Diagram: Roof Curb Installation - Depicts a unit being installed onto a roof curb structure.

GENERAL INFORMATION

WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DUE TO FIRE, EXPLOSIONS, SMOKE, SOOT, CONDENSATION, ELECTRIC SHOCK OR CARBON MONOXIDE, THIS UNIT MUST BE PROPERLY INSTALLED, REPAIRED, OPERATED, AND MAINTAINED.

This unit is approved for outdoor installation ONLY. Rated performance is achieved after 72 hours of operation. Rated performance is delivered at the specified airflow. See outdoor 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.

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.
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.

WARNING
TO PREVENT PROPERTY DAMAGE, THE UNIT SHOULD REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS. TO FACILITATE LIFTING AND MOVING WHEN A CRANE IS USED, PLACE THE UNIT IN AN ADEQUATE CABLE SLING.

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.

Diagram: Rigging - Illustrates the unit being lifted, emphasizing maintaining an upright position and using a cable sling.

GAS PIPING

IMPORTANT NOTE: This unit is factory set to operate on natural gas at the altitudes shown on the rating plate.

WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH WHEN USING PROPANE GAS ALONE OR AT HIGHER ALTITUDES, OBTAIN AND INSTALL THE PROPER CONVERSION KIT(S). FAILURE TO DO SO CAN RESULT IN UNSATISFACTORY OPERATION AND/OR EQUIPMENT DAMAGE. HIGH ALTITUDE KITS ARE FOR THE U.S. INSTALLATIONS ONLY AND ARE NOT APPROVED FOR USE IN CANADA.

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

Inlet Gas Pressure Must Not Exceed the Maximum Value Shown in Table Above.

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.

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. 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
9. 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 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.

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).

Diagram: Rigging - Illustrates the unit being lifted, emphasizing maintaining an upright position and using a cable sling.

Pressure = .50 PSIG or less and Pressure Drop of 0.3" W.C. (Based on 0.60 Specific Gravity Gas)

CFH = BTUH Furnace Input / Heating Value of Gas (BTU/Cubic Foot)

Diagram: Proper Piping Practice - Shows a schematic of gas piping with labels for manual shut-off valve, drip leg, and ground joint union.

To convert to Capacities at 15 PSIG Settings -- Multiply by 1.130

To convert to Capacities at 5 PSIG Settings -- Multiply by 0.879

*DATA IN ACCORDANCE WITH NFPA PAMPHLET NO. 54

WARNING
TO AVOID PROPERTY DAMAGE OR SERIOUS PERSONAL INJURY DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETECTING WARNING DEVICE.

IF THE PROPANE GAS UNIT IS INSTALLED IN AN EXCAVATED AREA OR A CONFINED SPACE, A WARNING DEVICE IS REQUIRED DUE TO:

• PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
• PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE.

Diagram: Typical Propane Gas Piping - Shows a schematic of propane gas piping with regulators and tank connections.

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.

UNIT VOLTAGE

The unit transformer is factory connected for 230V operation. If the unit is to operate on 208V, reconnect the transformer primary lead as shown on the unit wiring diagram. The induced draft blower on some models is equipped with a low speed 230V lead (blue) and a low speed 208V lead (black). If equipped, connect the induced draft blower low speed 208V lead (black) in place of the low speed 230V lead (blue). Place the unused 230V lead on the "PARK" terminal located on ignition control.

HEAT ANTICIPATOR SETTING

The heat anticipator is to be set by measuring the load (amperage) at the "R" circuit. Follow the instructions provided with the thermostat for more details.

Diagram: Electrical Power Directly To Junction Box - Shows external power supply wiring entering a junction box on the unit.

Diagram: Electrical Power Routed Through Bottom of Unit - Shows external power supply wiring entering the unit through the bottom.

Diagram: Typical Electrical Wiring Unit Voltage - Illustrates the general electrical connection points for unit voltage.

CIRCULATING AIR AND FILTERS

AIRFLOW CONVERSION

Units can easily be converted from horizontal to down-discharge airflow delivery. In down-discharge or high static installations, the installer should measure the total external static and review the blower performance charts before performing the installation. In some installations it will be necessary to change the blower speed to provide proper air flow.

Horizontal Air Flow

Single phase models are shipped without horizontal duct covers. If needed, these kits may be ordered through Goodman's Service Parts department.

Down Discharge Applications

Cut insulation around bottom openings and remove panels from the bottom of the unit, saving the screws holding the panels in place.

NOTE: Single phase models require installation of horizontal duct kit #20464501PDGK (medium chassis) and #20464502PDGK (large chassis).

Diagram: Duct Cover Installation - Shows panels being removed or installed for downflow duct applications.

DUCTWORK

Duct systems and register sizes must be properly designed for the C.F.M. and external static pressure rating of the unit. Ductwork should be designed in accordance with the recommended methods of Air Conditioning Contractors of America Manual D (Residential) or Manual Q (Commercial). All ductwork exposed to the outdoors must include a weatherproof barrier and adequate insulation.

A duct system should be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B.

