PACKAGE GAS ELECTRIC FURNACES INSTALLATION INSTRUCTIONS ATTENTION INSTALLATION PERSONNEL Prior to installation, thoroughly familiarize yourself with this instruction manual. Observe all safety warnings. During installation or repair, caution is to be observed. It is your responsibility to install the product safely and to educate the customer on its safe use. Placeholder for Bar Code Keep this literature in a safe place for future reference. Whirlpool Gold® Model WGGE43 WPIO-357A These installation instructions cover the outdoor installation of single package gas electric heating and cooling units. See the Specification Sheets or Technical Manual applicable to your model for information regarding accessories. Please contact your distributor or our website for the applicable Specification Sheets referred to in this manual. Tradewinds Distributing Company, LLC 14610 Breakers Drive Jacksonville, Florida 32258 TABLE OF CONTENTS SAFETY INSTRUCTIONS...............................................................3 TO THE INSTALLER.......................................................................4 IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY.................................................................4 REPLACEMENT PARTS ................................................................4 UNIT LOCATION.............................................................................4 Ground Level Installations Only ...................................................5 Rooftop Installations Only............................................................5 Roof Curb Installations Only ........................................................5 GENERAL INFORMATION.............................................................6 TRANSPORTATION DAMAGE ......................................................6 RIGGING DETAILS .........................................................................6 GAS PIPING ....................................................................................6 High Altitude Derate—U.S. Installations Only .............................7 Check Gas Piping ........................................................................8 ELECTRICAL WIRING..................................................................10 Thermostat Location ..................................................................10 Unit Voltage ................................................................................11 Heat Anticipator Setting.............................................................11 CIRCULATING AIR AND FILTERS..............................................11 Airflow Conversion .....................................................................11 Ductwork ....................................................................................11 Filters ..........................................................................................12 VENTING .......................................................................................12 CONDENSATE DRAIN .................................................................12 Condensate Drain Connection...................................................12 NORMAL SEQUENCES OF OPERATION...................................12 Heating .......................................................................................12 Cooling .......................................................................................13 Fan Only .....................................................................................13 START-UP, ADJUSTMENTS, AND CHECKS.............................13 Heating Start-Up ........................................................................13 Pre-Operation Checks ...............................................................13 Gas Supply Pressure Measurement ..........................................14 Gas Manifold Pressure Measurement and Adjustment ............15 Gas Input Rate Check—Natural Gas Only ................................15 Main Burner Flame Check .........................................................16 2 Temperature Rise Check............................................................16 External Static Pressure Check .................................................16 Blower Speed Adjustments........................................................16 Limit Check.................................................................................16 UNIT SHUTDOWN ........................................................................17 COOLING START-UP...................................................................17 Compressor Protection Devices ................................................17 Cooling Refrigerant Charging.....................................................17 TROUBLESHOOTING ..................................................................17 Ignition Control Error Codes ......................................................17 Abnormal Operation—Heating...................................................17 Abnormal Operation—Cooling...................................................18 MAINTENANCE ............................................................................18 Filter Replacement or Cleaning..................................................18 Cabinet Finish Maintenance.......................................................18 Clean Outside Coil—Qualified Servicer Only.............................18 Condenser, Evaporator and Induced Drafter Motors ................18 Flame Sensor—Qualified Servicer Only.....................................19 Flue Passages—Qualified Servicer Only ...................................19 Cleaning Flue Passages—Qualified Servicer Only ....................19 Main Burner Flame—Qualified Servicer Only ............................19 Burner Flame ..............................................................................19 Cleaning Burners........................................................................19 ACCESSORIES AND FUNCTIONAL PARTS ..............................20 Sheet Metal Accessories............................................................20 Functional Parts..........................................................................20 General Information....................................................................20 APPENDIX .....................................................................................20 Blower Performance Data—Single Phase .................................20 Ignition Control Diagnostic Indicator Chart ...............................25 Heating Timing Chart .................................................................26 Cooling Timing Chart .................................................................26 Unit Dimensions .........................................................................27 Minimum Clearances..................................................................27 Wiring Diagram—WGGE4324, 30, 36, 42..................................28 Wiring Diagram—WGGE4324, 30, 36, 42..................................29 Wiring Diagram—WGGE4348, 60..............................................30 Wiring Diagram—WGGE4348, 60..............................................31 ASSISTANCE OR SERVICE .........................................................32 SAFETY INSTRUCTIONS The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards. It is the owner’s and installer’s responsibility to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of personal injury, property damage and/or product damage. Recognize this symbol as a safety precaution. WARNING Hazards or unsafe practices1could result in property Goodman damage, product damage, severe personal injury or death. CAUTION Hazards or unsafe practices may result in property damage, product damage, personal injury or death. WARNING Do not connect to or use any device that is not designGoodman 36 damage, certified for use with this unit. Serious property personal injury, reduced unit performance and/or hazardous conditions may result from the use of such non-approved devices. WARNING HIGH VOLTAGE! Disconnect ALL power before servicing. WARNING To avoid property damage, personal injury or death, do not use this furnace if any part of the furnace has been under water. Immediately call a qualified service technician to inspect the furnace and to replace any part of the control system and any gas control having been under Goodman 81 water. WARNING This unit must not be used as a “construction heater” during the finishing phases of construction on a new Goodman 79 structure. This type of use may result in premature failure of the unit due to extremely low return air temperatures and exposure to corrosive or very dirty atmospheres. WARNING Installation and repair of this unit should be performed ONLY by individuals meeting the requirements of an “Entry Level Technician,” at a minimum, as specified by the Air-Conditioning, Heating and Refrigeration Institute (AHRI). Attempting to install or repair this unit without such background may result in product damage, personal injury or death. Goodman 42 Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. WARNING Should overheating occur or the gas43 supply fail to shut Goodman off, turn off the manual gas shutoff valve external to the furnace before turning off the electrical supply. WARNING This product containsGoodman or produces a45 chemical or chemicals which may cause serious illness or death and which are known to the State of California to cause cancer, birth defects or other reproductive harm. WARNING If the information in these instructions is not followed exactly, a fire or explosion may result causing property Goodman 42 damage, personal injury or loss of life. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. — Installation and service must be performed by a qualified installer, service agency or the gas supplier. WARNING To prevent the risk of property damage, personal injury, or death, do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this unit. 3 WARNING Heating unit should not be utilized without reasonable, routine inspection, maintenance and supervision. If the building in which any Goodman such device is47 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. In the event that the building may be exposed to freezing temperatures and will be vacant, any hydronic coil units should be drained as well, and, in such case, alternative heat sources should be utilized. DANGER IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY Your warranty certificate is supplied as a separate document with the unit installed by your contractor. Read the limited warranty certificate carefully to determine what is and is not covered. Keep the warranty certificate in a safe place. If you are unable to locate the warranty certificate, please contact your installing contractor, or contact customer service at 1-866-944-7575 to obtain a copy. To receive the 10-Year Parts Limited Warranty, online registration must be completed within 60 days of installation. Online registration is not required in California or Quebec. Full warranty details and instructions are available at www.whirlpoolhvac.com. To register your unit, go to www.whirlpoolhvac.com. Click on the manufacturer’s Comfort CommitmentTM Warranty link located at the bottom center of the home page. Next, click on the Click Here to Register Your Product link located at the top center of the page, and complete the forms in the manner indicated. REPLACEMENT PARTS CARBON MONOXIDE POISONING HAZARD Special Warning for Installation of Furnace or Air Handling Goodman 38 Utility Rooms or Units in Enclosed Areas such as Garages, Parking Areas. Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation. This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode. CO can cause serious illness including permanent brain damage or death. When reporting shortages or damages, or ordering repair parts, give the complete product model and serial numbers as stamped on the unit’s nameplate. Replacement parts for this product are available through your contractor or local distributor. For the location of your nearest distributor, consult the white business pages, the yellow page section of the local telephone book or contact: Tradewinds Distributing Company, LLC 14610 Breakers Drive Jacksonville, Florida 32258 1-866-944-7575 If you are replacing an air handler, the system must be manufacturer-approved and Air-Conditioning, Heating, and Refrigeration Institute (AHRI) matched. NOTE: Installation of unmatched systems is strongly discouraged. UNIT LOCATION WARNING To prevent possible equipment damage, Goodman 50 property damage, personal injury or death, the following bullet points must be observed when installing the unit. ■ TO THE INSTALLER Before installing this unit, please read this manual to familiarize yourself on the specific items which must be adhered to, including maximum external static pressure to unit, air temperature rise, minimum or maximum CFM and motor speed connections. 4 ■ For proper flame pattern within the heat exchanger and proper condensate drainage, the unit must be mounted level. The flue outlet hood must be at least 12" (30.5 cm) from any opening through which flue gases could enter a building, and at least 36" (91.4 cm) above any forced air inlet located within 10 ft (3 m). The economizer/manual fresh air intake/motorized fresh air intake and combustion air inlet mounted on the unit are not affected by this restriction. ■ ■ ■ ■ ■ To avoid possible corrosion of the heat exchanger, do not locate the unit in an area where the outdoor air (for example, combustion air for the unit) will be frequently contaminated by compounds containing chlorine or fluorine. Common sources of such compounds include swimming pool chemicals and chlorine bleaches, paint stripper, adhesives, paints, varnishes, sealers, waxes (which are not yet dried) and solvents used during construction and remodeling. Various commercial and industrial processes may also be sources of chlorine/fluorine compounds. To avoid possible illness or death of the building occupants, do not locate outside air intake device (economizer, manual fresh air intake, motorized fresh air intake) too close to an exhaust outlet, gas vent termination or plumbing vent outlet. For specific distances required, consult local codes. Allow minimum clearances from the enclosure for fire protection, proper operation, and service access. These clearances must be permanently maintained. The combustion air inlet and flue outlet hoods on the unit must never be obstructed. If used, do not allow the economizer/manual fresh air damper/ motorized fresh air damper to become blocked by snow or debris. In some climates or locations, it may be necessary to elevate the unit to avoid these problems. When the unit is heating, the temperature of the return air entering the unit must be between 50°F and 100°F (10ºC and 38ºC). Ground Level Installations Only ■ ■ When the unit is installed on the ground adjacent to the building, a level concrete (or equal) base is recommended. Prepare a base that is 3" (7.6 cm) larger than the package unit footprint and a minimum of 3" (7.6 cm) thick. The base should also be located where no runoff of water from higher ground can collect in the unit. Rooftop Installation ■ ■ The unit may be installed directly on wood floors or on Class A, Class B, or Class C roof covering material. To avoid possible personal injury, a safe, flat surface for service personnel should be provided. Roof Curb Installations Only ■ ■ ■ 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. Curb insulation, cant strips, flashing and general roofing material are furnished by the contractor. Roof Curb Installation Ground Level Installation Rooftop Installations Only NOTE: To ensure proper condensate drainage, unit must be installed in a level position. ■ To avoid possible property damage or personal injury, the roof must have sufficient structural strength to carry the weight of the unit(s) and snow or water loads as required by local codes. Consult a structural engineer to determine the weight capabilities of the roof. 5 GENERAL INFORMATION RIGGING DETAILS WARNING 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. To prevent property damage, the unit should remain in an upright position during all rigging and moving operations. To facilitate lifting and moving when a crane is used, place the unit in an adequate cable sling. This unit is approved for outdoor installation only. To assure that your unit operates safely and efficiently, it must be installed, operated, and maintained in accordance with these installation and operating instructions, all local building codes and ordinances, or in their absence, with the latest edition of the National Fuel Gas Code NFPA54/ANSI Z223.1 and National Standard of Canada CAN/CSA B149 Installation Codes. The heating and cooling capacities of the unit should be greater than or equal to the design heating and cooling loads of the area to be conditioned. The loads should be calculated by an approved method or in accordance with A.S.H.R.A.E. Guide or Manual J - Load Calculations published by the Air Conditioning Contractors of America. Obtain from: American National Standards Institute 430 Broadway New York, NY 10018 IMPORTANT: If using the bottom discharge with the roof curb, the ductwork should be attached to the curb prior to installing the unit. Ductwork dimensions are shown in the roof curb installation instructions. Refer to “Roof Curb Installations Only” for the proper curb installation. Curbing must be installed in compliance with the National Roofing Contractors Association Manual. Lower the unit carefully onto the roof mounting curb. While rigging the unit, the center of gravity will cause the condenser end to be lower than the supply air end. Rigging TRANSPORTATION DAMAGE Check the carton upon arrival for external damage. If damage is found, a request for inspection by carrier agent should be made in writing immediately. Carefully inspect the unit for damage including damage to the cabinetry. Any bolts or screws which may have loosened in transit must be retightened. In the event of damage, the receiver should: 1. Make notation on delivery receipt of any visible damage to shipment or container. 2. Notify carrier promptly and request an inspection. 3. In case of concealed damage, carrier should be notified as soon as possible—preferably within 5 days. 4. File the claim with the following supporting documents: a) Original Bill of Lading, certified copy, or indemnity bond. b) Original paid freight bill or indemnity in lieu thereof. c) Original invoice or certified copy thereof, showing trade and other discounts or reductions. d) Copy of the inspection report issued by carrier representative at the time damage is reported to the carrier. The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage. NOTE: When inspecting the unit for transportation damage, remove all packaging materials. Recycle or dispose of the packaging material according to local codes. 6 GAS PIPING IMPORTANT NOTE: This unit is factory set to operate on natural gas at the altitudes shown on the rating plate. WARNING To avoid property damage, personal injury or death when either using propane gas alone or at higher altitudes, obtain and installGoodman the proper 89 conversion kit(s). Failure to do so can result in unsatisfactory operation and/or equipment damage. High altitude kits are for U.S. installations only and are not approved for use in Canada. The rating plate is stamped with the model number, type of gas and gas input rating. Make sure the unit is equipped to operate on the type of gas available. Conversion to LP gas is permitted with the use of the factory-authorized conversion kit LPM-03. NOTES: ■ LPT-00A may be used on models with AA revisions. ■ LPT-03 is compatible with both the White Rodgers and the Honeywell gas control valves. 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. Overfiring of the unit could result in premature heat exchanger failure. High Altitude Derate—U.S. Installations Only IMPORTANT: The gas/electric units naturally derate with altitude. Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure. This can cause poor combustion and equipment failure. At all altitudes, the manifold pressure must be within 0.3" W.C. of that listed on the nameplate for the fuel used. At all altitudes and with either fuel, the air temperature rise must be within the range listed on the unit nameplate. Refer to the installation manual provided with the LP kit for conversion from Natural gas to propane gas and for altitude adjustments. NOTE: Up to 7,000 ft (2,134 m), no changes are required; above 7,000 ft (2,134 m), refer to High Altitude Kit HA-02. IMPORTANT NOTE: To avoid possible unsatisfactory operation or equipment damage due to under firing of equipment, do not undersize the Natural/propane gas piping from the meter/tank to the unit. When sizing a trunk line, include all appliances on that line that could be operated simultaneously. The rating plate is stamped with the model number, type of gas and gas input rating. Make sure that the unit is equipped to operate on the type of gas available. The gas line installation must comply with local codes, or in the absence of local codes, with the latest edition of the National Fuel Gas Code NFPA 54/ ANSI Z223.1. Pressure = 0.50 psig or less and pressure drop of 0.3" W.C. (Based on 0.60 specific gravity gas) Btu/h Unit Input CFH = Heating Value of Gas (Btu/Cu Ft) Refer to the “Proper Piping Practice” illustration for the general layout at the unit. The following rules apply: 1. Use black iron pipe and fittings for the supply piping. The use of a flex connector and/or copper piping is permitted as long as it is in agreement with local codes. 2. Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used. 3. Use ground joint unions. 4. Install a drip leg to trap dirt and moisture before it can enter the gas control valve. The drip leg must be a minimum of 3" (7.6 cm) long. 5. Use 2 pipe wrenches when making the connection to the gas control valve to keep the valve from turning. 6. Install a manual shutoff valve in a convenient location (within 6 ft [1.8 m] of the unit) between the meter and the unit. 7. Tighten all joints securely. 8. The unit must be connected to the building piping by one of the following methods: ■ Rigid metallic pipe and fittings ■ Semirigid metallic tubing and metallic fittings (aluminum alloy tubing must not be used in exterior locations) ■ Listed gas appliance connectors used in accordance with the terms of their listing that are completely in the same room as the equipment ■ The connector or tubing must be protected against physical and thermal damage. Aluminum alloy tubing and connectors must be coated to avoid external corrosion when in contact with masonry, plaster or insulation or are subject to repeated wettings by liquids (water—not rainwater, detergents or sewage). Proper Piping Practice Natural Gas Connection A Natural Gas Capacity of Pipe in Cu Ft (m3) of Gas Per Hour (CFH) Nominal Black Pipe Size Length of Pipe—ft (m) ¹⁄₂" ³⁄₄" 1" 1¹⁄₄" 1¹⁄₂" 10 (3) 132 278 520 1,050 1,600 20 (6.1) 92 190 350 730 1,100 30 (9.2) 73 152 285 590 980 40 (12.2) 63 130 245 500 760 50 (15.2) 56 115 215 440 670 60 (18.3) 50 105 195 400 610 70 (21.3) 46 96 180 370 560 80 (24.4) 43 90 170 350 530 90 (27.4) 40 84 160 320 490 100 (30.5) 38 79 150 305 460 B C D A. Manual shutoff valve B. Drip leg C. Ground joint union (installed upstream of gas control valve) D. Grommet NOTE: The unit gas supply entrance is factory sealed with plugs. Keep plugs in place until gas supply is ready to be installed. Once ready, replace the plugs with the supplied grommets and install gas supply line. 7 Check Gas Piping CAUTION To prevent property damage or personal injury due to fire, the following instructions must be performed regarding gas connections Goodman and pressure testing: 90 -The unit and its gas connections must be leak tested before placing in operation. Because of the danger of explosion or fire, never use a match or open flame to test for leaks. Never exceed specified pressures for testing. Higher pressure may damage gas control valve and cause overfiring which may result in premature heat exchange failure. -The unit and its gas shutoff valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of ¹⁄₂ psig (3.48 kPa). -This unit must be isolated from the gas supply system by closing its 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. There will be air in the gas supply line after testing for leaks on a new installation. Therefore, the air must be bled from the line by loosening the ground joint union until pure gas is expelled. Tighten the ground joint union and wait for 5 minutes until all gas has been dissipated in the air. Be certain there is no open flame in the vicinity during air bleeding procedure. The unit is placed in operation by closing the main electrical disconnect switch for the unit. NOTE: Propane gas conversion kits must be installed to convert units to propane gas. A gas detecting warning system is the only reliable way to detect a propane gas leak. Rust can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58. For satisfactory operation, propane gas supply pressure must be within 9.7" W.C. to 10.3" W.C. at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on 3 main factors: ■ Vaporization rate, depending on the temperature of the liquid and the wetted surface area of the container or containers. ■ Proper pressure regulation. Two-stage regulation is recommended for both cost and efficiency. ■ Pressure drop in the lines between the regulators, and between 2nd stage regulator and the appliance. Pipe size required will depend on the length of the pipe run and the total load of all appliances. 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. Propane Gas Installation—Typical A B C D WARNING To avoid property damage, personal injury or death due to fire or explosion caused by Goodman a propane gas 92 leak, install a gas detecting warning device. Since rust can reduce the level of odorant in propane gas, a gas detecting warning device is the only reliable way to detect a propane gas leak. Contact a local propane gas supplier about installing a gas detecting warning device. 8 A. 1st stage regulator B. 5 to 15 psig (20 psig maximum) C. 2nd stage regulator D. Continuous 11" W.C. NOTE: 200 psig maximum tank pressure. Sizing Between 1st and 2nd Stage Regulator* Maximum propane capacities listed are based on 1 psig pressure drop at 10 psig setting. Capacities in 1,000 Btu/h. Propane Gas Pipe Sizing Chart I 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" 30 (9.2) 309 700 1,303 2,205 3,394 1,843 3,854 40 (12.2) 265 599 1,115 1,887 2,904 1,577 3,298 50 (15.2) 235 531 988 1,672 2,574 1,398 2,923 60 (18.3) 213 481 896 1,515 2,332 1,267 2,649 70 (21.3) 196 446 824 1,394 2,146 1,165 2,437 80 (24.4) 182 412 767 1,297 1,996 1,084 2,267 90 (27.4) 171 386 719 1,217 1,873 1,017 2,127 100 (30.5) 161 365 679 1,149 1,769 961 2,009 150 (45.7) 130 293 546 923 1,421 772 1,613 200 (61) 111 251 467 790 1,216 660 1,381 250 (76.2) 90 222 414 700 1,078 585 1,224 300 (91.4) 89 201 378 634 976 530 1,109 350 (106.7) 82 185 345 584 898 488 1,020 400 (121.9) 76 172 321 543 836 454 949 To convert to capacities at 15 psig settings—multiply by 1.13. To convert to capacities at 5 psig settings—multiply by 0.879. 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 Pipe Sizing 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 (9.2) 27 61 114 192 296 161 336 632 1,299 1,946 40 (12.2) 23 52 97 164 253 137 284 541 1,111 1,665 50 (15.2) 20 46 86 146 224 122 255 480 985 1,476 60 (18.3) 19 42 78 132 203 110 231 436 892 1,337 80 (24.4) 16 36 67 113 174 94 198 372 764 1,144 100 (30.5) 14 32 59 100 154 84 175 330 677 1,014 125 (38.1) 12 28 52 89 137 74 155 292 600 899 150 (45.7) 11 26 48 80 124 67 141 265 544 815 200 (61) 10 22 41 69 106 58 120 227 465 697 250 (76.2) 9 19 36 61 94 51 107 201 412 618 300 (91.4) 8 18 33 55 85 46 97 182 374 560 350 (106.7) 7 16 30 51 78 43 89 167 344 515 400 (121.9) 7 15 28 47 73 40 83 156 320 479 Data in accordance with NFPA pamphlet Number 54. 9 WARNING To prevent property damage or serious personal injury due to fire or explosion caused by a propane gas leak, Goodman 102device. install a gas detecting warning If the propane gas unit is installed in an excavated area or a confined space, a warning device is required due to: -Propane gas is heavier than air and any leaking gas can settle in any low areas or confined spaces. -Propane gas odorant may fade, making the gas undetectable except with a warning device. Refer to the unit wiring diagram for electrical connections. When installed, the unit must be electrically grounded in accordance with local codes or in the absence of local codes, with the National Electrical Code, ANSI/NFPA No. 70, and/or the CSA C22.1 Electrical Code. Ensure that the low voltage connections are waterproof. WARNING Goodman 70 To avoid the risk of electrical shock, wiring to the unit must be polarized and grounded. WARNING ELECTRICAL WIRING Goodman 22 To avoid the risk of fire or equipment damage, use copper conductors. Thermostat Location Mount the thermostat approximately 5 ft (1.5 m) above the floor, in an area that has an inside, vibration-free wall and has good air circulation. Movement of air must not be obstructed by furniture, door, draperies, etc. The thermostat must not be mounted where it will be affected by drafts, hot or cold water pipes or air ducts in walls, radiant heat from fireplace, lamps, the sun, television, etc. Consult the Instruction Sheet packaged with the thermostat for mounting instructions. All units have 1 stage of heating and 1 stage of mechanical cooling. Units which will have economizers may use thermostats with 1 or 2 stages of cooling. WARNING HIGH VOLTAGE! 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. For unit protection, use a time-delay fuse or HACR circuit breaker that is in excess of the circuit ampacity, but less than or equal to the maximum overcurrent protection device. IMPORTANT: Do not exceed the maximum overcurrent device size shown on the unit data plate. All line voltage connections must be made through weatherproof fittings. All exterior power supply and ground wiring must be in approved weatherproof conduit. Low voltage wiring from the unit control panel to the thermostat requires coded cable. Disconnect ALL power before servicing. Electrical Power Directly to Junction Box Goodman 42 Multiple power sources may be present. NOTE: Junction box location shown is optional and is for illustration purposes only. Failure to do so may cause property damage, personal injury or death. The units are designed for operation on 60 hertz current and at voltages as shown on the rating plate. All internal wiring in the unit is complete. It is necessary to bring in the power supply to the contactor as shown on the unit wiring diagram which is supplied with each unit. 24-volt wiring must be connected between the unit control panel and the room thermostat. Low Voltage Wiring B18099-18 L2 HEAT COOL 1068-83-400A L2 K4 6 3 2 2 5 1 2 5 4 1 4 1 4 7 ECON F1 BREAK FOR TWO STAGE COMPRESSOR FUSE 3 AMP MAX 120 135 P3 P2 C22 T1 SPEED-UP 150 T2 10 3 6 9 6 9 12 12 9 8 7 11 11 10 8 10 11 12 7 10 3 K1 P1 R Y W G FS K2 ANSI Z21.20 AUTOMATIC IGNITION SYSTEM 24VAC 50/60Hz 400mA MAX. C R YWG Low Voltage Connector DI MODEL 1068-400 L1 L1 L2 L2 UNUSED K3 Electrical Power Routed Through Bottom of Unit Duct Cover Installations—Down-Discharge NOTE: Junction box location shown is optional and is for illustration purposes only. Remove the panels for down-discharge duct applications AB A. Supply air panel B. Return air panel Down-Discharge Applications Unit Voltage The unit transformer is factory-connected for 230V operation. If the unit is to operate on 208V, reconnect the transformer primary lead as shown on the unit wiring diagram. Heat Anticipator Setting The heat anticipator is to be set by measuring the load (amperage) at the R circuit. Follow the instructions provided by the thermostat for more details. Typical Thermostat and Unit 24V Wiring Hookup G Y R From Unit W R W Y G CIRCULATING AIR AND FILTERS Airflow Conversion Units can easily be converted from horizontal to down-discharge airflow delivery. In down-discharge or high-static installations, the installer should measure the total external static and review the blower performance charts before performing the installation. In some installations, it will be necessary to change the blower speed to provide proper airflow. Cut insulation around bottom openings and remove panels from the bottom of the unit, saving the screws holding the panels in place. NOTE: Single-phase models require installation of horizontal duct kit #20464501PDGK (medium chassis) and #20464502PDGK (large chassis). Ductwork Duct systems and register sizes must be properly designed for the C.F.M. and external static pressure rating of the unit. Ductwork should be designed in accordance with the recommended methods of Air Conditioning Contractors of America Manual D (Residential) or Manual Q (Commercial). All ductwork exposed to the outdoors must include a weatherproof barrier and adequate insulation. A duct system should be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B. The supply duct from the unit through a wall may be installed without clearance. However, minimum unit clearances must be maintained. The supply duct should be provided with an access panel large enough to inspect the air chamber downstream of the heat exchanger. A cover should be tightly attached to prevent air leaks. For duct flange dimensions on the unit, refer to the Unit Dimension illustration in the Appendix. For down-discharge applications, the ductwork should be attached to the roof curb prior to installing the unit. Ductwork dimensions are shown in the roof curb installation manual. If desired, supply and return duct connections to the unit may be made with flexible connections to reduce possible unit operating sound transmission. 11 Filters CONDENSATE DRAIN CAUTION To prevent property damage due to fire and loss of equipment efficiency or equipment damage due to dust and lint build up on internal parts, never operate unit without an air filter installed in the return air system. Even though a return air filter is not supplied with this unit, there must be a means of filtering all return air. All units may be externally filtered. Refer to the unit filter size chart in the Appendix for filter size information. Filters installed external to the unit should be sized in accordance with their manufacturer recommendations. A throwaway filter must be sized for a maximum face velocity of 300 ft per minute. Filter Installation IMPORTANT: When installing a filter, the airflow arrows on the filter must point toward the circulator blower. VENTING Install the flue exhaust hood, screen and lower flue hood prior to operation of the unit. To install the flue hood cover, please refer to IO-653*, included in the flue hood assembly box located in the blower compartment. Flue Hood and Bug Screen Installation A B C E A. Flue exhaust hood B. Screen C. Lower flue hood 12 D D. Combustion air intake hood E. Heat exchanger door Condensate Drain Connection A ³⁄₄" (1.9 cm) NPT drain connection is supplied for condensate piping. An external trap must be installed for proper condensate drainage. Drain Connection A F E B C D A. Drain connection B. 2" (5.1 cm) minimum C. 3" (7.6 cm) minimum D. Positive liquid seal (required) E. Flexible tubing, hose or pipe F. Unit NORMAL SEQUENCES OF OPERATION Heating This unit is equipped with an ignition control that automatically lights the main burner. NOTE: Do not attempt to light the main burners by any other method. 1. Thermostat calls for heat. The induced draft blower energizes for a 15-second pre-purge. 2. The spark igniter and gas control valve energizes for 7 seconds. NOTE: The igniter produces a very intense electrical spark that ignites the gas. 3. The 30-second Heat Fan On delay time begins. 4. The unit delivers heat to the conditioned space until the thermostat is satisfied. 5. The gas control valve de-energizes. The induced draft blower continues operation for a 29-second post-purge. 6. Ignition control begins timing the Heat Fan Off delay. There is an adjustable Heat Fan Off delay of approximately 120/135/ 150 seconds (factory-set at 150). After the Heat Fan Off delay time has elapsed, the blower will de-energize. This allows any additional heat in the heat exchanger to be transferred to the conditioned space. Rollout Protection on Burner Bracket Cooling 1. Thermostat calls for cooling. The compressor and outdoor fan are energized. 2. Approximately 7 seconds later, the indoor fan starts. 3. The unit will deliver cooling to the conditioned space until the thermostat is satisfied. 4. The compressor and outdoor fan will be de-energized when the thermostat opens. 5. The indoor fan continues to run for approximately 60 seconds after the thermostat is satisfied. This allows additional cooling from the indoor coil to be transferred to the conditioned space. Then, the indoor fan stops. NOTE: A 180-second anti-short cycle is integral to the control and prevents recycling of the compressor. A A. Rollout protection Fan Only 1. Thermostat calls for Fan Only by energizing G. 2. Approximately 7 seconds later, the indoor fan starts. 3. The indoor fan continues to run for approximately 60 seconds after G is de-energized. START-UP, ADJUSTMENTS, AND CHECKS Heating Start-Up 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. Once the blower compartment temperature drops below the limit reset temperature, the limit will automatically reset. Secondary Limit Control This unit is equipped with an electronic ignition device to automatically light the main burners. It also has a power vent blower to exhaust combustion products. On new installations, or if a major component has been replaced, the operation of the unit must be checked. Check unit operation as outlined in the following instructions. If any sparking, odors or unusual sounds are encountered, shut off electrical power and recheck for wiring errors or obstructions in or near the blower motors. Duct covers must be removed before operating unit. A Heat Anticipator Setting B Set the heat anticipator on the room thermostat to 0.4 amps to obtain the proper number of heating cycles per hour and to prevent the room temperature from overshooting the room thermostat setting. A. Secondary limit control B. Back of unit Rollout Protection Control The rollout protection device opens, cutting power to the gas control valve, if the flames from the burners are not properly drawn into the heat exchanger. The rollout protection device is located on the burner bracket. The reason for elevated temperatures at the control should be determined and repaired prior to resetting this manual reset control. WARNING To avoid property damage, personal injury or death due to fire or explosion, a qualifiedGoodman servicer must 94 investigate the reason for the rollout protection device to open before manually resetting the rollout protection device. Pre-Operation Checks 1. 2. 3. 4. Close the manual gas shutoff valve external to the unit. Turn off the electrical power supply to the unit. Set the room thermostat to its lowest possible setting. Remove the heat exchanger door on the side of the unit by removing the screws. IMPORTANT: This unit is equipped with an ignition device which automatically lights the main burner. Do not try to light burner by any other method. 5. Move the gas control valve switch to the OFF position. NOTE: Do not force the switch to turn. 6. Wait 5 minutes to clear out any gas. 7. Check for a gas odor around the unit, including near the ground because some types of gas are heavier than air. 13 IMPORTANT: If you have waited 5 minutes and you do smell gas, immediately leave the building and call your gas supplier or the fire department from a neighbor’s house. 8. If you have waited 5 minutes and there is no gas odor, move the gas control valve switch to the On position. 9. Replace the heat exchanger door on the side of the unit. 10. Open the manual gas shutoff valve external to the unit. 11. Turn on the electrical power supply to the unit. 12. Set the thermostat to the desired setting. The line pressure supplied to the gas control valve must be within the range specified in the Inlet Gas Supply Pressure chart on the next page. The supply pressure can be measured at the gas control valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the unit Off. To measure inlet pressure, use the following procedure. Gas Control Valve—White-Rodgers 36G22 D C Gas Control Valve—White-Rodgers 36G22 E A C A B F A. Inlet B. Inlet pressure tap C. Pressure regulator—under cap screw B A. Inlet B. On/Off selector switch C. Outlet Gas Control Valve—Honeywell VR8215 Single Stage Gas Control Valve—Honeywell VR8215 Single Stage C B C A B A. Inlet B. On/Off selector switch C. Outlet Gas Supply And Manifold Check Gas supply pressure and manifold pressure with the burners operating must be as specified on the rating plate. Gas Supply Pressure Measurement CAUTION To prevent unreliable operation or equipment damage, the inlet gas supply pressure must be as specified on the unit rating plate with all other household gas-fired appliances operating. 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. 14 D. Outlet pressure tap E. Outlet F. On/Off selector switch D E A F A. Inlet B. Inlet pressure tap C. Pressure regulator—under cap screw D. Outlet pressure tap E. Outlet F. On/Off selector switch 1. Turn off the gas supply to furnace at the manual gas shutoff valve external to the furnace. 2. Turn off all electrical power to the system. 3. Inlet pressure tap connections: ■ Honeywell VR8215 valve: Remove the inlet pressure boss plug. Install an ¹⁄₈" NPT hose barb fitting into the inlet pressure tap. ■ White-Rodgers 36G22 valve: Back inlet pressure test screw (inlet pressure boss) out one turn counterclockwise (not more than one turn). 4. Attach a hose and manometer to the inlet pressure barb fitting (Honeywell valve) or inlet pressure boss (White-Rodgers valve). 5. Turn on the gas supply. 6. Turn on power and close thermostat R and W1 contacts to provide a call for heat. 7. Using a leak detection solution or soap suds, check for leaks at the outlet pressure boss plug (Honeywell valve) or screw (White-Rodgers valve). Bubbles forming indicate a leak. IMPORTANT: If a leak is detected, turn off gas immediately and repair all leaks. 8. Measure the gas supply pressure with burners firing. Adjust supply pressure using the Inlet Gas Supply Pressure chart. If supply pressure reading differs from the chart, make necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility. Inlet Gas Supply Pressure Natural Gas Minimum: 5.0" W.C. Maximum: 10.0" W.C. Propane Gas Minimum: 11.0" W.C. Maximum: 13.0" W.C. 9. Turn off all electrical power and gas supply to the system. 10. Remove the manometer hose from the hose barb fitting or inlet pressure boss. 11. Replace inlet pressure tap: ■ Honeywell VR8215 valve: Remove the ¹⁄₈" NPT hose barb fitting from the inlet pressure tap. Replace the inlet pressure boss plug and seal with a high quality thread sealer. ■ White-Rodgers 36G22 valve: Turn inlet pressure test screw in to seal pressure port (clockwise, 7 in.-lb minimum). 12. Retest for leaks. IMPORTANT: If a leak is detected, turn off gas immediately and repair all leaks. 13. Turn on electrical power and gas supply to the system. 14. Turn on valve switch. Gas Manifold Pressure Measurement and Adjustment CAUTION To prevent unreliable operation Goodman 65 or equipment damage, the gas manifold pressure must be as specified on the unit rating plate. Only minor adjustments should be made by adjusting the gas control valve pressure regulator. 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. 1. Turn off the gas supply to furnace at the manual gas shutoff valve external to the furnace. 2. Turn off all electrical power to the system. 3. Outlet pressure tap connections: ■ Honeywell VR8215 valve: Remove the outlet pressure boss plug. Install an ¹⁄₈" NPT hose barb fitting into the outlet pressure tap. ■ White-Rodgers 36G22 valve: Back outlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more than one turn). 4. Attach a hose and manometer to the outlet pressure barb fitting (Honeywell valve) or outlet pressure boss (White-Rodgers valve). 5. Turn on the gas supply. 6. Turn on power and close thermostat R and W1 contacts to provide a call for heat. 7. Using a leak detection solution or soap suds, check for leaks at the outlet pressure boss plug (Honeywell valve) or screw (White-Rodgers valve). Bubbles forming indicate a leak. IMPORTANT: If a leak is detected, turn off gas immediately and repair all leaks. 8. Measure the gas manifold pressure with burners firing. 9. Adjust manifold pressure using the Manifold Gas Pressure chart. Manifold Gas Pressure Natural Gas 3.5" W.C. Propane Gas 10.0" W.C. 10. Remove the regulator cover screw from the outlet pressure regulator adjust tower. 11. Turn the screw clockwise to increase pressure or counterclockwise to decrease pressure. 12. Replace the regulator cover screw. 13. Turn off all electrical power and gas supply to the system. 14. Remove the manometer hose from the hose barb fitting or outlet pressure boss. 15. Replace the outlet pressure tap: ■ Honeywell VR8215 valve: Remove the ¹⁄₈" NPT hose barb fitting from the outlet pressure tap. Replace the outlet pressure boss plug and seal with a high quality thread sealer. ■ White-Rodgers 36G22 valve: Turn the outlet pressure test screw in to seal pressure port (clockwise, 7 in.-lb minimum). 16. Turn on electrical power and gas supply to the system. 17. Close the thermostat contacts to provide a call for heat. 18. Using a leak detection solution or soap suds, check for leaks at the outlet pressure boss plug (Honeywell valve) or screw (White-Rodgers valve). Bubbles forming indicate a leak. IMPORTANT: If a leak is detected, turn off gas immediately and repair all leaks. Gas Input Rate Check—Natural Gas Only To measure Natural gas input, use a gas meter and proceed as follows: 1. Turn off the gas supply to all other gas-burning appliances except the furnace. 2. While the unit is operating, time and record one complete revolution of the smallest gas meter dial. 3. Calculate the number of seconds per cubic foot (sec/ft3) of gas being delivered to the furnace. If the dial is a one cubic foot dial, divide the number of seconds recorded in Step 2 by one. If the dial is a 2 cubic foot dial, divide the number of seconds recorded in Step 2 by 2. 4. With the unit operating, time the smallest dial on the meter for one complete revolution. If this is a 2 cubic foot dial, divide the seconds by 2; if it is a 1 cubic foot dial, use the seconds as is. This gives the seconds per cubic foot of gas being delivered to the unit. 5. INPUT = GAS HTG VALUE x 3,600 / SEC. PER CUBIC FOOT Example: Natural gas with a heating value of 1,000 Btu per cubic foot and 34 seconds per cubic foot as determined by Step 2, then: Input = 1,000 x 3,600 / 34 = 106,000 Btu per Hour. 15 Some models are equipped with X-13 motors. X-13 motors are constant torque motors with very low power consumption. This motor is energized by 24V. Adjust the CFM for the unit by changing the 24V low voltage leads to the speed terminal block on the motor. Heating-White Lead ■ T4—Low Speed ■ T2—Medium Speed ■ T5—High Speed ■ T3—High Speed NOTE: Heating airflow must be adjusted to provide the temperature rise shown on rating plate. Limit Check Check limit control operation after 15 minutes of operation by blocking the return air grille(s). 1. After several minutes the main burners must go Off. Blower will continue to run. 2. Remove air restrictions and main burners will relight after a cool down period of a few minutes. 3. Adjust the thermostat setting below room temperature. ■ Main burners must go Off. Circulating Air Blower will continue to run for 120, 135 or 150 seconds, depending on the setting. 10 11 5 8 2 11 2 6 9 12 3 12 3 9 6 K1 FS C27 ■ 1 R10 R38 D3 C13 R8 R22 D9 R29 K2 D1 Z1 D10 L1 R34 R3 L1 R35 Check the temperature rise through the unit by placing thermometers in supply and return air registers as close to the unit as possible. Thermometers must not be able to sample temperature directly from the unit heat exchangers, or false readings could be obtained. 1. All registers must be open; all duct dampers must be in their final (fully or partially open) position and the unit operated for 15 minutes before taking readings. 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 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. A slower blower speed will increase the temperature rise. NOTE: Blower speed must be set to give the correct air temperature rise through the unit as marked on the rating plate. T1—Low Speed R25 Temperature Rise Check ■ D5 Flames should be stable, soft and blue (dust may cause orange tips but they must not be yellow) and extending directly outward from the burner without curling, floating or lifting off. Cooling-Yellow Lead R31 Main Burner Flame Check D7 NOTE: Btu content of the gas should be obtained from the gas supplier. This measured input must not be greater than shown on the unit rating plate. 6. Relight all other appliances turned off in Step 1. Be sure all pilot burners are operating. L2 UNUSED C20 L2 K3 L2 D14 K4 R11 R42 D12 COOL L2 D11 HEAT R4 External Static Pressure Check The total external static pressure must be checked on this unit to determine if the airflow is proper. R36 LED Blower Speed Adjustments WARNING Goodman 117 To avoid personal injury or death due to electrical shock, turn OFF power to the furnace before changing speed taps. Refer to the wiring diagram in the Appendix to verify speed tap settings. For models equipped with PSC type motors, blower speeds are to be changed at the ignition control board. Both heat speed and cool speed terminals are supplied on the board along with 2 unused motor lead terminals. 16 1068-83-400A NOTE: If necessary, adjust the Fan Off Delay settings to obtain satisfactory comfort level. WARNING This unit must not be used as a “construction heater” during the finishing phases of construction on a new structure. This type of use may result in premature failure of the unit due to extremely low return air temperatures and exposure to corrosive or very dirty atmospheres. UNIT SHUTDOWN 1. Set the thermostat to lowest setting. 2. Turn off the electrical power supply to the unit. 3. Remove the heat exchanger door on the side of the unit by removing screws. 4. Move the gas control valve switch to the Off position. NOTE: Do not force. 5. Close the manual gas shutoff valve external to the unit. 6. Replace the heat exchanger door on the unit. 7. If cooling and/or air circulation will be desired, turn on the electrical power. 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 protect the compressor against abnormal operating conditions. TROUBLESHOOTING Ignition Control Error Codes The following presents probable causes of questionable unit operation. Refer to Diagnostic Indicator Chart for an interpretation of the signal and to this section for an explanation. Remove the control box access panel and note the number of diagnostic LED flashes. Refer to Diagnostic Indicator Chart for an interpretation of the signal and to this section for an explanation. Abnormal Operation—Heating Internal Control Failure If the integrated ignition control in this unit encounters an internal fault, it will go into a “hard” lockout and turn off the diagnostic LED. If diagnostic LED indicates an internal fault, check the power supply to the unit for the proper voltage, check all fuses, circuit breakers and wiring. Disconnect electric power for 5 seconds. If LED remains off after restoring power, replace control. External Lockout WARNING To prevent personal injury or death, always disconnect electrical power before inspecting or servicing the unit. All compressor protection devices reset automatically, energizing the contactor and outdoor fan. Cooling Refrigerant Charging Check unit charge before putting the cooling section into full operation. The unit is factory charged with R-410A for nominal airflow and static pressure conditions. The unit has a piston flowrator expansion device. To ensure the unit is properly charged for the intended application, check the unit refrigerant superheat at the compressor. The refrigerant superheat is a function of outdoor ambient temperature and return air temperature of the conditioned space. It is the installing contractors responsibility to ensure the proper refrigerant superheat at the compressor is adjusted for each application. For example, 10º refrigerant superheat level is adequate for a 95ºF (35ºC) outdoor ambient temperature and a 78ºF to 80ºF (26ºC to 27ºC) for indoor return air temperature. As the outdoor ambient temperature rises, the superheat decreases and as the outdoor ambient temperature lowers the superheat increases. Proper superheat adjustment optimizes cooling performance. Cooling Operation NOTE: Mechanical cooling cannot be reliably provided at ambient temperatures below 50°F (10ºC). 1. Turn on the electrical power supply to the unit. 2. Place the room thermostat selector switch in the COOL position (or AUTO if available, and if automatic changeover from cooling to heating is desired). 3. Set the room thermostat to the desired temperature. An external lockout occurs if the integrated ignition control determines that a measurable combustion cannot be established within 3 consecutive ignition attempts. If flame is not established within the 7-second trial for ignition, the gas control valve is de-energized, 15-second inter-purge cycle is completed, and ignition is reattempted. The control will repeat this routine 3 times if a measurable combustion is not established. The control will then shut off the induced draft blower and go into a lockout state. If flame is established but lost, the control will energize the circulator blower at the heat speed and then begin a new ignition sequence. If flame is established then lost on subsequent attempts, the control will recycle for 4 consecutive ignition attempts (5 attempts total) before locking out. The diagnostic fault code is 1 flash for a lockout due to failed ignition attempts or flame dropouts. The integrated control will automatically reset after 1 hour, or it can be reset by removing the thermostat signal or disconnecting the electrical power supply for over 5 seconds. If the diagnostic LED indicates an external lockout, perform the following checks: ■ Check the supply and manifold pressures. ■ Check the gas orifices for debris. ■ Check gas control valve for proper operation. ■ Check secondary limit. A dirty filter, excessive duct static, insufficient airflow, a faulty limit or a failed circulator blower can cause this limit to open. Check filters, total external duct static, circulator blower motor, blower motor speed tap (see wiring diagram) and limit. An interruption in electrical power during a heating cycle may also cause the auxiliary limit to open. The automatic reset secondary limit is located on top of the circulator blower assembly. ■ Check rollout limit. If the burner flames are not properly drawn into the heat exchanger, the flame rollout protection device will open. Possible causes are restricted or blocked flue passages, blocked or cracked heat exchanger, a failed induced draft blower or insufficient combustion air. The rollout protection device is a manual reset limit located on the burner bracket. The cause of the flame rollout must be determined and corrected before resetting the limit. 17 Check flame sensor. A drop in flame signal can be caused by nearly invisible coating on the sensor. Remove the sensor and carefully clean with steel wool. Check wiring. Check wiring for opens/shorts and incorrect wiring. IMPORTANT: If you have to frequently reset your gas/electric package unit, it means that a problem exists that should be corrected. Contact a qualified servicer for further information. ■ ■ Pressure Switch Stuck Open A pressure switch stuck open can be caused by a faulty pressure switch, faulty wiring, a disconnected or damaged hose, a blocked or restricted flue or a faulty induced draft blower. If the control senses an open pressure switch during the prepurge cycle, the induced draft blower only will be energized. If the pressure switch opens after ignition has begun, the gas control valve is de-energized, the circulator blower heat-off cycle begins, and the induced draft blower remains on. The diagnostic fault code is 2 flashes. Pressure Switch Stuck Closed A stuck closed pressure switch can be caused by a faulty pressure switch or faulty wiring. If the control encounters a pressure switch stuck closed, the induced draft blower remains off. The diagnostic LED code for this fault is 3 flashes. Open Thermal Protection Device If the primary limit switch opens, the gas control valve is immediately de-energized, and the induced draft and air circulating blowers are energized. The induced draft and air circulator blowers remain energized until the limit switch recloses. The diagnostic fault code for an open limit is 4 flashes. A primary limit will open due to excessive supply air temperatures. This can be caused by a dirty filter, excessive duct static, insufficient airflow or a faulty limit. Check filters, total external duct static, blower motor, blower motor speed tap (see wiring diagram) and limit. This limit will automatically reset once the temperature falls below a preset level. Flame Detected with Gas Control Valve Closed If flame is detected with the gas control valve de-energized, the combustion and air circulator blowers are energized. The diagnostic fault code is 5 flashes for this condition. The control can be reset by removing the power supply to the unit or it will automatically reset after one hour. Incorrect wiring is the probable cause for this fault. Abnormal Operation—Cooling Short Cycle Compressor Delay The automatic ignition control has a built-in feature that prevents damage to the compressor in short-cycling situations. In the event of intermittent power losses or intermittent thermostat operation, the ignition control will delay output to the compressor contactor for 3 minutes from the time power is restored. Compressor is off a total of 3 minutes. The diagnostic LED will flash 6 times to indicate the compressor contactor output is being delayed. 18 NOTE: Some electronic thermostats also have a built-in compressor short-cycle timer that may be longer than the 3-minute delay given above. If you are using an electronic thermostat and the compressor has not started after 3 minutes, wait an additional 5 minutes to allow the thermostat to complete its short-cycle delay time. MAINTENANCE 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. Have the gas heating section of the unit checked at least once a year before the heating season begins to be sure that the combustion air inlet and flue outlet hoods are not blocked by debris, which would prevent adequate combustion air and a properly operating vent system. Filter Replacement or Cleaning A return air filter is not supplied with this unit; however, there must be a means of filtering all of the return air. The filter(s) may be located in the return air duct(s) or return air filter grille(s). Consult with your installing dealer for the actual location of the return air filter(s) for your unit. Dirty filters are the most common cause of inadequate heating or cooling performance. Filter inspection should be made at least every 2 months; more often if necessary because of local conditions and usage. Dirty throwaway filters should be discarded and replaced with a new, clean filter. Dirty permanent filters should be washed with water, thoroughly dried and sprayed with a filter adhesive before being reinstalled. (Filter adhesives may be found at many hardware stores.) Permanent filters should last several years. However, should one become torn or uncleanable, it should be replaced. Cabinet Finish Maintenance Use a fine grade automotive wax on the cabinet finish to maintain the finish’s original high luster. This is especially important in installations with extended periods of direct sunlight. Clean Outside Coil—Qualified Servicer Only The coil with the outside air flowing over it should be inspected annually and cleaned as frequently as necessary to keep the finned areas free of lint, hair and debris. Condenser, Evaporator and Induced Drafter Motors Bearings on the air circulating blower motor, condenser motor and the combustion fan motor are permanently lubricated. No additional oiling is required. Flame Sensor—Qualified Servicer Only A drop in the flame current can be caused by a nearly invisible coating on the flame sensor. This coating, created by the fuel or combustion air supply, can be removed by carefully cleaning the flame sensor with steel wool. NOTE: After cleaning, the microamp signal should be stable and in the range of 4 to 6 microamps DC. Main Burner Flame—Qualified Servicer Only Flames should be stable, soft and blue (dust may cause orange tips but must not be yellow). The flames must extend directly outward from the burner without curling, floating or lifting off. A NOTE: Check the burner flames for good adjustment, stable, soft and blue with no curling, floating or lifting off. Burner Flame A. Flame sensor Flue Passages—Qualified Servicer Only At the start of each heating season, inspect and, if necessary, clean the unit flue passage. Cleaning Flue Passages—Qualified Servicer Only 1. Shut off electric power and gas supply to the unit. 2. Remove burner assembly by disconnecting the gas line and removing the manifold bracket from the partition panel. 3. Remove the flue from the induced draft blower and the collector box cover from the partition panel. 4. The primary heat exchanger tubes can be cleaned using a round wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach a variable speed reversible drill to the other end of the spring cable. Slowly rotate the cable with the drill and insert it into one of the primary heat exchanger tubes. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Use a large cable for the large tube, and then repeat the operation with a small cable for the smaller tube. Repeat for each tube. 5. When all heat exchanger tubes have been cleaned, replace the parts in the reverse order in which they were removed. 6. To reduce the chances of repeated fouling of the heat exchanger, perform the steps listed in “Start-up, Adjustments and Checks.” WARNING To avoid personal injury or death due to electrical shock, do not remove any internal compartment covers or 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. NOTE: This will involve removing and reinstalling the heat exchanger door on the unit, which is held by 2 screws. If you are uncertain about your ability to do this, contact a qualified servicer. If a strong wind is blowing, it may alter the airflow pattern within the unit enough that an inspection of the burner flames is not possible. Cleaning Burners 1. Shut off electric power and gas supply to the unit. 2. Remove the screws securing the manifold to the burner retention bracket. Remove the manifold and rotate each burner counterclockwise to remove. Manifold Assembly A B C A. Burner bracket B. Burner C. Manifold 19 3. Remove the burners. 4. Use a bottle brush to clean burner insert and inside of the burners. 5. Replace burners and manifold, inspect the burner assembly for proper seating of burners in retention slots. 6. Reconnect electrical power and gas supply. CAUTION Always verify proper operation after servicing. For further information on the yearly inspection, consult the User Manual. It is recommended that a qualified servicer inspect and service the unit at least once each year. Turn the unit on at the thermostat. Wait a few minutes, since any dislodged dust will alter the normal flame appearance. Flames should be predominantly blue and directed into the tubes. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports. WARNING Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. ACCESSORIES AND FUNCTIONAL PARTS Functional Parts List Sheet Metal Accessories ■ Additional accessories can be purchased to fit specific application needs. Parts and instructions are available from your distributor. ■ ■ ■ Functional Parts ■ ■ Functional Parts List ■ ■ ■ ■ ■ ■ ■ Auxiliary Limit Switch Blower Housing Circulator Blower Motor Blower Wheel Burner Capacitor Compressor ■ ■ ■ ■ ■ ■ ■ Condenser Coil Condenser Fan Blade Condenser Fan Motor Contactor Gas Manifold Evaporator Coil ■ ■ ■ ■ ■ Ignition Control Induced Draft Blower Pressure Switch Pressure Switch Hose Transformer General Information Flame Roll-out Switch Flame Sensor Gas Orifice Gas Control Valve Heat Exchanger High Limit Switch Igniter ■ ■ ■ Refer to the description in Functional Parts List when ordering any of the listed functional parts. Be sure to provide the unit model and serial numbers with the order. Although only functional parts are shown, all sheet metal parts, doors, etc., may be ordered by description. Parts are available from your distributor. APPENDIX Blower Performance Data—Single Phase Unit Low Med High Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4324A045M Rise Range: 30º to 60º 0.1 600 150 0.67 57 850 230 1.02 40 1,190 380 1.67 NR 0.2 570 140 0.65 60 830 220 1.00 41 1,140 360 1.62 NR 0.3 510 130 0.63 NR 765 215 0.97 45 1,080 350 1.58 32 0.4 450 125 0.61 NR 715 210 0.94 48 1,025 340 1.54 33 0.5 380 120 0.58 NR 660 205 0.90 52 975 330 1.38 35 0.6 --- --- --- NR 610 195 0.88 56 920 310 1.37 37 0.7 --- --- --- NR --- --- --- NR 830 300 1.35 41 0.8 --- --- --- NR --- --- --- NR 730 290 1.32 47 20 Unit Low Med High Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4324A070M Rise Range: 35º to 65º 0.1 600 150 0.67 NR 850 230 1.02 NR 1,190 380 1.67 43 0.2 570 140 0.65 NR 830 220 1.00 NR 1,140 360 1.62 45 0.3 510 130 0.63 NR 765 215 0.97 NR 1,080 350 1.58 47 0.4 450 125 0.61 NR 715 210 0.94 NR 1,025 340 1.54 50 0.5 380 120 0.58 NR 660 205 0.90 NR 975 330 1.38 52 0.6 --- --- --- NR 610 195 0.88 NR 920 310 1.37 56 WGGE4330A045M Rise Range: 35º to 65º WGGE4330A070M Rise Range: 35º to 65º WGGE4336A070M Rise Range: 35º to 65º WGGE4336A090M Rise Range: 45º to 75º 0.7 --- --- --- NR --- --- --- NR 830 300 1.35 62 0.8 --- --- --- NR --- --- --- NR 730 290 1.32 NR 0.1 1,056 350 1.51 33 1,261 452 1.95 NR 1,370 509 2.23 NR 0.2 1,010 339 1.43 34 1,221 442 1.90 NR 1,310 492 2.13 NR 0.3 971 343 1.45 36 1.174 428 1.84 NR 1,262 489 2.09 NR 0.4 937 329 1.41 37 1,125 414 1.80 31 1,208 475 2.06 NR 0.5 878 318 1.27 39 1,063 398 1.70 32 1,140 453 1.93 30 0.6 811 306 1.29 43 1,004 380 1.66 34 1,081 440 1.90 32 0.7 723 291 1.21 48 919 368 1.59 38 1,006 425 1.88 34 0.8 545 259 1.10 NR 796 371 1.46 43 879 403 1.74 39 0.1 1,056 350 1.51 49 1,261 452 1.95 41 1,370 509 2.23 38 0.2 1,010 339 1.43 51 1,221 442 1.90 42 1,310 492 2.13 40 0.3 971 343 1.45 53 1.174 428 1.84 44 1,262 489 2.09 41 0.4 937 329 1.41 55 1,125 414 1.80 46 1,208 475 2.06 43 0.5 878 318 1.27 59 1,063 398 1.70 49 1,140 453 1.93 45 0.6 811 306 1.29 64 1,004 380 1.66 52 1,081 440 1.90 48 0.7 723 291 1.21 NR 919 368 1.59 56 1,006 425 1.88 NR 0.8 545 259 1.10 NR 796 371 1.46 65 879 403 1.74 NR 0.1 1,029 346 1.51 50 1,337 471 2.08 39 1,462 596 2.64 35 0.2 982 334 1.46 53 1,265 452 2.01 41 1,398 563 2.58 37 0.3 946 329 1.40 55 1,227 448 1.97 42 1,326 550 2.50 39 0.4 888 313 1.38 58 1,159 429 1.87 45 1,260 534 2.42 41 0.5 823 304 1.29 63 1,073 405 1.73 48 1,188 513 2.34 44 0.6 750 287 1.23 NR 1,008 393 1.71 51 1,090 496 2.22 47 0.7 668 271 1.16 NR 895 371 1.61 58 997 478 2.18 52 0.8 454 238 1.00 NR 760 346 1.49 68 852 454 2.12 61 0.1 1,029 346 1.51 50 1,337 471 2.08 NR 1,462 596 2.64 NR 0.2 982 334 1.46 53 1,265 452 2.01 NR 1,398 563 2.58 NR 0.3 946 329 1.40 55 1,227 448 1.97 NR 1,326 550 2.50 NR 0.4 888 313 1.38 58 1,159 429 1.87 45 1,260 534 2.42 NR 0.5 823 304 1.29 63 1,073 405 1.73 48 1,188 513 2.34 NR 0.6 750 287 1.23 NR 1,008 393 1.71 51 1,090 496 2.22 47 0.7 668 271 1.16 NR 895 371 1.61 58 997 478 2.18 52 0.8 454 238 1.00 NR 760 346 1.49 68 852 454 2.12 61 21 Unit Low Med High Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4342A070M Rise Range: 35º to 65º 0.1 1,100 340 1.55 46 1,450 480 2.15 35 1,575 585 2.64 NR 0.2 1,040 325 1.49 49 1,390 460 2.06 37 1,515 565 2.58 NR 0.3 1,000 320 1.44 51 1,300 445 1.98 39 1,430 550 2.50 36 0.4 925 305 1.38 55 1,215 425 1.89 42 1,340 525 2.42 38 0.5 860 290 1.32 59 1,115 395 1.79 46 1,240 505 2.34 41 0.6 800 275 1.22 64 1,030 375 1.71 50 1,130 465 2.22 45 0.7 690 255 1.16 NR 945 350 1.60 54 1,010 450 2.18 51 0.8 --- --- --- NR 860 335 1.54 59 910 430 2.12 56 0.1 1,100 340 1.55 62 1,450 480 2.15 47 1,575 585 2.64 NR 0.2 1,040 325 1.49 66 1,390 460 2.06 49 1,515 565 2.58 45 0.3 1,000 320 1.44 68 1,300 445 1.98 52 1,430 550 2.50 48 0.4 925 305 1.38 74 1,215 425 1.89 56 1,340 525 2.42 51 0.5 860 290 1.32 NR 1,115 395 1.79 61 1,240 505 2.34 55 0.6 800 275 1.22 NR 1,030 375 1.71 66 1,130 465 2.22 60 0.7 690 255 1.16 NR 945 350 1.60 72 1,010 450 2.18 67 0.8 --- --- --- NR 860 335 1.54 NR 910 430 2.12 75 WGGE4342A070M Rise Range: 45º to 75º Unit T1 Heating Speed T2 Heating Speed T3 Heating Speed Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4348A070M Rise Range: 35º to 65º 0.1 --- --- --- --- --- --- --- --- --- --- --- --- 0.2 914 125 1.07 56 1,105 186 1.56 46 1,397 323 2.57 NR 0.3 822 134 1.14 62 1,024 193 1.60 50 1,346 331 2.67 NR 0.4 733 140 1.20 69 967 202 1.65 53 1,288 342 2.76 NR 0.5 664 150 1.26 NR 884 214 1.76 58 1,273 352 2.82 NR 0.6 606 154 1.28 NR 816 220 1.75 62 1,178 359 2.88 NR 0.7 584 162 1.32 NR 769 230 1.85 66 1,120 369 2.97 45 0.8 551 164 1.34 NR 698 236 1.89 73 1,057 381 3.09 48 Unit T4 Cooling Speed 22 T5 Cooling Speed Static CFM Watts Amps CFM Watts Amps 0.1 --- --- --- --- 0.2 1,593 449 3.55 1,669 532 4.22 0.3 1,545 463 3.69 1,654 239 4.25 0.4 1,506 476 3.82 1,610 551 4.30 0.5 1,448 481 3.87 1,545 557 4.36 0.6 1,400 493 3.95 1,512 566 4.41 0.7 1,341 502 4.00 1,433 578 4.59 0.8 1,289 511 4.11 1,392 591 4.65 --- --- Unit T1 Heating Speed T2 Heating Speed T3 Heating Speed Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4348A090M Rise Range: 45º to 75º 0.1 --- --- --- --- --- --- --- --- --- --- --- --- 0.2 914 125 1.07 75 1,105 186 1.56 62 1,397 323 2.57 49 0.3 822 134 1.14 NR 1,024 193 1.60 67 1,346 331 2.67 51 0.4 733 140 1.20 NR 967 202 1.65 71 1,288 342 2.76 53 0.5 664 150 1.26 NR 884 214 1.76 NR 1,273 352 2.82 54 0.6 606 154 1.28 NR 816 220 1.75 NR 1,178 359 2.88 58 0.7 584 162 1.32 NR 769 230 1.85 NR 1,120 369 2.97 61 0.8 551 164 1.34 NR 698 236 1.89 NR 1,057 381 3.09 65 Unit T4 Cooling Speed T5 Cooling Speed Static CFM Watts Amps CFM Watts Amps 0.1 --- --- --- --- 0.2 1,593 449 3.55 1,669 532 4.22 0.3 1,545 463 3.69 1,654 239 4.25 0.4 1,506 476 3.82 1,610 551 4.30 0.5 1,448 481 3.87 1,545 557 4.36 0.6 1,400 493 3.95 1,512 566 4.41 0.7 1,341 502 4.00 1,433 578 4.59 0.8 1,289 511 4.11 1,392 591 4.65 Unit T1 Heating Speed --- --- T2 Heating Speed T3 Heating Speed Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4348A115M Rise Range: 45º to 75º 0.1 --- --- --- --- --- --- --- --- --- --- --- --- 0.2 914 125 1.07 NR 1,105 186 1.56 77 1,397 323 2.57 49 0.3 822 134 1.14 NR 1,024 193 1.60 NR 1,346 331 2.67 51 0.4 733 140 1.20 NR 967 202 1.65 NR 1,288 342 2.76 53 0.5 664 150 1.26 NR 884 214 1.76 NR 1,273 352 2.82 54 0.6 606 154 1.28 NR 816 220 1.75 NR 1,178 359 2.88 58 0.7 584 162 1.32 NR 769 230 1.85 NR 1,120 369 2.97 61 0.8 551 164 1.34 NR 698 236 1.89 NR 1,057 381 3.09 65 Unit T4 Cooling Speed T5 Cooling Speed Static CFM Watts Amps CFM Watts Amps 0.1 --- --- --- --- 0.2 1,593 449 3.55 1,669 532 4.22 0.3 1,545 463 3.69 1,654 239 4.25 0.4 1,506 476 3.82 1,610 551 4.30 0.5 1,448 481 3.87 1,545 557 4.36 0.6 1,400 493 3.95 1,512 566 4.41 0.7 1,341 502 4.00 1,433 578 4.59 0.8 1,289 511 4.11 1,392 591 4.65 --- --- 23 Unit T1 Heating Speed T2 Heating Speed T3 Heating Speed Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4360A090M Rise Range: 45º to 75º 0.1 1,125 162 1.44 61 1,466 315 2.67 47 1,780 496 3.33 NR 0.2 1,049 168 1.53 65 1,384 322 2.74 50 1,730 506 3.89 NR 0.3 1,000 178 1.60 69 1,347 329 2.78 51 1,664 520 4.01 NR 0.4 910 184 1.64 75 1,291 341 2.83 53 1,608 526 4.03 NR 0.5 857 197 1.75 NR 1,237 350 2.90 55 1,568 532 4.12 NR 0.6 809 201 1.83 NR 1,185 362 3.05 58 1,515 546 4.14 45 0.7 739 207 1.86 NR 1,134 369 3.09 60 1,477 552 4.18 46 0.8 703 218 1.96 NR 1,087 382 3.21 63 1,422 562 4.23 48 Unit T4 Cooling Speed T5 Cooling Speed Static CFM Watts Amps CFM Watts Amps 0.1 1,942 649 4.83 2,067 792 5.81 0.2 1,883 657 4.87 2,030 811 5.85 0.3 1,859 670 4.96 1,982 814 5.88 0.4 1,827 675 4.97 1,909 808 5.86 0.5 1,749 683 4.99 1,842 798 5.85 0.6 1,706 693 5.10 1,789 772 5.65 0.7 1,655 703 5.12 1,703 763 5.58 0.8 1,588 705 5.11 1,618 732 5.29 Unit T1 Heating Speed T2 Heating Speed T3 Heating Speed Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4360A115M Rise Range: 45º to 75º 0.1 1,125 162 1.44 NR 1,466 315 2.67 58 1,780 496 3.33 48 0.2 1,049 168 1.53 NR 1,384 322 2.74 62 1,730 506 3.89 49 0.3 1,000 178 1.60 NR 1,347 329 2.78 63 1,664 520 4.01 51 0.4 910 184 1.64 NR 1,291 341 2.83 66 1,608 526 4.03 53 0.5 857 197 1.75 NR 1,237 350 2.90 69 1,568 532 4.12 54 0.6 809 201 1.83 NR 1,185 362 3.05 72 1,515 546 4.14 56 0.7 739 207 1.86 NR 1,134 369 3.09 NR 1,477 552 4.18 58 0.8 703 218 1.96 NR 1,087 382 3.21 NR 1,422 562 4.23 60 Unit T4 Cooling Speed 24 T5 Cooling Speed Static CFM Watts Amps CFM Watts Amps 0.1 1,942 649 4.83 2,067 792 5.81 0.2 1,883 657 4.87 2,030 811 5.85 0.3 1,859 670 4.96 1,982 814 5.88 0.4 1,827 675 4.97 1,909 808 5.86 0.5 1,749 683 4.99 1,842 798 5.85 0.6 1,706 693 5.10 1,789 772 5.65 0.7 1,655 703 5.12 1,703 763 5.58 0.8 1,588 705 5.11 1,618 732 5.29 Unit T1 Heating Speed T2 Heating Speed T3 Heating Speed Model Static CFM Watts Amps Rise CFM Watts Amps Rise CFM Watts Amps Rise WGGE4360A140M Rise Range: 45º to 75º 0.1 1,125 162 1.44 NR 1,466 315 2.67 71 1,780 496 3.33 59 0.2 1,049 168 1.53 NR 1,384 322 2.74 NR 1,730 506 3.89 60 0.3 1,000 178 1.60 NR 1,347 329 2.78 NR 1,664 520 4.01 63 0.4 910 184 1.64 NR 1,291 341 2.83 NR 1,608 526 4.03 65 0.5 857 197 1.75 NR 1,237 350 2.90 NR 1,568 532 4.12 67 0.6 809 201 1.83 NR 1,185 362 3.05 NR 1,515 546 4.14 69 0.7 739 207 1.86 NR 1,134 369 3.09 NR 1,477 552 4.18 71 0.8 703 218 1.96 NR 1,087 382 3.21 NR 1,422 562 4.23 74 Unit T4 Cooling Speed T5 Cooling Speed Static CFM Watts Amps CFM Watts Amps 0.1 1,942 649 4.83 2,067 792 5.81 0.2 1,883 657 4.87 2,030 811 5.85 0.3 1,859 670 4.96 1,982 814 5.88 0.4 1,827 675 4.97 1,909 808 5.86 0.5 1,749 683 4.99 1,842 798 5.85 0.6 1,706 693 5.10 1,789 772 5.65 0.7 1,655 703 5.12 1,703 763 5.58 0.8 1,588 705 5.11 1,618 732 5.29 NOTES: ■ NR = Heating Temperature Rise Not Recommended ■ The Shaded area indicates ranges in excess of maximum external static pressure allowable when heating. For satisfactory operation, external static pressure should not exceed 0.5" W.C. Ignition Control Diagnostic Indicator Chart Refer to “Abnormal Operation—Heating” and “Abnormal Operation—Cooling” sections of this manual. Light Signal Equipment Status Check Off No power or internal control failure Check input power, fuse on control and/or replace control. 