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INSTALLATION INSTRUCTIONS FORPACKAGE GAS ELECTRIC FURNACES

GAS HEATING/ELECTRIC COOLING SAFETY

48289K005

Whirlpool® Home Cooling and Heating14610 Breakers Drive

Jacksonville, FL 32258

Whirlpool® Models W2PG, W4PG

Table of ContentsGAS HEATING/ELECTRIC COOLING SAFETY ...........................1INSTALLATION REQUIREMENTS................................................2

Tools and Parts ............................................................................2Location Requirements................................................................3Ductwork Requirements ..............................................................4Electrical Requirements ...............................................................4Gas Supply Requirements ...........................................................4

FURNACE INSTALLATION INSTRUCTIONS ...............................5Inspect Shipment .........................................................................5Place Furnace in Final Location...................................................5Convert to Downflow ...................................................................6Exhaust Vent Assembly ...............................................................6Connect Condensate Drain .........................................................6Install Ductwork............................................................................7Make Electrical Connections .......................................................7High Altitude Conversion .............................................................9

Make Gas Connections................................................................9Check the Furnace Input Rate ...................................................10Adjust Manifold Pressure ...........................................................10Complete Installation..................................................................11Adjust Blower Speed Multi-Speed Motor Only .........................11Adjust Blower Speed Variable-Speed Motor Only ....................12Measure Temperature Rise........................................................13Shut Down..................................................................................13

SEQUENCE OF OPERATION ......................................................14Cooling System ..........................................................................14Heating System..........................................................................14Circulating Air Blower.................................................................14Controls ......................................................................................15

TROUBLESHOOTING ..................................................................15ASSISTANCE OR SERVICE.........................................................19

Accessories ................................................................................19

You can be killed or seriously injured if you don't immediately

You can be killed or seriously injured if you don't follow

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what canhappen if the instructions are not followed.

Your safety and the safety of others are very important.We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages.

This is the safety alert symbol.

This symbol alerts you to potential hazards that can kill or hurt you and others.

All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING.”These words mean:

follow instructions.

instructions.

DANGER

WARNING

2

ADDITIONAL SAFETY INFORMATION

INSTALLATION REQUIREMENTSThese 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 the installation.The installation of the furnace, wiring, warm air ducts, venting, etc., must conform to the requirements of the National Fire Protection Association; the National Fuel Gas Code, ANSI Z223.1/NFPA No. 54 (latest edition) and the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States, and any state laws, local ordinances (including plumbing or wastewater codes), or local gas utility requirements. Local authorities having jurisdiction should be consulted before installation is made. Such applicable regulations or requirements take precedence over the general instructions in this manual.

Tools and PartsGather the required tools before starting installation. Read and follow the instructions provided with any tools listed here.

Tools needed

Parts neededCheck local codes and with gas supplier. Check existing gas supply, electrical supply, and venting, and read “Electrical Requirements,” “Gas Supply Requirements,” and “Ductwork Requirements” before purchasing parts.

SAVE THESE INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS■ Use only with type of gas approved for this furnace.

Refer to the furnace rating plate. ■ Install this furnace only in a location and position as

specified in the “Location Requirements” section of these instructions.

■ Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Make Gas Connections” section of these instructions.

■ Always install furnace to operate within the furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Complete Installation” section of these instructions. See furnace rating plate.

■ The furnace is not to be used for temporary heating of buildings or structures under construction.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm.

This appliance can cause low-level exposure to some of the substances listed, including benzene, formaldehyde, carbon monoxide, toluene, and soot.

In the State of Massachusetts, the following installation instructions apply:

■ Installations and repairs must be performed by a qualified or licensed contractor, plumber, or gasfitter qualified or licensed by the State of Massachusetts.

■ If using a ball valve, it shall be a T-handle type.

■ A flexible gas connector, when used, must not exceed 3 feet.

■ Pipe wrenches

■ Screwdriver

■ Tape measure

■ Thread sealant

■ Noncorrosive leak detection solution

■ Test gauge with ¹⁄₈" NPT connection(for measuring gas supply pressure)

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 designed to be located outdoors with

sufficient clearance for free entrance to the inlet and discharge air openings. The location must also allow for adequate service access. See “Minimum Clearances.”

■ Where possible, select a location for the furnace which is shaded from the direct rays of the sun most of the time. North or east locations are usually most desirable. Position the furnace to avoid direct contact with water, snow or ice from a roofline overhead.

■ The furnace must be installed on a solid, level mounting pad that will not settle or shift. Isolate the pad from the building structure to avoid possible transmission of sound or vibration from the furnace into the conditioned space.