The supply duct from the unit through a wall may be installed without clearance. However, minimum unit clearances as shown in the appendix must be maintained. The supply duct should be provided with an access panel large enough to inspect the air chamber downstream of the heat exchanger. A cover should be tightly attached to prevent air leaks.

For duct flange dimensions on the unit refer to the Unit Dimension illustration in the appendix. For down-discharge applications, the ductwork should be attached to the roof curb prior to installing the unit. Ductwork dimensions are shown in the roof curb installation manual.

If desired, supply and return duct connections to the unit may be made with flexible connections to reduce possible unit operating sound transmission.

FILTERS

Even though a return air filter is not supplied with this unit, there must be a means of filtering all return air. All units may be externally filtered. Refer to the unit filter size chart in the appendix for filter size information. Filters installed external to the unit should be sized in accordance with their manufacturer recommendations. A throwaway filter must be sized for a maximum face velocity of 300 feet per minute.

Filter Installation

IMPORTANT NOTE: When installing a filter, the air flow arrows on the filter must point toward the circulator blower.

CAUTION
TO PREVENT PROPERTY DAMAGE DUE TO FIRE AND LOSS OF EQUIP- MENT EFFICIENCY OR EQUIPMENT DAMAGE DUE TO DUST AND LINT BUILD-UP ON INTERNAL PARTS, NEVER OPERATE THE UNIT WITHOUT AN AIR FILTER INSTALLED IN THE RETURN AIR SYSTEM.

VENTING

NOTE: Venting is self-contained. Do not modify or block.

INSTALLATION - FLUE HOOD EXHAUST

1. Locate the flue hood assembly box in the unit.
2. Slide screen over flanges on the lower flue hood.
3. Slide screen and lower flue hood into hood.
4. Using the three screws provided, attach the hood (with the opening facing down) over the flue exhaust opening in the utility panel.

Diagram: Flue Hood Exhaust Installation - Shows the components (hood, screen, lower flue hood) and their assembly for the exhaust vent.

INSTALLATION - COMBUSTION AIR INTAKE HOOD

1. Locate the second hood.
2. Using the three screws provided, attach the hood (with the opening facing down) to the heat exchanger access door.

CONDENSATE DRAIN

CONDENSATE DRAIN CONNECTION

A 3/4" NPT drain connection is supplied for condensate piping. An external trap must be installed for proper condensate drainage.

Diagram: Condensate Drain Connection - Illustrates the drain connection port on the unit and the requirement for an external trap, showing minimum distances.

NORMAL SEQUENCES OF OPERATION

HEATING

This unit is equipped with an ignition control that automatically lights the main burner. DO NOT attempt to light the main burners by any other method.

1. Thermostat calls for low or high stage heating.
2. Induced draft blower energizes for 15-second pre-purge.
3. The spark igniter and low and high stage gas valve are energized for 7 seconds. NOTE: The igniter produces a very intense electrical spark that ignites the gas.
4. Main burners light and control detects presence of flame.
5. If the call is for low stage heat, the induced draft blower switches to low speed and the high stage gas valve closes 5 seconds after the main burners light. If call is for high stage heat, induced draft blower remains at high speed and high stage gas valve remains open.
6. NOTE: If a single stage thermostat is used, the control will step to low stage after the main burners light and remain at low stage for 5 or 10 minutes, depending on jumper position. If the call for HEAT remains after the transition delay time expires, the control will transition from low stage to high stage.
7. The 30-second HEAT FAN ON delay time begins after the main burners light.
8. The unit delivers heat to the conditioned space until the thermostat is satisfied.
9. Gas valve(s) de-energizes. The induced draft blower continues operation for a 30-second post-purge.
10. Induced draft blower remains at low speed (or switches from high to low if operating at high stage heat) for the 30-second post purge.
11. Ignition control begins timing the HEAT FAN OFF delay. There is an adjustable HEAT FAN OFF delay of approximately 90/120/ 150/180 seconds (factory set at 150). If the unit is operating at high stage when the call for heat is removed, the blower will operate for 30 seconds at high heat speed then switch to low heat speed for the remainder of the selected HEAT FAN OFF delay.
12. NOTE: After the HEAT FAN OFF delay time has elapsed, the blower will de-energize. This allows any additional heat in the heat exchanger to be transferred to the conditioned space.

COOLING

1. Thermostat calls for low or high stage cooling.
2. If the thermostat call is for low stage cooling, the compressor and outdoor fan are energized at low stage. If the thermostat call is for high stage cooling, the compressor and outdoor fan are energized at high stage.
3. The indoor blower will energize approximately 6 seconds later.
4. The unit delivers cooling to the conditioned space until the thermostat is satisfied.
5. The compressor and outdoor fan will be de-energized when the thermostat opens.
6. The indoor blower continues to run at low cool speed for approximately 60 seconds after the thermostat is satisfied. This allows additional cooling from the indoor coil to be transferred to the conditioned space. Then, the indoor blower is de-energized.

NOTE: A 180-second anti-short cycle is integral to the control and prevents recycling of the compressor.

