Whirlpool Gold WGFM295 Installation Instructions Manual Download

Page: 48 / 52

■

Furnace fails to
operate.

■

Integrated
control module
LED display
provides “b1”
error code.

■

Integrated
control module
has lost
communication
s with circulator
blower motor.

■

Loose wiring
connection at
circulator motor
control leads.

■

Failed circulator
blower motor.

■

Failed integrated
control module.

■

Tighten or correct
wiring connection.

■

Check circulator
blower motor. Replace
if necessary.

■

Check integrated
control module.
Replace if necessary.

■

Turn off power prior to
repair.

■

Replace circulator
motor with correct
replacement part.

■

Replace integrated
control module with
correct replacement
part.

■

Furnace fails to
operate.

■

Integrated
control module
LED display
provides “b2”
error code.

■

Circulator
blower motor
horse power in
shared data set
does not match
circulator
blower motor
horse power.

■

Incorrect circulator
blower motor in
furnace.

■

Incorrect shared
data set in
integrated control
module.

■

Verify circulator blower
motor horse power is
the same specified for
the specific furnace
model. Replace if
necessary.

■

Verify shared data set
is correct for the
specific model.
Repopulate data using
correct memory card, if
required.

■

Turn off power prior to
repair.

■

Replace motor with
correct replacement
part.

■

Use memory card for
the specific model

■

Insert memory card
before turning on
power. Memory card
may be removed after
data is loaded.

■

Turn off power before
removing memory
card.

■

Error code will be
cleared once shared
data and motor horse
power match.

■

Furnace
operates at
reduced
performance.

■

Airflow
delivered is less
than expected.

■

Integrated
control module
LED display
provides “b3”
error code.

■

Circulator
blower motor is
operating in a
power,
temperature or
speed limiting
condition.

■

Blocked filters.

■

Restrictive
ductwork.

■

Undersized
ductwork.

■

High ambient
temperatures.

■

Check filters for
blockage. Clean filters
or remove obstruction.

■

Check ductwork for
blockage. Remove
obstruction. Verify all
registers are fully open.

■

Verify ductwork is
appropriately sized for
system. Resize/replace
ductwork if necessary.

■

See “Product
Description” and
“Location
Requirements and
Considerations” for
furnace installation
requirements.

■

Turn off power prior to
repair.

■

Furnace fails to
operate.

■

Integrated
control module
LED display
provides “b4”
error code.

■

Circulator
blower motor
senses a loss of
rotor control.

■

Circulator
blower motor
senses high
current.

■

Abnormal motor
loading, sudden
change in speed or
torque, sudden
blockage of
furnace air inlet or
outlet.

■

High loading
conditions, blocked
filters, very
restrictive
ductwork,
blockage of
furnace air inlet or
outlet.

■

Check filters, filter
grills/registers, duct
system and furnace air
inlet/outlet for
blockages.

■

Turn off power prior to
repair.

Symptoms of
Abnormal
Operation

Diagnostic/
Staus LED
Code

Fault Description Possible Causes

Corrective Actions

Notes and Cautions

Summary of Contents for Gold WGFM295

Page 1: ...ion 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 ...

Page 2: ...r Right Side Panel 22 Horizontal Installations Right Side Down 22 Horizontal Installations Left Side Down 23 Horizontal Drain Trap Mounting Left or Right Side Panel 23 ELECTRICAL CONNECTIONS 23 Wiring Harness 23 115 Volt Line Connections 24 Junction Box Relocation 24 24 Volt Thermostat Wiring 24 24 Volt Dehumidistat Wiring 25 Fossil Fuel Applications 26 115 Volt Line Connection of Accessories Humi...

Page 3: ...formed by a qualified installer service agency or the gas supplier WARNING 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 Heating unit should not be utilized without reasonable routine inspection maintenance and supervision If the build...

Page 4: ...egrated control module or connecting wiring after following the discharge process in Step 2 NOTE Do not recharge your body with static electricity by moving or shuffling your feet or touching ungrounded objects If you touch an ungrounded object 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...