■ The furnace foundation should be raised to a minimum of 3" above finish grade. In areas which have prolonged periods of temperature below freezing and snowfall, the furnace should be elevated above the average snow line. If the furnace is to be installed on a flat roof, it should be on a platform or other support which will raise the base a minimum of 8" above the surface of the flat roof.

■ This furnace can be installed on combustible Class A, Class B or Class C roof covering material.

■ Avoid placing a furnace near areas such as sleeping quarters or study rooms. Normal operating sound levels may be louder than desired if the furnace is placed near certain rooms.

Minimum Clearances

High Altitude Installations

■ This furnace is approved for operation at altitudes from 0 to 4,500 ft above sea level without any required modifications.

IMPORTANT:For installations above 4,500 ft, the furnace input rate is to be reduced per the requirements of the National Fuel Gas Code (ANSI Z223.1/NFPA 54, latest edition), at the rate of 4 percent for each 1,000 ft above sea level.This furnace is not recommended for installation above 10,000 ft.

Explosion Hazard

Keep flammable materials and vapors, such as gasoline, away from furnace.

Failure to follow these instructions can result in death, explosion, or fire.

WARNING

A. Supply air ductB. Return air ductC. Filter access panel

D. Evaporator coil access panelE. Blower access panelF. Burner access panel

Minimum Clearance Requirements

To Combustible Material

For Optimum Service Access

For Optimum Operation

Front 24" 48" 24"

Rear 0" 24" 3"

Condenser End

0" 24" 3"

Blower End 0" 30" 0"

Top 0" 36" 36"

30"

2"

36" 30"

24"

30"

Minimum - 0"Recommended - 3"

A

B

C

DE

F

Front side of unit

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 against physical damage. Caulking, flashing or other means of adequately providing a permanent weather seal should be used where duct penetrates a building or structure opening.

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 the rating plate for the maximum over current protection, minimum service ampacity, and operating voltage. See the wiring connection diagrams in “Troubleshooting.”

■ This furnace must be electrically grounded in accordance with National Electric Code (ANSI/NFPA 70) requirements, applicable requirements of UL, or local codes, where applicable.

Gas Supply RequirementsThis furnace is equipped for use with Natural gas. A conversion kit is required for use with propane. To order the correct conversion kit, see “Accessories.”■ Gas supply piping should be installed in accordance with

local, state and national codes and the regulations of the utility. Piping must be of adequate size to prevent undue pressure drop. Consult the local utility or gas supplier for complete details on special requirements for sizing gas piping.

■ If local codes allow the use of a flexible gas appliance connector, use an CSA design-certified outdoor flexible stainless steel appliance connector or rigid gas supply line as needed.

WARNING

Rating Plate Ampacity

Less than 15

16 - 20

21 - 30

AWG

14

12

10

Electrical Shock Hazard

Electrically ground furnace.

Connect ground wire to ground terminal marked “GROUND”.

Use copper wire for supply connection.

Correct wire gauge is shown in the chart below.

Failure to follow these instructions can result in death or electrical shock.

31 - 50 8

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.NOTE: If any damages are discovered and reported to the carrier, do not install the furnace as your claim may be denied.

Place Furnace in Final Location

IMPORTANT: Place the furnace in the final location and position it in the proper orientation to the house so that connecting ducts, electrical and gas supplies is easily done. Hoisting may be required.

Hoisting

An accessory lift kit must be purchased to hoist the furnace. See “Accessories.” Attach the rigging to the lifting brackets on each corner.NOTE: All access panels must be secured in place before hoisting.The furnace should be hoisted with 2 lifting slings. Attach the slings to rigging shackles that have been hooked through holes in the lifting brackets.Place 2 spreaders on top of the furnace to protect the furnace from damage from the pressure exerted by the slings. Make sure that all equipment is rated to handle at least 750 lbs and that the slings will not allow the furnace to shift. See “Typical Sling Configuration.”

Typical Sling Configuration

WARNING

Explosion Hazard

Furnace must be installed and serviced by a qualified person.

Examples of a qualified person include:

licensed heating personnel, authorized gas company personnel.

Read and follow all instructions provided for installation, adjustment, service, alteration, or maintenance.

Failure to follow these instructions can result in death, explosion, fire, or carbon monoxide poisoning.

WARNINGExcessive Weight Hazard

Use two or more people and mechanical equipment to lift, move and install furnace.

Failure to do so can result in back or other injury.

