Goodman GPC/GPH Series Self-Contained Package Air Conditioners and Heat Pumps
Installation & Operating Instructions
Introduction
This manual provides instructions for the installation and operation of Goodman GPC/GPH series self-contained package air conditioners and heat pumps. It is intended for installers and includes important safety information for homeowners.
Checking Product Received
Upon receiving the unit, inspect it for any shipping damage. File claims immediately with the shipping company. Verify the unit model number, specifications, electrical characteristics, and accessories are correct. Do not install an incorrectly shipped unit; return it to the supplier.
Message to the Homeowner
This manual contains useful maintenance information that should be kept for future reference after installation.
Before Beginning Installation
Read all instructions carefully before starting. Ensure all steps and considerations are understood. Gather all necessary tools, hardware, and supplies. Assess the installation location, noting potential obstacles.
Replacement Parts
Ordering Parts
When ordering parts or reporting shortages/damages, provide the complete unit model and serial numbers from the unit's nameplate. Replacement parts are available through your contractor or local distributor. Contact Goodman Manufacturing Company, L.P. for assistance.
Important Safety Instructions
Recognize Safety Symbols, Words, and Labels:
The symbols and labels in this manual indicate immediate or potential hazards. Failure to heed safety information can result in serious personal injury, death, property damage, or product damage.
WARNING: HIGH VOLTAGE! Disconnect all power before installing or servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
WARNING: This unit should not be connected to or used with any devices not certified or approved by Goodman. Use of unapproved devices may result in serious property damage, personal injury, reduced performance, or hazardous conditions.
WARNING: Do not connect ductwork to any other heat-producing device such as a fireplace insert or stove. Unauthorized use may result in property damage, fire, carbon monoxide poisoning, explosion, personal injury, or death.
Codes and Regulations
General
The GPC & GPH series units are designed for outdoor use only and are available in cooling capacities from 2 to 5 nominal tons. Optional field-installed heat kits are available. These units are self-contained and require only duct, line voltage, low voltage wiring, and drain connections. They are ETL listed and ARI certified.
EPA Regulations
Follow all EPA regulations regarding the introduction and disposal of refrigerants. Contact the local EPA office for specific guidance. Certified technicians should perform work on this unit.
National Codes
Install the product in accordance with National Codes and prevailing local codes and regulations.
Major Components
The unit includes a sealed refrigerating system (compressor, condenser coil, evaporator coil, flowrator), indoor blower, condenser fan, and internal electrical wiring. Heat pump models also include a reversing valve, defrost control, and loss of charge protection. The system is factory evacuated, charged, and performance tested.
Installation
Pre-Installation Checkpoints
- Structural strength of supporting members.
- Clearances and provision for servicing.
- Power supply and wiring.
- Air duct connections.
- Drain facilities and connections.
- Location considerations for noise and aesthetics.
Clearance
The unit requires unobstructed condenser air inlet and discharge. Maintain adequate clearance for servicing. For close-to-wall installations, a minimum of 10" (4" minimum) is recommended. Provide 18" minimum for service access to the compressor compartment. Ensure the top of the unit is unobstructed. If located under an overhang, maintain 36" clearance and ensure warm discharge air is deflected away.
Location
Consider the impact of outdoor fan noise on occupied spaces. Place the unit to avoid directing condenser air discharge towards windows less than 25 feet away. The unit should be mounted on a solid, level foundation, preferably a concrete slab at least 4 inches thick, elevated for drainage. For rooftop installations, ensure adequate structural support and weather-tight integrity. Heat pumps require special consideration for snow accumulation and sub-freezing temperatures, ensuring unobstructed drainage of defrost water and ice.
Ducting
WARNING: Do not connect return ductwork to any other heat-producing devices. Unauthorized use may result in property damage, fire, carbon monoxide poisoning, explosion, personal injury, or death.
Ductwork should be fabricated according to local codes and industry standards. Use non-flammable, weatherproof flexible connectors for supply and return connections to reduce noise transmission. Proper sealing of all ductwork and air handling compartments is crucial for unit efficiency.
