Whirlpool WPG Installation Instructions

HIGH ALTITUDE / NATURAL GAS

TO PROPANE CONVERSION KIT

20491502 INSTALLATION INSTRUCTIONS

FOR ALTITUDES 4,500 - 7,000 FT. ONLY

Table of Contents

HIGH ALTITUDE KIT/PROPANE CONVERSION KIT SAFETY ................ 1

INSTALLATION REQUIREMENTS .............................................................2

Tools and Parts.........................................................................................2

Natural Gas Requirements .......................................................................2

LP Gas Requirements............................................................................... 3

INSTALLATION INSTRUCTIONS ...............................................................3

Convert Furnace - High Altitude Natural Gas Conversion....................... 3

Convert Furnace - High Altitude LP Gas Conversion .............................. 4

Make Gas Connections ............................................................................ 6

Check the Furnace Input Rate ................................................................. 7

Adjust the Furnace Input Rate.................................................................. 7

Complete Installation................................................................................ 7

HIGH ALTITUDE KIT/PROPANE CONVERSION KIT SAFETY

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 follow instructions.

can be killed or seriously injured if you don't

You follow instructions.

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

This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fire, explosion, or production of carbon monoxide may result, causing property damage, personal injury, or loss of life. The qualified service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer’s instructions supplied with the kit.

happen if the instructions are not followed.

WARNING

Model WPG

20563001

Caution:

The gas supply shall be shut off prior to disconnecting the electrical power, before proceeding with the conversion.

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 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 instructions supplied with separate equipment before starting the installation.

This kit contains parts and instructions for converting natural gas furnaces for use at altitudes from 4,500 to 7,000 ft. and also parts and instructions for converting furnaces from natural gas to propane at altitudes from 4,500 to 7,000 ft. In these instructions, LP is an abbreviation for propane.

IMPORTANT:

■ For altitudes 7,000 to 10,000 ft above sea level, see Table F.4

in Appendix F of the National Fuel Gas Code (ANSI Z223.1/ NFPA 54, latest edition) for the correct orifice sizes.

■ The furnace is not recommended for installations above

10,000 ft.

■ It is recommended that the conversion be completed prior to

making final gas connections.

Tools and Parts

Check that you have everything necessary for correct installation. Proper installation is your responsibility.

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

Tools Needed:

■ Flat-blade and Phillips

screwdrivers

■ ³⁄₁₆ in. Allen wrench

■ ⁵⁄₁₆ in. nut driver

■ ¹⁄₄ in. nut driver

■ ⁷⁄₁₆ in. open-end wrench

■ Pipe wrench

■ Adjustable wrench

■ Thread sealant

■ Noncorrosive leak

detection solution

■ Test g aug e wi th ¹⁄₈ in. NPT

connection (for measuring gas supply pressure)

Parts Supplied:

High Altitude Conversion for Natural Gas:

■ Pressure switch

High Altitude Conversion for Propane:

■ Pressure switch

■ #8 x 1 in. spoiler

screws (5)

■ Conversion plate label

■ #55 size orifice (5)

■ Gas conversion manifold

label

■ Conversion kit for gas

control valve

Parts Needed:

■ For high altitude conversion for natural gas, read “LP Gas

Requirements” and check local codes and ordinances before purchasing parts.

■ For high altitude conversion to propane, read “Natural Gas

Requirements” before purchasing parts.

Natural Gas Requirements

■ The minimum Natural Gas pressure required at the furnace is

4.5 in. W.C.

■ The maximum Natural Gas pressure allowed at the furnace is

10 in. W.C.

■ An orifice change is required. See “Natural Gas Orifice

Requirements” chart.

Natural Gas Orifice Requirements Altitude (ft) 4,500-6,000 6,000-7,000 Orifice size 44 45

LP Gas Requirements

4 5

The furnace has a regulator in the gas control valve. A regulator is also required on the propane tank. Another regulator is required at the house or unit.

■ The minimum LP Gas pressure required at the furnace

is 11 in. W.C.

■ The maximum LP Gas pressure allowed at the furnace

is 13 in. W.C.

■ An orifice change is required. Use the #55 orifices provided in

the kit for propane conversion.

INSTALLATION

INSTRUCTIONS

Convert Furnace - High Altitude

Natural Gas Conversion

3. Remove the burner access door.

4. Remove the pressure tube and wires from the pressure

switch.

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.

WARNING

1. Orifice locations

2. Rollout switch location

3. Mounting screws

5. Replace the pressure switch with the pressure switch

provided in the kit.

6. Connect the pressure tube and wires to the new pressure

switch.

7. Disconnect all wires from gas control valve.

8. Disconnect the rollout switch and flame sensor wires.

9. Remove the manifold pipe from the burner assembly by

removing the 4 mounting screws.

10. Slide the manifold pipe (with gas control valve) forward and

out of the control compartment.

11. Remove the orifices from the manifold. Thread in the new

Natural Gas orifices of the correct size. See “Natural Gas Orifice Requirements” chart.

Natural Gas Orifice Requirements Altitude (ft) 4,500-6,000 6,000-7,000 Orifice size 44 45

NOTE: Make sure that the orifices are straight and positioned

at a 90º angle to the manifold.

12. Reinstall the manifold pipe to the burner assembly.

13. Reconnect all wires on the gas control valve.

14. Reconnect rollout switch and flame sensor wires.

15. Replace the burner access door.

16. Dispose of all remaining parts.

17. Go to “Make Gas Connections.”

4. Flame sensor location

5. Manifold

6. Pressure switch

Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.

1. Turn off gas supply at manual gas shutoff valve.

2. Disconnect power.

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