A. SpreadersB. PalletC. Cables

D. Lifting bracket (accessory lift kit)

E. Sheet metal screw

WARNINGExcessive Weight Hazard

Use two or more people and mechanical equipment to lift, move and install furnace.

Failure to do so can result in back or other injury.

D

E

A

B

C

6

Convert to DownflowThis 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 Assembly1. Place the screen over the exhaust port.2. Place the internal vent hood over the exhaust port.3. Place the outer cover over the internal vent hood and exhaust

port. 4. Align the screw holes in the covers with the holes in the

exhaust port.5. Attach the covers using the four #10 screws provided.

Connect Condensate DrainThe condensate drain outlet is a ³⁄₄" threaded PVC fitting located at the bottom on the side of the furnace. A ³⁄₄" drain line with trap must be installed on all applications to avoid accumulation of condensate under or around the furnace.

Install Condensate Trap

1. Construct the condensate trap from PVC tubing as shown in “Condensate Trap Construction.”

NOTES:■ The condensate trap allows a standing column of water of

at least 2" (50 mm).

■ The top of the drain trap inlet must be at least least 1" (25 mm) above the top of the drain trap outlet.

■ The trap should be installed as close to the furnace as possible, while still providing proper drainage.

■ For service access, do not block heat exchanger access panel or the filter access panel with the drain line.

2. Thread the drain assembly into the ³⁄₄" PVC fitting.NOTE: Do not glue the threaded fitting so it can be removed during servicing of unit.

3. Run the drain line to an open drain or other suitable disposal point.

Condensate Trap Construction

A. Filter access panelB. Horizontal return and supply air openingsC. Downflow duct cover plates

A. ScreenB. Exhaust port

C. Internal vent hood—slotted side faces condenser coil

D. Outer cover

C

B

A

Top View

C

Front View

B

A

A

DPreformed

A. ³⁄₄" PVC fitting (threaded) drain condensate connectionB. ³⁄₄" drain pipes, field providedC. Drain trap outletD. Drain trap inlet

A

B

1" Min.

12" Max.

2" Min.

3" Min.

C

D

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’s responsibility to install a filter rack with the ductwork and to install properly sized filters in accordance with the Minimum Required Surface Area for Disposable Filters chart.All return air must pass through a filter before entering the furnace. An electronic air cleaner, filter rack or other accessible filter arrangement must be installed in the return air ductwork. Minimum recommended filter areas are listed in the Minimum Required Surface Area for Disposable Filters chart, and are based on a face velocity of 325 ft (99.1 m) per min. for disposable filters and 525 ft (160 m) per min. for cleanable filters.

Make Electrical Connections

IMPORTANT: ■ Electrical wiring, disconnect means and over-current

protection are to be supplied by the installer. Refer to the rating plate for the maximum over-current protection, minimum circuit ampacity and operating voltage. See the wiring connection diagrams in “Troubleshooting.”

■ Install an adequate sized branch circuit disconnect, according to the NEC, within sight of and readily accessible to furnace.

■ The cable or conduit and fittings connected from the disconnect switch to the furnace wiring connections shall be rated for outdoor use.

■ Check the furnace rating plate to determine whether the system is rated single phase or three phase and follow the appropriate instructions for connecting the pigtail leads.

■ Plug unused side entry holes with field-supplied plugs to prevent moisture from entering the furnace.

■ Low voltage wiring must be separated from line voltage wiring.

Minimum Required Surface Area for Disposable Filters

Nominal Cooling Filter Area (sq. ft)

24,000 2.67

30,000 3.33

36,000 4.00

42,000 4.67

48,000 5.33

60,000 6.67

WARNING


Disconnect power before servicing.

Replace all parts and panels before operating.

Failure to do so can result in death or electrical shock.

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 using UL listed wire nuts.

For three phase units:

■ Connect the field supply wires (L1, L2, L3) to the 3 black pigtail leads using UL listed wire nuts.

NOTE: Check compressor operation for proper rotation. If the rotation is not correct, then reverse any two leads (for example: L1 and L2). Incorrect rotation is identified by excessive sound or improper system pressures.

Line and Low Voltage Connections

1. Route the low voltage supply wires through the low voltage entry opening to the low voltage connection area providing sufficient length to connect to the low voltage pigtail leads.

2. Using UL listed wire nuts, connect the low voltage supply wires to the matching colors of the low voltage leads.

3. Replace the burner access panel.4. Replace the blower access panel.

WARNING

Rating Plate Ampacity

Less than 15

16 - 20

21 - 30

AWG

14

12

10


Electrically ground furnace.