Connecting the Return and Supply Flexible Duct in Manufactured or Modular Housing Application
Use factory-designed square-to-round converter transitions for connecting flexible ductwork. Refer to the specification sheets for model numbers and dimensions. Ensure ducts are appropriately sized for the unit's CFM. If larger ducts are required, use reducers at the unit.
| NOMINAL SIZE (INCHES) | NOMINAL AREA (SQ. FT.) |
|---|---|
| 10x20 | 1.4 |
| 14x20 | 1.9 |
| 14x25 | 2.4 |
| 15x20 | 2.1 |
| 16x20 | 2.2 |
| 16x25 | 2.8 |
| 20x20 | 2.8 |
| 20x25 | 3.5 |
| 25x25 | 4.3 |
Plenum Application
Construct a suitable plenum or square duct, sized according to industry manuals. Insulate ductwork exposed to outdoor conditions with a vapor barrier. Balancing dampers are recommended for supply branches. Ensure ductwork is properly supported.
Filters
Filters are not provided and must be installed by the installer in the return duct system. A field-installed filter grille is recommended for easy access. Ensure filters have adequate face area for the unit's airflow requirements. Refer to air delivery tables for recommended filter sizes.
Piping
Condensate Drain
The condensate drain connection is a 3/4" N.P.T. coupling. A trap must be installed for proper drainage. Ensure the unit is level or slightly inclined toward the drain. Do not operate without a trap.
A positive liquid seal is required for the condensate trap.
Wiring
All wiring must comply with the National Electrical Code and local codes. Verify power supply voltage, frequency, and phase match the unit's requirements. Install a branch circuit fused disconnect near the unit. Use appropriate wire sizes and overcurrent protection as specified on the unit nameplate and wiring diagrams. Never use wire sizes smaller than recommended.
WARNING: HIGH VOLTAGE! Disconnect all power before installing or servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
High Voltage Wiring
Connect power leads to terminals L1 & L2 (single phase) or L1, L2, L3 (three phase) in the electrical control section using the specified wire sizes.
Low Voltage Wiring
Connect 24V wires from the thermostat to the control box using No. 18 AWG wire as follows:
| LEAD | THERMOSTAT |
|---|---|
| Red | R (24V) |
| Green | G (Fan) |
| Yellow | Y (Cool) |
| White | W1 (Heat)* |
| Brown | W2 (Heat)* |
*Optional field installed heat connections
| TERMINAL | THERMOSTAT |
|---|---|
| Red | R (24V) |
| Green | G (Fan) |
| Orange | O (Rev. Valve) |
| White | W1 (Heat, 2nd)* |
| Brown | W2 (Heat 3rd)* |
| Yellow | Y (Cool) |
| C (Blue) | C (Common) |
*Optional field installed heat connections
Internal Wiring
Refer to the internal wiring diagram on the electrical box cover. Use wire gauge and insulation matching the original wiring if replacement is necessary. The transformer is wired for 230 volts on 208/230 models; see the wiring diagram for 208 volt wiring.
| BRANCH CIRCUIT AMPACITY | 50 | 100 | 150 | 200 | 250 | 300 | 350 | 400 |
|---|---|---|---|---|---|---|---|---|
| SUPPLY WIRE LENGTH - FEET | 14 | 12 | 10 | 8 | 6 | 6 | 4 | 4 |
| 15 | 14 | 12 | 10 | 8 | 6 | 6 | 4 | 4 |
| 20 | 12 | 10 | 8 | 6 | 6 | 4 | 4 | 3 |
| 25 | 10 | 8 | 6 | 6 | 4 | 4 | 3 | 3 |
| 30 | 10 | 8 | 6 | 6 | 4 | 4 | 3 | 3 |
| 35 | 8 | 6 | 6 | 4 | 4 | 3 | 3 | 2 |
| 40 | 8 | 6 | 6 | 4 | 4 | 3 | 3 | 2 |
| 45 | 6 | 6 | 4 | 4 | 3 | 3 | 2 | 2 |
| 50 | 6 | 4 | 4 | 3 | 3 | 2 | 2 | 2 |
1. For branch circuit wiring, use Table 4 to determine minimum wire size based on circuit ampacity and length. For wiring from the disconnect to the unit, the smallest allowable wire size in Table 4 may be used. 2. Wire size is based on 60°C rated wire insulation and 30°C ambient temperature. 3. Derate conductor ampacity per NEC for more than 3 conductors in a raceway.
