INSTALLATION & OPERATING
INSTRUCTIONS FOR
SELF CONTAINED PACKAGE
AIR CONDITIONERS AND
HEAT PUMPS
GPC/GPH SERIES
All information contained herein is subject to change without notice.
IO-313
Goodman Manufacturing Company, L.P.
2550 North Loop West, Suite 400, Houston, TX 77092
www.goodmanmfg.com
www.amana-hac.com
© 2005-2006 Goodman Manufacturing Company, L.P.
06/06
INDEX
ADJUSTING SPEED TAP FOR INDOOR
BLOWER MOTOR ...................................................... 10
INTRODUCTION ........................................................... 2
CHECKING CHARGE .................................................. 10
Checking Product Received ......................................... 2
Message to the Homeowner ........................................ 2
Before Beginning Installation ...................................... 2
ELECTRIC HEAT INSTALLATION & ADJUSTMENT... 11
MAINTENANCE .......................................................... 11
Recognize Safety Symbols, Words, and Labels ....... 3
Service ........................................................................... 11
Inadequate Air Volume Through Indoor Coil .......... 11
Outside Air Into Return Duct ...................................... 11
Undercharge ................................................................. 11
Poor “Terminating” Sensor Contact ......................... 11
Malfunctioning Reversing Valve................................ 11
CODES AND REGULATIONS ....................................... 3
TROUBLESHOOTING CHART ................................... 12
General ............................................................................ 3
EPA Regulations ............................................................. 3
National Codes ............................................................... 3
INTRODUCTION
REPLACEMENT PARTS ............................................... 2
Ordering Parts ................................................................ 2
SERVICE PARTS DEPARTMENT ................................... 2
MPORTANT SAFETY INSTRUCTIONS ........................ 3
Start-Up Procedure and Checklist ............................... 6
Heat Pump Start-Up Procedure ................................... 7
Final System Checks ..................................................... 7
Checking Product Received
Upon receiving the unit, inspect it for damage from shipment.
Claims for damage, either shipping or concealed, should
be filed immediately with the shipping company. Check the
unit model number, specifications, electrical characteristics
and accessories to determine if they are correct. In the
event an incorrect unit is shipped, it must be returned to
the supplier and must NOT be installed. The manufacturer
assumes no responsibility for installation of incorrectly
shipped units.
Message to the Homeowner
These instructions are addressed primarily to the installer;
however, useful maintenance information is included and
should be kept, after installation, for future reference.
Before Beginning Installation
Carefully read all instructions for the installation prior to
installing unit. Make sure each step or procedure is
understood and any special considerations are taken into
account before starting installation. Assemble all tools,
hardware and supplies needed to complete the installation.
Some items may need to be purchased locally. After
deciding where to install unit, closely look the location over
- both the inside and outside of home. Note any potential
obstacles or problems that might be encountered as noted
in this manual. Choose a more suitable location if
necessary.
COMPONENTS ............................................................ 7
REPLACEMENT PARTS
Contactor .........................................................................
Crankcase Heater ..........................................................
Condenser Motor ............................................................
Contactor Relay ..............................................................
Defrost Control ................................................................
Outdoor Thermostat ......................................................
Reversing Valve Coil .....................................................
Indoor Blower Motor .....................................................
Blower Interlock Relay .................................................
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:
SERVICE PARTS DEPARTMENT
GOODMAN MANUFACTURING COMPANY, L.P.
2550 NORTH LOOP WEST, SUITE 400
HOUSTON, TEXAS 77092
(713) 861 – 2500
MAJOR COMPONENTS ............................................... 3
General ............................................................................ 3
INSTALLATION ............................................................ 3
Pre-Installation Checkpoints ........................................ 3
Clearance ........................................................................ 3
Location ........................................................................... 4
Outside Slab Installation (Figure 1) ............................ 4
Rooftop Installation (Figure 2) ..................................... 4
DUCTING ...................................................................... 4
Connecting the Return and Supply Flexible Duct .... 4
Plenum Application ....................................................... 5
Filters ............................................................................... 5
PIPING ......................................................................... 5
Condensate Drain .......................................................... 5
WIRING ........................................................................ 5
High Voltage Wiring ...................................................... 6
Low Voltage Wiring ....................................................... 6
Internal Wiring ............................................................... 6
OPERATION ................................................................. 6
7
7
7
7
7
7
7
8
8
EXPLANATION AND GUIDANCE (HEAT PUMP) .......... 8
HEAT PUMP REFRIGERANT CIRCUIT ......................... 8
DEFROST CONTROL ................................................... 9
AIR FLOW MEASUREMENT AND ADJUSTMENT ....... 9
2
IMPORTANT SAFETY INSTRUCTIONS
phase units in this series are not covered under the DOE
certified program. The efficiency ratings of these units are a
product of thermal efficiency determined under continuous
operating conditions independent of any installed system.
Recognize Safety Symbols, Words, and Labels
The following symbols and labels are used throughout this
manual to indicate immediate or potential hazards. It is the
owner’s responsibility to read and comply with all safety
information and instructions accompanying these symbols.
Failure to heed safety information increases the risk of
serious personal injury or death, property damage and/or
product damage.
EPA Regulations
IMPORTANT: THE UNITED STATES ENVIRONMENTAL
PROTECTION AGENCY (EPA) HAS ISSUED VARIOUS
REGULATIONS REGARDING THE INTRODUCTION AND
DISPOSAL OF REFRIGERANTS IN THIS UNIT. FAILURE TO
FOLLOW THESE REGULATIONS MAY HARM THE
ENVIRONMENT AND CAN LEAD TO THE IMPOSITION OF
SUBSTANTIAL FINES. BECAUSE REGULATIONS MAY VARY
DUE TO PASSAGE OF NEW LAWS, WE SUGGEST A
CERTIFIED TECHNICIAN PERFORM ANY WORK DONE ON
THIS UNIT. SHOULD YOU HAVE ANY QUESTIONS PLEASE
CONTACT THE LOCAL OFFICE OF THE EPA.
WARNING
HAZARDS OR UNSAFE PRACTICES COULD RESULT IN
PROPERTY DAMAGE, PRODUCT DAMAGE, SEVERE
PERSONAL INJURY OR DEATH.
WARNING
National Codes
This product is designed and manufactured to permit
installation in accordance with National Codes. It is the
installer’s responsibility to install the product in accordance
with National Codes and/or prevailing local codes and
regulations.
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.
MAJOR COMPONENTS
General
The unit includes a hermetically sealed refrigerating system
(consisting of a compressor, condenser coil, evaporator coil
with flowrator), an indoor blower, a condenser fan and all
necessary internal electrical wiring. The heat pump also
includes a reversing valve, solenoid, defrost thermostat and
control and loss of charge protection. The system is factoryevacuated, charged and performance tested. Refrigerant
amount and type are indicated on rating plate.
WARNING
THIS UNIT SHOULD NOT BE CONNECTED TO, OR USED
IN CONJUNCTION WITH, ANY DEVICES THAT ARE NOT
DESIGN CERTIFIED FOR USE WITH THIS UNIT OR HAVE
NOT BEEN TESTED AND APPROVED BY GOODMAN.
SERIOUS PROPERTY DAMAGE OR PERSONAL INJURY,
REDUCED UNIT PERFORMANCE AND/OR HAZARDOUS
CONDITIONS MAY RESULT FROM THE USE OF DEVICES
THAT HAVE NOT BEEN APPROVED OR CERTIFIED BY
GOODMAN.
INSTALLATION
Pre-Installation Checkpoints
Before attempting any installation, the following points should
be considered:
• Structural strength of supporting members
• Clearances and provision for servicing
• Power supply and wiring
• Air duct connections
• Drain facilities and connections
• Location may be on any four sides of a home,
manufactured or modular, to minimize noise
Clearance
The unit is designed to be located outside the building with
unobstructed condenser air inlet and discharge. Additionally,
the unit must be situated to permit access for service and
installation. Condenser air enters from three sides. Air
discharges upward from the top of the unit. Refrigerant gauge
connections are made on the right side of the unit as you
face the compressor compartment. Electrical connections
can be made either on the right or left sides of the unit. The
best and most common application is for the unit to be located
10” from wall (4” minimum) with the connection side facing
the wall. This “close to the wall” application minimizes
exposed wiring.
Close to the wall application assures free, unobstructed air
to the other two sides. In more confined application spaces,
such as corners provide a minimum 10” clearance on all air
inlet sides. Allow 18” minimum for service access to the
WARNING
DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT
DUCT WORK TO ANY OTHER HEAT PRODUCING DEVICE
SUCH AS FIREPLACE INSERT, STOVE, ETC. UNAUTHORIZED USE OF SUCH DEVICES MAY RESLUT IN PROPERTY DAMAGE, FIRE, CARBON MONOXIDE POISONING,
EXPLOSION, PERSONAL INJURY OR DEATH.
CODES AND REGULATIONS
General
The GPC & GPH series air conditioners and heat pumps
are designed for OUTDOOR USE ONLY. This series is available in cooling Capacities of 2, 2 ½, 3, 3 ½, 4 and 5 nominal
tons of cooling. Optional field installed heat kits are available in 5,8,10,15 and 20 KW. The units can be easily installed in manufactured or modular homes with existing highstatic duct work. The units can also be easily converted to
accommodate a plenum for normal or low-static applications. The GPC & GPH series are self contained packaged
units so the only connections needed for installation are the
supply and return ducts, the line and low voltage wiring and
drain connection. The units are ETL listed and ARI certified.
The information on the rating plate is in compliance with
the FTC & DOE rating for single phase units. The three
3
Rooftop Installation (Figure 2)
compressor compartment and controls. The top of the unit
should be completely unobstructed. If units are to be located
under an overhang, there should be a minimum of 36”
clearance and provisions made to deflect the warm discharge
air out from the overhang.
Location
Consider the affect of outdoor fan noise on conditioned space
and any adjacent occupied space. It is recommended that
the unit be placed so that condenser air discharge does
not blow toward windows less than 25 feet away.
The unit should be set on a solid, level foundation - preferably
a concrete slab at least 4 inches thick. The slab should be
above ground level and surrounded by a graveled area for
good drainage. Any slab used as a unit’s foundation should
not adjoin the building as it is possible that sound and
vibration may be transmitted to the structure. For rooftop
installation, steel or treated wood beams should be used
as unit support for load distribution.
Heat pumps require special location consideration in areas
of heavy snow accumulation and/or areas with prolonged
continuous subfreezing temperatures. Heat pump unit bases
have holes under the outdoor coil to permit drainage of defrost
water accumulation. The unit must be situated to permit
free unobstructed drainage of the defrost water and ice. A
minimum 2" clearance under the outdoor coil is required in
the milder climates.
Outside Slab Installation (Figure 1)
1.
2.
3.
Before locating the unit on the roof, make sure that the
strength of the roof and beams is adequate to support the
weight involved. (See specification sheet for weight of
units.) This is very important and the installer’s
responsibility.
Make proper consideration for the weather–tight integrity
of the roof and proper drainage of condensate.
