Whirlpool W2PG Installation Instructions Manual

Text of Whirlpool W2PG User Guide:

• Whirlpool W2PG, INSTALLATION INSTRUCTIONS FOR PACKAGE GAS ELECTRIC FURNACES GAS HEATING/ELECTRIC COOLING SAFETY 48289K005 Whirlpool ® Home Cooling and Heating 14610 Breakers Drive Jacksonville, FL 32258 Whirlpool ® Models W2PG, W4PG Table of Contents GAS HEATING/ELECTRIC COOLING SAFETY ...........................1 INSTALLATION REQUIREMENTS................................................2 Tools and Parts ............................................................................2 Location Requirements................................................................3 Ductwork Requirements ....................................

• 2 ADDITIONAL SAFETY INFORMATION INSTALLATION REQUIREMENTS These instructions are intended as a general guide only for use by qualified persons. 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 separate equipment, before starting

• Whirlpool W2PG, 3 Location Requirements IMPORTANT: Do not use the furnace as a heater in a building under construction. The furnace can be severely damaged due to the abnormal environment caused by construction. Chlorides from sources such as paint, stain, or varnish; tile and counter cements; adhesives; and foam insulation are abundant in a structure under construction and can be highly corrosive. Low return air temperature can cause condensation in the furnace and other damage that can shorten the life of the furnace. ■ This furnace is designe

• Whirlpool W2PG, 4 Ductwork Requirements ■ Install all conditioned air plenums, ducts and air filters in accordance with NFPA 90B Standard for the Installation of Warm Air Heating and Air-Conditioning Systems (latest edition). ■ The furnace is provided with flanges for the connection of the plenum and ducts. ■ All air filters must be listed as Class 2 air filters. ■ All ductwork must be made of materials and insulated to meet local, state and national codes. Ductwork installed outdoors must be sealed, weatherproof and protected

• Whirlpool W2PG, 5 FURNACE INSTALLATION INSTRUCTIONS Inspect Shipment This furnace is shipped in one package, completely assembled and wired. The indoor thermostat and accessories are shipped in a separate carton when ordered. 1. Check the furnace rating plate to confirm specifications are as ordered. 2. Upon receipt of equipment, inspect it for possible shipping damage. Be sure to examine the furnace inside the carton if the carton is damaged. If damage is found, it should be noted on the carrier’s freight bill. Damage claims should be filed with the carrier immediately. Claims of shortages should be filed with the seller within 5 days. NOT

• Whirlpool W2PG, 6 Convert to Downflow This furnace is factory-built for horizontal airflow applications and may also be field-converted for downflow use. To convert to downflow use: 1. Remove the filter access panel. 2. Remove the two downflow duct cover plates (one screw and tab for each) found in the return and supply air compartments. 3. Using eight #10 x ³⁄₄" screws (field supplied), install the previously removed duct covers on the horizontal return and supply air openings. Use the pilot holes provided. 4. Reinstall the filter access panel. Exhaust Vent Assembly 1. Place the screen over t

• Whirlpool W2PG, 7 Install Ductwork ■ Install ductwork in accordance with NFPA 90B and any local codes. ■ The use of flexible, noncombustible connectors between the main trunk ducts and the supply and return air plenums is recommended to minimize vibration transmission. ■ Plenums must be individually sealed to furnace casing with ducts terminating inside the structure. ■ Flashing used to cover ductwork must permit removal of access panels and top. See “Minimum Clearances” in the “Locations Requirements” section. Filters Filters are not supplied with these furnaces; however, filters must be used. It is the installer�

• 8 Line Voltage Connections 1. Disconnect power. 2. Remove the blower access panel. 3. Remove the burner access panel. 4. 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. 5. For single phase units: ■ Connect the field supply wires (L1, L2) to the 2 black pigtail leads

• Whirlpool W2PG, 9 208 Volt Conversion 1. Disconnect power. 2. Remove the burner access panel. 3. Move the black wire lead from the 240-volt terminal on the transformer to the 208-volt terminal (center tap) on the transformer. See the wiring connection diagrams in “Troubleshooting.” 4. Replace the burner access panel. High Altitude Conversion (if required) Ratings are shown on the rating plate for elevations up to 4,500 ft. For elevations above 4,500 ft, ratings should be reduced at a rate of 4 percent for each 1,000 ft above sea level. See the National Fuel Gas Code Z223.1 (latest edition) or the Canadian Installation Codes CAN/CGA-B149.1 and B149.2 for further details. Not recommended for o

• 10 Gas Control Valve 4. Turn on the gas supply at the manual gas shutoff valve. Set the room thermostat to a point above room temperature to light the main burners. NOTE: This furnace is equipped with an ignition device, which automatically lights the burner. This furnace cannot be lighted manually. Do not try to light the burner by hand. 5. Turn on the elect

