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Whirlpool WFCU Installation Instructions Manual

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90+ GAS FURNACE INSTALLATION INSTRUCTIONS
GAS FURNACE SAFETY................................................................1
INSTALLATION REQUIREMENTS ................................................3
Tools and Parts ............................................................................3
Location Requirements................................................................4
Installation Configurations ...........................................................5
Ductwork Requirements ..............................................................5
Electrical Requirements ...............................................................6
Gas Supply Requirements ...........................................................6
Venting Requirements..................................................................6
INSTALLATION INSTRUCTIONS ..................................................8
Inspect Shipment .........................................................................8
Plan Vent System .........................................................................8
Determine Vent Pipe Direction...................................................10
Install Ductwork..........................................................................17
Filter Specifications....................................................................17
We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety
messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word "DANGER" or "WARNING."
These words mean:
WARNING
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can
happen if the instructions are not followed.
®
Whirlpool
and Whirlpool Gold
WFCU, WFCC, WGFDC, WGFDU
46948B008

GAS FURNACE SAFETY

Your safety and the safety of others are very important.
DANGER
®
Models

Table of Contents

Make Electrical Connections .....................................................18
Make Gas Connections..............................................................19
Check the Furnace Input Rate (if required) ................................20
Adjust the Furnace Input Rate (if required) ................................20
Complete Installation..................................................................21
Shut Down..................................................................................21
SEQUENCE OF OPERATION ......................................................22
Heating Cycle .............................................................................22
Fan On Cycle..............................................................................22
Cooling Cycle .............................................................................22
CONTROLS ...................................................................................23
TROUBLESHOOTING ..................................................................24
ASSISTANCE OR SERVICE .........................................................27
Accessories ................................................................................27
You can be killed or seriously injured if you don't immediately
follow instructions.
You can be killed or seriously injured if you don't follow
instructions.
Whirlpool
®
Home Cooling and Heating
14610 Breakers Drive
Jacksonville, FL 32258

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Table of Contents
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  • Page 1: Table Of Contents

    All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed. Whirlpool ® Home Cooling and Heating ® ® Whirlpool and Whirlpool Gold Models 14610 Breakers Drive WFCU, WFCC, WGFDC, WGFDU Jacksonville, FL 32258 46948B008...
  • Page 2: Save These Instructions

    IMPORTANT SAFETY INSTRUCTIONS Use only with type of gas approved for this furnace. When a furnace is installed so that supply ducts Refer to the furnace rating plate. carry air circulated by the furnace to areas outside the space containing the furnace, the return air Install this furnace only in a location and position shall also be handled by duct(s) sealed to the as specified in the “Location Requirements”...
  • Page 3: Installation Requirements

    WARNING: Gas leaks cannot always be detected by smell. Gas suppliers recommend that you use a gas detector approved by UL or CSA. For more information, contact your gas supplier. If a gas leak is detected, follow the “What to do if you smell gas” instructions. The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.
  • Page 4: Location Requirements

    Location Requirements All models are suitable for closet or utility room installation. WARNING Utility room installation requires: A door opening large enough for the widest part of the furnace. A door opening large enough to remove/replace any other appliance located in the utility room, such as a water heater. Any other appliances arranged so that each appliance can be removed/replaced without disturbing the furnace.
  • Page 5: Installation Configurations

    Installation Configurations WGFDU and WFCU models must be installed only as upflow 1. Cut a hole in the floor, sized to provide 1" (2.5 cm) clearance furnaces. between all 4 sides of the duct and the edge of the flooring.
  • Page 6: Electrical Requirements

    Existing Venting Systems Electrical Requirements When an existing furnace is removed or replaced, the original WARNING venting system may no longer be sized to properly vent the attached appliances. An improperly sized venting system can result in the spilling of flue products into the living space, the formation of condensate, leakage, etc.
  • Page 7 When a furnace is installed in an unconfined space in a building, Venting Options it can be assumed that the infiltration will be sufficient to supply the required air. The furnace can be installed as either direct vent or nondirect If the furnace is installed in a ventilated attic or crawl space, it is vent units.
  • Page 8: Installation Instructions

    INSTALLATION INSTRUCTIONS IMPORTANT: WARNING The venting system must be supported with mounting straps to keep any weight load from being applied to the vent blower. Horizontal vent pipe must be supported every 5 ft and vertical pipe should be supported every 10 ft to avoid sagging and provide rigid support.
  • Page 9 Vent Pipe Size and Length The vent pipe and air intake pipe (in direct vent installations) should be sized in accordance with the information found in the Vent Table charts. One 90° elbow is equivalent to 5 ft (1.5 m) of pipe. Two 45° elbows are equivalent to one 90° elbow. The minimum length certified for use with this furnace is 5 ft (1.5 m) and one elbow, not including the vent and air intake terminals.
  • Page 10: Determine Vent Pipe Direction