Consideration should also be given to shade, appearance
and noise.
36"
FIGURE 2
UN
IT
PL
EN
UM
24"
PL
AT
FO
RM
RB
CU
36"
1. The unit must be mounted on a solid, level foundation.
2. Select a location that will minimize the length of the supply
and return ducts.
3. Select a location where external water drainage cannot collect
around the unit.
4. Consideration should also be given to shade, appearance
and noise.
DUCTING
WARNING
DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT
RETURN DUCTWORK TO ANY OTHER HEAT PRODUCING
DEVICES SUCH AS FIREPLACE INSERT, STOVE, ETC. UNAUTHORIZED USE OF SUCH DEVICES MAY RESULT IN
PROPERTY DAMAGE, FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY OR DEATH.
FIGURE 1
10"
36"
WALL
Ducting work should be fabricated by the installing
contractor in accordance with local codes. Industry manuals
may be used as a guide when sizing and designing the
duct system- such as NESCA (National Environmental
Systems Contractors Association, 1501 Wilson Blvd.,
Arlington, Virginia 22209).
The unit should be placed as close as possible to the space
to be air-conditioned allowing clearance dimensions as
indicated. Ducts should run as directly as possible to supply
and return outlets. Use of non-flammable weatherproof
flexible connectors on both supply and return connections
at the unit to reduce noise transmission is recommended.
It is preferable to install the unit on the roof of the structure
if the registers or diffusers are located in the wall or ceiling.
A slab installation is recommended when the registers are
low on the wall or in the floor.
UNIT
36"
36"
4
Connecting the Return and Supply Flexible Duct in
Manufactured or Modular Housing Application
The return and supply fittings are to be attached at the unit
to a suitable square to round duct converter. Your distributor
has a factory designed square to round converter transition.
The model #’s of these kits are as follows: Small Chassis
25” SQRPCH101, Medium Chassis 27.5” SQRPCH102,
Large and Extra Large Chassis 32.5:” and 36” SQRPCH103
(See Specification Sheets for Dimension details). The
SQRPCH101 has 14" duct collar on supply and 16" duct
collar (equivalent diameter, opening is oval) on the return.
The SQRPCH102 and SQRPCH103 have 14" duct collar on
supply and 18" duct collar (equivalent diameter, opening is
oval) on the return. The collars are to be slipped into the
openings, and the flanges bent around the converter. The
square to round converter is attached to the flanges of the
square duct openings. The flexible duct is then clamped
on to the collars. Once the duct is affixed to the unit, seal
the collars and flanges with a proper waterproof sealant
(See Figure 3).
It is strongly encouraged to use appropriately sized ducts
based upon the CFM for your application (unit’s CFM). If
duct sizing through industry manuals or air duct calculators
require larger ducts than converter openings, run larger duct
size up to unit converter openings and reduce with a reducer
duct fitting or transition right at the unit.
M INIM U M FILTER SIZE
NOMINAL SIZE (INCHES)
NO MINAL AREA
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
A suitable plenum or square duct must be constructed. The
duct cross-sectional area should be determined by industry
duct sizing manuals or air duct calculators.
On ductwork exposed to outside air conditions of
temperature and humidity, use an insulation with a good K
factor, and a vapor barrier. Industry practices should be
followed. Balancing dampers are recommended for each
branch duct in the supply system. Ductwork should be
properly supported from the unit.
NOTE: Proper sealing of all duct work and air handling
compartments is extremely important to overall unit
efficiency.
Filters
Filters are not provided with unit, and must be supplied and
installed in the return duct system by the installer. A field
installed filter grille is recommended for easy and convenient
access to the filters for periodic inspection and cleaning.
Filters must have adequate face area for the rated quantity
of the unit. See air delivery tables (Figure 4) for
recommended filter size.
PIPING
Condensate Drain
The condensate drain connection of the evaporator is a half
coupling of ¾” N.P.T. A trap must be provided to have Proper
condensate drainage.
(SQ . FT.)
2" Minimum
Unit
Drain
Connection
Flexible
Tubing-Hose
Or Pipe
3" Minimum
A Positive Liquid Seal
Is Required
FIGURE 5
Install condensate drain trap as shown. Use ¾ “ drain
connection size or larger. Do not operate without trap. Unit
must be level or slightly inclined toward drain.
TABLE 1
SQUARE TO ROUND
DUCT CONVERTER PANEL
WIRING
OUTER FLANGE
All wiring should be made in accordance with the
National Electrical Code. The local Power Company
should be consulted to determine the availability of sufficient
power to operate the unit. The voltage, frequency, and phase
at the power supply should be checked to make sure it
corresponds to the unit’s RATED VOLTAGE
REQUIREMENT.
Install a branch circuit fused disconnect near the unit, in
accordance with the N.E.C. or local codes. Wire sizes and
overcurrent protection should be determined from the unit
nameplate ampacity and in accordance with Table 4 (page
6) or the N.E.C. Under no circumstances should wiring be
sized smaller than is recommended by either of these two
sources.
Fuses smaller than that recommended on the wiring diagrams
could result in unnecessary fuse failure or service calls.
The use of protective devices of larger size than indicated
could result in extensive damage to the equipment. The
manufacturer bears no responsibility for damage caused to
equipment as result of the use of larger than is recommended
size protective devices.
BEAD
STARTER FLANGE
FIGURE 3
Nominal Filter Area
Square Feet
7
6
5
4
DIS
P
F
LE
AB
OS
1000
R
EN T
MAN
PER
3
2
500
E
ILT
1500
2000
E
FIL T
2500
R
3000
3500
Airflow - SCFM
FIGURE 4
5
b.