Connect ground wire to ground terminal marked “GROUND”.

Use copper wire for supply connection.

Correct wire gauge is shown in the chart below.

Failure to follow these instructions can result in death or electrical shock.

31 - 50 8

A. Line voltage supply conduit B. Ground terminal connection C. Line voltage field supply

connections

D. Low voltage connectionsE. Electrical connection box F. Low voltage supply conduit

E D

CB

A

F

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 over 10,000 ft.

Make Gas ConnectionsIMPORTANT: This furnace requires conversion for use with propane. To order the correct conversion kit, see “Accessories.”1. Provide a sediment trap on the outside of the furnace section.2. Install a manual gas shutoff valve in the gas line, outside the

unit in accordance with any local codes.3. Install a test gauge connection with a ¹⁄₈" NPT plugged

tapping immediately upstream of the manual gas shutoff valve as shown.

Connect the gas pipe to the furnace gas valve threaded fitting provided, installing a ground joint union as close to the controls as possible to facilitate removal of controls and manifold. Pipe-joint compounds suitable for use with Natural and LP gas must be used. Do not use Teflon®† tape.

Side entry is the usual method of routing the gas supply to the unit. Use the factory provided grommet to seal the opening around the gas pipe preventing rain and moisture from entering the unit around the gas pipe and reduce noise.

Check Inlet Pressure

1. Remove the burner access panel.2. Turn off the gas supply at the manual gas shutoff valve.

3. Remove the inlet pressure tap plug on the gas control valve. Install a ¹⁄₈" NPT hose connector and connect the pressure gauge tube.

WARNING





†®Teflon is a registered trademark of E.I. Dupont de Nemours and Company.

A. Manual gas shutoff valveB. ¹⁄₈" NPT plugged tappingC. Sediment trap

D. Ground joint unionE. Grommet

A. Closed valveB. Open valve

AB

C

D

E

6" Min.

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

A

B

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 electrical power to the furnace.6. Check minimum inlet gas supply pressure.

■ Turn on all other gas appliances.

■ Observe the pressure rating on the pressure gauge.

■ The minimum inlet gas supply pressure is 5" W.C. for Natural gas and 11" W.C. for propane gas.

7. Check maximum inlet gas supply pressure.■ Turn off all other gas appliances.

■ Observe the pressure reading on the pressure gauge.

■ The maximum inlet gas supply pressure is 10.5" W.C. for Natural gas and 13" W.C. for propane gas.

IMPORTANT: If the inlet gas supply pressure is not within the minimum and maximum range as shown on the rating plate, contact your gas supplier.8. Turn off the electrical power to the furnace.9. Turn off the gas supply at the manual gas shutoff valve.

Remove the pressure gauge tube and the ¹⁄₈" hose connector.10. Replace the inlet pressure tap plug on the gas control valve.11. Turn on the gas supply at the manual gas shutoff valve.12. Test all connections by brushing on an approved

noncorrosive leak-detection solution. Bubbles will show a leak. Correct any leak found.■ At test pressures greater than ¹⁄₂ psig (3.5 kPa), the

furnace and the manual gas shutoff valve must be disconnected from the gas supply piping system.

■ At test pressures less than or equal to ¹⁄₂ psig (3.5 kPa), the furnace must be isolated from the gas supply piping system by closing the manual gas shutoff valve.

13. Replace the burner access panel.

Check the Furnace Input Rate(if required)

IMPORTANT: ■ The furnace input rate must not exceed the input rating on

the furnace rating plate.

■ This furnace is equipped for rated input at manifold pressures of 3.5" W.C. for Natural gas and 11.0" W.C. for propane gas.

■ At altitudes above 4,500 ft the furnace input rate must not exceed that on the furnace rating plate reduced by 4 percent for each 1,000 ft above sea level.

1. For Natural gas, check the furnace rate by observing the gas meter, making sure all other gas appliances are turned off. The test hand on the meter should be timed for at least one revolution.

2. The actual heating value of your gas can be obtained from your local utility company.

NOTE: If the input exceeds the input rating on the furnace rating plate, adjust the manifold pressure.

Adjust Manifold Pressure1. Remove the burner access panel.2. Turn off the gas supply at the manual gas shutoff valve. Use

only your hand to move the gas control knob; tools are not required.

3. Remove the outlet pressure tap plug on the gas control valve and connect pressure gauge to the ¹⁄₈" NPT outlet pressure tap.

