Whirlpool WGFD28 Installation Instructions Manual Download

Page: 33 / 40

■

Induced draft
blower runs
continuously
with no further
furnace
operation.

■

Integrated
control module
LED display
provides “E2”
error code.

■

Low-stage
pressure switch
circuit is not
closed.

■

Pressure switch
hose blocked,
pinched or
connected
improperly.

■

Blocked flue and/or
inlet air pipe,
blocked drain
system or weak
induced draft
blower.

■

Incorrect pressure
switch setpoint or
malfunctioning
switch contacts.

■

Loose or
improperly
connected wiring.

■

Inspect pressure
switch hose. Repair/
replace, if necessary,

■

Inspect flue and/or
inlet air piping for
blockage, proper
length, elbows and
termination.

■

Check drain system.
Correct as necessary.

■

Check induced draft
blower performance.
Correct as necessary.

■

Correct pressure
switch setpoint or
contact motion.

■

Tighten or correct
wiring connection.

■

Turn off power 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
LED display
provides “E3”
error code.

■

Primary limit or
auxiliary limit
circuit is open.

■

Rollout limit
circuit is open.

■

Insufficient
conditioned air
over the heat
exchanger.
Blocked filters,
restrictive
ductwork, improper
circulator blower
speed, or failed
circulator blower.

■

Flame rollout.

■

Misaligned
burners, 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 as necessary.

■

Check induced draft
blower for proper
performance. Replace,
if necessary.

■

Tighten or correct
wiring connection.

■

Turn off power prior to
repair.

■

See Specification
Sheet applicable to
your model for
allowable rise range
and proper circulator
speed.

■

See “Vent/Flue Pipe”
section for piping
details.

■

Induced draft
blower and
circulator
blower runs
continuously.
No furnace
operation.

■

Integrated
control module
LED display
provides “E4”
error code.

■

Flame sensed
with no call for
heat.

■

Short to ground in
flame sense circuit.

■

Lingering burner
flame.

■

Slow closing gas
control valve.

■

Correct short at flame
sensor or in flame
sensor wiring.

■

Check for lingering
flame.

■

Verify proper operation
of gas control valve

■

Turn off power prior to
repair.

■

No furnace
operation.

■

Integrated
control module
LED display
provides “E5”
error code.

■

Open fuse.

■

Short in low voltage
wiring.

■

Locate and correct
short in low voltage
wiring.

■

Turn off power prior to
repair.

■

Replace fuse with 3A
automotive fuse.

Symptoms of
Abnormal
Operation

Diagnostic/
Staus LED
Code

Fault Description Possible Causes

Corrective Actions

Notes and Cautions

Summary of Contents for WGFD28

Page 1: ...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 ...

Page 2: ...work Airflow 20 Filters Read this Section Before Installing the Return Air Ductwork 20 START UP PROCEDURE AND ADJUSTMENT 21 Heat Anticipator Setting 21 Furnace Operation 21 Furnace Start Up 21 Furnace Shutdown 21 Gas Supply Pressure Measurement 21 Gas Manifold Pressure Measurement and Adjustment 23 Gas Input Rate Measurement Natural Gas Only 23 Temperature Rise 24 Circulator Blower Speeds 24 Blowe...

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: ... applicable to both installed and non installed ungrounded furnaces 1 Disconnect all power to the furnace NOTE Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground 2 Firmly touch a clean unpainted metal surface of the furnace away from the control Any tools held in a person s hand during grounding will be di...

Page 5: ...certified for outdoor applications The furnace must be installed indoors for example attic space crawl space or garage area provided the garage area is enclosed with an operating door This furnace can be used in the following nonindustrial commercial applications NOTE In such applications the furnace must be installed with the following stipulations It must be installed according to the installati...

Page 6: ...8 are not approved for horizontal or upflow installations For these models use only the instructions for downflow installation only Follow the instructions listed below when selecting a furnace location Refer also to the guidelines provided in Combustion and Ventilation Air Requirements Centrally locate the furnace with respect to the proposed or existing air distribution system Check that the tem...

Page 7: ...st be installed so that the ignition source and burners are located not less than 18 45 7 cm above the floor and are protected or located to prevent physical damage by vehicles A gas furnace must not be installed directly on carpeting tile or other combustible materials other than wood flooring FurnaceSuspension If suspending the furnace from rafters or joists use threaded rod and 2 x 2 x 5 1 cm x...

Page 8: ...ces Appliances that pull air out of the house clothes dryers exhaust fans fireplaces etc increase the problem by starving appliances for air House depressurization can cause back drafting or improper combustion of gas fired appliances thereby exposing building occupants to gas combustion products that could include carbon monoxide If this furnace is to be installed in the same space with other gas...

Page 9: ...otated accordingly 11 Reconnect the induced draft blower power leads NOTE If the wires are not long enough pull extra wire from the wire bundle in the blower compartment 12 Reconnect the flue pipe and the pressure switch tubing Ensure that all wires and the pressure switch tubing are at least 1 2 5 cm from the flue pipe or any other hot surface 13 Reconnect electrical power to the furnace Counterf...