FAN ONLY

1. Thermostat calls for FAN ONLY by energizing "G".
2. The indoor blower is immediately energized at the low heat speed.
3. The indoor blower is immediately de-energized once thermostat call for FAN is removed.

STARTUP, ADJUSTMENTS, AND CHECKS

HEATING STARTUP

This unit is equipped with an electronic ignition device to automatically light the main burners. It also has a power vent blower to exhaust combustion products.

On new installations, or if a major component has been replaced, the operation of the unit must be checked. Check unit operation as outlined in the following instructions. If any sparking, odors, or unusual sounds are encountered, shut off electrical power and check for wiring errors, or obstructions in or near the blower motors. Duct covers must be removed before operating unit.

Heat Anticipator Setting

Set the heat anticipator on the room thermostat to 0.4 amps to obtain the proper number of heating cycles per hour and to prevent the room temperature from overshooting the room thermostat setting.

Rollout Protection Control

The rollout protection device opens, cutting power to the gas valve, if the flames from the burners are not properly drawn into the heat exchanger. The rollout protection device is located on the burner bracket. The reason for elevated temperatures at the control must be determined and repaired prior to resetting this manual reset control.

WARNING
TO AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE OR EXPLOSION, A QUALIFIED SERVICER MUST INVESTIGATE THE REASON FOR THE ROLLOUT PROTECTION DEVICE TO OPEN BEFORE MANUALLY RESETTING THE ROLLOUT PROTECTION DEVICE.

Diagram: Rollout Protection on Burner Bracket - Shows the location of the rollout protection device on the burner assembly.

Secondary Limit Control

The secondary limit control is located on the top of the blower scroll assembly. This control opens when elevated temperatures are sensed. Elevated temperatures at the control are normally caused by blower failure. The reason for the opening should be determined and repaired prior to resetting.

If the power to the unit is interrupted during the heating cycle, it may cause the secondary limit to trip. Once the blower compartment temperature drops below the limit reset temperature, the limit will automatically reset.

Diagram: Secondary Limit Control - Shows the location of the secondary limit control on the blower scroll assembly.

Pre-Operation Checks

1. Close the manual gas valve external to the unit.
2. Turn off the electrical power supply to the unit.
3. Set the room thermostat to its lowest possible setting.
4. Remove the heat exchanger door on the side of the unit by removing screws.
5. This unit is equipped with an ignition device which automatically lights the main burner. DO NOT try to light burner by any other method.
6. Move the gas control valve switch to the OFF position. Do not force.
7. Wait five minutes to clear out any gas.
8. Smell for gas, including near the ground. This is important because some types of gas are heavier than air. If you have waited five minutes and you do smell gas, immediately follow the warnings on page 3 of this manual. If having waited for five minutes and no gas smell is noted, move the gas control valve switch to the ON position.
9. Replace the heat exchanger door on the side of the unit.
10. Open the manual gas valve external to the unit.
11. Turn on the electrical power supply to the unit.
12. Set the thermostat to desired setting.

Gas Supply And Manifold Check

Gas supply pressure and manifold pressure with the burners operating must be as specified on the rating plate.

Gas Inlet Pressure Check

Gas inlet pressure must be checked and adjusted in accordance to the type of fuel being consumed.

With Power And Gas Off:

1. Back inlet pressure test screw (inlet pressure boss) out one turn (counterclockwise, not more than one turn). Alternately, inlet gas pressure may be measured by removing the cap from the drip leg and installing a predrilled cap with a hose barb fitting.
2. Connect a water manometer or adequate gauge to the inlet pressure tap of the gas valve (or hose barb fitting on predrilled cap).

With Power And Gas On:

1. Put unit into heating cycle and turn on all other gas consuming appliances.
2. Turn off all electrical power and gas supply to the system.
3. Remove manometer hose from the outlet pressure boss (or remove hose from hose barb).
4. Turn inlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum). Alternately, remove predrilled cap from drip leg. Reinstall original cap, sealing with pipe thread compound.
5. Turn on electrical power and gas supply to the system.
6. Turn on system power and energize valve.
7. Using a leak detection solution or soap suds, check for leaks at the pressure boss screw (or drip leg cap). Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY.

Manifold Pressure Check

1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace.
2. Turn off all electrical power to the system.
3. Back outlet pressure test screw (outlet pressure boss) out one turn (counterclockwise, not more than one turn).
4. Attach a hose and manometer to the outlet pressure boss of the valve.
5. Turn ON the gas supply.
6. Turn on power and energize main (M) solenoid. Do not energize the HI solenoid.
7. Measure gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table.
8. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure, or counterclockwise to decrease pressure.
9. Energize main (M) solenoid as well as the HI terminal.
10. Remove regulator cover screw from the HI outlet pressure regulator adjust tower and turn screw clockwise to increase pressure, or counterclockwise to decrease pressure.
11. Turn off all electrical power and gas supply to the system.
12. Remove manometer hose from outlet pressure boss.
13. Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum).
14. Turn on electrical power and gas supply to the system.
15. Turn on system power and energize valve.
16. Using a leak detection solution or soap suds, check for leaks at pressure boss screw. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY.