    Vent Table—112,000 to 125,000 Btu/h Models Vent Pipe Length—ft (m) Minimum Pipe Diameter—in. (cm) 5 (1.5) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 2¹⁄₂ (6.4) 10 (3) 2¹⁄₂ (6.4) 2¹⁄₂...
  • Page 11 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 12 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 13 Direct Vent Installation—Upflow Installations Refer to the appropriate vent table for proper pipe size, vent For proper operation, the vent and air intake pipe must be length and the number of elbows allowed, and air intake installed in the same pressure zone. Therefore, in horizontal length and the number of elbows allowed.
  • Page 14 Nondirect Vent Installation—Upflow Installations Refer to appropriate tables for proper pipe size, vent length Attach a 90° elbow (not supplied) to the inlet coupler and and the number of elbows allowed. install the inlet air restrictor plate inside the elbow. Refer to “Materials”...
  • Page 15 Direct Vent Installation—Counterflow Installations Refer to appropriate tables for proper pipe size, vent length For proper operation, the vent and air intake pipe must be and the number of elbows allowed, and air intake length and installed in the same pressure zone. Therefore, in horizontal the number of elbows allowed.
  • Page 16 Inlet Air Assembly—45,000 & 67,000 Btu/h Furnaces NOTE: The vent for this appliance shall not terminate over public walkways, or near soffit vents or crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or cause property damage, or where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.
  • Page 17: Install Ductwork

    The 45,000 and 67,000 Btu/h models contain an inlet air Inlet Air Assembly—45,000 & 67,000 Btu/h Units assembly that uses two 22.5° elbows that attach separately from the straight inlet pipe, as shown. This allows the inlet pipe assembly to be removed if needed for service. A.
  • Page 18: Make Electrical Connections

    Typical filter sizes are shown; however, any combination of filters whose area equals or exceeds the minimum area shown is satisfactory. Minimum Filter Requirements Chart Disposable Filters Cleanable Filters Airflow Minimum Area— Minimum Area— Descriptor sq. in. (cm Size—in. (cm) Quantity sq.
  • Page 19: Make Gas Connections

    WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 20: Check The Furnace Input Rate (If Required)

    Check the Furnace Input Rate (if required) IMPORTANT: For natural gas, check the furnace rate by observing the gas meter, making sure all other gas appliances are turned off. The furnace input rate must not exceed the input rating on The test hand on the meter should be timed for at least one the furnace rating plate.
  • Page 21: Complete Installation

    Complete Installation IMPORTANT: Do not use this furnace if any part has been under 3. If furnace doesn't maintain temperature rise within the range water. Immediately call a qualified person to inspect the furnace shown on the furnace rating plate, adjust the blower speed. and to replace any part of the control system and gas control which has been under water.
  • Page 22: Sequence Of Operation

    SEQUENCE OF OPERATION If a call for cooling is energized during a fan on call, the fan Heating Cycle continues to operate at the COOL speed. If a call for heat is energized during a fan on call, the control de-energizes the fan During a call for heat, the thermostat closes R - W circuit of the immediately and begins the heat call/ignition sequence.
  • Page 23: Controls

    CONTROLS Pressure Switch(s) Ignition Control Board The pressure switch is a normally open switch that monitors combustion airflow. Inadequate airflow resulting from excessive WARNING venting system restriction or a failed combustion blower will cause the switch to remain open. Rollout Switch(es) The rollout switch(es) are normally closed switch(es) that open when abnormal temperatures exist in the burner area.
  • Page 24: Troubleshooting

    TROUBLESHOOTING Furnace Fails to Operate Properly Failure Codes Review “Sequence of Operation” and visually inspect the The furnace has a built-in, self-diagnostic capability. If a system following before troubleshooting: problem occurs, a failure code is indicated by the LED on the ignition control board.
  • Page 25 Wiring Connection Diagram—Honeywell ® VR 8205 System Line Voltage - Factory Line Voltage - Field Hot Surface Igniter Low Voltage - Factory Low Voltage - Field Interlock Switch Circulation Blower W (Neutral) R (Lo) OR (Med/Lo) BU (Med) Y (Med/Hi) BK (Hi) Induced Draft...
  • Page 26 Wiring Schematic—Honeywell ® VR 8205 System 120 / 1 / 60 Interlock Switch Neutrals Hot Surface Igniter Neutrals Humidifier Neutrals Induced Draft Blower Neutrals Air Cleaner Heat Neutrals Blower Motor Cool Neutrals 120 VAC Transformer 24 VAC Pin 3 Pin 6 If Used Flame Sensor Pin 2...
  • Page 27: Assistance Or Service

    ® Whirlpool Home Cooling and Heating To order accessories ask for the appropriate part number listed 14610 Breakers Drive below or contact your Whirlpool ® Home Cooling and Heating Jacksonville, FL 32258 dealer. Please include a daytime phone number in your correspondence.
  • Page 28 Honeywell is a trademark of Honeywell International, Inc. 46948B008 ®Registered Trademark/TM Trademark of Whirlpool, U.S.A., 3/08 © 2008. All rights reserved. Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida Printed in U.S.A.

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