Instruction manual

ManualsBrandsWhirlpool ManualsFurnaceWGGE45

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 ..............................................................6

Filter Requirements......................................................................6

Electrical Requirements ...............................................................7

Gas Supply Requirements...........................................................7

INSTALLATION INSTRUCTIONS..................................................7

Inspect Shipment .........................................................................7

Place Unit in Final Location .........................................................7

Airflow Conversion .......................................................................7

Hood Installation ..........................................................................8

Connect Condensate Drain .........................................................8

Install Ductwork............................................................................8

Make Electrical Connections .......................................................9

Make Gas Connections..............................................................10

Start-up, Adjustments and Checks ...........................................14

Gas Manifold Pressure Measurement and Adjustment.............15

Blower Speed Adjustments........................................................17

Blower Performance Data..........................................................17

Unit Shutdown............................................................................19

Cooling Start-Up ........................................................................19

SEQUENCE OF OPERATION ......................................................20

Heating System ..........................................................................20

Cooling System ..........................................................................20

Fan Only .....................................................................................21

Cooling Start-Up ........................................................................21

MAINTENANCE ............................................................................22

TROUBLESHOOTING ..................................................................23

Unit Fails to Operate Properly....................................................23

Ignition Control Error Codes ......................................................23

Abnormal Operation—Heating...................................................24

Abnormal Operation—Cooling...................................................25

ASSISTANCE OR SERVICE.........................................................28

Accessories ................................................................................28

WPIO-325C

Whirlpool

Home Cooling and Heating

14610 Breakers Drive

Jacksonville, FL 32258

Whirlpool Gold

Models

WGGE45

Goodman 1

Hazards or unsafe practices could result in property

damage, product damage, severe personal injury or death.

Hazards or unsafe practices may result in property

damage, product damage, personal injury or death.

WARNING

CAUTION

Placeholder

for

Bar

Code

Goodman 9

Hazards or unsafe practices may result in property

or product damage.

CAUTION

Summary of content (28 pages)