NOTE: Inlet Gas Pressure Must Not Exceed the Maximum Value Shown. If operating pressures differ from above, make necessary pressure regulator adjustments, check piping size, etc., and/or consult with local utility.

Manifold Gas Pressure

Diagram: White-Rodgers Model 36G54 connected to Manometer - Shows a specific gas regulator model connected to a manometer for pressure testing.

Diagram: Measuring Inlet Gas Pressure Alternate Method - Illustrates using a drip leg cap with a fitting for manometer connection.

Gas Input (Natural Gas Only) Check

To measure the gas input use a gas meter and proceed as follows:

1. Turn off gas supply to all other appliances except the unit.
2. With the unit operating, time the smallest dial on the meter for one complete revolution. If this is a 2 cubic foot dial, divide the seconds by 2; if it is a 1 cubic foot dial, use the seconds as is. This gives the seconds per cubic foot of gas being delivered to the unit.
3. INPUT = GAS HTG VALUE x 3600 / SEC. PER CUBIC FOOT
   Example: Natural gas with a heating value of 1000 BTU per cubic foot and 36 seconds per cubic foot as determined by Step 2, then: Input = 1000 x 3600 / 36 = 100,000 BTU per Hour. NOTE: BTU content of the gas should be obtained from the gas supplier. This measured input must not be greater than shown on the unit rating plate.
4. Relight all other appliances turned off in step 1. Be sure all pilot burners are operating.

Main Burner Flame Check

Flames should be stable, soft and blue (dust may cause orange tips but they must not be yellow) and extending directly outward from the burner without curling, floating or lifting off.

Temperature Rise Check

Check the temperature rise through the unit by placing thermometers in supply and return air registers as close to the unit as possible. Thermometers must not be able to sample temperature directly from the unit heat exchangers, or false readings could be obtained.

1. All registers must be open; all duct dampers must be in their final (fully or partially open) position and the unit operated for 15 minutes before taking readings.
2. The temperature rise must be within the range specified on the rating plate.

NOTE: Air temperature rise is the temperature difference between supply and return air.

With a properly designed system, the proper amount of temperature rise will normally be obtained when the unit is operated at rated input with the recommended blower speed.

If the correct amount of temperature rise is not obtained, it may be necessary to change the blower speed. A higher blower speed will lower the temperature rise. A slower blower speed will increase the temperature rise.

NOTE: Blower speed MUST be set to give the correct air temperature rise through the unit as marked on the rating plate.

External Static Pressure Check

The total external static pressure must be checked on this unit to determine if the airflow is proper.

Blower Speed Adjustments

Blower speeds are changed at the indoor blower. The ignition control board has four blower speeds: LOW HEAT, HI HEAT, LOW COOL and HIGH COOL.

NOTE: FAN ONLY energizes at LOW HEAT speed. The GPG16 models are equipped with EEM motors. EEM motors are constant torque motors with very low power consumption. This motor is energized by 24VAC. Adjust the CFM for the unit by changing the 24 VAC leads to the speed terminal block on the motor.

WARNING
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, REMOVE ELECTRICAL POWER FROM THE UNIT BEFORE CHANGING SPEED TAPS ON THE BLOWER MOTOR.

Limit Check

Check limit control operation after 15 minutes of operation by blocking the return air grille(s).

1. After several minutes the main burners must go OFF. Blower will continue to run.
2. Remove air restrictions and main burners will relight after a cool down period of a few minutes.

Adjust the thermostat setting below room temperature.

1. Main burners must go OFF.
2. Circulating Air Blower will continue to run for 90, 120, 150 or 180 seconds, depending on the setting.

NOTE: If necessary, adjust fan OFF delay settings to obtain satisfactory comfort level.

Diagram: Control Board (Top) - Shows the layout of the integrated control module with various terminals and jumper settings.

Unit Shutdown

1. Set the thermostat to lowest setting.
2. Turn off the electrical power supply to the unit.
3. Remove the heat exchanger door on the side of the unit by removing screws.
4. Move the gas control valve switch to the OFF position. Do not force.
5. Close manual gas shutoff valve external to the unit.
6. Replace the heat exchanger door on the unit.
7. If cooling and/or air circulation will be desired, turn ON the electrical power.

COOLING STARTUP

NOTE: Check all manual reset limit controls in heating circuit if cooling mode does not operate.

Compressor Protection Devices

The compressor includes components which are designed to protect the compressor against abnormal operating conditions.

Cooling Refrigerant Charging (Models with TXV)

Check unit charge before putting the cooling section into full operation. The unit has a thermostatic expansion valve metering device. To ensure the unit is properly charged for the intended application, check the unit refrigerant sub-cooling at the condenser. The refrigerant sub-cooling is a function of outdoor ambient temperature and return air temperature of the conditioned space. It is the installing contractor's responsibility to ensure the proper refrigerant sub-cooling at the condenser is adjusted for each application. As the outdoor ambient temperature rises the sub-cooling decreases and as the outdoor ambient temperature lowers, the sub-cooling increases.