Page 5: ...s are provided and sealed to the furnace A return air temperature range between 60ºF 16ºC and 80ºF 27ºC is maintained Air filters are installed in the system and maintained during construction replaced as appropriate during construction and upon completion of construction The input rate and temperature rise are set according to the furnace rating plate 100 outside air is provided for combustion ai...

Page 6: ...s Carbon tetrachloride Halogen type refrigerants Cleaning solutions such as perchloroethylene Printing inks Paint removers Varnishes Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials Seal off a nondirect vent furnace if it is installed near an area frequently contaminated by any of the above substances This protects the nondirect vent...

Page 7: ... leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building 4 Close fireplace dampers 5 Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fa...

Page 8: ...he side panel s and or base pan For horizontal upflow furnaces the return air ductwork must be attached to the base pan For both the upright or horizontal counterflow furnaces the return air ductwork must be attached to the base pan top end of the blower compartment NOTE Do not attach the ductwork to the back of the furnace Contact your local distributor for the proper airflow requirements and the...

Page 9: ...drain kit See Alternate Flue Vent Location illustration NOTE Alternate vertical piping connections cannot be used when an upflow furnace is installed with the supply air discharging to the right or when a counterflow furnace is installed with the supply air discharging to the left In either case use the standard flue and combustion air piping connections Alternate Flue Vent Location NOTES The fiel...

Page 10: ... may be installed as a nondirect vent single pipe or direct vent dual pipe appliance A nondirect vent installation requires only a vent flue pipe while a direct vent installation requires both a vent flue pipe and a combustion air intake pipe Refer to the appropriate section for details concerning piping size length number of elbows furnace connections and terminations 2 or 3 5 1 cm or 7 6 cm nomi...

Page 11: ...and direct vent must terminate at least 3 ft 91 4 cm above any forced air inlet located within 10 ft 3 m NOTE This provision does not apply to the combustion air intake termination of a direct vent application The vent termination of a nondirect vent application must terminate at least 4 ft 121 9 cm below 4 ft 121 9 cm horizontally from or 12 30 5 cm above any door window or gravity air inlet into...

Page 12: ...obable material conflicts do not use other commercially available no hub connectors The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling CombustionAirPipe NondirectVentInstallations A minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage Standard Connection Upflow Standard Conn...

Page 13: ...ts Cut the vent flue pipe 3 9 5 cm from the blower deck coupling See Vent Flue Pipe Cuts illustration Save vent flue pipe attached to the blower deck coupling for use in the alternate location Discard remaining pipe and elbows Vent Flue Pipe Cuts Upflow Units 6 Remove the plastic plug from the alternate vent flue location 7 Relocate and install the plastic plug in the standard vent flue location t...

Page 14: ... panel and the flange s flat spot facing forward secure the combustion air intake coupling to the cabinet using the screws removed in Step 1 or with field supplied 8 self drilling screws 9 For nondirect vent installations installed horizontally a minimum of one 90 elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage NOTE No elbow is required on the ...

Page 15: ...o the combustion air intake to prevent inadvertent blockage The tee used in the vent flue termination must be included when determining the number of elbows in the piping system NOTES One 90º elbow should be secured to the combustion air intake connection Minimum requirement for each vent flue pipe is 5 ft 1 5 m and 1 elbow tee Tee used in the vent flue termination must be included when determinin...

Page 16: ...h of pipe connecting 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 In a basement installation the vent flue pipe can be run between joist spaces NOTE If the vent pipe must go below a joist and then up into the last joist...

Page 17: ...lbows tabulated represents the number of elbows and or tees in each vent flue and combustion air intake pipe Elbows and or tees used in the terminations must be included when determining the number of elbows in the piping systems If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable insulation of the combustio...

Page 18: ...ng vent Vertical Vent Terminations Dual Pipe Counterflow 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 1 2 3 4 5 6 7 8 70 000 Standard 2 or 2 5 12 or 6 4 49 14 9 46 14 43 13 1 40 12 2 37 11 3 34 10 4 31 9 5 28 8 5 3 7 6 71 21 6 68 20 7 65 19 8 62 18 9 59 18 56 17 1 53 16 2 50 15 2 Alterna...

Page 19: ...f MultipleDirectVentFurnaces If more than one direct vent furnace is to be installed vertically through a common roof top maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent furnaces as with the exhaust vent and air intake terminations of a single furnace If more than one direct vent furnace is to be installed horizontally through a common side wal...

Page 20: ... slope toward the drain Do not trap the drain line in any other location than at the drain trap supplied with the furnace Do not route the drain line outside where it may freeze If the drain line is routed through an area which may see temperatures near or below freezing precautions must be taken to prevent the condensate from freezing within the drain line If an air conditioning coil is installed...

Page 21: ...ht side panel grommet drain hole 13 Secure Tube 2 to Hose A with a green hose clamp 14 Insert the short end of the remaining Tube 2 into Hose B from the rubber elbow and secure with a green hose clamp 15 Ensure that the hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding Alternate Upright Upflow Connections Right Side Only Counterflow Similar UprightInstalla...

Page 22: ...xternally mounted rubber elbow Discard cut portion 5 Insert Tube 1 into the rubber elbow drain port and secure with a silver hose clamp NOTE Angle tube outward toward front of furnace 6 Cut 17 45 1 cm from the long end of Hose B Discard cut portion 7 Secure the remaining end of Hose B to exposed end of Tube 1 with a green hose clamp 8 Route Hose B to the front right down side panel grommet holes 9...

Page 23: ... concerning the mounting of the drain trap refer to Horizontal Drain Trap Mounting in this section Horizontal Upflow Connections Left Side Down Counterflow Similar HorizontalDrainTrapMounting LeftorRight SidePanel 1 Position the drain trap against the side panel with the drain tubes inserted into the trap NOTE The trap may be orientated with the outlet facing either the furnace s top cover or base...

Page 24: ...per unit grounding the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel NOTE Do not use gas piping as an electrical ground To confirm proper unit grounding turn off the electrical power and perform the following check 1 Measure the resistance between the neutral white connection and one of the burners 2 Resistance...

Page 25: ... dehumidistat call for dehumidification This can be done through an independent dehumidistat or through a thermostat s DEHUM terminal if available This lower blower speed enhances dehumidification of the conditioned air as it passes through the AC coil For proper function a dehumidistat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise To install conn...

Page 26: ... box The integrated control module humidifier terminals HUM are energized with 115 volts whenever the induced draft blower is energized The integrated control module electronic air cleaner terminals EAC are energized with 115 volts whenever the circulator blower is energized 24 Volt Humidifier A 5 12 7 cm long brown wire in the wire harness at the low fire pressure switch provides 24 VAC humidifie...

Page 27: ...rovided on the valve The gas control valve has a manual On Off control located on the gas control valve itself This control may be set only to the On or Off position Refer to the lighting instructions label or see Start Up Procedure and Adjustment for use of this control during the start up and shutdown periods GasPipingConnections When sizing a trunk line be sure to include all appliances which w...

Page 28: ...with their instructions Gas connectors must be fully in the same room as the furnace Protect gas connectors and semirigid tubing against physical and thermal damage when installed Ensure aluminum alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry plaster insulation or subjected to repeated wetting by liquids such as water except rain water det...

Page 29: ...ure testing supply piping system with test pressures equal to or less than psig 3 48 kPa PropaneGasTanksandPiping 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 mus...

Page 30: ...g maximum C 200 psig maximum D 2nd stage regulator E Continuous 11 W C A E D B C Propane Gas Piping Chart I Tubing Size O D Type L Nominal Pipe Size Schedule 40 Pipe or Tubing Length ft m 10 3 730 1 700 3 200 5 300 8 300 3 200 7 500 20 6 1 500 1 100 2 200 3 700 5 800 2 200 4 200 30 9 2 400 920 2 000 2 900 4 700 1 800 4 000 40 12 2 370 850 1 700 2 700 4 100 1 600 3 700 50 15 2 330 770 1 500 2 400 3...

Page 31: ...anges around the perimeter of the opening using a pair of seamer pliers or seamer tongs NOTE Airflow area will be reduced by approximately 18 if duct flanges are not unfolded This could cause performance issues and noise issues Duct Flange Cutouts When the furnace is used in connection with a cooling unit the furnace should be installed in parallel with or on the upstream side of the cooling unit ...

Page 32: ...g airflow requirement Minimum Filter Requirements Chart Upflow Cooling Airflow Requirement CFM Permanent 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 0453_XA 376 384 480 576 0704_XA 627 627 672 768 0905_XA 836 836 836 960 1155_XA 940 940 940 960 Counterflow Cooling Airflow Requirement CFM Permanent Minimum Fil...

Page 33: ...Operation 1 Purge the gas lines of air prior to start up NOTE Be sure not purge lines into an enclosed burner compartment 2 Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other approved method 3 Verify that all required kits propane gas high altitude etc have been appropriately installed FurnaceStart Up 1 Close the manual gas shuto...

Page 34: ... at either the gas control valve inlet pressure boss or the gas piping drip leg See Gas Control Valve Honeywell VR9205 Connected to Manometer or Gas Control Valve White Rodgers 36G54 Connected to Manometer for location of inlet pressure boss tap NOTE If measuring the gas pressure at the drip leg or on the Honeywell VR9205 gas control valve a field supplied hose barb fitting must be installed prior...

Page 35: ...erclockwise to decrease pressure 11 Replace regulator cover screw 12 Close thermostat R and W2 contacts to provide a call for high stage heat 13 Remove the regulator cover screw from the high HI outlet pressure regulator adjust tower 14 Turn the screw clockwise to increase pressure or counterclockwise to decrease pressure 15 Replace the regulator cover screw 16 Turn off all electrical power and ga...

Page 36: ...turn and supply ducts as close to the furnace as possible Thermometers must not be influenced by radiant heat from the heat exchanger 4 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Allow adequate time for thermometer readings to stabilize 5 Adjust the temperature rise by adjusting the circulator blower speed Increase blower speed to redu...

Page 37: ...ng performance and increase the comfort level The ramping profiles are selected using DIP switches 5 and 6 See the Profile illustrations for DIP switch positions and their corresponding taps Verify CFM by noting the number displayed on the dual 7 segment LED display Profile A Provides a 1 minute Off delay at 100 of the cooling demand airflow Profile B Ramps up to 50 of the full cooling demand airf...

Page 38: ...ect the model and desired high stage cooling airflow 2 Determine the corresponding tap A B C or D 3 Set DIP switches 1 and 2 to the appropriate On Off positions 4 Select the model and desired high stage heating airflow 5 Determine the corresponding tap A B C or D 6 Set DIP switches 7 and 8 to the appropriate On Off positions 7 Select the airflow adjustment factor taps A and D are 1 Tap B is 10 Tap...

Page 39: ...at changes the call from low heat to high heat the integrated control module will immediately switch the induced draft blower gas control valve and circulator blower to their high stage settings If the 2 stage thermostat changes the call from high heat to low heat the integrated control module will immediately switch the induced draft blower and gas control valve to their low stage settings The ci...

Page 40: ...rcuits are continuously monitored during furnace operation by the integrated control module IntegratedControlModule The integrated control module is an electronic device which if a potential safety concern is detected will take the necessary precautions and provide diagnostic information through an LED PrimaryLimitControl The primary limit control is located on the partition panel and monitors hea...

Page 41: ...e for removal 4 Turn on electrical power to the furnace Media Air Filter or Electronic Air Cleaner Removal Follow the manufacturer s directions for service Burners Visually inspect the burner flames periodically during the heating season Turn on the furnace at the thermostat and allow several minutes for flames to stabilize since any dislodged dust will alter the flames normal appearance Flames sh...

Page 42: ...staticDischarge ESD Precautions NOTE Discharge static electricity accumulated in the body before touching the unit An electrostatic discharge can adversely affect electrical components Use the following steps during furnace installations and servicing to protect the integrated control module from damage By putting the furnace the control and the person at the same electrostatic potential these ste...

Page 43: ...hooting the unit Internal control fault no power O P Normal operation E 0 Lockout due to excessive retries E 1 Low stage pressure switch stuck closed at start of heating cycle E 2 Low stage pressure switch stuck open E 3 Open high limit switch E 4 Flame detected when no flame should be present E 5 Open fuse E 6 Low flame signal E 7 Igniter fault or improper grounding E 8 High stage pressure switch...

Page 44: ...E0 Furnace lockout due to an excessive number of ignition retries 3 total Failure to establish flame Cause may be no gas to burners front cover pressure switch stuck open bad igniter or igniter alignment improper orifices or coated oxidized or improperly connected flame sensor Loss of flame after establishment Cause may be interrupted gas supply lazy burner flames improper gas pressure or restrict...

Page 45: ...ers blocked flue and or air inlet pipe or failed induced draft blower Loose or improperly connected wiring Check filters and ductwork for blockage Clean filters or remove obstruction Check circulator blower speed and performance Correct speed or replace blower if necessary Check burners for proper alignment Check flue and air inlet piping for blockage proper length elbows and termination Correct a...

Page 46: ...ly on low stage Integrated control module LED display provides E8 error code E8 High stage pressure switch circuit is closed at start of heating cycle Induced draft blower is operating Furnace is operating on low stage only High stage pressure switch contacts sticking Shorts in pressure switch circuit wiring Replace high stage pressure switch Repair short in wiring Turn off power prior to repair R...

Page 47: ...cted by integrated control module Verify shared data set is correct for the specific model Repopulate data using correct memory card if required Turn off power prior to repair Use memory card for the specific model Insert memory card before turning on power Memory card may be removed after data is loaded Turn off power before removing memory card Error code will be cleared once data is loaded Furn...

Page 48: ...be removed after data is loaded Turn off power before removing memory card Error code will be cleared once shared data and motor horse power match Furnace operates at reduced performance Airflow delivered is less than expected Integrated control module LED display provides b3 error code b3 Circulator blower motor is operating in a power temperature or speed limiting condition Blocked filters Restr...

Page 49: ...rnace installation requirements Turn off power prior to repair Furnace fails to operate Integrated control module LED display provides b7 error code b7 Circulator blower motor does not have enough information to operate properly Motor fails to start 40 consecutive times Error with integrated control module Motor has a locked rotor condition Check integrated control module Verify control is populat...

Page 50: ...Manual Reset Auxiliary Limit Controls 40 VA Transformer Y2 14 IND LO Manual Reset Rollout Limit Controls 9 W N Humidifier Indoor Air Circulator Blower High Fire Pressure Switch 2 Stage Gas Control Valve C W PSO 7 2 HUM 2 Circuit Connector Y GND VAC W Chassis Ground 2 3 Low Fire Pressure Switch Door Switch W OR 2 MVC 8 Hot Surface Igniter R W 2 24V Humidifier Integrated Control Module LINE 5 DEHUM ...

Page 51: ...ou need further assistance you can write to the below address with any questions or concerns Whirlpool Home Cooling and Heating 14610 Breakers Drive Jacksonville FL 32258 Please include a daytime phone number in your correspondence ...

Page 52: ...WPIO 368 2009 All rights reserved Registered Trademark TM Trademark of Whirlpool U S A Manufactured under license by Tradewinds Distributing Company LLC Jacksonville Florida 10 09 Printed in U S A ...

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Whirlpool Gold WGFM295, Installation Instructions Manual

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Summary of Contents for Gold WGFM295

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