All units have undergone a run test prior to packaging for
shipment. This equipment has been started at minimum
rated voltage and checked for satisfactory operation. Do
not attempt to operate this unit if the voltage is not within
the minimum and maximum voltages shown on nameplate.
All exterior wiring must be within approved weatherproof
conduit. The unit must be permanently grounded in
accordance with local codes, or in absence of local codes,
with N.E.C ANSI/ NFPA NO. 70-1984 or latest edition by
using ground lug in the control box.
Fuses or HACR type circuit breakers may be used where
codes permit.
Heat Pumps- Connect 24V wires from the thermostat to
the corresponding wires in the control box using No.
18AWG as follows:
TERMINAL
Red
Green
Orange
W hite
Brown
Yellow
C (Blue)
THERMOSTAT
R (24V)
G (Fan)
O (Rev. Valve)
W 1 (Heat, 2nd)*
W 2 (Heat 3rd)*
Y (Cool)
C (Common)
*Optional field installed heat connections
FOR INTERNAL WIRING SEE WIRING LABEL ATTACHED TO UNIT
T1
Internal Wiring:
A diagram detailing the internal wiring of this unit is located
on the electrical box cover. If any of the original wire supplied
with the appliance must be replaced, the wire gauge and
insulation must be the same as the original wiring.
Transformer is wired for 230 volts on the 208/230 models.
See wiring diagram for 208 volt wiring.
Y G R W
L2
R
W
Y
G
THERMOSTAT
SUBBASE
HIGH VOLTAGE POWER WIRING
24 VOLT CONTROL WIRING
HEAT
HIGH VOLTAGE
DISCONNECT
SWITCH
FAN
L3
COMMON
T3
L1
CONTACTOR
COOL
T2
TABLE 3
LOW VOLTAGE CONNECTORS
BRANCH CIRCUIT AMPACITY 15 20 25 30 35 40 45 50
SUPPLY WIRE LENGTH FEET
200
6
4
4
4
3
3
2
2
L3 CONNECTION - 3 PHASE ONLY
FIGURE 6
Note: Some single phase units are equipped with a single
pole contactor. Caution must be exercised when servicing
as only one leg of the power supply is broken with the
contractor.
To wire the unit, make the following high and low voltage
connections.
High Voltage Wiring: (See Figure 6)
Single Phase- Two leads should be connected to terminals
L1 & L2 in the electrical control section, using wire sizes
specified in wiring table.
Three Phase- Three leads should be connected to
terminals L1, L2 and L3 in the electrical section, using
wire sizes specified in wiring table.
4
4
4
3
3
8
6
6
6
4
4
14 12 10 10
8
8
6
6
For branch circuit wiring (main power supply to unit
disconnect), the minimum wire size for the length of the
run can be determined from Table 4 using the circuit
ampacity found on the unit rating plate. From the unit
disconnect to unit, the smallest wire size allowable in Table
4 may be used for the ampacity, as the Disconnect must
be in sight of the unit.
2.
Wire size based on 60° C rated wire insulation and 30° C
Ambient Temperature (86° F).
3.
For more than 3 conductors in a raceway or cable, see the
N.E.C. for derating the ampacity of each conductor.
OPERATION
Start-Up Procedure and Checklist
Begin with power turned off at all disconnects.
WARNING
Air Conditioners- Connect 24V wires from the thermostat
to the corresponding wires in the control box using No.
18AWG as follows:
LEAD
Red
Green
Yellow
W hite
Brown
6
8
1.
Low Voltage Wiring: (See Figure 6)
a.
6
10
TABLE 4
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.
b.
8
100
50
WARNING
a.
150
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.
THERMOSTAT
R (24V)
G (Fan)
Y (Cool)
W 1 (Heat)*
W 2 (Heat)*
TABLE 2
6
1.
Turn thermostat system switch to “Cool,” and fan switch to
“Auto” and turn temperature setting as high as it will go.
2.
Inspect all registers and set them to the normal open
position.
3.
Turn on the electrical supply at the disconnect.
4.
Turn the fan switch to the “ON” position. The blower should
operate after a 7 second delay.
5.
Turn the fan switch to “Auto” position. The blower should
stop after a 65 second delay.
6.
Slowly lower the cooling temperature until the unit starts.
The compressor, blower and fan should now be operating.
Allow the unit to run 10 minutes, make sure cool air is
being supplied by the unit.
7.
8.
15. If checking the unit in the wintertime, when the outdoor coil
is cold enough to actuate the defrost control, observe at
least one defrost cycle to make sure the unit defrosts
completely.
Final System Checks
16. Check to see if all supply and return air grilles are adjusted
and the air distribution system is balanced for the best
compromise between heating and cooling.
Turn the temperature setting to the highest position,
stopping the unit. The indoor blower will continue to run for
65 seconds.
17. Check for air leaks in the ductwork.
Turn the thermostat system switch to “OFF” and disconnect
all power when servicing the unit.
19. Make sure the unit is free of “rattles”, and the tubing in the
unit is free from excessive vibration. Also make sure tubes
or lines are not rubbing against each other or sheet metal
surfaces or edges. If so, correct the trouble.
18. See Sections on Air Flow Measurement and Adjustment
and Checking Charge.
WARNING
20. Set the thermostat at the appropriate setting for cooling
and heating or automatic changeover for normal use.
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.
21. Be sure the Owner is instructed on the unit operation, filter,
servicing, correct thermostat operation, etc.
The foregoing “Start-up Procedure and Check List” is
recommended to serve as an indication that the unit will
operate normally.