NOTE: Proper sub-cooling adjustment optimizes cooling performance. Models equipped with thermostatic expansion valve, charge the system to sub-cooling, range shown on chart, when necessary, adjust expansion valve stem for superheat setting.

NOTE: The expansion valve will not need adjustment for most applications. Ensure system superheat is set within range listed on chart.

Superheat Adjustment

To adjust superheat, remove the control box cover and locate the expansion valve on the liquid line of the evaporator. Unscrew the cover from the expansion valve, locate the adjustment screw, and turn it clockwise (in) to increase superheat or counterclockwise (out) to decrease superheat. Replace adjustment cap. Wait a minimum of 10 minutes between adjustments to allow time for the TXV and pressures to stabilize.

Cooling Operation

NOTE: Mechanical cooling cannot be reliably provided at ambient temperatures below 50° F.

1. Turn on the electrical power supply to the unit.
2. Place the room thermostat selector switch in the COOL position (or AUTO if available, and if automatic changeover from cooling to heating is desired).
3. Set the room thermostat to the desired temperature.

TROUBLESHOOTING

IGNITION CONTROL ERROR CODES

The following presents probable causes of questionable unit operation. Refer to Diagnostic Indicator Chart for an interpretation of the signal and to this section for an explanation.

Remove the control box access panel and note the number of diagnostic LED flashes. Refer to Diagnostic Indicator Chart for an interpretation of the signal and to this section for an explanation.

FAULT RECALL

The ignition control is equipped with a momentary push-button switch that can be used to display on the diagnostic LED the last five faults detected by the control. The control must be in Standby Mode (no thermostat inputs) to use the feature. Depress the push-button switch for approximately 2 seconds. NOTE: Do not hold for longer than 4 seconds. Holding the button for 4 seconds or higher will erase the memory! Release the switch when the LED is turned off. The diagnostic LED will then display the flash codes associated with the last five detected faults. The order of display is the most recent fault to the least recent fault.

ABNORMAL OPERATION - HEATING

INTERNAL CONTROL FAILURE

If the integrated ignition control in this unit encounters an internal fault, it will go into a "hard" lockout and turn off the diagnostic LED. If diagnostic LED indicates an internal fault, check power supply to unit for proper voltage, check all fuses, circuit breakers and wiring. Disconnect electric power for five seconds. If LED remains off after restoring power, replace control.

EXTERNAL LOCKOUT

An external lockout occurs if the integrated ignition control determines that a measurable combustion cannot be established within three (3) consecutive ignition attempts. If flame is not established within the seven (7) second trial for ignition, the gas valve is de-energized, 30 second inter-purge cycle is completed, and ignition is re-attempted. The control will repeat this routine three times if a measurable combustion is not established. The control will then shut off the induced draft blower and go into a lockout state.

If flame is established but lost, the control will energize the circulator blower at the heat speed and then begin a new ignition sequence. If flame is established then lost on subsequent attempts, the control will recycle the ignition sequence.

The diagnostic fault code is 1 flash for a lockout due to failed ignition attempts. The integrated control will automatically reset after one hour, or it can be reset by removing the thermostat signal or disconnecting the electrical power supply for over five seconds.

If the diagnostic red LED indicates an external lockout, perform the following checks:

• Check the supply and manifold pressures
• Check the gas orifices for debris
• Check gas valve for proper operation
• Check flame sensor
  A drop in flame signal can be caused by nearly invisible coating on the sensor. Remove the sensor and carefully clean with steel wool.
• Auxiliary/Secondary Limit
  A dirty filter, excessive duct static, insufficient air flow, a faulty limit, or a failed circulator blower can cause this limit to open. Check filters, total external duct static, circulator blower motor, blower motor speed tap (see wiring diagram), and limit. An interruption in electrical power during a heating cycle may also cause the auxiliary limit to open. The automatic reset secondary limit is located on top of the circulator blower assembly.
• Rollout Limit
  If the burner flames are not properly drawn into the heat exchanger, the flame rollout protection device will open. Possible causes are restricted or blocked flue passages, blocked or cracked heat exchanger, a failed induced draft blower, or insufficient combustion air. The rollout protection device is a manual reset limit located on the burner bracket. The cause of the flame rollout must be determined and corrected before resetting the limit.
• Check wiring
  Check wiring for opens/shorts and miswiring.

IMPORTANT NOTE: If you have to frequently reset your gas/electric package unit, it means that a problem exists that should be corrected. Contact a qualified servicer for further information.

PRESSURE SWITCH STUCK OPEN

A pressure switch stuck open can be caused by a faulty pressure switch, faulty wiring, a disconnected or damaged hose, a blocked or restricted flue, a blocked pressure tap or a faulty induced draft blower.

If the control senses an open pressure switch during the pre-purge cycle, the induced draft blower only will be energized. If the pressure switch opens after ignition has begun the gas valve is de-energized, the circulator blower heat off cycle begins, and the induced draft blower remains on. The diagnostic LED (red) code is two (2) flashes.

PRESSURE SWITCH STUCK CLOSED

A stuck closed pressure switch can be caused by a faulty pressure switch or faulty wiring. If the control encounters a pressure switch stuck closed, the induced draft blower remains off. The diagnostic red LED code for this fault is three (3) flashes.