Note: Some single-phase units have a single-pole contactor; exercise caution during servicing as only one power supply leg is broken.
Operation
Start-Up Procedure and Checklist
WARNING: HIGH VOLTAGE! Disconnect all power before installing or servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
- Turn thermostat system switch to "Cool," fan to "Auto," and set temperature high.
- Inspect and open all registers.
- Turn on electrical supply at the disconnect.
- Turn fan switch to "ON." Blower should start after a 7-second delay.
- Turn fan switch to "Auto." Blower should stop after a 65-second delay.
- Lower cooling temperature setting until the unit starts. Compressor, blower, and fan should operate. Allow unit to run for 10 minutes, verifying cool air supply.
- Turn temperature setting to highest position to stop the unit. Indoor blower will run for 65 seconds.
- Turn thermostat system switch to "OFF" and disconnect power when servicing.
Heat Pump Start-Up Procedure
- Check cooling mode as above. Reversing valve should be energized (audible click). Lower temperature setting to call for cooling; compressor, blower, and fan should operate. Turn thermostat to "OFF" after checking.
- Turn thermostat system switch to "HEAT" and fan to "AUTO."
- Slowly raise heating temperature setting. Compressor, blower, and fan should operate with the reversing valve in the de-energized (heating) position. Verify heated air supply.
- If outdoor ambient is above 80°F, the unit may trip on high pressure during heating. Postpone testing to suitable conditions if necessary. If outdoor ambient is low and unit operates correctly, check high pressure cutout by blocking return air until unit trips.
- If unit operates correctly in heating, raise temperature setting for second stage heat. Supplemental resistance heat should activate.
- For thermostats with an emergency heat switch, move the switch to "Emergency Heat." The heat pump will stop, the blower will continue, all heaters will activate, and the emergency heat light will illuminate.
- If testing in winter, observe at least one defrost cycle to ensure complete defrosting when outdoor coil is cold enough to actuate the defrost control.
Final System Checks
- Adjust supply and return air grilles for optimal heating and cooling balance.
- Check ductwork for air leaks.
- Refer to Air Flow Measurement and Adjustment and Checking Charge sections.
- Ensure the unit is free of rattles and excessive vibration. Correct any rubbing of tubing against surfaces.
- Set the thermostat for normal use (cooling, heating, or automatic changeover).
- Instruct the owner on unit operation, filter maintenance, and thermostat usage.
The "Start-up Procedure and Check List" is recommended to ensure normal unit operation.
Components
- Contactor: Activated by the thermostat to supply power to the compressor and outdoor fan motor.
- Crankcase Heater: "ON" when power is supplied, warming the compressor crankcase to prevent liquid migration.
- Condenser Motor: Activated by the contactor during heating and cooling (except defrost/emergency heat).
- Compressor: Activated by the contactor for heating and cooling (except emergency heat), protected by an internal overload.
- Contactor Relay: Activated by the thermostat to supply power to the contactor.
- Defrost Control: Provides time/temperature initiation and termination of the defrost cycle. Shifts reversing valve to "cooling" mode, stops outdoor fan, and activates supplemental heat during defrost.
- Outdoor Thermostat: Optional controls used to prevent full electric heater operation at specific outdoor ambient temperatures.
- Reversing Valve Coil: Activated by the thermostat in cooling mode and during defrost to position the reversing valve for cooling operation.
- Indoor Blower Motor: Activated by the thermostat in cooling/heating or FAN ON positions.
- Blower Interlock Relay: Energizes the blower during electric heat operation when the room thermostat does not.
Explanation and Guidance (Heat Pump)
A heat pump operates like an air conditioner in cooling mode. In heating mode, the refrigerant flow is redirected by a reversing valve. The compressor's hot discharge vapor goes to the indoor coil (acting as a condenser), transferring heat to the indoor air. The refrigerant then flows to the outdoor coil (acting as an evaporator), where it absorbs heat from the outdoor air before returning to the compressor.