4. Be sure the manual gas shutoff valve has been in the Off position for at least 5 minutes before starting the furnace.

5. Turn on the gas supply at the manual gas shutoff valve.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.

6. Turn on the electrical power to the furnace.7. Set the room thermostat to a point above room temperature

to light the main burners.8. Observe the pressure reading on the pressure gauge.9. Refer to the rating plate for the correct manifold pressure. If

necessary, remove the regulator adjusting cap on the gas valve and turn the regulator adjusting screw clockwise to increase pressure, or counterclockwise to decrease pressure.IMPORTANT: If the manifold pressure cannot be adjusted to the value on the furnace rating plate, contact your gas supplier.

10. Turn off the gas supply at the manual gas shutoff valve.11. Disconnect the pressure gauge from the ¹⁄₈" NPT outlet

pressure tap.12. Replace outlet pressure tap plug and the regulator adjusting

cap on the gas valve.

A. Regulator adjusting cap B. NPT inletC. ¹⁄₈" NPT inlet pressure tap

D. ¹⁄₈" NPT outlet pressure tapE. NPT outletF. Gas control switch

A

B

CD

E

F

BTU/HR INPUT

= Cubic feet per Revolution x 3600 x Heating Value# Seconds per Revolution

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 InstallationIMPORTANT: 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 part of the control system and gas control which has been under water.1. Check to be sure you have all of your tools.2. Dispose of/recycle all packaging materials.3. Check the furnace in its final location. Be sure the exhaust

vent is not blocked.

Adjust Blower Speed Multi-Speed Motor Only

You can choose the same speed or different speeds for COOL or HEAT.NOTE: See the wiring connection diagrams in “Troubleshooting.”1. If the temperature rise is too high, change the speed tap to

one step higher. 2. If the temperature rise is too low, change the speed tap to

one step lower.

Blower Speed Tap Change

Manifold Pressure vs. Altitude Chart

Natural Gas

Altitude (ft)Heating Value (Btu/ft3)

Manifold Pressure (in. W.C.) Input Factor

2,000 948 3.50 0.9666

3,000 914 3.50 0.9499

4,000 881 3.50 0.9332

4,500 865 3.50 0.9249

5,000 849 3.29 0.8900

5,500 833 3.27 0.8790

6,000 818 3.25 0.8680

6,500 802 3.23 0.8570

7,000 787 3.21 0.8460

7,500 771 3.19 0.8350

A. Blower motor connector

WARNING





LOWMEDHIGHCOM

A

RedBlue

White

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 Connector1. 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 Board1. Remove the blue and black wires from the HEAT and COOL

terminals and the black jumper wire from the UNUSED terminal.

2. Connect the blue wire to the UNUSED terminal.3. Connect the black jumper wire (piggyback end) to the COOL

terminal.4. Connect the other end of the black jumper wire to the HEAT

terminal.5. Connect the black wire to the black jumper wire (piggyback

end) on the COOL terminal.6. Replace the blower and burner access panels.7. Reconnect power.

To Select Different Speeds for COOL and HEAT

At the Blower Motor Connector1. Disconnect power.2. Remove blower and burner access panels.

3. Place black wire on the HIGH, MED or LOW motor speed tap, as desired for COOLING.

4. Place blue wire on any of the other motor speed taps for HEATING.

At the Unit Control Board1. Place blue wire on the COOL terminal.2. Place red wire on the HEAT terminal.3. Replace blower and burner access panels.4. Reconnect power.

Adjust Blower Speed Variable-Speed Motor Only

Circulation Airflow AdjustmentsThe controls include a variable-speed motor interface board. The ADJUST tap can be used to raise (+) or lower (-) the airflow by 15 percent.

Heating and Cooling AirflowsThe units are factory-set for the correct heating and cooling airflows. However, airflow changes can be made by moving the position of the HEAT and COOL taps. See Adjusting Airflow for Variable-Speed Motor chart.

Continuous BlowerThe comfort level of the living space can be enhanced when using this feature by allowing continuous circulation of air between calls for cooling or heating. The continuous circulation of air occurs at half the full cooling airflow rate. To use this feature, place the thermostat fan switch into the On position.

Cooling Airflow Ramp UpAt the beginning of a call for cooling, the blower will run at 80 percent of full airflow for 7.5 minutes. This improves the system’s moisture removal and saves blower power during cooling start.

Reduced Airflow Operation (Dehumidification)For situations where humidity control is an issue, the variable-speed motor can be connected to operate at a 25 percent reduction in the normal airflow rate. The variable-speed motor interface board provides for connection of a humidistat on the HUM terminal. When a humidistat is connected, the dehumidifier resistor on the interface must be cut. The humidistat should be wired to open during high humidity, which will reduce blower airflow.