Page 10: ...ted within 10 ft 3 m The chimney must extend at least 5 ft 1 5 m above the highest connected equipment draft hood outlet or flue collar If the chimney does not meet these termination requirements but all other requirements in the checklist can be met it may be possible for a mason to extend the chimney If this will not be practical see Fix 1 Liner Termination A Crown B Wash C Roof line D Clay tile...

Page 11: ...er Condition If a metal liner is present it must be checked It cannot be assumed that all existing metal liners are correctly installed and in good condition Remove the lowest existing vent connector and examine the inside of the elbow or tee at the base of the liner A small amount of soot may be considered acceptable provided the installer vacuums it away If rusted pieces of the liner have collec...

Page 12: ... some cases a shorter extension above the roof may be possible with a liner than would be required with a masonry chimney For further information on relining see Fix 4 Relining Fix 2 Change Venting Arrangements If the masonry chimney has more than one channel it may be possible to vent the gas appliances into one channel and vent the solid or liquid fuel appliance s into another channel s Do not v...

Page 13: ...If any of the original wire 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 t...

Page 14: ...or is opened for servicing NOTE Do not defeat this switch 24 VoltThermostatWiring As a 2 stage furnace the furnace integrated control module provides terminals for both W1 and W2 and Y1 and Y2 thermostat connections This allows the furnace to support the following system applications 2 stage heating only 2 stage heating with single stage cooling and 2 stage heating with 2 stage cooling Refer to th...

Page 15: ...utral wire typically the white lead to the terminal marked DEHUM on the furnace integrated control module 3 Secure the dehumidistat hot wire typically the black lead to the terminal marked R on the furnace integrated control module 4 Secure the dehumidistat ground wire typically the green lead to the ground screw on the furnace junction box NOTE Ground wire may not be present on all dehumidistats ...

Page 16: ...4 VAC humidifier control This wire is powered any time the pressure switch is closed To connect 24 VAC HUM connect the 24 VAC line of the humidifier to the 5 12 7 cm brown wire The connection can be made by either stripping the wire and using a wire connector or by using a field supplied quick connect terminal The wiring must conform to all local and national codes Connect the COM side of the humi...

Page 17: ...The indicated kits must be used to ensure safe and proper furnace operation All conversions must be performed by a qualified installer or service agency GasPipingConnections When sizing a trunk line be sure to include all appliances which will operate simultaneously The gas piping supplying the furnace must be properly sized based on the gas flow required specific gravity of the gas and the length...

Page 18: ... 2 Close nipple Straight pipe to reach the exterior of the furnace Ground joint union Drip leg Manual shutoff valve Transition piece from to another pipe size if needed When the gas piping enters through the left side of the furnace the installer must supply the following fittings starting from the gas control valve Straight pipe to reach the exterior of the furnace Ground joint union Drip leg Man...

Page 19: ... 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 such as Gasolac Stalactic Clyde s or John Crane are satisfactory Refer to Propane Gas Installation Typical for typical propane gas installations and piping Propane Gas Instal...

Page 20: ... 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 unit it is recommended that a removable access panel be provided in the outlet air duct This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be view...

Page 21: ...er s instructions on how to adjust the heat anticipator setting FurnaceOperation 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 be...

Page 22: ...ontrol valve a field supplied hose barb fitting must be installed prior to making the hose connection If using the inlet pressure boss on the White Rodgers 36G54 gas control valve then use the 36G Valve Pressure Check Kit Part Number 0151K00000S 4 Turn on the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line 5 Measure the furnace gas supply press...

Page 23: ... decrease pressure 15 Replace the regulator cover screw 16 Turn off electrical power and gas supply to the system 17 Remove the manometer hose from the hose barb fitting or outlet pressure boss 18 Replace the outlet pressure tap Honeywell VR9205 valve Remove the NPT hose barb fitting from the outlet pressure tap Replace the outlet pressure boss plug and seal with a high quality thread sealer White...

Page 24: ...for thermometer readings to stabilize 5 Adjust the temperature rise by adjusting the circulator blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise Refer to Circulator Blower Speeds for speed changing details Temperature Rise Measurement Rise Supply air temperature Return air temperature CirculatorBlowerSpeeds This furnace is equipped wi...

Page 25: ...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 26: ...tage 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 C 10 8 Set DIP switches 3 and 4...

Page 27: ...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 28: ...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 29: ...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 30: ...ct 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 steps will help avoid exposing the integrated control module to electrostatic discharge This procedure is applicable to both installed and uninstalled ungrounded f...

Page 31: ...losed 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 stuck closed at start of heating cycle E 9 High stage pressure switch stuck open E A Reversed 115 VAC polarity d 0 Data not yet on network d 4 ...

Page 32: ...e 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 restri...

Page 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 38: ...sure Switch 2 Stage Gas Control Valve 2 Circuit Connector Hot Surface Igniter 24V Humidifier Manual Reset Rollout Limit Controls BU Auto Reset Auxiliary Limit Control 40 VA Transformer Diagnostic LEDs 24V Thermostat Connections NEUTRAL GND LINE Induced Draft Blower Fuse Blower Compartment Burner Compartment COOL See NOTE 5 DELAY T STAT 2ND STG DLY DEHUM HEAT ADJUST UNUSED HEAT OFF DELAY 5 Circuit ...

Page 39: ...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 40: ...WPIO 369 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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