Whirlpool WGGE45 Installation Instructions Manual

Text of Whirlpool WGGE45 User Guide:

• Whirlpool WGGE45, PACKAGE GAS ELECTRIC FURNACES INSTALLATION INSTRUCTIONS GAS FURNACE SAFETY Recognize this symbol as a safety precaution. Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing or operating the furnace. Table of Contents GAS FURNACE SAFETY................................................................1 INSTALLATION REQUIREMENTS................................................4 Tools and Parts ............................................................................4 Location Requirements................................................................4 Ductwork Requirements .........................

• 2 To the Installer Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, Btu imput rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM and motor speed connections and

• 3 Goodman 47 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 wat

• 4 INSTALLATION REQUIREMENTS These instructions are intended as a general guide only for use by qualified persons and do not supersede any national or local codes in any way. Compliance with all local, state, or national codes pertaining to this type of equipment should be determined prior to installation. Read this entire instruction manual, as well as the instructions supplied in s

• 5 ■ The unit may be installed directly on wood floors or on Class A, Class B, or Class C roof covering material. ■ A safe, flat surface for service personnel should be provided. 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 i

• Whirlpool WGGE45, 6 Unit Dimensions—Inside Minimum Clearances NOTE: Roof overhang should be no more than 36" (91.4 cm). Ductwork Requirements ■ Install all conditioned air plenums, ducts and air filters (if not provided on the unit) in accordance with NFPA 90B Standard for the Installation of Warm Air Heating and Air-Conditioning Systems (latest edition). ■ The unit is provided with flanges for the connection of the plenum and ducts. ■ All air filters must be listed as Class 2 furnace air filters. ■ All ductwork must be ma

• 7 Electrical Requirements NOTE: All outdoor wiring must be suitable for outdoor use. Use copper conductors only. ■ All field wiring must be done in accordance with National Electrical Code requirements, applicable requirements of UL, or local codes, where applicable. ■ Electrical wiring, disconnect means and over-current protection are to be supplied by the installer. Refer to

• Whirlpool WGGE45, 8 Downflow Application For downflow applications, horizontal supply and return duct cover kits must be ordered from your distributor. Kit number 20464501PDGK is for the medium chassis and kit number 20464502PDGK is for the large chassis. Cut insulation around the bottom openings and remove the panels from the bottom of the unit, saving the screws holding the panels in place. Hood Installation Install Flue Exhaust Hood Install the flue exhaust hood, screen and lower flue hood prior to operation of the unit. To install the flue hood, screen and lower flue hood: 1.

• Whirlpool WGGE45, 9 ■ Flashing used to cover ductwork must permit removal of access panels and top. See “Minimum Clearances” in the “Locations Requirements” section. Make Electrical Connections Thermostat Thermostat Location Mount the thermostat approximately 5 ft (1.5 m) 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

• Whirlpool WGGE45, 10 3. Disconnect power. 4. Remove the control access panel. 5. Route the field supply wires through the line voltage conduit opening to the electrical connection area, providing sufficient length to connect to the pigtail leads. 6. Connect the field supply wires (L1, L2) to the 2 black pigtail leads using UL-Listed wire connectors. To avoid damage to the unit, use a fuse or HACR circuit breaker that is in excess of the circuit ampacity, but less than or equal to the maximum over-current pro

• Whirlpool WGGE45, 11 NOTE: Inlet gas pressure must not exceed the maximum value shown in the Inlet Gas Pressure chart. The minimum supply pressure should not vary from that shown in the Inlet Gas Pressure chart, 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. High Altitude Derate—U.S. Installations Only IMPORTANT: 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 equi

• Whirlpool WGGE45, 12 Proper Piping Practice 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. Check Gas Piping IMPORTANT: ■ The unit and its gas connections must be leak tested before placing in operation. ■ Do not use a match or open flame to test for leaks. ■ Do not exceed specified pressures for testing. ■ Disconnect this unit and its shutoff valve from the gas supply during any pressure testing of the system at test pressures in

• Whirlpool WGGE45, 13 Tanks and Piping Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers. Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used. Shellac-based compounds resistant to the actions of liquefied petroleum gases are satisfactory. Propane Gas Installation—Typical NOTE: 200 psig maximum tank pressure. Sizing Between 1 st and 2 nd Stage Regulator* Maximum propane capacities listed are based on 1 psig pressure drop at 10 psig setting. Capacities in 1,000 Btu/h. To

• Whirlpool WGGE45, 14 Sizing Between Single or 2 nd Stage Regulator and Appliance* Maximum propane capacities listed are based on ¹⁄₂" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 Btu/h. Data in accordance with NFPA pamphlet Number 54. Start-up, Adjustments and Checks Heating Start-up 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 th

• Whirlpool WGGE45, 15 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 control to trip. Once the blower compartment temperature drops below the limit reset temperature, the limit will auto

• Whirlpool WGGE45, 16 Measuring Inlet Gas Pressure Alternate Method Manifold Pressure Check 1. Turn off gas supply to furnace at the manual gas shutoff valve external to the furnace. 2. Disconnect all electrical power to the system. 3. Loosen outlet pressure test screw (inlet/outlet pressure boss) 1 turn. NOTE: Turn counterclockwise, and not more than 1 turn. 4. Connect a calibrated water manometer and ⁵⁄₁₆" hose to the outlet pressure boss on the gas control valve. The hose should overlap by ³⁄₈" (1 cm). 5. Turn on the gas supply. 6. Reconnect all electrical power to the system. 7. Turn on the system

• Whirlpool WGGE45, 17 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 the 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