• Whirlpool W2PG, 11 13. Turn on the gas supply at the manual gas shutoff valve. 14. Replace the burner access panel. 15. Set the room thermostat to the desired temperature. For altitudes 7,500 to 10,000 ft above sea level Do not adjust manifold pressure. An orifice change is required. For the correct orifice size, see Table F.4 in Appendix F of the National Fuel Gas Code (ANSI Z223.1/NFPA 54, latest edition). Complete Installation IMPORTANT: Do not use this furnace if any part has been under water. Immediately call a qualified person to inspect the furnace and to replace any par

• 12 To Select the Same Speed for COOL and HEAT NOTE: Some models have the same speed for COOL and HEAT already connected. At the Blower Motor Connector 1. Disconnect power. 2. Remove blower and burner access panels. 3. Place black wire on the HIGH, MED or LOW motor speed tap, as desired. 4. Place blue wire on any of the other motor speed taps. At the Furnace Control Board 1. Remove the blu

• Whirlpool W2PG, 13 Measure Temperature Rise 1. After 20 minutes of heating operation, measure the furnace temperature rise. Take air temperature readings in both the return air ducts and the heated air ducts. NOTE: If more than one run of return or heated air ducts is used, air temperature measurements should be taken in each duct. These measurements can be converted to an average to obtain the temperature rise of the whole system. 2. If the furnace doesn't maintain temperature rise within the range shown on the furnace rating plate, adjust the blower speed. See the appropriate “Adjust Blower Speed” section for your model. Shut Down If the construction will contin

• Whirlpool W2PG, 14 SEQUENCE OF OPERATION Cooling System The cooling system is a complete factory package utilizing an air- cooled condenser. The compressor is hermetically-sealed and base-mounted with rubber-insulated hold-down bolts. Furnace compressors have internal protection. In the event there is an abnormal rise in the temperature of the compressor, the protector will open and cause the compressor to stop. Cooling Sequence of Operation When the thermostat calls for cooling, R is closed to G and Y. See the wiring connection diagrams in “Troubleshooting.” This action completes the low voltage control circuit, energizing the

• Whirlpool W2PG, 15 Variable-Speed Motor Units equipped with a variable-speed circulation air blower motor will deliver a constant airflow within a wide range of external static pressures. For other features of this variable-speed motor, see “Adjust Blower Speed Variable-Speed Motor Only.” Start/Stop The variable-speed motor will slowly ramp up to normal operating speed. This minimizes noise and increases comfort by eliminating the initial blasts of air encountered with standard motors. At the end of a cooling or heating cycle, the motor will slowly ramp down. Controls Limit Control This contr

• Whirlpool W2PG, 16 Wiring Connection Diagram—Single Phase, Multi-Speed YGW1 RC Y G W R C BU G Y W R 24VAC 1 625 4 3 Flame Flame Sense GY BR BU OR R BK W PR BK G PR OR W PR Main Limit Switch R ollout Switch Pressure Switch Aux. Limit Switch (If used) Gas Valve Fuse Ignition Control BU Y R Y Contactor Thermostat Y Y High Pressure Switch (If used) L1 T1 T2 L2 C H F Condenser Fan Motor Compressor Contactor Compressor Contactor Dual Capacitor Compressor Transformer C S R L1 CMB BLWR Spark Comb. Air Blower Ignition Control BK W L2 L1 BK BR PR R R BK 208V 240V 24V Indoor Blower Motor BK S4 S1 K1 A3 GV1 S21 S18 S47 S10 T1 B3 B6 B4 K1-2 C12 B1 K1-1 A3 Ground BU Y LED Y E1 C4 Capacit

• Whirlpool W2PG, 17 Wiring Connection Diagram—Single Phase, Variable-Speed 208/230V-1-60 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Y G W1 R C Y G W R C BU G Y W R Y R C Comfort Alert G Y1 Y2 O W1 EM C1 R HUM Indoor Blower Motor ICM Board BU R 24VAC 1 625 4 3 Flame Flame Sense GY BR BU OR R Y G BK W PR BK G PR OR WT PR Main Limit Switch Rollout Switch Pressure Switch Aux. Limit Switch (If used) Gas Valve Fuse Ignition Control OR BU G BU Y R R BU R Y Contactor Thermostat Y Y High Pressu

• Whirlpool W2PG, 19 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 ask for the appropriate part number listed below or contact your Whirlpool ® Home Cooling and Heating dealer. Part Number Accessory Model(s) 48193-004 ALPKT804-1 LP Conversion Kit W2PG324A068 through W2PG336A090 48193-005 ALPKT805-1 LP Conversion Kit W2

• Whirlpool W2PG, 48289K005 © 2005. All rights reserved. Honeywell and SmartValve are trademarks of Honeywell International, Inc. ®Registered Trademark/TM Trademark of Whirlpool, U.S.A., Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida 11/05 Printed in U.S.A.

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