The reversing valve's solenoid coil, when energized, shifts the valve's piston, changing the refrigerant flow path. Heat pumps are equipped with expansion devices (flowrator distributors) and check valves for both indoor and outdoor coils, as well as a defrost control system. The outdoor coil acts as an evaporator in heating mode, requiring its temperature to be below the outdoor air temperature to extract heat. Supplementary heat is recommended in areas where temperatures drop below 45°F, and to handle heating needs during component failure.
Frost can form on the outdoor coil in heating mode under certain temperature and humidity conditions. To melt this frost, the unit reverses to the cooling cycle, stopping the outdoor fan to hasten temperature rise. The indoor blower continues to run, and supplemental heaters are activated.
Defrost Control
The defrost control circuit board is managed by a temperature sensor clamped to a feeder tube entering the outdoor coil. Defrost timing periods (30, 60, 90 minutes) can be selected. The timing period begins when the sensor closes (approx. 31°F) and the thermostat calls for heat. The defrost cycle initiates if the sensor remains closed at the end of the timing period. The defrost cycle terminates when the sensor opens (approx. 75°F). A 10-minute override interrupts the defrost period if the sensor temperature does not terminate it.
Suggested Field Testing/Troubleshooting
- Run the unit in heating mode.
- Check for proper refrigerant charge (frost bands on the condenser coil indicate low charge).
- Disconnect the outdoor fan motor lead from "DF2" on the defrost control.
- Restart the unit and allow frost to accumulate.
- Verify the defrost thermostat closes (check for 24V between "DFT" and "C"). If the temperature is below 28°F and the thermostat is open, it is defective.
- When the defrost thermostat closes, short the test pins on the defrost board until the reversing valve shifts (up to 21 seconds). Remove the short immediately after initiation.
- After the defrost thermostat terminates, check for 0V between "DFT" and "C" (sensor should be open).
- Reconnect the outdoor fan motor lead to "DF2" and restore power.
Air Flow Measurement and Adjustment
Blower curves are based on external static pressure (ESP). Ensure ESP is maintained to deliver proper airflow. A general rule of thumb is 400 CFM per ton of cooling capacity, but this can vary based on load requirements. Verify ESP and CFM against blower curves in the specification sheets. Units have three-speed blower motors. Never run CFM below 350 CFM per ton to avoid evaporator freezing or poor performance.
Adjusting Speed Tap for Indoor Blower Motor
PSC Motor: Adjust CFM by changing the speed tap connection at the EBTDR "com" to "M1" or "M2" (Black-High, Blue-Medium, Red-Low).
X-13 Motor: Blower speed is controlled by three 24V low voltage leads (green for fan-only, yellow for cooling/heat pump heating, white for electric heat). Adjust speed by moving yellow and/or white wires to higher speed taps (T4, T5). The motor uses the highest speed setting if multiple leads are energized.
Refer to the Specification Sheet for GPC/GPH model series for CFM vs ESP tables.
Checking Charge
The unit is factory charged for 400 CFM per ton at minimum ESP. Adjust charge if air quantity or ESP differs. All package units are charged using the superheat method at the compressor suction line. For warmer months, aim for 10°F superheat at the compressor suction line under specific indoor and outdoor conditions (95°F outdoor ambient, 80°F DB / 67°F WB indoor ambient). Use a superheat charge chart for other conditions. Checking sub-cooling at the condenser coil liquid line out is also recommended (10-15°F is adequate).