ADJUST, HEAT, and COOL Taps and Dehumidify Resistor

Blower Speed Chart for Multi-Speed Motor

Unit Factory-Shipped Settings

Cooling Input Heating Input Heat (BU) Cool (BK)

24 68 MED LOW

30 68 MED MED

36 68 MED HIGH

36 90 HIGH HIGH

42 83 LOW LOW

42 110 LOW LOW

48 83 LOW MED

48 110 LOW MED

48 138 MED MED

60 83 LOW HIGH

60 110 LOW HIGH

60 138 MED HIGH

WARNING





A. Dehumidify LEDB. Dehumidify resistor

DEHUMIDIFY

CUT TO ENABLE

COOLHEATADJUST

NORM ABCD

ABCD

(+)(–)

TEST

D1A

B

13

Measure Temperature Rise1. 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 continue or the package unit will not be used for a period of time, follow the shut down procedure.1. Set the room thermostat to the lowest setting.2. Disconnect power.3. Remove burner access panel.4. Turn off the gas supply at the manual gas shutoff valve.5. Replace the burner access panel.

Gas Control Valve

Adjusting Airflow for Variable-Speed Motor

Model

Motor HP

ADJUST Setting

HEAT Setting

Cooling CFM @ .50 Static

Nominal Cooling kBTU

Heating Input kBTU

COOL Setting A

COOL Setting B

COOL Setting C

COOL Setting D

24, 30 68 ¹⁄₃ NORM A 1,000 800 600 900

36 68 ¹⁄₂ NORM B 1,200 1,000 800 1,100

36 90 ¹⁄₂ NORM A 1,200 1,000 800 1,100

42, 48, 60 83 ³⁄₄ NORM C 1,800 1,600 1,400 1,200

42, 48, 60 110 ³⁄₄ NORM C 1,800 1,600 1,400 1,200

42, 48, 60 138 ³⁄₄ NORM A 1,800 1,600 1,400 1,200

Blower Speed Chart for Variable-Speed Motor

Unit Factory-Shipped Settings

Cooling Input

Heating Input Adjust

Heat (BU)

Cool (BK)

24 68 NORM A B

30 68 NORM A A

36 68 NORM B A

36 90 NORM A A

42 83 NORM C C

42 110 NORM C C

48 83 NORM C B

48 110 NORM C B

48 138 NORM A B

60 83 NORM C A

60 110 NORM C A

60 138 NORM A A

A. Regulator adjusting cap B. NPT inletC. ¹⁄₈" NPT inlet pressure tap

D. ¹⁄₈" NPT outlet pressure tapE. NPT outletF. Gas control switch

A

B

CD

E

F

14

SEQUENCE OF OPERATIONCooling 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 compressor, condenser fan motor and blower motor.

Blower Delay—Cooling

The circulating air blower is controlled by a timing circuit in the integrated blower/ignition control. Timings are not adjustable. Blower “on” delay is 5 seconds after the compressor starts and blower “off” timing is 90 seconds after the cooling system shuts down.

System Performance

For maximum performance of the cooling system, operating temperatures and pressure should be checked. Superheat should be determined at Standard ARI test conditions of 82ºF (27.8ºC) outdoor and 80ºF (26.7ºC) indoor dry bulb/67ºF (19.4ºC) wet bulb. If superheat measured deviates from values found in the Suction Superheat table, refrigerant charge should be adjusted accordingly for maximum performance.

Heating SystemWith the proper thermostat and subbase, continuous blower operation is possible by closing the R to G circuit. Cooling blower delay is also functional in this mode.

Heating Sequence of operation

1. When the thermostat calls for heat, the combustion blower is energized by the ignition control.

2. When the speed of the combustion blower reaches proper RPM, the pressure switch closes, initiating the pre-purge timing (30 seconds nominal).

3. When pre-purge has expired, the ignition control energizes the gas control valve, the spark electrode and the flame sensor. The igniter sparks for 10 seconds, and the flame sensor senses that flame has been established. If the flame sensor does not sense that flame has been established in the 10-second interval, the ignition control will de-energize the gas control valve.

4. The ignition control is designed to repeat this “trial for ignition” a total of three times. If, at the end of the third trial, a flame still has not been established, the ignition control will repeat the trial for ignition sequence 1 hour later. The 1-hour retry is indefinite.