PRIMARY LIMIT

A primary limit will open due to excessive supply air temperatures. This can be caused by a dirty filter, excessive duct static, insufficient air flow, or a faulty limit. Check filters, total external duct static, blower motor, blower motor speed tap (see wiring diagram), and limit. This limit will automatically reset once the temperature falls below a preset level.

If a limit switch opens, the gas valve is immediately de-energized, the induced draft and air circulating blowers are energized. The induced draft and air circulator blowers remain energized until the limit switch re-closes. The diagnostic LED (red) code for an open limit is four (4) flashes.

NOTE: If the primary limit opens five (5) times within the same call for heat, the ignition control will lock out for one (1) hour with the air circulating blower energized at high heat speed. The diagnostic LED (red) code for this condition is seven (7) flashes.

FLAME DETECTED WITH GAS VALVE CLOSED

If flame is detected with the gas valve de-energized, the combustion and air circulator blowers are energized. The diagnostic fault code is five (5) flashes (red LED) for this condition. The flame diagnostic LED (amber) will flash (2) times to indicate this condition. The control can be reset by removing the power supply to the unit or it will automatically reset after one hour. Miswiring is the probable cause for this fault.

LOW FLAME SIGNAL

Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame signal. If the flame signal drops below a predetermined value, the ignition control will display an error code of (1) flash on the amber diagnostic LED. The unit will continue to operate until the control can no longer detect flame.

ABNORMAL OPERATION - COOLING

SHORT CYCLE COMPRESSOR DELAY

The automatic ignition control has a built-in feature that prevents damage to the compressor in short cycling situations. In the event of intermittent power losses or intermittent thermostat operation, the ignition control will delay output to the compressor contactor for three minutes from the time power is restored or thermostat call for cooling is restored. (Compressor is off a total of three minutes). The diagnostic red LED will flash six (6) times to indicate the compressor contactor output is being delayed.

NOTE: Some electronic thermostats also have a built-in compressor short cycle timer that may be longer than the three minute delay given above. If you are using an electronic thermostat and the compressor has not started after three minutes, wait an additional five minutes to allow the thermostat to complete its short cycle delay time.

HIGH PRESSURE SWITCH/LOSS OF CHARGE SWITCH

Some models include a high pressure cutout switch and/or a loss of charge cutout switch. The high pressure cutout switch protects the refrigeration system from excessive operating pressures. The loss of charge cutout switch protects the refrigeration system from very low operating pressures due to a loss of refrigerant. Compressor operation will be disabled if either of these devices opens. If either devices opens, the diagnostic red LED will flash (9) times to indicate that a refrigeration system pressure switch is open.

MAINTENANCE

Have the gas heating section of the unit checked at least once a year before the heating season begins, to be sure that the combustion air inlet and flue outlet hoods are not blocked by debris, which would prevent adequate combustion air and a properly operating vent system.

FILTER REPLACEMENT OR CLEANING

A return air filter is not supplied with this unit; however, there must be a means of filtering all of the return air. The filter(s) may be located in the return air duct(s), or return air filter grille(s). Consult with your installing dealer for the actual location of the return air filter(s) for your unit.

Dirty filters are the most common cause of inadequate heating or cooling performance. Filter inspection should be made at least every two months; more often if necessary because of local conditions and usage.

Dirty throwaway filters should be discarded and replaced with a new, clean filter. Dirty permanent filters should be washed with water, thoroughly dried and sprayed with a filter adhesive before being reinstalled. (Filter adhesives may be found at many hardware stores.) Permanent filters should last several years. However, should one become torn or uncleanable, it should be replaced.

CABINET FINISH MAINTENANCE

Use a fine grade automotive wax on the cabinet finish to maintain the finish's original high luster. This is especially important in installations with extended periods of direct sunlight.

CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)

The coil with the outside air flowing over it should be inspected annually and cleaned as frequently as necessary to keep the finned areas free of lint, hair and debris.

CONDENSER, EVAPORATOR, AND INDUCED DRAFT MOTORS

Bearings on the air circulating blower motor, condenser motor and the combustion fan motor are permanently lubricated. No additional oiling is required.

FLAME SENSOR (QUALIFIED SERVICER ONLY)

A drop in the flame current can be caused by a nearly invisible coating on the flame sensor. This coating, created by the fuel or combustion air supply, can be removed by carefully cleaning the flame sensor with steel wool.

NOTE: After cleaning, the microamp signal should be stable and in the range of 4 - 6 microamps DC.

Diagram: Flame Sensor - Shows the flame sensor component.

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

At the start of each heating season, inspect and, if necessary, clean the unit flue passage.

