Goodman GPG10 - User Manual

This document is an installation and operating manual for Goodman Manufacturing Company's GPG10 and GPG12 single package gas-electric heating and cooling units. It covers various aspects from installation and startup to maintenance and troubleshooting.

Function Description:

The GPG10 and GPG12 units are single package gas-electric heating and cooling systems designed for outdoor installation. They provide both heating (gas-fired) and mechanical cooling functions for conditioned spaces. The heating section utilizes an electronic ignition device to automatically light the main burners and a power vent blower to exhaust combustion products. The cooling section uses R-22 refrigerant and includes a piston flowrator expansion device. The units are designed to comply with requirements embodied in the American National Standard / National Standard of Canada (ANSI Z21.47-CSA 2.3 Central Furnaces).

Important Technical Specifications:

Gas Type: Factory set for natural gas, convertible to LP gas with a factory-authorized conversion kit (LPT-OOA).
Inlet Gas Pressure (Natural Gas): Minimum 5.0" W.C., Maximum 10.0" W.C.
Inlet Gas Pressure (Propane): Minimum 11.0" W.C., Maximum 13.0" W.C.
Manifold Pressure (Natural Gas): 3.2 to 3.8 inches W.C. (3.5 nominal) with burners operating.
Manifold Pressure (Propane Gas): 9.7 to 10.3 inches W.C. (10.0 nominal) with burners operating.
Electrical Power: Designed for 60 hertz current, 208V or 230V operation (transformer primary lead and induced draft blower motor leads may need reconnection for 208V).
Refrigerant: Factory charged with R-22.
Minimum Return Air Temperature (Heating): 50°F.
Maximum Return Air Temperature (Heating): 100°F.
Minimum Cooling Ambient Temperature: Mechanical cooling cannot be reliably provided below 50°F ambient.
Clearances: Minimum 12" from sides, 3" from top, and 48" for service access. Specific clearances to combustible materials are also provided.
Recommended Filter Sizes: Vary by unit tonnage:
- 2 Ton: (1)20 x 20 x 1
- 2 1/2 Ton: (1)20 x 25 x 1
- 3 Ton: (1)25 x 25 x 1
- 3 1/2 - 4 Ton: (2)20 x 20 x 1
- 5 Ton: (2)20 x 25 x 1

Usage Features:

Installation Flexibility: Can be installed on ground level (with a concrete base) or rooftops (with structural support and a roof curb).
Airflow Conversion: Units can be easily converted from horizontal to down-discharge airflow delivery.
Electronic Ignition: Automatic ignition for main burners, eliminating the need for manual lighting.
Safety Controls: Equipped with various safety devices including:
- Rollout Protection Device: Manual reset control located on the burner bracket, opens if flames are not properly drawn into the heat exchanger.
- Secondary Limit Control: Automatic reset control on the blower scroll assembly, opens due to elevated temperatures (e.g., blower failure).
- Primary Limit Switch: Opens if supply air temperatures are excessive (e.g., dirty filter, insufficient airflow).
- Compressor Protection Devices: Components designed to protect the compressor against abnormal operating conditions.
- Short Cycle Compressor Delay: Built-in feature to prevent damage from short cycling, delaying compressor output for three minutes after power restoration.
Diagnostic Indicator Chart: An LED on the ignition control board provides diagnostic error codes (flashes) to help identify operational issues such as internal control failure, external lockout, pressure switch problems, thermal protection device open, or flame detected with gas valve closed.
Adjustable Heat Anticipator: Set on the room thermostat to optimize heating cycles and prevent temperature overshooting.
Adjustable Heat Fan OFF Delay: Approximately 120/135/150 seconds (factory set at 150) to transfer residual heat from the heat exchanger.
Cooling Fan Operation: Indoor fan continues to run for approximately 60 seconds after the thermostat is satisfied to transfer additional cooling from the indoor coil.

Maintenance Features:

Routine Inspections: Recommended annual inspection and service by a qualified servicer.
Filter Replacement/Cleaning: Although not supplied with the unit, a return air filter system is required. Filters should be inspected every two months (or more frequently depending on local conditions). Throwaway filters should be replaced, and permanent filters washed, dried, and treated with adhesive.
Cabinet Finish Maintenance: Use a fine grade automotive wax to maintain the cabinet's high luster, especially in direct sunlight.
Outside Coil Cleaning (Qualified Servicer Only): Annually inspect and clean the finned areas of the coil to remove lint, hair, and debris.
Motor Lubrication: Condenser, evaporator, and induced draft motors have permanently lubricated bearings and do not require additional oiling.
Flame Sensor Cleaning (Qualified Servicer Only): Clean annually with steel wool to remove invisible coating that can reduce flame current.
Flue Passage Inspection and Cleaning (Qualified Servicer Only): Inspect at the start of each heating season and clean if necessary. This involves removing the burner assembly, flue, and collector box cover, then using a wire brush to clean the heat exchanger tubes.
Main Burner Flame Check (Qualified Servicer Only): Visually check flames annually for stability, color (soft blue, no yellow tips), and proper extension without curling, floating, or lifting off.
Burner Cleaning: Involves shutting off power and gas, removing the manifold and burners, cleaning burner inserts with a bottle brush, and reassembling.
Temperature Rise Check: Verify the temperature rise through the unit (difference between supply and return air) is within the range specified on the rating plate. Blower speed adjustments may be necessary to achieve the correct temperature rise.
External Static Pressure Check: Must be checked to ensure proper airflow.
Cooling Refrigerant Charging: Check unit charge and refrigerant superheat at the compressor to ensure proper operation for the intended application.