PACKAGE UNITS GPG 10 AND 12 SEER

TECHNICAL SUPPORT 888-593-9988 MARK STOKES 713-861-2500 EXT. 630

Model Number Chart

09 is for the month it was built 04 is for the year it was built SERIAL NUMBER 09 is for the month it was built 0409456678 04 is for the year it was built

12 & 10 SEER Packaged Gas Electric Fits in a standard size Pickup! 47” Wide

12 & 10 SEER Packaged Gas Electric Cooling Features: Convenient access panels to the compressor High-efficiency Scroll and Energy-efficient reciprocating compressor. Copper tube/aluminum fin coil. Liquid line filter drier. Fully charged R-22 system. Louvered Guard Protection

10 & 12 SEER Packaged Gas Electric Control Features: Convenient access panels to the Evaporator coil and control section. Direct spark ignition system, which includes a microprocessor based control for the entire ignition sequence, all blower operation and all safety circuits. Diagnostic Indicator provided for trouble shooting system faults.

Design Objectives 2 – 5 ton Single Phase 3, 4 & 5 ton Three Phase 12 &10 SEER Cooling, 80% AFUE Heating Capable of expansion to higher SEER ratings Convertible Easy Access Service Panels Architectural Gray

12 & 10 SEER Packaged Gas Electric Heating Features: Convenient access panels to the heating section. Redundant gas valve, natural gas and easy conversion to propane. Power-assisted combustion. L.P. Conversion Kit Available 12 & 10 SEER units offer a durable, T-140 Aluminized Steel tubular heat exchanger. California Low Nox Approved

We begin with T-140 Aluminized Steel tubes Wrinkle-bend Process We begin with T-140 Aluminized Steel tubes Manufacturing stress including wall-thinning is minimized Wrinkles are placed precisely where we want them Wrinkles promote turbulence to aid heat transfer and efficiency

Dual-diameter/Muffler-joint We apply a patented process to join tubes 1-3/4” diameter fits inside a 1-1/4” diameter Tubes are joined with a proprietary process Velocity of combustion products is optimized Efficiency is maximized

Tubular Technology Renders Clamshell Obsolete 800°F 1,000°F 1,000°F 300°F 300°F 300°F 300°F 110°F Non-uniform thermal growth Eyelets can pop Stress-cracks can form Tube can grow in length and diameter Growth is uniform at the cross-section No opportunity for stress-cracks

INSTALLATION

CLEARENCE FROM COMBUSTIBLE MATERIALS

CURB INSTALLATION

RIGGING

PIPING

CONDENSATE DRAIN

FLUE HOOD & BUG SCREEN

12 & 10 SEER Packaged Gas Electric McDaniel Metals Accessories By

10 & 12 SEER Packaged Gas Electric Blower Features: Convenient access panels to the blower section. Filter rack included on 12 SEER large (4 &5 ton) chassis. Easy removal of blower with two screws. Multi-speed evaporator blower. Fully insulated with blankets of fiberglass.

12 & 10 SEER Packaged Gas Electric Base Features: 042 Aluminized Steel Bottom/Base Pan 2” High Base Rails Shipped with four panels

DUST COVER INSTALLATION

RECOMMENDED FILTER SIZES

Electrical 208/230 Volt Power connections and 460 Volt available in 5 Ton Cool only model Single Phase and Three phase models available Maximum Over current Protection determined by model

Wiring All wiring should be made in accordance with the National Electrical Code. Wire sizes and over current protection should be determined from the unit nameplate ampacity. Wire sizes should not be smaller than recommended by these two sources. All exterior wiring must be within approved weatherproof conduit. The unit must be permanently grounded in accordance with local codes.

HIGH VOLTAGE WIRING

LOW VOLTAGE WIRING

CHECKING THE COMPRESSOR

CHECKING CONTACTOR

CHECKING CAPACITOR

COMPRESSOR NORMINCLATURE

COMPRESSOR DIAGONSTICS

TESTING FOR GROUNDED COMPRESSOR

FLOW RATER

EVACUATION

HEATING SIDE OF GPG

CHECKING GAS PRESSURE Manifold Outlet Gas Pressure Natural…. Min. 3.2” W.C., Max 3.8” W.C. Propane….Min. 9.7” W.C., Max. 10.3” W.C.

CHECKING BURNERS

Burner

BURNER BOX REMOVAL

CHECKING BURNERS

CHECKING LIMIT SWITCH

Pressure Switch Check Meter on AC Voltage Setting ; between Quick Connect on Pressure Switch and Ground Prior to Operation check for open side of Pressure Switch (No Voltage Present) When Pressure Switch Closes 24 Volts should be present on N/O side Issue: Watch for switch bounce on windy days Issue: Watch for P.S. drop-out for low pressure

CHECKING PRESSURE SWITCH

CHECKING PRESSURE SWITCH

PRESSURE SWITCH

INDUCED DRAFT BLOWER

Understanding ECM Motors

Understanding ECM Motors What does ECM mean? How does the ECM work? Variable Speed vs Constant Volume. What is PWM How does the ECM sense static pressure? Troubleshooting ECM motors. In this discussion we will be covering the following topics; What does ECM mean? Who came up with that acronym? How does the ECM work? Variable Speed vs. Constant Volume. What is PWM How does the ECM sense static pressure? Troubleshooting ECM motors.

BLOWER MOTOR & HOUSING

Electronic Controls

B18099-18 Control B18099-21 Has Green Diagnostic LED B18099-21 Cannot be used alone; must be used with B18099-22 Control B18099-21 Control is set up for 50Hz Operation and for use in Europe (CE Mark)

Control Environment +80 to -40 Degrees Celsius (+176 to -40 F) 10% to 95% R.H. Non-Condensing 98 to 132VAC Line Voltage 18 to 30VAC Control Voltage Frequency - 60Hz UL & cUL Approved

General Functions “W” Input Off (Call for Heat Satisfied) “W” Input On (Call for Heat) Checks to see pressure switch open Turns on Inducer Pressure Switch Closes; 15 Second Pre-Purge Starts Sparking & Gas Valve Turns On for 7 Seconds Flame Sensed Anytime During Spark Gas Valve Stays On Blower Comes On after 30 Second Delay “W” Input Off (Call for Heat Satisfied) Gas Valve De-Energizes Immediately Inducer Remains on for 29 Second Post Purge Indoor Blower De-Energizes after Selected Blower Off Delay

General Functions Continued.... Single Compressor Mode (Tab is not Broken) “Y” Input On (Call for Cooling) 3 Minute Anti-Short Cycle Timer from the time the compressor was last on. Cooling Speed Blower after a 7 second delay “Y” Input Off (Call for Cool Satisfied) Cooling Speed Fan Off after 60 Second Delay Dual Compressor Mode (Tab is Broken) 1st Stage Compressor is Energized Externally “Y” Input On for 2nd Stage Cooling after 7 Second Delay “Y” Input Off ; Cooling Speed Fan off after 60 Second Delay

General Functions Continued.... “G” Input On (Call For Fan) Fan Immediately on Heat Speed “G” Input Off Fan Immediately Shuts Off If “Y” input Occurs During “G” Blower Switches to Cooling Speed If “W” Occurs During “G” Blower off when Heat Blower On Delay Begins Continuous Fan Operates while control is in Heat Mode Lockout Test/Speed-Up Bypasses Compressor Short-Cycle Timer If Shorted for Over 4 Minutes ; Control Ignores = Operates Normal

Diagnostic Codes Steady On = Normal Operation in Standby 1 Flash = Lockout for Ignition Failure or Flame Dropouts 3 Trials for Ignition or 5 Flame Losses 2 Flashes = Pressure Switch Open with Inducer On 3 Flashes = Pressure Switch Stuck Closed with Inducer Off 4 Flashes = Limit Switch Open Heat Speed Blower and Inducer On Until Limit Closes Blower Runs thru Off Delay; Inducer runs thru 29 Second Post-Purge 5 Flashes = Flame Detected with Gas Valve Off Blower and Inducer Both On Until No Longer Sensed Control Locks out But Senses Limit and Flame Control is Reset By Removing Power or after 1 Hour Automatically 6 Flashes = Compressor Delayed for Short Cycle/Staging Timer Status Light Off = Board Hardware Fault

Flame Sense Checking Digital Meter set for lowest uA Setting Meter in series with Flame Sense Rod Wire Control must read a minimum of .5uA during flame sensing period Average current reading is around 3-5uA. Control constantly monitors Flame during heating operation Issue: Flame Sense Rod gets corroded ; Clean w/ steel wool Issue: Flame Rod not situated in Flame Correctly

Ground Check Meter set to Ohms or Resistance Setting Place Meter from P1-6 or COM quick connect to chassis ground Reading should be near Zero ohms Issue: COM Quick Connect Loose ; causes board resetting when blower starts Issue: Flame Sensing problems if improper grounding in system

GPG TROUBLESHOOTING THEORY OF OPERATION Control of heating, cooling, and fan functions in response to a standard thermostat Direct spark ignition using a microprocessor to control timing, flame sensing, and ignition retries Monitoring of system pressure switch and limit switch Control of gas valve, indoor fan, and induced draft motor based on the thermostat demand and status of safety inputs Control of compressor contactor Diagnostic indicator to provide information on power to the control and control status

GPG TROUBLESHOOTING Summary of Timing Functions (in seconds) Function Signal Name Delay-On Delay-Off Heat Speed MV (1) 30 120, 135,150 (2) Cool Speed Y 7 60 Compressor 60 (3) 180 (4) Induced Draft 15 (5) 29 1. Heat speed delay on and off occur only after flame has been sensed and main valve (MV) is energized Selectable with jumpers 3. Indicates timing when “Two Stage Comp” tab is broken off, timer becomes delay on make 4. Indicates timing when “Two Stage comp”tab is not broken off, timer becomes compressor lock out between cycles(I.e. Minimum timing between compressor cycles) 5. Prepurge timing (not delay on )

GPG TROUBLESHOOTING Inputs Limit Switch –The limit switch is connected to control pins 4 and 5. The limit switch is connected is electrically between fused 24 VAC and the thermostat R Pressure Switch-The pressure switch is connected on pins 6 and 8. The pressure switch “W and the gas valve relay contacts Thermostat call for Heat “W”-24 VAC thermostat input. Connection via pin 10 Thermostat call for cool “Y”- 24 VAC thermostat input connections via pin 11 Thermostat call for fan “G”- 24 VAC thermostat inputs. Connection via pin 7 Flame Sense- Open circuit flame sense voltage shall be approximately 100 VAC . The control requires at least .5 microamperes DC flame current to guarantee flame is sensed

12 & 10 SEER Packaged Gas Electric Leading Warranties: 12 SEER offers an Aluminized Steel Heat Exchanger with a 20Year limited Warranty and10 Year Limited Warranty on the Compressor and Parts. 10 SEER offers an Aluminized Steel Heat Exchanger with a 20Year limited Warranty and 5 Year Limited Warranty on the Compressor and Parts.