PAGE 1
PACKAGE GAS ELECTRIC FURNACES INSTALLATION INSTRUCTIONS Table of Contents GAS FURNACE SAFETY................................................................1 INSTALLATION REQUIREMENTS ................................................4 Tools and Parts ............................................................................4 Location Requirements ................................................................4 Ductwork Requirements ..............................................................
PAGE 2
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. ■ Provide adequate combustion and ventilation air to the furnace space as specified in the “Venting Requirements” section of these instructions. ■ Combustion products must be discharged outdoors.
PAGE 3
WARNING 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 water-bearing pipes should be drained, the building should be properly winterized and the water source closed.
PAGE 4
INSTALLATION REQUIREMENTS WARNING ■ To prevent property damage, personal injury or death, due to fire, explosions, smoke, soot, condensation, electric shock or carbon monoxide, this unit must be properly installed, repaired, operated and maintained. 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.
PAGE 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. Unit Dimensions—Rear Roof Curb Installations Only ■ ■ ■ B A Sufficient structural support must be determined prior to locating and mounting the curb and package unit. Ductwork must be constructed using industry guidelines. The ductwork must be placed into the roof curb before mounting the package unit.
PAGE 6
Unit Dimensions—Inside Ductwork Requirements ■ A ■ ■ ■ E F B B 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.
PAGE 7
Electrical Requirements Gas Supply 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.
PAGE 8
Downflow Application Install Combustion Air Intake Hood 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. 1. Locate the second hood. 2.
PAGE 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 WARNING Single-Stage Thermostat To use a single-stage thermostat, move the jumper located to the left of the terminal strip labeled “Stage Delay” from “NONE” to “5 MIN” or “10 MIN.” This selection will cause the control to run on low stage for the selected time (5 or 10 minutes), and then shift to high stage.
PAGE 10
WARNING Goodman 22 Electrical Power Routed Through Bottom of Unit NOTE: Junction box location shown is optional and is for illustration purposes only. To avoid the risk of fire or equipment damage, use copper conductors. CAUTION Label all wires prior to disconnection Goodman 59 when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 3. Disconnect power. 4. Remove the control access panel. 5.
PAGE 11
NOTE: Inlet gas pressure must not exceed the maximum value shown in the Inlet Gas Pressure chart. Inlet Gas Pressure Natural Minimum: 5.0" W.C. Maximum: 10.0" W.C. Propane Minimum: 11.0" W.C. Maximum: 13.0" W.C. 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.
PAGE 12
Proper Piping Practice ■ ■ A Disconnect this unit and its shutoff valve from the gas supply during any pressure testing of the system at test pressures in excess of ¹⁄₂ psig (3.48 kPa). Close the manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ¹⁄₂ psig (3.48 kPa). WARNING To avoid property damage or 91 personal injury, be sure Goodman there is NO OPEN FLAME in the vicinity during air bleeding. B C D A. Manual shutoff valve B.
PAGE 13
Propane Gas Installation—Typical 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. A B C A. 1st stage regulator B.
PAGE 14
Sizing Between Single or 2nd 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. Propane Gas Piping Chart II Tubing Size, O.D. Type L Nominal Pipe Size Schedule 40 Pipe or Tubing Length—ft (m) ³⁄₈" ¹⁄₂" ⁵⁄₈" ³⁄₄" ⁷⁄₈" ¹⁄₂" ³⁄₄" 1" 1¹⁄₄" 1¹⁄₂" 10 (3) 49 110 206 348 539 291 608 1,146 2,353 3,525 20 (6.1) 34 76 141 239 368 200 418 788 1,617 2,423 30 (9.
PAGE 15
Gas Control Valve—White-Rodgers 35G54 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.
PAGE 16
Measuring Inlet Gas Pressure Alternate Method A B C D G F E A. Gas supply line B. Gas shutoff valve C. Gas supply line to furnace D. Open to atmosphere E. Manometer F. Manometer hose G. Dripleg cap with fitting 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.
PAGE 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.
PAGE 18
WGGE4549A115M—Rise Range: 45º to 75º WGGE4537A090M—Rise Range: 45º to 75º Unit Static Unit Static 0.1 0.2 0.3 0.4 0.5 0.6 T1—1st- CFM 1,065 1,003 961 913 855 814 Stage Heating Watts 168 174 185 195 202 212 Speed Amps 1.42 1.48 1.55 1.62 1.69 1.76 Rise 49 52 54 57 60 63 0.7 749 713 218 227 1.82 1.87 69 57 59 62 T3— CFM 1,148 1,092 1,044 994 Cooling Speed Watts 170 176 184 194 Amps 1.55 1.66 1.66 68 70 811 763 715 210 222 224 236 2.03 2.
PAGE 19
Limit Check Cooling Start-Up 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.
PAGE 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.
PAGE 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.
PAGE 22
MAINTENANCE WARNING HIGH VOLTAGE! NOTE: After cleaning, the microamp signal should be stable and in the range of 4 to 6 microamps DC. Flame Sensor Goodman 6 servicing. Disconnect ALL power before A Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
PAGE 23
Manifold Assembly Burner Flame A B Check the burner flames for good adjustment, a stable, soft and blue flame that is not curling, floating or lifting off. C WARNING To avoid personal injury or death due to electrical shock, 96 covers or do not remove anyGoodman internal compartment attempt any adjustment. Contact a qualified servicer at once if an abnormal flame should develop. At least once a year, prior to or during the heating season, make a visual check of the burner flames.
PAGE 24
Diagnostic Indicator Chart Fault Recall The status light on the unit control may be used as a guide to troubleshooting the appliance.
PAGE 25
Rollout Limit Switch 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 prepurge cycle, the induced draft blower will be energized only.
PAGE 26
Wiring Diagram—WGGE45(24, 30, 37, 42, 49, 60) WARNING HIGH VOLTAGE! 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 BU/PK Y LPS Optional Refrigerant Switches Compressor 2nd-stage solenoid not present on all models.
PAGE 27
Wiring Diagram—WGGE45(24, 30, 37, 42, 49, 60) WARNING HIGH VOLTAGE! 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 L1 CC T1 L2 R C COMP L1 H S LO HI C L2 F CM L2 Integrated Ignition Control LO Integrated Ignition Control VM L2 EM L2 HI L1 L1 P1 2 L2 For 208-volt transformer operation, move black wire from Terminal 3 to Terminal 2 on transformer.
PAGE 28
Heating Timing Chart High Circulator Blower Low Off Gas Control Valve High Igniter On Off Induced Draft Blower High Thermostat Low Off Placeholder Low Off High Low Off Seconds 0 15 22 27 52 0 30 90, 120, 150, 180 Cooling Timing Chart High Circulator Blower Low Off High Compressor Low Off Outdoor Fan Placeholder High Low Off Thermostat High Low Off Seconds ASSISTANCE OR SERVICE If you need further assistance, you can write to the below address with any questions or concerns: