Whirlpool Gold WFD193 Installation Instructions Manual Download | Manualshive

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GAS-FIRED WARM AIR FURNACE INSTALLATION INSTRUCTIONS

(Type FSP Category IV Direct or Nondirect Vent Air Furnace)

These furnaces comply with requirements embodied in the
American National Standard/National Standard of Canada ANSI
Z21.47 CSA-2.3 Gas Fired Central Furnaces.

NOTE: Please contact your distributor or our website for
applicable Specification Sheet referred to in this manual.

WPIO-299N

Tradewinds Distributing Company, LLC

14610 Breakers Drive

Jacksonville, Florida 32258

Whirlpool Gold

®

Models

WGFM195, WFD195,
WFD193, WFM195

ATTENTION INSTALLATION PERSONNEL

As a professional installer, you have an obligation to know the product better than the customer. This includes all
safety precautions and related items. Prior to actual installation, thoroughly familiarize yourself with this instruction
manual. Pay special attention to all safety warnings. Often during installation or repair, it is possible to place
yourself in a position which is more hazardous than when the unit is in operations.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a
customer in its safe use. Safety is a matter of common sense...a matter of thinking before acting. Most dealers have
a list of specific good safety practices...follow them.

The precautions listed in this installation manual are intended as supplemental to existing practices. However, if
there is a direct conflict between existing practices and the content of this manual, the precautions listed here take
precedence.

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Summary of Contents for Gold WFD193

Page 1: ...es all safety precautions and related items Prior to actual installation thoroughly familiarize yourself with this instruction manual Pay special attention to all safety warnings Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operations Remember it is your responsibility to install the product safely and to know i...

Page 2: ...Horizontal Installations Left Side Down 24 Horizontal Drain Trap Mounting Left or Right Side Panel 25 ELECTRICAL CONNECTIONS 25 Wiring Harness 25 115 Volt Line Connections 25 Junction Box Relocation 26 24 Volt Thermostat Wiring 26 WFM19 Furnace with 2 Stage Condenser Field Wiring 26 115 Volt Line Connection of Accessories Humidifier and Electronic Air Cleaner 27 GAS SUPPLY AND PIPING 28 High Altit...

Page 3: ...be performed by a qualified installer service agency or the gas supplier WARNING Goodman 45 This product contains or produces a 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 Goodman 47 Heating unit should not be utilized without reasonable routine inspection maintenance ...

Page 4: ...rtified copy of the invoice showing trade and other discounts or reductions Copy of the inspection report issued by carrier s representative at the time damage is reported to carrier The carrier is responsible for making prompt inspection of the damage and for a thorough investigation of each claim The distributor or manufacturer will not accept claims from dealers for transportation damage ToTheI...

Page 5: ...oned space All other warranty exclusions and restrictions apply A Gas control valve B Gas line entrance alternate C Pressure switch D Gas manifold E Combustion air intake connection coupling F Hot surface igniter G Rollout limit switch H Burners I Flame sensor J Flue pipe connection coupling K Flue pipe L Primary limit switch M Gas line entrance N Flue pipe connection alternate O Rubber elbow P In...

Page 6: ...re proper furnace operation you must install operate and maintain the furnace in accordance with these installation and operation instructions all local building codes and ordinances In their absence follow the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CSA B149 Installation Codes local plumbing or waste water codes and other applicable codes A copy of the National...

Page 7: ...18 45 7 cm above the floor Protect the furnace from physical damage by vehicles If the furnace is installed horizontally ensure the furnace access doors are not on the up top or down bottom side of the furnace The furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger Do not connect the furnace to a chimney flue that serves a separate appliance designed...

Page 8: ...s and any other gas burning appliance to their previous conditions of use 9 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or National Gas and Propane Installation Code CSA B149 1 05 If resizing is required on any portion of the venting system use the appropriate table in Appen...

Page 9: ...ion equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5 3 3 and 5 3 4 f Air requirements for the operation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements 5 3 2 Equipment Located in Unconfined Spaces In unconfined space...

Page 10: ...ll and the air openings communicate directly with the outdoors each opening shall have a free area of not less than 1 sq in 6 5 cm2 per 4 000 Btu h of the total input rating of all appliances in the enclosure 4 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall not be less th...

Page 11: ... may dictate many of the installation s specifics such as airflow direction ductwork connections flue and combustion air pipe connections etc The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation When installing a furnace horizontally additional consideration must be given to the following Drain trap and lines Leveling the furnace Alternat...

Page 12: ...s a P trap Recommended Installation Positions Upright Upflow Recommended Installation Positions Upright Counterflow Recommended Installation Positions Horizontal Upflow Left Side Panel Discharge Recommended Installation Positions Horizontal Counterflow Right Side Panel Discharge Recommended Installation Positions Horizontal Upflow Right Side Panel Discharge A Vent Drain B Airflow C Field supplied ...

Page 13: ...s must be used to insure proper furnace operation All conversions must be performed by a qualified installer or service agency VENT FLUE PIPE AND COMBUSTION AIR PIPE General A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place Because of the relatively low flu...

Page 14: ... measures 3 7 8 cm minimum from the plane of one opening to the centerline of the other opening for 2 5 1 cm diameter pipe and 4 11 6 cm minimum for 3 7 6 cm pipe ProperVent FlueandCombustionAir Piping Practices Adhere to these instructions to ensure safe and proper furnace performance The length diameter and number of elbows of the vent flue pipe and combustion air pipe when applicable affects th...

Page 15: ...nd worm gear hose clamps provided with this furnace See Standard Connections illustration The rubber coupling allows separation of the vent flue pipe from the furnace during servicing Combustion air and vent piping should be routed in a manner to avoid contact with refrigerant lines metering devices condensate drain lines etc If necessary clearances may be increased by utilizing two 45º long sweep...

Page 16: ...ctions follow the upflow instructions Upflow Units 1 Remove and save the 4 screws securing the vent flue coupling to the furnace top panel Counterflow Units Remove and save the 4 screws securing the vent flue coupling to the furnace base pan Also remove the 3 screws securing the furnace s internal vent flue piping to the blower deck Upflow and Counterflow Units 2 Loosen the worm gear hose clamps o...

Page 17: ...or upright installations requires the drain trap to be installed on the same side of the furnace as the flue pipe 13 For horizontal installations externally secure the field supplied vent flue pipe directly to the vent flue coupling using a PVC or ABS coupling or elbow Alternate Vent Flue Location Upflow Alternate Vent Flue Location Counterflow Upright Upflow Similar Alternate Vent Flue Location C...

Page 18: ...ased clearance configurations using two 45º long sweep elbows should be considered equivalent to one 90º elbow Vent FluePipeTerminations NOTE If either a 90º or 45º elbow is used for termination it must be pointed downward The vent flue pipe may terminate vertically as through a roof or horizontally as through an outside wall Vertical vent flue pipe terminations should be as shown in Vertical Vent...

Page 19: ...specific details on termination constructions For details concerning connection of pipes to the furnace refer to the Standard Furnace Connections or Alternate Furnace Connections in this section Vent FlueandCombustionAirPipeLengthsand Diameters Refer to the following chart for applicable length elbows and pipe diameter for construction of the vent flue and combustion air intake pipe systems of a d...

Page 20: ...ng the 2 couplings The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall The wall penetration should be sealed with silicone caulking material Direct Vent Dual Pipe Maximum Allowable Length of Vent Flue and Combustion Air Intake Pipe ft m Number of Elbows Unit Input Btu Termination Style Pipe in cm 2 3 4 5 6 7 8 ...

Page 21: ... always terminate all air intakes at the same elevation Horizontal Venting of Multiple Furnaces A 24 61 cm maximum 3 7 6 cm minimum B 12 30 5 cm minimum from wall C Vent flue tee D 12 30 5 cm minimum to roof or highest anticipated snow level E Combustion air intake F Screen optional G 45º or 90º medium radius elbow A 90º medium radius elbow B Vent flue pipe C 12 30 5 cm minimum from wall D Screen ...

Page 22: ...rain line If an air conditioning coil is installed with the furnace a common drain may be used An open tee must be installed in the drain line near the cooling coil to relieve positive air pressure from the coil s plenum This is necessary to prohibit any interference with the function of the furnace s drain trap StandardRightorLeftSide Drain Hose Connections All installation positions require the ...

Page 23: ...nd are not kinked or binding Alternate Upright Upflow Connections Right Side Only Counterflow Similar UprightInstallations TraponLeftSide NOTE For left side trap installation grommets must be moved to the left side of the furnace and the plugs installed on the right side of the furnace 1 Remove the rubber plug cap from the left side of the front cover drain port 2 Secure Hose A to the front cover ...

Page 24: ...ard the radius pieces 10 Insert approximately 1 2 5 cm of each Tube 2 through the right down side panel grommet holes 11 Secure the tubes to Hose A and Hose B using the green hose clamps NOTE Ensure that the hoses and tubes maintain a downward slope for proper drainage and are not kinked or bound For details concerning the mounting of the drain trap refer to Horizontal Drain Trap Mounting in Conde...

Page 25: ... as supplied with the furnace must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C Any replacement wiring must be a copper conductor 115 VoltLineConnections Before proceeding with electrical connections ensure that the supply voltage frequency and phase correspond to that specified on the unit rating plate Power supply to the furnace must be NEC C...

Page 26: ...rip Thermostat Diagram This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment Consult the wiring diagram located on the blower compartment door for further details of 115 volt and 24 volt wiring NOTE To apply a single stage heating thermostat the thermostat selector switch on the integrated control module must be set on single stage WFM19Furnacewith2 StageC...

Page 27: ...ed control module electronic air cleaner terminals EAC are energized with 115 volts whenever the circulator blower is energized 24 Volt Humidifier The yellow wire connected to the induced draft blower pressure switch is powered anytime the pressure switch is closed and provides 24 VAC humidifier control 1 Remove the yellow wire and connect the supplied brown jumper wire to the pressure switch term...

Page 28: ...ular listing of appropriate altitude ranges and corresponding manufacturer s pressure switch kits PropaneGasConversion This furnace is configured for Natural gas The appropriate manufacturer s propane gas conversion kit must be applied for propane gas installations Refer to Propane Gas and or High Altitude Installations section for details Contact your distributor for a tabular listing of appropri...

Page 29: ...on the manifold must be maintained as shipped from the factory Maximum torque for the gas control valve connection is 375 in lbs NOTE Excessive overtightening may damage the gas control valve Install a manual shutoff valve between the gas meter and the furnace within 6 ft 1 8 m of the furnace If a union is installed the union must be downstream of the manual shutoff valve between the shutoff valve...

Page 30: ... pipe NOTE The straight pipe must be long enough to reach the outside of the cabinet so as to seal the grommet cabinet penetration and to install the ground joint union outside of the cabinet A semirigid connector to the gas piping can be used outside the cabinet according to local codes A Manual shutoff valve upstream from ground joint pipe union B Alternate gas line location C Plug in alternate ...

Page 31: ...pe run and the total load of all appliances 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 liq...

Page 32: ...s used to control the flow of air must be adequate to prevent chilled air from entering the furnace and if manually operated must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position When the furnace is installed without a cooling coil it is recommended that a removable access panel be provided in the outlet air duct This opening shall b...

Page 33: ...rnace rating plate check for closed dampers registers undersized and or oversized poorly laid out ductwork Checking Static Pressure 80 Furnace Shown 90 Furnace Similar BottomReturnAirOpening UpflowModels The bottom return air opening on upflow models utilizes a lance and cut method to remove sheet metal from the duct opening in the base pan 1 To remove simply press out the lanced sections by hand ...

Page 34: ...t Minimum Filter Area sq in Based On 600 ft 182 9 m Per Minute Filter Face Velocity Input Airflow 600 800 1 000 1 200 1 400 1 600 2 000 040_3BXA or 045_3BXA 194 194 240 288 060_3BXA or 070_3BXA 324 324 324 336 070_4CXA 291 291 336 384 090_4CXA 432 432 432 432 080_5CXA or 090_5DXA 388 388 388 480 100_5DXA or 115_5DXA 486 486 486 486 Cooling Airflow Requirement CFM Permanent Minimum Filter Area sq i...

Page 35: ... the Off position 6 Wait 5 minutes and then check for a gas odor NOTE Check near the floor since some types of gas are heavier than air 7 If a gas odor is detected follow the instructions in Gas Furnace Safety Precautions in this manual 8 If no gas odor is detected move the furnace gas control valve manual control to the On position 9 Replace the burner compartment door 10 Open the manual gas shut...

Page 36: ... within the range specified in the Inlet Gas Supply Pressure chart If the supply pressure differs from chart make the necessary adjustments to the pressure regulator gas piping size etc and or consult with local gas utility 6 Turn off the gas supply to the furnace at the manual shutoff valve 7 Disconnect the manometer 8 Reinstall plug before turning on gas supply to furnace 9 Turn off any unnecess...

Page 37: ...iately and repair all leaks NOTE For gas to gas conversion consult your dealer for appropriate conversion GasInputRateMeasurement NaturalGasOnly The gas input rate to the furnace must never be greater than that specified on the unit rating plate To measure Natural gas input using the gas meter use the following procedure 1 Turn off the gas supply to all other gas burning appliances except the furn...

Page 38: ... are the same a jumper wire must be used between the heat and cool terminals 4 Connect all of the unused blower motor leads to the PARK terminals on the integrated control module Any leads not connected to the PARK terminals must be taped 5 Turn on the power to furnace 6 Verify the proper temperature rise as outlined in Temperature Rise NORMAL SEQUENCE OF OPERATION PowerUp The normal power up sequ...

Page 39: ...blower remains at low heat speed for the selected delay off period If the furnace is operating in high stage heating mode when the thermostat contacts open the circulator blower remains at high heat speed for the selected heat off delay period The circulator blower then switches to low heat speed for the remainder of the selected heat off delay period For example the selected heat off delay period...

Page 40: ...ses the principle of flame rectification to determine the presence or absence of flame MAINTENANCE AnnualInspection The furnace should be inspected by a qualified installer or service agency at least once per year This check should be performed at the beginning of the heating season This will ensure that all furnace components are in proper working order and that the heating system functions appro...

Page 41: ...e sensor should be carefully cleaned by a qualified servicer using emery cloth or steel wool Following cleaning the flame sense signal should be 1 to 6 microamps at 115 volts Igniter QualifiedServicerOnly If the igniter and the surrounding air are at about 70 F 21ºC and the igniter wires are not connected to any other electrical components the resistance of the igniter should not exceed 75 ohms If...

Page 42: ...bject repeat Step 2 before touching the control or wires 4 Follow steps 1 through 3 before removing a new control from its container or installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object FaultRecall The ignition control is equipped with a momentary pushbutton switch that can be used to display the last 5 faults detected by t...

Page 43: ...module with current replacement parts LED display is steady on Continuous On Normal operation Normal operation None Normal operation Furnace fails to operate Integrated control module diagnostic LED is flashing 1 flash 1 flash Furnace lockout due to an excessive number of ignition retries 3 total Failure to establish flame No gas to burners front cover pressure switch stuck open bad igniter or ign...

Page 44: ...ower prior to repair Replace pressure switch with correct replacement part Replace induced draft blower with correct replacement part Circulator blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing 4 flashes 4 flashes Primary limit or auxiliary limit circuit is open Insufficient conditioned air over the heat exchanger Blocked filters restrictive ductwo...

Page 45: ...sure or combustion air Sand flame sensor if coated oxidized Inspect for proper sensor alignment Compare current gas pressure to rating plate info Adjust as needed Turn off power prior to repair Sand flame sensor with emery cloth See Vent Flue Pipe section for piping details See rating plate for proper gas pressure No furnace operation Integrated control module diagnostic LED is flashing 8 flashes ...

Page 46: ...5 Med 3 5 1 752 34 1 724 34 1 667 36 1 603 37 1 488 40 1 402 1 290 1 082 Med Lo 3 0 1 437 41 1 437 41 1 417 42 1 369 43 1 320 45 1 256 1 140 984 Low 2 5 1 184 50 1 177 50 1 161 51 1 132 52 1 095 54 1 047 928 837 WGFM1950904CXA MED HI High 4 0 1 970 40 1 874 42 1 757 45 1 667 48 1 566 51 1 431 1 334 1 182 Med 3 5 1 713 46 1 650 48 1 572 50 1 510 52 1 418 56 1 313 1 211 1 079 Med Lo 3 0 1 439 55 1 4...

Page 47: ...63 1 244 65 1 184 68 1 148 70 1 098 73 1 034 953 849 WFD195090S5DXA MED HI High 5 0 2 189 37 2 109 38 2 025 40 1 948 41 1 862 43 1 757 1 644 1 537 Med 4 0 1 885 43 1 831 44 1 776 45 1 711 47 1 637 49 1 539 1 453 1 346 Med Lo 3 5 1 665 48 1 627 50 1 584 51 1 524 53 1 462 55 1 400 1 323 1 220 Low 3 0 1 474 55 1 440 56 1 401 57 1 356 59 1 310 61 1 255 1 193 1 109 WFD1955115S5D MED HI High 5 0 2 134 4...

Page 48: ...2 0 904 58 851 62 804 66 761 69 708 75 664 612 572 T3 Med 2 5 1 125 47 1 075 49 1 045 51 999 53 956 55 921 877 839 T4 Med High 3 0 1 312 40 1 271 42 1 228 43 1 202 44 1 165 45 1 127 1 087 1 044 T5 High 3 5 1 423 37 1 386 38 1 354 39 1 321 40 1 278 41 1 210 1 134 1 032 WFM195080E5CX MED HI T1 Low 3 0 1 297 54 1 253 56 1 209 58 1 161 61 1 111 63 1 067 1 022 974 T2 Med Low 3 5 1 507 47 1 455 48 1 422...

Page 49: ...Reset Auxiliary Limits 1 In upflow blower deck 2 In counterflow blower housing OR To 115 VAC 10 60 Hz Power Supply with Overcurrent Protection Device OR Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring Low Voltage 24V High Voltage 115V Junction Terminal Internal To Integrated Control Plug Connection Equipment GND Field GND Field Splice Switc...

Page 50: ...witch Overcurrent Prot Device High Voltage Field Color Gray White Black Red Blue Orange Yellow Green Pink Azure Violet Brown Symbol GY W BK R BU OR Y G PK A V BR Low Voltage Field 0 C 7 6 5 4 3 2 1 8 Steady On Off 1 Flash 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes 8 Flashes Continuous Rapid Flashes Normal Operation Control Failure System Lockout Retries Exceeded Pressure Switch St...

Page 51: ...it Switch or Open Fuse Low Flame Signal Check Igniter or Improper Grounding Reversed 115 VAC Polarity 24 VAC Humidifier 24V Thermostat Connections R C G W Y Integrated Control Module Fuse 2nd Stage Delay Mode Heat Off Delay Factory Settings Shown Diagnostic LED See Note 6 115 VAC HOT and PARK Terminals HEAT H See Note 4 Circulator Blower Blower Compartment Burner Compartment Induced Draft Blower A...

Page 52: ...e number in your correspondence Or call toll free 1 866 944 7575 WPIO 299N 2011 All rights reserved 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 COMFORT COMMITMENT is a trademark of Tradewinds Distributing Comp...

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