5. Thirty seconds (nominal) after the initial trial for ignition, the circulation air blower will start.

6. When the thermostat is satisfied, the combustion blower and gas control valve are de-energized. The circulating air blower motor will continue to run for a short period after the thermostat is satisfied.

Circulating Air BlowerDepending on the package unit model, the blower motor will be either a multi-speed or variable-speed motor.

Multi-Speed Motor

The circulating air blower is controlled by a timing circuit in the integrated blower/ignition control. Timings are not adjustable.

CoolingBlower “on” delay is 30 seconds after call for cooling. Blower “off” delay is 90 seconds after the cooling system shuts down.

HeatingBlower “on” delay is 30 seconds (nominal) after burner ignition. Blower “off” delay is approximately 120 seconds after the thermostat is satisfied.

Suction Superheat

Series Size

Suction Superheat @ ARI Conditions 82ºF (27.8ºC) OD / 80ºF (26.7ºC) IDDB/67ºF (19.4ºC) IDWB

PGE/SG1324 22º

30, 36, 42, 48, 60 20º

PGEX/SGX1524, 30 15º

36, 42 12º

48, 60 10º

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/StopThe 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 control is located inside the heating compartment and is designed to open at abnormally high air temperatures. It resets automatically. The limit control operates when a high temperature condition, caused by inadequate airflow, occurs. This causes the ignition control to close the gas control valve. The circulation air blower continues to operate in this situation.

Pressure Switch

The pressure switch prevents the gas control valve and igniter from being energized if there is insufficient combustion air due to a failed combustion blower or a blocked vent.

Flame Sensor

If the ignition control does not receive a signal from the flame sensor indicating that the burners have established flame, the gas control valve closes after the 10-second trial for ignition period.

Rollout Switch

The switch is located above the main burners. In the event of a sustained flame rollout, the rollout switch causes the ignition control to close the gas control valve. To reset, push the button on top of the switch.

Auxiliary Limit (42, 48 and 60 units only)

This control is located in the side of the circulation air blower housing. The switch causes the ignition control to close the gas control valve should the circulation blower fail to operate. This control resets automatically.

TROUBLESHOOTINGFurnace Fails to Operate Properly

Review “Sequence of Operation” and visually inspect the following before troubleshooting:

Is the power to the furnace on?Is the manual gas shutoff valve to the furnace open?

Failure Codes

The furnace has a built-in, self-diagnostic capability. The furnace control continuously monitors its own operation and the operation of the system. If a system problem occurs, the LED on the furnace control board flashes a failure code.

See the Failure Codes chart for a description of the LED flash codes.

WARNING





Failure Codes

LED Status Flashing Rate Fault Description

Slow Flash One flash per second Normal Operation: No call for heat

Fast Flash Two flashes per second

Normal operation: Call for heat

2 Flashes Two flashes per second with 1-second pause

System lockout: Failed to detect or sustain flame

3 Flashes Three flashes in 1.5 seconds with 1-second pause

Pressure switch open or closed

4 Flashes Four flashes in 2 seconds with 1-second pause

High limit or rollout switch open

5 Flashes Five flashes in 2.5 seconds with 1-second pause

Flame sensed and gas valve not energized

Steady-

Internal failure: Micro-controller failure; self-check

16

Wiring Connection Diagram—Single Phase, Multi-Speed

YG

W1

RC

YG WR C

BU

G

Y

W

R

24V

AC

16

25

43

Fla

me

FlameSense

GY

BR

BU

OR

R

BK

W

PR

BK

G

PR

OR

W

PR

Mai

nLi

mit

Sw

itch

Rol

lout

Sw

itch

Pre

ssur

eS

witc

h

Aux

.Li

mit

Sw

itch

(If u

sed)

Gas

Val

ve

Fus

e

Igni

tion

Con

trol

BU

Y

R

Y

Contactor

The

rmos

tat

YY

Hig

h P

ress

ure

Sw

itch

(If u

sed)

L1 T1

T2

L2

C HF

Con

dens

erFa

n M

otor

Com

pres

sor

Con

tact

orCom

pres

sor

Con

tact

or

Dua

lC

apac

itor

Com

pres

sor

Transformer

CS

R

L1C

MB

BLW

R

Spa

rk

Com

b.A

irB

low

er

Igni

tion

Con

trol

BK

W

L2L1

BK

BR

PR

R

R

BK

208V

240V

24V

Indo

orB

low

erM

otor

BK

S4

S1

K1

A3

GV

1

S21

S18

S47

S10

T1

B3

B6

B4

K1-

2

C12

B1

K1-

1

A3

Gro

und

BU

Y

LED

Y

E1

C4

Cap

acito

r

HM

LC

ACBCool

ACBHeat

BK

BUJumper (installedon some models)