CLEANING FLUE PASSAGES (QUALIFIED SERVICER ONLY)

1. Shut off electric power and gas supply to the unit.
2. Remove burner assembly by disconnecting the gas line and removing the manifold bracket from the partition panel.
3. Remove the flue from the induced draft blower and the collector box cover from the partition panel.
4. The primary heat exchanger tubes can be cleaned using a round wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach a variable speed reversible drill to the other end of the spring cable. Slowly rotate the cable with the drill and insert it into one of the primary heat exchanger tubes. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Use a large cable for the large tube, and then repeat the operation with a small cable for the smaller tube. Repeat for each tube.
5. When all heat exchanger tubes have been cleaned, replace the parts in the reverse order in which they were removed.
6. To reduce the chances of repeated fouling of the heat exchanger, perform the steps listed in "Startup, Adjustments, and Checks".

MAIN BURNER FLAME (QUALIFIED SERVICER ONLY)

Flames should be stable, soft and blue (dust may cause orange tips but they must not be yellow). The flames must extend directly outward from the burner without curling, floating or lifting off.

At least once a year, prior to or during the heating season, make a visual check of the burner flames.

NOTE: This will involve removing and reinstalling the heat exchanger door on the unit, which is held by two screws. If you are uncertain about your ability to do this, contact a qualified servicer. If a strong wind is blowing, it may alter the airflow pattern within the unit enough that an inspection of the burner flames is not possible.

CLEANING BURNERS

1. Shut off electric power and gas supply to the unit.
2. Remove the screws securing the manifold to the burner retention bracket. Remove the manifold and rotate each burner counterclockwise to remove.
3. Remove the burners.
4. Use a bottle brush to clean burner insert and inside of the burners.
5. Replace burners and manifold, inspect the burner assembly for proper seating of burners in retention slots.
6. Reconnect electrical power and gas supply.

For further information on the yearly inspection, consult the User Manual. It is recommended that a qualified servicer inspect and service the unit at least once each year.

Turn the unit on at the thermostat. Wait a few minutes, since any dislodged dust will alter the normal flame appearance. Flames should be predominantly blue and directed into the tubes. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports.

Diagram: Burner Flame - Shows a properly adjusted burner flame, indicating characteristics like stability, color, and direction.

Diagram: Manifold Assembly - Illustrates the gas manifold and burner assembly.

WARNING
TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. CONTACT A QUALIFIED SERVICER AT ONCE IF AN ABNORMAL FLAME SHOULD DEVELOP.

ACCESSORIES AND FUNCTIONAL PARTS

SHEET METAL ACCESSORIES

Additional accessories can be purchased to fit specific application needs. Parts and instructions are available from your distributor.

FUNCTIONAL PARTS

• Auxiliary Limit Switch
• Blower Housing
• Blower Wheel
• Burner
• Circulator Blower Motor
• Capacitor
• Compressor
• Condenser Coil
• Condenser Fan Blade
• Condenser Fan Motor
• Contactor
• Gas Manifold
• Evaporator Coil
• Flame Rollout Switch
• Flame Sensor
• Gas Orifice
• Gas Valve
• Heat Exchanger
• High Limit Switch
• High Pressure Switch
• Igniter
• Ignition Control
• Induced Draft Blower
• Pressure Switch Hose
• Thermostatic Expansion Valve
• Transformer

GENERAL INFORMATION

1. Refer to the description in Functional Parts List when ordering any of the listed functional parts. Be sure to provide the unit model and serial numbers with the order.

2. Although only functional parts are shown, all sheet metal parts, doors, etc. may be ordered by description.

3. Parts are available from your distributor.

CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.

CAUTION
ALWAYS VERIFY PROPER OPERATION AFTER SERVICING.

APPENDIX

IGNITION CONTROL DIAGNOSTIC INDICATOR CHART

HEATING TIMING CHART

Diagram: Heating Timing Chart - Shows the sequence and timing of blower, gas valve, igniter, and thermostat states during a heating cycle.

COOLING TIMING CHART

Diagram: Cooling Timing Chart - Shows the sequence and timing of blower, compressor, outdoor fan, and thermostat states during a cooling cycle.

UNIT DIMENSIONS

Diagram: Unit Dimensions - Provides a 3D view of the unit with various dimensions labeled (A, B, C) and callouts for features like flue exhaust, gas supply, and access panels.

WIRING DIAGRAM

WARNING
HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Diagram: Wiring Diagram - A detailed schematic showing electrical connections for the unit, including power supply, control module, motors, gas valve, and other components. It includes a component legend, wire code, and notes for installation and troubleshooting.

Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

MINIMUM CLEARANCES

Diagram: Minimum Clearances - Illustrates the required clearances around the unit for installation and service, showing measurements like 48" MIN, 12" MIN, and 36" MIN (for service).

NOTE: Roof overhang should be no more than 36".

RECOMMENDED FILTER SIZES

BLOWER PERFORMANCE DATA

The following tables provide blower performance data for various models and operating conditions.

NOTE: The shaded area indicates ranges in excess of maximum external static pressure allowable when heating. For satisfactory operation, external static pressure should not exceed 0.8" w.c.

Table: Blower Performance Data - Detailed tables showing CFM, Watts, and Temperature Rise for different External Static Pressure (E.S.P.) values across various heating and cooling speeds for different unit models (GPG1624060M41, GPG1630080M41, GPG1636080M41, GPG1642100M41, GPG1648100M41).

HOMEOWNER'S ROUTINE MAINTENANCE RECOMMENDATIONS

We strongly recommend a bi-annual maintenance checkup be performed by a qualified service agency before the heating and cooling seasons begin.

REPLACE OR CLEAN FILTER

IMPORTANT NOTE: Never operate unit without a filter installed as dust and lint will build up on internal parts resulting in loss of efficiency, equipment damage and possible fire.

A return air filter is not supplied with this unit; however, there must be a means of filtering the return air. An indoor air filter must be used with your comfort system. A properly maintained filter will keep the indoor coil of your comfort system clean. A dirty coil could cause poor operation and/or severe equipment damage.

The installer of your unit can tell you where your filter(s) are and how to clean or replace them. Check your return filter(s) at least once every two months. When they are dirty, replace or clean as required. Disposable type filters should be replaced. Reusable type filters may be cleaned.

NOTE: Reusable type filters should be washed with warm water, dried completely and sprayed with an adhesive according to the manufacturers recommendations.

You may want to ask your dealer about high efficiency filters. High efficiency filters are available in both electronic and non-electronic types. These filters can do a better job of catching small airborne particles.

Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. When replacing a filter, it must be replaced with a filter of the same type and size and always make certain the air flow arrows on the filter point in the proper direction.

CONDENSER, EVAPORATOR AND INDUCED DRAFT MOTORS

The bearings on the air circulating blower motor, condenser motor and the combustion fan motor are permanently lubricated and require no further lubrication.

COMPRESSOR

The compressor motor is hermetically sealed and does not require additional oiling.

ANNUAL INSPECTION (QUALIFIED SERVICER ONLY)

Your package unit should be inspected by a qualified installer, or service agency at least twice every year. This check should be performed before the heating and cooling seasons begin. This will ensure that adequate combustion air is being drawn and the vent system is working properly. Particular attention should be paid to the following items. Repair as necessary.

• Check physical support of the unit. Ensure it is sound without any sagging, cracks, or gaps, around the base.
• Check for obvious signs of deterioration of the unit.
• Flue Hood and Combustion Air Inlet. Check for blockage (wasp nest, etc.) and corrosion.
• Return Air Connection. Check for physical soundness and ensure that the connection is firmly sealed to the package unit casing.
• Heat exchanger. Check for corrosion and/or obstructions within the heat exchanger passageways.
• Burners. Check for proper ignition, burner flame, and flame sense.
• Wiring. Check wires for damage. Check electrical connections for tightness and/or corrosion.
• Filters. Check that filters are clean and in the proper placement in the unit or duct system.
• Louvers. Inspect air inlet louvers inside the heat exchanger compartments. Ensure the area is clean and free of dirt and debris.

CLEAN OUTSIDE COIL (QUALIFIED SERVICER ONLY)

The outdoor coil should be inspected annually. It is important to keep the outdoor coil clean. Dirt, leaves, or debris could restrict the airflow. If cleaning of the outdoor coil becomes necessary, hire a qualified servicer. Inexperienced people could easily puncture the tubing in the coil.

BEFORE CALLING YOUR SERVICER

• Check the thermostat to confirm that it is properly set.
• Check the disconnect switch near the unit to confirm that it is closed.
• Check the electrical panel for tripped circuit breakers or failed fuses. Reset the circuit breakers or replace fuses as necessary.
• Check for blockage of the indoor air inlets and outlets. Confirm that they are open and have not been blocked by objects (rugs, curtains or furniture).
• Check for obstructions on the unit. Confirm that it has not been covered on the sides or the top. Remove any obstruction that can be safely removed. If the unit is covered with dirt or debris, call a qualified servicer to clean it.
• Check the filter. If it is dirty, clean or replace it.

Start-up Checklist

Pre Start-Up

(Check each item as completed)

• Verify all packaging material has been removed.
• Remove all shipping brackets per installation instructions.
• Verify the job site voltage agrees with the unit serial plate.
• Verify condensate connection is installed per installation instructions.
• Verify proper clearance around the unit for safety, service, maintenance and proper unit operation.
• Verify proper weatherproofing of all ductwork, roof curbs and electrical connections.
• Check that the flue screen is in place.
• Check gas piping for leaks.
• Verify gas pressure to the unit is within the range specified on the serial plate.
• Check to ensure that all fans, pulleys and wheels are secure.
• Check for proper belt tension and alignment per installation instructions.
• Check refrigerant piping for rubbing and leaks. Repair if necessary.
• Check unit wiring to ensure it is not in contact with refrigerant piping or sharp metal edges.
• Check all electrical connections and terminals. Tighten as needed.
• Verify that the crankcase heaters have been energized for 24 hours.
• Verify the scroll compressor(s) are rotating in the right direction.
• Verify all accessories are installed and operating correctly.
• Check filters and replace if necessary.
• Verify the installation of the thermostat.

Start-Up

(Insert the values as each item is completed.)

ELECTRICAL

BLOWER EXTERNAL STATIC PRESSURE

TEMPERATURES

PRESSURES

(HEAT PUMP ONLY)