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Whirlpool Gold WFD193 Installation Instructions Manual

93 percent convertible multispeed gas furnace.
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93% CONVERTIBLE MULTISPEED GAS FURNACE
GAS FURNACE SAFETY................................................................2
INSTALLATION REQUIREMENTS ................................................3
Tools and Parts ............................................................................4
Component Identification.............................................................4
Electrostatic Discharge (ESD) ......................................................5
Location Requirements ................................................................5
Installation Configurations ...........................................................7
Ductwork Requirements ..............................................................8
Electrical Requirements ...............................................................9
Gas Supply Requirements ...........................................................9
Venting Requirements..................................................................9
INSTALLATION INSTRUCTIONS ................................................11
Inspect Shipment .......................................................................11
Plan Vent System .......................................................................12
Determine Vent Pipe Direction...................................................14
Connect Venting.........................................................................22
Standard Vent/Flue Drain Hose Connections............................23
Alternate Vent/Flue Drain Hose Connections............................24
Install Ductwork..........................................................................26
Filter Specifications....................................................................26
Make Electrical Connections .....................................................27
Make Gas Connections..............................................................28
Check the Furnace Input Rate ...................................................33
Adjust the Furnace Input Rate ...................................................33
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.
bar code
Whirlpool Gold
®
Model
WFD193
WPIO-299F
INSTALLATION INSTRUCTIONS

Table of Contents

Complete Installation..................................................................34
Furnace Shut Down....................................................................34
SEQUENCE OF OPERATION ......................................................35
Power Up....................................................................................35
Cooling Mode .............................................................................35
Fan Only Mode ...........................................................................36
CIRCUIT/SWITCH DESCRIPTIONS............................................36
Integrated Control Module .........................................................36
Primary Limit Switch ..................................................................36
Auxiliary Limit Switches..............................................................36
Rollout Limit Switches................................................................36
Pressure Switches......................................................................36
Flame Sensor..............................................................................36
Circulator Blower Speeds ..........................................................36
Electronic Air Cleaner.................................................................37
MAINTENANCE ............................................................................37
Resetting from Lockout..............................................................37
Annual Inspection.......................................................................37
Filters ..........................................................................................37
Repair and Replacement Parts ..................................................38
TROUBLESHOOTING ..................................................................39
ASSISTANCE OR SERVICE .........................................................42
Accessories ................................................................................42
Whirlpool
®
Home Cooling and Heating
14610 Breakers Drive
Jacksonville, Florida 32258

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Table of Contents

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   Summary of Contents for Whirlpool Gold WFD193

  • Page 1: Table Of Contents

    Whirlpool ® Home Cooling and Heating Whirlpool Gold ® Model 14610 Breakers Drive WFD193 Jacksonville, Florida 32258 WPIO-299F...
  • Page 2: Gas Furnace Safety

    GAS FURNACE SAFETY CAUTION Recognize this symbol as a safety precaution. Goodman 9 WARNING Hazards or unsafe practices may result in property or product damage. Hazards or unsafe practices could result in property damage, product damage, severe personal injury or death. Goodman 1 CAUTION Hazards or unsafe practices may result in property...
  • Page 3: Installation Requirements

    WARNING WARNING Goodman 43 Should overheating occur or the gas supply fail to shut If the information in these instructions is not followed off, turn off the manual gas shutoff valve external to the exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 4: Tools And Parts

    The installation of the furnace, wiring, warm air ducts, venting, Local authorities having jurisdiction should be consulted before etc., must conform to the requirements of the National Fire installation is made. Such applicable regulations or requirements Protection Association; the National Fuel Gas Code, ANSI take precedence over the general instructions in this manual.
  • Page 5: Electrostatic Discharge (esd)

    Electrostatic Discharge (ESD) NOTE: Discharge static electricity accumulated in the body 2. Firmly touch a clean, unpainted, metal surface of the furnace before touching the unit. An electrostatic discharge can adversely near the control. Any tools held in a person’s hand during affect electrical components.
  • Page 6 Seal off a nondirect vent furnace if it is installed near an area High Altitude Installations frequently contaminated by any of the above substances. This protects the nondirect vent furnace from airborne contaminants. To ensure that the enclosed nondirect vent High Altitude Derate furnace has an adequate supply of combustion air, vent from When this furnace is installed at high altitudes, the appropriate...
  • Page 7: Installation Configurations

    For installations above 7,000 ft (2,133.6 m), refer to your local Recommended Installation Positions—Horizontal distributor for required kit(s). Upflow—Left Side Panel Discharge Manifold Pressure Pressure High Switch Altitude Orifice Stage Stage Change Natural None #43 3.5" 1.9" None 0 to W.C.
  • Page 8: Ductwork Requirements

    Drain Trap and Lines Alternate Electrical and Gas Line Connections In horizontal applications, the condensate drain trap is secured to This furnace has provisions allowing for electrical and gas line the furnace side panel, suspending it below the furnace. A connections through either side panel.
  • Page 9: Electrical Requirements

    Do not attach ductwork to the back of the furnace. Proper polarity of the supply connections (“HOT” and “NEUTRAL”) must be observed to be sure that the control Flexible joints may be used for supply and return connections system provides the damage avoidance intended. to reduce noise transmission.
  • Page 10 Existing Venting Systems Combustion and Ventilation Air Requirements When an existing furnace is removed or replaced, the original venting system may no longer be sized to properly vent the WARNING attached appliances. An improperly sized venting system can result in the spilling of flue products into the living space, the Goodman 51 To avoid property damage, personal injury or death, formation of condensate, leakage, etc.
  • Page 11: Installation Instructions

    It is the responsibility of the installer to follow the manufacturers’ Outdoor Air as the Source of Combustion Air recommendations and to verify that all vent/flue piping and connectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all If the furnace is installed in a confined space, it is recommended piping and connections possess adequate structural integrity and that the necessary combustion air come from the outdoors by...
  • Page 12: Plan Vent System

    Plan Vent System WARNING Piping and Fitting Specifications Goodman 53 Piping and Fitting Material ASTM Specification Failure to follow these instructions can result in bodily injury or death. Carefully read and follow all instructions Schedule 40 PVC (Pipe) D1785 given in this section. Schedule 40 PVC (Cellular Core Pipe) F891 Schedule 40 PVC (Fittings)
  • Page 13 Canadian Venting Requirements In Canada, venting must conform to the requirements of the current CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed, ULC- S636 compliant 2" or 3" diameter PVC, PVC ceill core or ABS pipe, solvent cement and fittings throughout. The certified piping should be clearly marked with the ULC Std “S636”...
  • Page 14: Determine Vent Pipe Direction

    Nondirect Vent Applications Refer to the following tables for applicable length, elbows and pipe diameter for construction of the vent/flue pipe systems of a nondirect vent (single pipe) installation. In addition to the vent/flue pipe, a single 90º elbow should be secured to the combustion air intake to avoid inadvertent blockage.
  • Page 15 Sidewall Vent Terminal Clearances—Direct Vented Furnaces (Horizontal Venting) Vent Terminal Air Supply Intake Inside Corner Detail Area Where Terminal Is Not Permitted Operable Fixed Closed Fixed Closed Operable U.S. Installations Clearance above grade, veranda, porch, deck, or balcony 12" (30.5 cm) Clearance to window or door that may be opened 6"...
  • Page 16 Sidewall Vent Terminal Clearances—Nondirect Vented Furnaces (Horizontal Venting) Vent Terminal Air Supply Intake Inside Corner Detail Area Where Terminal Is Not Permitted Operable Fixed Closed Fixed Closed Operable U.S. Installations Clearance above grade, veranda, porch, deck, or balcony 12" (30.5 cm) Clearance to window or door that may be opened 48"...
  • Page 17 Standard Connection—Counterflow Vent Pipe Installation—Standard Furnace Connections It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported. Attachment “couplings” for vent/flue and combustion air intake pipe connections are provided on the furnace’s top cover (upflow) or base pan (counterflow).
  • Page 18 3. Remove the vent/flue pipe from the furnace. Alternate Vent/Flue Location—Upflow 4. Cut the vent/flue pipe 3³⁄₄" (9.5 cm) from the flanged end of the pipe. See “Vent/Flue Pipe Cuts” illustration. NOTE: The section of pipe attached to the coupling will reach through the side panel to the induced draft blower.
  • Page 19 Vent/Flue Pipe Cuts Alternate Vent/Flue Location—Counterflow C. 3 ³⁄₄ " (9.5 cm) A. Flange B. Cut location A. Vent/flue pipe D. Plastic plug—alternate vent/flue location 8. Remove the plastic plug from the alternate vent/flue location. B. Screw locations (4) E. Rubber elbow 9.
  • Page 20 Alternate Combustion Air Intake Location—Counterflow Vent/Flue Pipe Terminations The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.
  • Page 21 Standard Horizontal Vent Termination (Single Pipe) A 3" (7.6 cm) diameter hole is required for a 2¹⁄₂" (6.4 cm) pipe. A 3¹⁄₂" (8.9 cm) diameter hole is required for 3" (7.6 cm) diameter pipe. To secure the pipe passing through the wall and avoid damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a pipe connecting the 2 couplings.
  • Page 22: Connect Venting

    Alternate Horizontal Vent Terminations (Dual Pipe) Vent/Intake Terminations for Installation of Multiple Direct Vent Furnaces 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.
  • Page 23: Install Condensate Condensate Drain Lines And Drain Trap-standard Vent/flue Drain Hose Connections

    Install Condensate Condensate Drain Lines and Drain Trap—Standard Vent/Flue Drain Hose Connections A condensing gas furnace achieves its high level of efficiency by 1. Remove the rubber plug from the front cover drain port (right extracting almost all of the heat from the products of combustion or left side, depending on the intended drain trap mounting).
  • Page 24: Install Condensate Condensate Drain Lines And Drain Trap-alternate Vent/flue Drain Hose Connections

    9. For left side drains, cut 0" to 7" (17.8 cm) from the long end of 15. Ensure that the hoses and tubes maintain a downward slope Hose B and discard. See the following chart. for proper drainage and are not kinked or binding. 10.
  • Page 25 8. Route Hose B to the front right (down) side panel grommet Alternate Horizontal Upflow Connections—Left Side Down holes. (Counterflow Similar) 9. Cut 5¹⁄₂" (14 cm) straight length from the long end of each Tube 2. Alternate Horizontal Upflow Connections—Right Side Down (Counterflow Similar) A.
  • Page 26: Install Ductwork

    Install Ductwork IMPORTANT: Install ductwork in accordance with NFPA 90B and any local codes. When the furnace is installed so that the supply ducts carry A. Supply air circulated by the furnace to areas outside the space B. Return containing the furnace, the return air shall be handled by a duct or ducts sealed to the furnace casing and terminated Installation without an Evaporator Coil outsides the space containing the furnace.
  • Page 27: Make Electrical Connections

    Upright Installations Make Electrical Connections Depending on the installation and/or customer preference, filters WARNING can be installed in the central return register or a side panel Goodman 70 external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter.
  • Page 28: Make Gas Connections

    3. Remove the cover from the furnace electrical connection box. Make Gas Connections 4. Route the field supply wires to the furnace electrical connection box. The furnace rating plate includes the approved furnace gas input 5. Using UL listed wire connectors, connect the field supply rating and gas types.
  • Page 29 When connecting gas piping: Gas Piping Connections WARNING Goodman 56 WARNING Edges of sheet metal holes may be sharp. Use gloves as a precaution when removing hole plugs. Goodman 52 Possible property damage, personal injury or death may occur if the correct conversion kits are not installed. The Use black iron or steel pipe and fittings for building piping.
  • Page 30 Gas Piping Connections—Upflow Gas Piping Connections—Horizontal Upflow A. Alternate gas line location F. Height required by local codes B. Manifold G. Drip leg A. Gas control valve F. Drain trap C. Gas control valve H. Grommet in standard gas line hole B.
  • Page 31 Direct/Standard Inlet Piping Propane Gas Tanks and Piping When gas piping enters directly to the gas control valve through the standard inlet hole, the installer must supply straight pipe WARNING with a ground joint union to reach the exterior of the furnace. The rigid pipe must be long enough to reach the outside of the If the gas furnace is installed in a basement, and cabinet to seal the grommet cabinet penetration.
  • Page 32 Sizing Between 1 and 2 Stage Regulator* Maximum propane capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 Btu/h. Propane Gas Piping Chart I Tubing Size, O.D. Type L Nominal Pipe Size Schedule 40 Pipe or Tubing Length—ft (m) ³⁄₈...
  • Page 33: Check The Furnace Input Rate

    Check the Furnace Input Rate (if required) (12.45 cm) W.C. (1 stage) and 10.0" (25.4 cm) W.C. CAUTION stage) for propane gas. For Natural gas, check the furnace rate by observing the gas To prevent unreliable operation or equipment damage, Goodman 61 meter, making sure all other gas appliances are turned off.
  • Page 34: Complete Installation

    10. Turn on the electrical power to the furnace. Complete Installation 11. Adjust the thermostat to a setting above room temperature. 12. After the burners are lit, set the thermostat to the desired IMPORTANT: Do not use this furnace if any part has been under temperature.
  • Page 35: Sequence Of Operation

    SEQUENCE OF OPERATION Low-stage and high-stage gas control valves open at the end Power Up of the igniter warm up period, delivering gas to the burners and establishing flame. The normal power up sequence is as follows: High-stage gas control valve closes after 5 seconds; 115 VAC power applied to furnace.
  • Page 36: Fan Only Mode

    Circulator blower runs; integrated control module monitors safety circuits continuously. Fan Only Mode R and G thermostat contacts open, completing the call for The normal operational sequence in fan only mode is as follows: fan. R and G thermostat contacts close, initiating a call for fan. Circulator blower is de-energized.
  • Page 37: 115-volt Line Connection Of Accessories-electronic Air Cleaner

    All field wiring must conform to applicable codes. 115-Volt Line Connection of Accessories—Electronic Optional Accessories Wiring Air Cleaner Connections should be made as shown below. WARNING HIGH VOLTAGE! Goodman 6 Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
  • Page 38: Repair And Replacement Parts

    To remove filters from an external filter rack in an upright upflow 5. Remove the recuperator coil front cover to expose the coil installation, follow the directions provided with external filter rack tubes and turbulators. kit. 6. Remove the recuperator coil turbulators individually by slowly pulling each turbulator forward firmly.
  • Page 39: Troubleshooting

    TROUBLESHOOTING See “Electrostatic Discharge (ESD)” before touching any Is the blower compartment door securely closed? electronic part on this furnace. Are the manual shutoff valves in the gas line to the furnace open? Furnace Fails to Operate Properly Are all wiring connections secure? Start the system by setting thermostat above room temperature.
  • Page 40 Problem LED Code Fault/Cause Solution Induced draft blower runs 3 flashes Pressure switch circuit not closed. Inspect pressure switch hose. Repair, if continuously with no necessary, Induced draft blower is operating. further furnace operation. Inspect flue and/or inlet air piping for Pressure switch hose blocked, pinched Integrated control module blockage, proper length, elbows, and...
  • Page 41: Wiring Diagram

    Wiring Diagram Steady On = Normal Operation 1 Flash = System Lockout (Retries/Recycles Exceeded 2 Flashes = Low Fire Pressure Switch Stuck Closed 3 Flashes = Low Fire Pressure Switch Stuck Open 4 Flashes = Thermal Protective Device Open 5 Flashes = Flame Sensed With Gas Control Valve De-energized 7 Flashes = Low Flame Sense Signal 8 Flashes = Check Igniter Or Improper Grounding 9 Flashes = High Fire Pressure Switch Stuck Open...
  • Page 42: Assistance Or Service

    Accessories ® Whirlpool Home Cooling and Heating ® to order accessories, contact your Whirlpool Home Cooling and 14610 Breakers Drive Heating dealer. Jacksonville, FL 32258 Please include a daytime phone number in your correspondence.
  • Page 43 Notes...
  • Page 44 WPIO-299F ®Registered Trademark/TM Trademark of Whirlpool, U.S.A., 8/09 © 2009. All rights reserved. Manufactured under license by Tradewinds Distributing Company, LLC., Jacksonville, Florida Printed in U.S.A.

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