1 flash Ignition failure, open rollout switch or open auxiliary limit switch Check gas flow, gas pressure, gas control valve, flame sensor or flame rollout. Check for a bad switch or open auxiliary limit. 2 flashes Pressure switch open Check pressure switch. 3 flashes Pressure switch closed without inducer on Check pressure switch. 4 flashes Thermal protection device open Check main limit open or bad switch. 5 flashes Flame detected with gas control valve closed Check for sticking gas control valve. 6 flashes Short cycle compressor delay (cooling only) Check 3-minute compressor anti-cycle timer. 25 Heating Timing Chart 100% Circulator On Blower Off Gas Control Valve On Off Igniter On Off Induced Draft On Blower Off Thermostat Seconds On Off 0 15 22 45 52 0 29 120, 135, 150 Cooling Timing Chart 100% Circulator On Blower Off Outdoor Fan On and Compressor Off Thermostat Seconds 26 On Off 0 7 30 0 60 Unit Dimensions—Side Unit Dimensions Unit Dimensions—Rear A D B A E F B C G J C G D H H I F I F L E J X W K L V K U T M R S N O P Q A. 47" (119.4 cm) B. 51" (129.5 cm) C. 18⁷⁄₁₆" (46.8 cm) D. Medium: 9¹⁄₂" (24.2 cm), large: 14" (35.6 cm) E. 7¹⁵⁄₁₆" (20.2 cm) F. 16" (40.6 cm) G. 1³⁄₈" (3.5 cm) H. 5¹⁄₂" (14 cm) I. Medium: 32" (81.3 cm), large: 40" (101.6 cm) J. 2³⁄₄" (7 cm) R. 4³⁄₄" (12.1 cm) K. Air return S. Gas supply entrance L. Medium: 16" T. Condensate drain (40.6 cm), large: connection—³⁄₄" 18" (45.7 cm) (1.9 cm) NPT female M. Air supply U. Heat exchange access panel N. 3" (7.6 cm) V. Flue exhaust hood O. Evaporator/ W. Combustion air inlet control panel access panel X. Suction/liquid pressure ports P. 16¹⁄₈" (40.9 cm) behind compressor Q. 19¹⁄₈" (48.6 cm) access panel A. Center of gravity B. 20" (50.8 cm) C. 24" (61 cm) D. Power supply wire entrance E. 7⁵⁄₁₆" (17.6 cm) F. 7⁷⁄₈" (30 cm) G. Control wire entrance H. Flue exhaust hood I. Control access panel J. 5¹⁄₄" (13.3 cm) K. Combustion air intake Minimum Clearances NOTE: Roof overhang should be no more than 36" (91.4 cm). A Unit Dimensions—Inside A B D C B E F B A. 48" (121.9 cm) minimum B. 12" (30.5 cm) minimum C. 36" (91.4 cm) minimum service access D. 3" (7.6 cm) minimum B E D C A. Blower access panel B. 22" (55.9 cm) C. Air return D. Air supply E. 11" (27.9 cm) F. 5³₄" (14.6 cm) 27 Wiring Diagram—WGGE4324, 30, 36, 42 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. R Y R BK PR GND BK S R C T2 T1 BU BU BK R BU COMP BU BK L1 BK CC Y L2 BK BK Crankcase Heater (optional) Connected at L1, L2 Crankcase Heater (optional) PR BR Power Supply 208 to 230/1/60 BK 1 C PR 2 208 3 240 BK TR A N S CM For 208 volt transformer operation, move the black wire from Terminal 3 to Terminal 2 on transformer. 24 V For different than factory speed tap, change cooling speed at Cool Terminal (IIC) and change heating speed at Heat Terminal (IIC). PR (L 2) BU High BR BU/PK R IMPORTANT: HPS BR BU/PK GY 1 2 3 4 5 EM PR BU R EM Medium BK PR LS BR Low R R CAP 2 3 speed optional R Y CAP. 2 BU Alternate 3 speed motor BK PR 4 speed motor BK - High Speed BU - Medium High Speed Y (4-speed motor only) - Medium Low Speed R - Low Speed Y BU Y Y R ALS PR BK BK PS Y PR Y Accessory economizer plug (on select models) adjacent to blower RS housing in return air compartment. EC O N G PL Y 3 6 2 5 1 4 Y BU PR PR Y PR MV BU MV R PR Y IIC W BU G GV GV BU FS Honeywell Gas Control Valve (alternate) White-Rodgers Gas Control Valve VM IG N FS R PR OR Y/Y2 Y1 C R W G To THC see THC Field Wiring Diagram OR R PR BU R Y R R BK PR PR For different than factory speed tap, change cooling speed at Cool Terminal (IIC) and change heating speed at Heat Terminal (IIC). BK - High Speed BU - Medium High Speed YY (4-speed motor only) - Medium Low Speed R - Low Speed BR Y 28 CAP 1 F H C R Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. Replacement wire must be the same size and type of insulation as original (use copper conductor only). Wiring Diagram—WGGE4324, 30, 36, 42 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. L1 L2 Supply Voltage 208 -230 /1/6 0 For different than factory speed tap, change cooling speed at Cool Terminal (IIC) and change heating speed at Heat Terminal (IIC). Crankcase Heater (optional) CC T2 R T1 L1 C COMP L2 C CC H CAP 1 S L1 L1 C H L1 D1 CM (High) (Low) EM L2 TRANS 1 IGN Fuse FS L2 Some models have vent motors equipped with a 230V lead (red) and a 208V (black). If equipped, connect vent motor black lead in L2 place of the red lead at IIC (DI) for 208V operation. 2 For 208 volt transformer operation, move the black wire from Terminal 3 to Terminal 2 on transformer. VM L1 BK - High Speed BU - Medium High Speed Y (4-speed motor only) - Medium Low Speed R - Low Speed CAP 2 F FS THC Field Wiring Diagram THC - No Economizer W W G G R R Y Y BU C 4 LS 5 2-Stage Cooling ALS RS 3 GV II C 6 PS 8 ECON 9 7 HPS 10 12 CC 11 W W G G R R PR Y1 Y Y2 BU C ALS CAP COMP CM CC CH EM FS GV IIC IGN LS PL PS RS THC TRANS VM BK BU BR G OR PK PR R W Y Auxillary Limit Switch Capacitor Compressor Condenser Motor Contactor Crankcase Heater Evaporator Motor Flame Sensor Gas Control Valve Integrated Ignition Control Igniter Limit Switch Plug Pressure Switch Rollout Switch Thermostat Heat and Cool Transformer Vent Motor Black Blue Brown Green Orange Pink Purple Red White Yellow Wire Splice Marked Terminal Unmarked Terminal Line Voltage Low Voltage Field Installed Power Field Installed Control IMPORTANT: 6 5 4 3 2 PL R G W Y1 Y/Y2 C 1 To THC See THC Field Wiring Diagram Accessory economizer plug (on select models) adjacent to blower housing in return air compartment. Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. Replacement wire must be the same size and type of insulation as original (use copper conductor only). 29 Wiring Diagram—WGGE4348, 60 WARNING Goodman 6 Long 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. NOTE: Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. Y R R BK PR S R BK C T1 T2 GND BU Y BU BK COMP L1 BK L2 C Crankcase Heater Optional Crankcase Heater Optional BK PR Connected At L1, L2 Crankcase heater not supplied on all units. BK BK BU BK BK BK Power Supply 208-230/1/60 Use copper conductors only. ††Use NEC Class 2 wire. PR PR BR PR For 208-volt transformer operation, move black wire from Terminal 3 to Terminal 2 on transformer. BK CM HPS BU/PK BU/PK C 3 240 3 4 TR PR LS L G N 2 24V R G BU 2 208 1 C BK 1 BU VMR R BU BU BU R R R PR Y W EM T1 T2 T3 T4 T5 R C22 T1 P2 Speed-Up OR 150 P3 ALS 135 FUSE 3 AMP MAX 120 8 11 9 12 6 7 3 10 2 5 PR Y Y Y W BU G 5 1 4 Y BU Y BU Honeywell Gas Control Valve (alternate) MV PR Y R W BU G BU BU Unused Heat Cool PR PR R W BU R L1 White Rodgers Gas Control Valve 2 L2 Accessory economizer plug (on select models) adjacent to PRblower housing in return air compartment 6 DI PLF Y 3 FS RS BU OR R W R BR Y G 4 Y Y R 1 PS R BU F1 P1 R PR EC O N PR Break For Two Stage Compressor Y T2 W Mount Screw Required For different than factory speed tap, change cooling speed at Motor T4 and T5 terminals. Change heating speed at Motor T2, T2 and T3 terminals. Cooling Speed (Yellow Wire) T4 Low Speed T5 High Speed Heating Speed (White Wire) T1 Low Speed T2 Medium Speed T3 High Speed L1 and L2 on ICC control is 24V input. IIC GV GV BU MV Y/Y2 Y1 C R W G BU To Thermostat VM FS R IGN OR R Y W PR R RCCF PR BU F H C R Y W BR 30 BR Y R Y Wiring Diagram—WGGE4348, 60 WARNING Goodman 6 Long 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. NOTE: Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. IMPORTANT: Crankcase heater not supplied on all units. Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. Replacement wire must be the same size and type of insulation as original (use copper conductor only). For 208-volt transformer operation, move black wire from Terminal 3 to Terminal 2 on transformer. L1 and L2 on ICC control is 24V input. L1 and L2 on ICC control is 24V input. HPS Placeholder for ALS COMP CM C CH EM F FC FS GND GV IIC IGN LS PLF PS RS TR VM VMR Auxillary Limit Switch Compressor Condenser Motor Contactor Crankcase Heater Evaporator Motor Fuse Fan Capacitor Flame Sensor Equipment Ground Gas Control Valve Integrated Ignition Control Igniter Limit Switch Female Plug/Connector Pressure Switch Rollout Switch Transformer Vent Motor Vent Motor Relay BK BU BR G OR PK PR R W Y Black Blue Brown Green Orange Pink Purple Red White Yellow Wire Splice Marked Terminal Unmarked Terminal Line Voltage Low Voltage Field Installed Power Field Installed Control Accessory economizer plug (on select models) adjacent to blower housing Wiring Diagram in return air compartment Thermostat Field Wiring ++ 2-Stage Cooling With Economizer No Economizer Y/Y2 ++ Use NEC Class 2 wire W G R W G R Y Y BU C W W G G R R PR Y1 Y Y2 BU C 31 ASSISTANCE OR SERVICE If you need further assistance, you can write to the below address with any questions or concerns: Tradewinds Distributing Company, LLC 14610 Breakers Drive Jacksonville, FL 32258 WPIO-357A © 2010. All rights reserved. Please include a daytime phone number in your correspondence. Or call toll free: 1-866-944-7575. ®Registered Trademark/TM Trademark of Whirlpool, U.S.A., Manufactured under license by Tradewinds Distributing Company, LLC, Jacksonville, Florida. Warranty provided by manufacturer. All other trademarks are owned by their respective companies. 5/10 Printed in U.S.A.