Heat Pump Start-Up Procedure
9.
Check the cooling mode for the heat pump in the same
manner as above. The reversing valve is energized when
the thermostat is placed in the cooling position. A clicking
sound should be noticeable from the reversing valve. By
lowering the temperature setting to call for cooling, the
contractor is energized. The compressor, blower and fan
should then be running. After the cooling mode is checked
out, turn the thermostat system switch to “OFF”.
COMPONENTS
1.
Contactor - This control is activated (closed) by the room
thermostat for both heating and cooling. The contactor has
a 24V coil and supplies power to the compressor and
outdoor fan motor.
2.
Crankcase Heater – This item is “ON” whenever power is
supplied to the unit. It warms the compressor crankcase
thereby preventing liquid migration and subsequent
compressor damage. The insert type heater is self
regulating. It is connected electrically to the contactor L1
and L2 terminals.
3.
Condenser Motor - This item is activated by the contactor
during heating and cooling, except during defrost and
emergency heat operation.
4.
Compressor - This item is activated by the contactor for
heating and cooling, except during emergency heat. It is
protected by an internal overload.
5.
Contactor Relay - This control is activated by the thermostat
(24V coil) and supplies power to the contactor.
6.
Defrost Control - The Defrost control provides time/
temperature initiation and termination of the defrost cycle.
When a Defrost cycle is initiated, the defrost control shifts
the reversing valve to “cooling” mode, stops the outdoor
fan and brings on supplemental heat. Normally, a Defrost
cycle will take only 2-3 minutes unless system is low on
charge or outdoor conditions are severe. (Windy and cold)
7.
Outdoor Thermostat - These optional controls are used
to prevent full electric heater operation at varying outdoor
ambient (0° F-to 45° F). They are normally open above
their set points and closed below to permit staging of
indoor supplement heater operation. If the outdoor ambient
temperature is below 0° F (-18° C) with 50% or higher RH,
an outdoor thermostat (OT) must be installed and set at
(0°) on the dial. Failure to comply with this requirement
may result in damage to the product which may not be
covered by the manufacturer’s warranty.
8.
Reversing Valve Coil - This coil is activated by the
thermostat, in the cooling mode and during defrost. It
positions the reversing valve pilot valve for cooling
operation.
10. Turn the thermostat system switch to “HEAT” and fan switch
to “AUTO”.
11. Slowly raise the heating temperature setting. When the
heating first stage makes contact, stop raising the
temperature setting.. The compressor, blower and fan
should now be running with the reversing valve in the deenergized (heating) position. After giving the unit time to
settle out, make sure the unit is supplying heated air.
12. If the out door ambient is above 80°F, the unit may trip on
its high pressure cut out when on heating. The compressor
should stop. The heating cycle must be thoroughly
checked, so postpone the test to another day when
conditions are more suitable but-DO NOT FAIL TO TEST.
If the out door ambient is low and the unit operates properly
on the heating cycle, you may check the pressure cutout
operation by blocking off the indoor return air until the unit
trips.
13. If unit operates properly in the heating cycle, raise the
temperature setting until the heating second stage makes
contact. Supplemental resistance heat, if installed should
now come on. Make sure it operates properly.
NOTE: If outdoor thermostats are installed the outdoor
ambient must be below the set point of these
thermostats for the heaters to operate. It may be
necessary to jumper these thermostats to check heater
operation if outdoor ambient is mild.
14. For thermostats with emergency heat switch, return to step
11. The emergency heat switch is located at the bottom of
the thermostat. Move the switch to emergency heat. The
heat pump will stop, the blower will continue to run, all
heaters will come on and the thermostat emergency heat
light will come on.
7
Indoor Blower Motor
EXPLANATION AND GUIDANCE (HEAT PUMP)
This item is activated by the room thermostat
by COOLING/HEATING or FAN ON position. The motor is
energized through the EBTDR for PSC motors.
The heat pump is a relatively simple device. It operates
exactly as a Summer Air Conditioner unit when it is on the
cooling cycle. Therefore, all the charts and data for service
that apply to summer air conditioning apply to the heat pump
when it is on the cooling cycle, and most apply on the
heating cycle except that “condenser” becomes “evaporator”,
“evaporator” becomes “condenser”, “cooling” becomes
“heating”.
When the heat pump is on the heating cycle, it is necessary
to redirect the refrigerant flow through the refrigerant circuit
external to the compressor. This is accomplished with a
reversing valve. Thus, the hot discharge vapor from the
compressor is directed to the indoor coil (evaporator on the
cooling cycle) where the heat is removed, and the vapor
condenses to liquid. It then goes through the expansion
device to the outdoor coil (condenser on the cooling cycle)
where the liquid is evaporated, and the vapor goes to the
compressor.
5-Ton “AB” Units with X-13 Motors Only
The “AB” X-13 model indoor blower motor is activated by
the room thermostat by COOLING/HEATING or FAN ON
position. The motor is energized by a 24 volt control signal
(from thermostat Y, G or W) for X-13 motors. X-13 motors
are constant torque motors with very low power
consumption.
(See Air Flow Measurement and Adjustment for speed
adjustment instructions).
10. Blower Interlock Relay - This relay is used to energize the
blower during the electric heat operation. Some room
thermostats do not energize the motor during electric heat.
This relay insures blower operation when the room
thermostat energizes heat. This relay has a 240 volt coil
and an 8 amp contact relay. This relay is energized by the
electric heat kit sequencer.
HEAT PUMP REFRIGERANT CIRCUIT
C O O LING
S E RV IC E P O R T
R E V E RS ING V A L V E
SE RV IC E V A LV E
S E RV IC E P O R T
A C C U M UL A TO R
CO M P R E SS O R
IND O O R
CO IL
EX P A N S IO N D E V IC E
CONDENSER
EVAPORATOR
DIS T R IBU TO R
S E R V IC E PO RT
CH EC K V A L V E
O R IF IC E S E RV IC E
VALVE
C H E C K V A L VE
O R IF ICE
O U TD O O R
CO IL
H EA TIN G
S E RV IC E P O R T
R E V E RS ING V A L V E
SE RV IC E V A LV E
AC CU M UL A TO R
CONDENSER
CO M PR E SS O R
IN D O O R
CO IL
DIS T RIB U TO R
D IST R IBU TO R
S E RV IC E P O R T
CH E C K V A L VE
O R IF IC E S E R V IC E
V A LV E
C H E CK V A L VE
O R IF ICE
8
EVAPORATOR
9.
O U TDO O R
C O IL
When the solenoid valve coil is operated either from heating
to cooling or vice versa, the piston in the reversing valve to
the low pressure (high pressure) reverse positions in the
reversing valve.
The following figures show a schematic of a heat pump on
the cooling cycle and the heating cycle. In addition to a
reversing valve, a heat pump is equipped with an expansion
device and check valve for the indoor coil, and similar
equipment for the outdoor coil. It is also provided with a
defrost control system.
The expansion devices are flowrator distributors and perform
the same function on the heating cycle as on the cooling
cycle. The flowrator distributors also act as check valves
to allow for the reverse of refrigerant flow.
When the heat pump is on the heating cycle, the outdoor
coil is functioning as an evaporator. The temperature of the
refrigerant in the outdoor coil must be below the temperature
of the outdoor air in order to extract heat from the air. Thus,
the greater the difference in the outdoor temperature and
the outdoor coil temperature, the greater the heating capacity
of the heat pump. This phenomenon is a characteristic of a
heat pump. It is a good practice to provide supplementary
heat for all heat pump installations in areas where the
temperature drops below 45° F. It is also a good practice to
provide sufficient supplementary heat to handle the entire
heating requirement should there be a component failure of
the heat pump, such as a compressor, or refrigerant leak,
etc.
Since the temperature of the liquid refrigerant in the outdoor
coil on the heating cycle is generally below freezing point,
frost forms on the surfaces of the outdoor coil under certain
weather conditions of temperature and relative humidity.
Therefore, it is necessary to reverse the flow of the refrigerant
to provide hot gas in the outdoor coil to melt the frost
accumulation. This is accomplished by reversing the heat
pump to the cooling cycle. At the same time, the outdoor
fan stops to hasten the temperature rise of the outdoor coil
and lessen the time required for defrosting. The indoor blower
continues to run and the supplementary heaters are
energized.
DF2
TEST
JUMPER WIRE
90
60
30
A
DF1
C
Y
W2 R
R DFT
FIGURE 7
SUGGESTED FIELD TESTING/TROUBLE SHOOTING
1. Run unit in the heating mode (room thermostat calling for
heat).
2. Check unit for proper charge. Note: Bands of frost on the
condenser coil indicate low refrigerant charge.
3. Shut off power to unit.
4. Disconnect outdoor fan by removing the purple lead from
“DF2” on defrost control.
5. Restart unit and allow frost to accumulate.
6. After a few minutes of operation, the unit’s defrost
thermostat should close. To verify this, check for 24 volts
between “DFT” and “C” on board. If the temperature at the
thermostat is less than 28° F and the thermostat is open,
replace the unit’s defrost thermostat, as it is defective.
7. When the unit’s defrost thermostat has closed, short the
test pins on the defrost board until the reversing valve shifts,
indicating defrost. This should take up to 21 seconds
depending on what timing period the control is set on.
After defrost initiation, the short must instantly be removed
or the unit’s defrost period will only last 2.3 seconds.
8. After the unit’s defrost thermostat has terminated, check
the defrost thermostat for 24 volts between “DFT” and “C”.
The reading should indicate 0 volts (open sensor).
9. Shut off power to unit.
10. Replace outdoor fan motor lead to terminal “DF2” on defrost
board and turn on power.
AIR FLOW MEASUREMENT AND ADJUSTMENT
After reviewing section on DUCTING, proceed with airflow
measurements and adjustments. Unit’s blower curves (in
Specification Sheets) are based on external static pressure
(ESP, in. of W.C.). The duct openings on the unit are
considered internal static pressure, so as long as ESP is
maintained, the unit will deliver the proper air up to the
maximum static pressure listed for the CFM required by
the application (i.e. home, building, etc.)
In general 400 CFM per ton of cooling capacity is a rule of
thumb. Some applications depending on the sensible and
latent capacity requirements may need only 350 CFM or up
to 425 CFM per ton. Check condition space load
requirements (from load calculations) and equipment
expanded ratings data to match CFM and capacity.
After unit is set and ducted, verify ESP with a 1" inclined
manometer with pitot tubes or a Magnahelic gauge and
confirm CFM to blower curves in the specification sheets.
All units have three speed blower motors. If low speed is
not utilized, the speed tap can be changed to medium or
high speed. Never run CFM below 350 CFM per ton,
evaporator freezing or poor unit performance is possible.
DEFROST CONTROL
During operation the power to the circuit board is controlled
by a temperature sensor, which is clamped to a feeder tube
entering the outdoor coil. Defrost timing periods of 30,60
and 90 minutes may be selected by connecting the circuit
board jumper to 30, 60 and 90 respectively. Accumulation
of time for the timing period selected starts when the sensor
closes (approximately 31° F), and when the wall thermostat
calls for heat. At the end of the timing period, the unit’s
defrost cycle will be initiated provided the sensor remains
closed. When the sensor opens (approximately 75° F), the
defrost cycle is terminated and the timing period is reset. If
the defrost cycle is not terminated due to the sensor
temperature, a ten minute override interrupts the unit’s
defrost period.
9
ADJUSTING SPEED TAP FOR INDOOR BLOWER
MOTOR
PSC Motor
Adjust the CFM for the unit by changing the speed tap of
the indoor blower motor at the EBTDR “com” connection
with one of the speed taps on “M1” or “M2”. (Black-High
Speed, Blue-Medium Speed, Red-Low Speed.)
X-13 Motor
The blower motor speed for the X-13 motor is controlled
by three 24V low voltage leads: green, yellow, and white.
The green lead sets the speed for fan-only mode. The
yellow lead sets the speed for cooling and heat pump
heating mode (if applicable). The white lead sets the
speed for electric heat mode (emergency heat and second
stage heat, if applicable).
The leads are factory connected as follows: Green to T1,
Yellow to T2, and White to T3. T1 is the low speed setting
and is dedicated to fan-only mode. T2 and T3 are medium
speed settings. T4 and T5 are high speed settings. To
adjust the blower speed, move the yellow and/or white
wires to T4 and T5. NOTE: If more than one lead is
energized at the same time, the motor will use the higher
speed setting.
See Specification Sheet for GPC/GPH model series for
CFM vs ESP tables.
Suction Pressure
Saturated Suction
Temperature (°F)
50
53
55
58
61
63
66
69
72
75
78
81
84
87
26
28
30
32
34
36
38
40
42
44
46
48
50
52
TABLE 5
Suction Pressure Temperature (R-22)
OUTDOOR
TEMP. °F
INDOOR
TEMP. °F
DB
115
75
105
75
95
75
85
75
75
75
65
75
CHECKING CHARGE
After completing airflow measurements and adjustments,
the unit’s refrigerant charge must be checked. The unit
comes factory charged, but this charge is based on 400
CFM per ton at minimum ESP per ARI test conditions
(generally between .15 - .25 ESP). When air quantity or
ESP is different than above, charge must be adjusted to
the proper amount. All package units are charged to the
superheat method at the compressor suction line (these
are fixed orifice devices).
For charging in the warmer months, 10ºF superheat at the
compressor is required at conditions: 95ºF outdoor ambient
(dry bulb temperature), 80ºF dry bulb / 67ºF wet bulb indoor
ambient, approximately 50% humidity. This superheat
varies when conditions vary from the conditions described.
A superheat charge chart is available for other operating
conditions. Use it to provide the correct superheat at the
conditions the unit is being charged at.
After superheat is adjusted it is recommended to check
unit sub-cooling at the condenser coil liquid line out. In
most operating conditions 10 - 15 ºF of sub-cooling is
adequate.
WB
LIQUID
PRESSURE
PSIG
SUCTION
PRESSURE
PSIG
63
67
71
63
67
71
63
67
71
63
67
71
63
67
71
63
67
71
301 - 332
306 - 335
311 - 342
268 - 299
273 - 304
278 - 309
233 - 264
238 - 269
243 - 274
198 - 229
203 - 234
208 - 239
172 - 203
175 - 206
180 - 211
144 - 175
149 - 180
155 - 186
73 - 83
77 - 78
82 - 92
72 - 82
77 - 87
80 - 90
67 - 77
72 - 82
77 - 87
62 - 72
67 - 77
71 - 81
57 - 67
61 - 71
66 - 76
52 - 62
56 - 66
60 - 70
TABLE 6
Operating Pressures
Ambient Condenser
Inlet Temp (°F
Drybulb)
65
70
75
80
85
100
95
90
85
80
75
70
65
60
10
10
13
17
10
10
13
17
19
25
10
12
13
15
17
20
26
30
10
10
15
17
21
25
28
32
33
10
10
18
20
26
29
32
35
37
Return Air Temp. (°F Drybulb)
TABLE 7
System Superheat
10
Common Causes of Unsatisfactory Operation of Heat Pump
on the Heating Cycle.
Inadequate Air Volume Through Indoor Coil
When a heat pump is in the heating cycle, the indoor coil is
functioning as a condenser. The return air filter must always
be clean, and sufficient air volume must pass through the
indoor coil to prevent excessive discharge pressure, and
high pressure cut out.
Outside Air Into Return Duct
Do not introduce cold outside air into the return duct of a
heat pump installation. Do not allow air entering the indoor
coil to drop below 65° F. Air below this temperature will
cause low discharge pressure, thus low suction pressure,
and excessive defrost cycling resulting in low heating output.
It may also cause false defrosting.
Undercharge
SUPERHEAT CAN BE DETERMINED AS FOLLOWS:
1.
Read suction pressure. Determine Saturated Suction
Temperature from tables or pressure gauge saturated
temperature scale (R-22).
2. Read suction line temperature.
3. Use the following formula:
SUPERHEAT = SUCTION LINE TEMP - SAT. SUCTION TEMP
ELECTRIC HEAT INSTALLATION & ADJUSTMENT
This series of electric cooling and heat pump package
equipment is designed to accept a field installed electric
heat kit. The unit is equipped to easily install the HKR Series
Electric Heat Kit. Full Installation Instructions are included
in this kit. Please use this document for guidance in field
equipping the package unit with electric heat.
