Whirlpool W2PG, W4PG Installation Instructions Manual
INSTALLATION INSTRUCTIONS FOR
PACKAGE GAS ELECTRIC FURNACES
Table of Contents
GAS HEATING/ELECTRIC COOLING SAFETY ...........................1
INSTALLATION REQUIREMENTS................................................2
Tools and Parts ............................................................................2
Location Requirements................................................................3
Ductwork Requirements ..............................................................4
Electrical Requirements ...............................................................4
Gas Supply Requirements...........................................................4
FURNACE INSTALLATION INSTRUCTIONS ...............................5
Inspect Shipment......................................................................... 5
Place Furnace in Final Location...................................................5
Convert to Downflow ...................................................................6
Exhaust Vent Assembly ...............................................................6
Connect Condensate Drain .........................................................6
Install Ductwork............................................................................7
Make Electrical Connections .......................................................7
High Altitude Conversion .............................................................9
GAS HEATING/ELECTRIC COOLING SAFETY
Make Gas Connections................................................................9
Check the Furnace Input Rate ...................................................10
Adjust Manifold Pressure...........................................................10
Complete Installation..................................................................11
Adjust Blower Speed Multi-Speed Motor Only .........................11
Adjust Blower Speed Variable-Speed Motor Only ....................12
Measure Temperature Rise........................................................13
Shut Down..................................................................................13
SEQUENCE OF OPERATION ......................................................14
Cooling System ..........................................................................14
Heating System ..........................................................................14
Circulating Air Blower.................................................................14
Controls ......................................................................................15
TROUBLESHOOTING ..................................................................15
ASSISTANCE OR SERVICE.........................................................19
Accessories ................................................................................19
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:
You can be killed or seriously injured if you don't immediately
DANGER
WARNING
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can
happen if the instructions are not followed.
Whirlpool® Models
W2PG, W4PG
48289K005
Whirlpool® Home Cooling and Heating
follow instructions.
can be killed or seriously injured if you don't
You
instructions.
14610 Breakers Drive
Jacksonville, FL 32258
follow
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
■ 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.
connections, as specified in the “Make Gas
Connections” section of these instructions.
SAVE THESE INSTRUCTIONS
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.
ADDITIONAL SAFETY INFORMATION
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.
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 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.
Gather the required tools before starting installation. Read and
follow the instructions provided with any tools listed here.
Tools needed
■ Pipe wrenches
■ Screwdriver
■ Tape measure
■ Thread sealant
Parts needed
Check 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.
Tools and Parts
■ Noncorrosive leak detection solution
■ Test g auge w i th ¹⁄₈" NPT connection
(for measuring gas supply pressure)
2
Location Requirements
WARNING
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.
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
Minimum - 0"
A
30"
36"
2"
B
30"
C
Recommended - 3"
24"
30"
Front side of unit
F
D
E
A. Supply air duct
B. Return air duct
C. Filter access panel
D. Evaporator coil access panel
E. Blower access panel
F. Burner access panel
Minimum Clearance Requirements
To
Combustible
Material
Front 24" 48" 24"
Rear 0" 24" 3"
Condenser
0" 24" 3"
End
Blower End 0" 30" 0"
Top 0" 36" 36"
For
Optimum
Service Access
For
Optimum
Operation
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.
3
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
WARNING
■ 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 Requirements
This 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.
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.
Rating Plate Ampacity
Less than 15
16 - 20
21 - 30
31 - 50 8
NOTE: All outdoor wiring must be suitable for outdoor use. Use
copper conductors only.
AWG
14
12
10
4
FURNACE INSTALLATION INSTRUCTIONS
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.
Inspect Shipment
WARNING
Excessive 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.
Place Furnace in Final Location
WARNING
Excessive 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.
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
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.
A
A. Spreaders
B. Pallet
C. Cables
C
D
E
B
D. Lifting bracket
(accessory lift kit)
E. Sheet metal screw
5
Convert to Downflow
B
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.
B
A
C
Connect Condensate Drain
The 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 panel
B. Horizontal return and supply air openings
C. Downflow duct cover plates
Exhaust Vent Assembly
1. 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.
Front View
A
Preformed
Top View
A
D
C
A
12" Max.
1" Min.
C
D
3" Min.
2" Min.
A.
³⁄₄
" PVC fitting (threaded) drain condensate connection
B.
³⁄₄
" drain pipes, field provided
C. Drain trap outlet
D. Drain trap inlet
B
A. Screen
B. Exhaust port
C. Internal vent hood—slotted side
faces condenser coil
D. Outer cover
6
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