| Suction Pressure (PSIG) | Saturated Suction Temperature (°F) |
|---|---|
| 50 | 26 |
| 53 | 28 |
| 55 | 30 |
| 58 | 32 |
| 61 | 34 |
| 63 | 36 |
| 66 | 38 |
| 69 | 40 |
| 72 | 42 |
| 75 | 44 |
| 78 | 46 |
| 81 | 48 |
| 84 | 50 |
| 87 | 52 |
| OUTDOOR TEMP. °F | INDOOR TEMP. °F | LIQUID PRESSURE PSIG | SUCTION PRESSURE PSIG | |
|---|---|---|---|---|
| DB | WB | |||
| 115 | 75 | 63 | 301 - 332 | 73 - 83 |
| 67 | 306 - 335 | 77 - 78 | ||
| 71 | 311 - 342 | 82 - 92 | ||
| 105 | 75 | 63 | 268 - 299 | 72 - 82 |
| 67 | 273 - 304 | 77 - 87 | ||
| 71 | 278 - 309 | 80 - 90 | ||
| 95 | 75 | 63 | 233 - 264 | 67 - 77 |
| 67 | 238 - 269 | 72 - 82 | ||
| 71 | 243 - 274 | 77 - 87 | ||
| 85 | 75 | 63 | 198 - 229 | 62 - 72 |
| 67 | 203 - 234 | 67 - 77 | ||
| 71 | 208 - 239 | 71 - 81 | ||
| 75 | 75 | 63 | 172 - 203 | 57 - 67 |
| 67 | 175 - 206 | 61 - 71 | ||
| 71 | 180 - 211 | 66 - 76 | ||
| 65 | 75 | 63 | 144 - 175 | 52 - 62 |
| 67 | 149 - 180 | 56 - 66 | ||
| 71 | 155 - 186 | 60 - 70 | ||
| Ambient Condenser Inlet Temp (°F Drybulb) | Return Air Temp. (°F Drybulb) | ||||
|---|---|---|---|---|---|
| 65 | 70 | 75 | 80 | 85 | |
| 100 | - | - | - | 10 | 10 |
| 95 | - | - | 10 | 10 | 10 |
| 90 | - | - | 12 | 15 | 18 |
| 85 | - | 10 | 13 | 17 | 20 |
| 80 | - | 10 | 15 | 21 | 26 |
| 75 | 10 | 13 | 17 | 25 | 29 |
| 70 | 10 | 17 | 20 | 28 | 32 |
| 65 | 13 | 19 | 26 | 32 | 35 |
| 60 | 17 | 25 | 30 | 33 | 37 |
Superheat Calculation: SUPERHEAT = SUCTION LINE TEMP - SAT. SUCTION TEMP.
Electric Heat Installation & Adjustment
This series of equipment is designed to accept a field-installed electric heat kit (HKR Series). Follow the instructions included with the kit for installation. Permanently mark the unit's nameplate with the installed model number. Adjust indoor blower motor speed taps as needed for continuous operation to prevent nuisance trips, referring to the table below.
| Unit Model Number | Electric Heat KW | 5 | 8 | 10 | 15 | 20 |
|---|---|---|---|---|---|---|
| GPC/GPH1324H21A | M(F) | M(F) | M(F) | H | na | |
| GPC/GPH1330H21A | L(F) | L(F) | L(F) | M | na | |
| GPC/GPH1336H21A | M(F) | M(F) | M(F) | H | na | |
| GPC/GPH1342H21A | L(F) | L(F) | M | M | H | |
| GPC/GPH1348H21A | M(F) | M(F) | M(F) | M(F) | H | |
| GPC/GPH1360H21A | 2(F) | 2(F) | 2(F) | 2(F) | 2(F) |
Speed Taps Description: H/3 - High; M/2 - Medium; L/1 - Low (PSC: 3/2/1 - X-13)
Maintenance
WARNING: HIGH VOLTAGE! Disconnect all power before installing or servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
Proper installation ensures years of reliable operation. Homeowners should inspect the unit before seasonal start-up: ensure coils are free of debris, registers are unobstructed, and filters are clean or replaced. Refer to the Troubleshooting Chart for issue identification.
Service
The following information is for qualified service agencies only.
Common Causes of Unsatisfactory Operation of Heat Pump on the Heating Cycle
- Inadequate Air Volume Through Indoor Coil: Ensure the return air filter is clean and sufficient airflow passes through the indoor coil to prevent high discharge pressure.
- Outside Air Into Return Duct: Do not introduce cold outside air into the return duct. Maintain indoor coil air temperature above 65°F to prevent low discharge pressure, low suction pressure, excessive defrost cycling, and low heating output.
- Undercharge: An undercharged system on heating will result in low discharge and suction pressures and frost accumulation on the outdoor coil.
- Poor "Terminating" Sensor Contact: Ensure the defrost terminating sensor makes good thermal contact with the outdoor coil tubing to prevent premature high discharge pressure cutouts.
- Malfunctioning Reversing Valve: This can be due to the solenoid not being energized, no voltage at the solenoid, or the valve not shifting. Check for magnetic hold on the solenoid nut, unit voltage, and potential obstructions or damage to the valve body.
Troubleshooting Chart
WARNING: DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. FAILURE TO FOLLOW THIS WARNING MAY RESULT IN PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK.
| SYMPTOM | POSSIBLE CAUSE | REMEDY |
|---|---|---|
| High head - low suction | a. Restriction in liquid line or flowrator | a. Remove or replace with proper size flowrator. |
| High head - high or normal suction | a. Dirty condenser coil b. Overcharged c. Condenser fan not running |
a. Clean coil b. Correct System charge c. Repair or Replace |
| Low head - high suction | a. Incorrect flowrator b. Defective compressor valves c. Flowrator not seating properly |
a. Replace with correct flowrator b. Replace compressor c. Check for debris under flowrator or deformed flowrator. Remove debris or replace flowrator. |
| Unit will not run | a. Power off or loose electrical connection b. Thermostat out of calibration set too high c. Defective contactor d. Blown fuses or tripped breaker e. Transformer defective f. High or low pressure control open (Optional) g. Compressor overload contacts open |
a. Check for unit voltage at contactor in unit b. Reset c. Check for 24 volts at contactor coil; replace if contacts are open d. Replace fuse or reset breaker. Check wiring; replace transformer. f. Reset high pressure control or check unit charge. High pressure control opens at 425 psig; Low pressure control opens at 25 psig. g. Replace compressor. NOTE: Wait at least 2 hours for overload to reset. |
| Condenser fan runs, compressor doesn't | a. Loose connection b. Compressor stuck, grounded or open winding; open internal overload c. Low voltage connection d. Capacitor weak, open, or shorted |
a. Check for unit voltage at compressor; check & tighten all connections. b. Wait at least 2 hours for overload to reset. If still open, replace the compressor. c. At compressor terminals, voltage must be within 10% of nameplate volts when unit is operating. d. Check capacitor. If defective, replace. |
| Low suction - cool compressor Iced evaporator coil | a. Low indoor airflow | a. Increase speed of blower or reduce restriction; replace air filters. |
| Compressor short cycles | a. Defective overload protector b. Unit cycling on low pressure control |
a. Replace; check for correct voltage. b. Check refrigerant charge and/or airflow. |
| Registers sweat | a. Low airflow | a. Increase speed of blower or reduce restriction; replace air filters. |
| High suction pressure | a. Excessive load b. Defective compressor c. Reversing valve not seating properly. |
a. Recheck load calculation. b. Replace. c. Replace. |
| Insufficient cooling | a. Improperly sized unit b. Improper airflow c. Incorrect refrigerant charge. d. Incorrect voltage |
a. Recalculate load. b. Check - should be approximately 400 CFM per ton. c. Charge per procedure attached to unit service panel. d. At compressor terminals, voltage must be within 10% of nameplate volts when unit is operating. |
| Evaporator coil freezing or frosting | a. Low airflow b. Low refrigerant charge c. Operating unit in cooling mode below 65°F outdoor temperature |
a. Check - should be approximately 400 CFM per ton, dirty air filters, all duct outlets open. b. Properly charge unit. c. Install or check low ambient control, should be open below 65°F outdoor temperature. |
NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE.
Quality Makes the Difference!
Goodman systems are designed and manufactured with high quality standards. They are engineered to reduce common causes of product failure, are simple to service, and forgiving to operate. Every unit is run-tested before leaving the factory.
Visit the Goodman website at www.goodmanmfg.com for information on Goodman Products, Parts, Warranties, Contractor Programs and Training, Customer Services, and Financing Options.