See

Blo

wer

Spe

ed C

hart

For

Wiri

ng

208/230V-1-60

Wiri

ng C

onne

ctio

n D

iagr

amS

ingl

e S

tage

Hea

t, S

ingl

e P

hase

P/N

481

29-0

01

WARNING





17

Wiring Connection Diagram—Single Phase, Variable-Speed

208/230V-1-60

12

34

56

78

910

1112

1314

1516

12

34

56

78

910

1112

1314

1516

YG

W1

RC

YG WR C

BU

G

Y

W

R

Y RC

ComfortAlert

GY1

Y2OW1

EM

C1

RHU

M

Indo

or B

low

erM

otor

ICM

Boa

rd

BUR

24V

AC

16

25

43

Fla

me

FlameSense

GY

BR

BU

OR

R

YG

BK

W

PR

BK

G PR

OR

WT

PR

Mai

nLi

mit

Sw

itch

Rol

lout

Sw

itch

PressureSwitch

Aux

. Lim

it S

witc

h(I

f use

d)

Gas

Val

ve

Fus

e

Igni

tion

Con

trol

OR

BU

G

BU

Y

R

R

BU R

Y

Con

tact

or

The

rmos

tat

YY

Hig

h P

ress

ure

Sw

itch

(If u

sed)

L1 T1

T2

L2

C HF

Con

dens

erFa

n M

otor

Com

pres

sor

Con

tact

orCom

pres

sor

Con

tact

or

Dua

lC

apac

itor

Com

pres

sor

Tra

nsfo

rmer

CS

R

L1C

MB

BLW

R

Spa

rk

Com

b.A

irB

low

er

Igni

tion

Con

trol

BK

BK W

L2L1

BK

BR

PR

R

R

BK

208V

240V

24V

Indo

orB

low

erM

otor

5 4 3

See

Blo

wer

Spe

edC

hart

BK

S4

S1

K1

A3

GV

1S

21

S18

S47S10

T1

B3

B6

B4

K1-

2

C12

B1

K1-

1

A3

A54 B

3

Gro

und

BU

Y

A13

2

AD

JUS

TH

EAT

CO

OL

NO

RM

(+)

(-)

(TE

ST

)

AB C DA

B C D

DIA

GN

OS

TIC

S

The

follo

win

g ig

nitio

n co

ntro

l boa

rd L

ED

cod

es w

illin

dica

te n

orm

al o

r ab

norm

al o

pera

tions

:

SLO

W F

LAS

H N

orm

al o

pera

tion,

no

call

for

heat

.FA

ST

FLA

SH

Nor

mal

ope

ratio

n, c

all f

or h

eat.

2 F

LAS

HE

S S

yste

m lo

ckou

t.3

FLA

SH

ES

Pre

ssur

e sw

itch

sens

es in

corr

ect p

ress

ure.

.4

FLA

SH

ES

Mai

n lim

it op

en o

r ro

llout

sw

itch

open

.5

FLA

SH

ES

Fla

me

sens

ed a

nd g

as v

alve

not

ene

rgiz

ed.

ST

EA

DY

Int

erna

l fai

lure

(m

icro

-con

trol

ler

failu

re;s

elf c

heck

).

LED

Y

E1

Wiri

ng C

onne

ctio

n D

iagr

amS

ingl

e S

tage

Hea

t, V

aria

ble

Spe

ed, S

ingl

e P

hase

P/N

481

07-0

01

WARNING





18

Typical Low Voltage Connections

R R

CC

YY

W

THERMOSTAT OUTDOOR UNIT

G G

WITH ECONOMIZER

C

RR

Y1Y1

THERMOSTAT OUTDOOR UNIT ECONOMIZER

Y

W

G GG

Y2BK

CBU

G

Y2

WW

OR (Not Used)

WITHOUT ECONOMIZER

19

ASSISTANCE OR SERVICEIf you need further assistance, you can write to the below address with any questions or concerns:

Whirlpool® Home Cooling and Heating14610 Breakers DriveJacksonville, FL 32258

Please include a daytime phone number in your correspondence.

AccessoriesTo 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 ALPKT804-1LP Conversion Kit

W2PG324A068 through W2PG336A090

48193-005 ALPKT805-1 LP Conversion Kit

W2PG342A083 through W2PG360B110

48193-001 ALIFT801-1 Lifting Bracket Kit

All

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, Florida11/05

Printed in U.S.A.

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