• Whirlpool WGGE45, 18 WGGE4537A090M—Rise Range: 45º to 75º Unit Static 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 T1—1 st - Stage Heating Speed CFM 1,065 1,003 961 913 855 814 749 713 Watts 168 174 185 195 202 212 218 227 Amps 1.42 1.48 1.55 1.62 1.69 1.76 1.82 1.87 Rise 49 52 54 57 60 63 69 72 T2—2 nd - Stage Heating Speed CFM 1,255 1,217 1,165 1,113 1,073 1,018 991 - Watts 257 269 274 285 296 302 313 - Amps 2.10 2.19 2.21 2.30 2.36 2.41 2.48 - Rise 55 57 59 62 64 68 70 - T3— Cooling Speed CFM 1,148 1,092 1,044

• Whirlpool WGGE45, 19 Limit Check Check the limit control operation after 15 minutes of operation. 1. Block the return air grille(s). 2. After several minutes, the main burners must go off. The circulating air blower will continue to run. 3. Remove air restrictions and main burners will relight after a cool down period of a few minutes. 4. Adjust the thermostat setting below room temperature. 5. The main burners must go off. 6. The circulating air blower will continue to run for 120, 135 or 150 seconds, depending on the setting. NOTE: On the WGGE4348,60 model only, the circulating air blower will continue to run for 180 seconds. Control Board—Top NOTE: If necessar

• Whirlpool WGGE45, 20 On models equipped with a thermostatic expansion valve, charge the system to 10º of subcooling. When necessary, adjust the expansion valve stem for superheat setting. NOTE: The expansion valve will not need adjustment for most applications. Check that the system superheat is set between 12ºF and 15ºF after final adjustment. Superheat Adjustment 1. To adjust superheat, remove the control box cover and locate the expansion valve on the liquid line of the evaporator. 2. Unscrew the cover from the expansion valve 3. Locate the adjustment screw, and turn it clockwise (in) to increase superheat or counter

• Whirlpool WGGE45, 21 Fan Only 1. The thermostat calls for Fan Only by energizing “G.” 2. Immediately, the indoor blower fan Is energized at the low-heat speed. 3. The indoor blower fan is immediately de-energized once the thermostat call for Fan Only is removed. Cooling Start-Up 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 keep the compressor from abnormal operating conditions. Refrigerant Charge Check—Units with Fixed Orifice Devices After completing the airflow measurements and adjustments, the unit’s refrigerant

• Whirlpool WGGE45, 22 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 block adequate combustion air and a keep the vent system from operating properly. 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 y

• Whirlpool WGGE45, 23 Burner Flame Check the burner flames for good adjustment, a stable, soft and blue flame that is not 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 2 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 patte

• Whirlpool WGGE45, 24 Diagnostic Indicator Chart The status light on the unit control may be used as a guide to troubleshooting the appliance. Fault Recall The ignition control is equipped with a momentary pushbutton switch that can be used to display on the diagnostic LED the last 5 faults detected by the control. The control must be in Standby Mode (no thermostat inputs) to use the feature. 1. Depress the pushbutton switch for approximately 2 seconds. NOTE: Do not hold for longer than 4 seconds. Holding the button for 4 seconds or longer will erase the memory. 2. Release the switch when the LED is turned off. The diagnostic LED will then display the flash codes associated with the last 5 de

• 25 Pressure Switch Stuck Open—2 Flashes (Red LED) Causes: ■ Faulty pressure switch ■ Faulty wiring ■ Disconnected or damaged hose ■ Blocked or restricted flue ■ Faulty induced draft blower If the control senses an open pressure switch during the pre- purge cycle, the induced draft blower will be energized only. If the pressure switch opens after ignition has begun, the gas control

• Whirlpool WGGE45, 26 Wiring Diagram—WGGE45(24, 30, 37, 42, 49, 60) HIGH VOLTAGE! WARNING Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. Y/BK Y/BK Y Y Y/BK Y Y Y Y Y Y Y R R R R Y Y Y Y Y Y Y R PR PR PR PR PR PR PR PR PR Y BK PR PR PR PR PR PR PR PR PR R R R BU BU BU/PK BU/PK BU/PK BU BU BU BU BU BU BU PR PR PR R FS LS BK BK BK BK BK BK BK BK BR BU BR BR BR BR BR BR OR OR OR OR OR W OR W BU G G BR CM COMP SOL SRC LPS Optional Refrigerant Switches HPS Compressor 2 nd- stage solenoid not present on all models. BK BK T1 T2 L2L1 CC For 208-volt transf

• Whirlpool WGGE45, 27 Wiring Diagram—WGGE45(24, 30, 37, 42, 49, 60) HIGH VOLTAGE! WARNING Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. Supply Voltage 208-230/1/60 COMP S R C T1 CC L1 L1 L1 L1 HI LO HI LO 2 1 3 6 8 9 7 5 1 R W1 Y2 C W2 4 5 3 6 2 2 3 ECON SOL 5 4ECON ALS PS LS EM VM L2 L2 L2 L2 L2 RS CC Optional Refrigerant Switches GV M HI C CM TR For 208-volt transformer operation, move black wire from Terminal 3 t

• Whirlpool WGGE45, Heating Timing Chart Cooling Timing Chart ASSISTANCE OR SERVICE If you need further assistance, you can write to the below address with any questions or concerns: Whirlpool ® Home Cooling and Heating 14610 Breakers Drive Jacksonville, FL 32258 Please include a daytime phone number in your correspondence. Accessories To order accessories, contact your Whirlpool ® Home Cooling and Heating dealer. Placeholder 90, 120, 150, 180 Circulator Blower High Off Seconds Gas Control Valve Igniter Induced Draft Blower Thermostat 0 15 22 27 52 0 30 Low H

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