Choose the heat kit that fits the application for the specific
installation. Permanently mark the unit’s nameplate with
the model being installed. High and low voltage connections
are detailed in the heat kit instructions.
Indoor Blower motor speed tap selection may need to be
modified to accommodate normal continuous operation to
prevent a nuisance trip. See table below.
An undercharged heat pump on the heating cycle will
cause low discharge pressure resulting in low suction
pressure and frost accumulation on the outdoor coil.
Poor “Terminating” Sensor Contact
The unit’s defrost terminating sensor must make good
thermal contact with the outdoor coil tubing. Poor contact
may not terminate the unit’s defrost cycle quickly enough
to prevent the unit from cutting out on high discharge
pressure.
Malfunctioning Reversing Valve
This may be due to:
Electric Heat KW
Unit Model Number
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)
1.
H / 3 - High; M / 2 - Medium; L / 1 - Low
2.
Speed Taps Description: H/M/L - PSC: 3/2/1 - X-13
MAINTENANCE
3.
Solenoid not energized - In order to determine if the
solenoid is energized, touch the nut that holds the solenoid
cover in place with a screwdriver. If the nut magnetically
holds the screwdriver, the solenoid is energized and the
unit is in the cooling cycle.
No voltage at unit’s solenoid - Check unit voltage. If no
voltage, check wiring circuit.
Valve will not shift:
a . Undercharged - check for leaks;
b. Valve Body Damaged - Replace valve;
c. Unit Properly Charged - If it is on the heating
cycle, raise the discharge pressure by restricting airflow
through the indoor coil. If the valve does not shift, tap it
lightly on both ends with a screwdriver handle. Do Not
Tap The Valve Body. If the unit is on the cooling cycle,
raise the discharge pressure by restricting airflow through
the outdoor coil. If the valve does not shift after the above
attempts, cut the unit off and wait until the discharge
and suction pressure equalize, and repeat above steps.
If the valve does not shift, replace it.
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.
The Self Contained Package Air Conditioner and Heat Pump
should operate for many years without excessive service
calls if the unit is installed properly. However it is
recommended that the homeowner inspect the unit before
a seasonal start up. The coils should be free of debris so
adequate airflow is achieved. The return and supply registers
should be free of any obstructions. The filters should be
cleaned or replaced. These few steps will help to keep the
product up time to a maximum. The Troubleshooting Chart
(on page 11) should help in identifying problems if the unit
does not operate properly.
SERVICE
THE FOLLOWING INFORMATION IS FOR USE BY
QUALIFIED SERVICE AGENCY ONLY: OTHERS SHOULD
NOT ATTEMPT TO SERVICE THIS EQUIPMENT.
11
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
High head - low suction
High head - high or normal suction
Low head - high suction
Unit will not run
POSSIBLE CAUSE
a.
a.
b.
c.
a.
b.
c.
Restriction in liquid line or flowrator
Dirty condenser coil
Overcharged
Condenser fan not running
Incorrect flowrator
Defective compressor valves
Flowrator not seating properly
a. Power off or loose electrical connection
REMEDY
a.
a.
b.
c.
a.
b.
c.
Remove or replace with proper size flowrator.
Clean coil
Correct System charge
Repair or Replace
Replace with correct flowrator
Replace compressor
Check for debris under flowrator or deformed
flowrator. Remove debris or replace flowrator.
a. Check for unit voltage at contactor in unit
b. Thermostat out of calibration set too high b. Reset
c. Defective contactor
c. Check for 24 volts at contactor coil replace if
contacts are open
d. Blown fuses or tripped breaker
e. Transformer defective
f. High or low pressure control open
(Optional)
g. Compressor overload contacts open
Condenser fan runs,
compressor doesn't
Low suction - cool compressor
Iced evaporator coil
Compressor short cycles
a. Loose connection
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
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. Low voltage connection
c. At compressor terminals, voltage must be within
10 % of nameplate volts when unit is operating
d. Capacitor weak, open, or shorted
d. Check capacitor. If defective, replace.
a. Low indoor airflow
a. Increase speed of blower or reduce restriction replace air filters
a. Replace - check for correct voltage
b. Check refrigerant charge and / or airflow
a. Defective overload protector
b. Unit cycling on low pressure control
a. Low airflow
High suction pressure
a.
b.
c.
a.
b.
Evaporator coil freezing or frosting
f. Reset high pressure control or check unit charge
b. Compressor stuck, grounded or open
winding open internal overload
Registers sweat
Insufficient cooling
d. Replace fuse or reset breaker Check wiring replace transformer
Excessive load
Defective compressor
Reversing valve not seating properly.
Improperly sized unit
Improper airflow
a. Increase speed of blower or reduce restriction
replace air filters
a. Recheck load calculation
b. Replace
c. Replace
a. Recalculate load
b. Check - should be approximately 400 CFM per
ton
c. Incorrect refrigerant charge.
c. Charge per procedure attached to unit service
panel
d. Incorrect voltage
d. At compressor terminals, voltage must be within
10% of nameplate volts when unit is operating
a. Low airflow
a. Check - should be approximately 400 CFM per
ton, dirty air filters, all duct outlets open
b. Low refrigerant charge
c. Operating unit in cooling mode below
65°F outdoor temperature
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!
All of our systems are designed and manufactured with the same high quality standards regardless of size or efficiency.
We have designed these units to significantly reduce the most frequent causes of product failure. They are simple to
service and forgiving to operate. We use quality materials and components. Finally, every unit is run tested before it
leaves the factory. That’s why we know. . .There’s No Better Quality.
Visit our website at www.goodmanmfg.com for information on:
• Goodman Products
• Warranties
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12
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