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Whirlpool Gold WGFD295 Installation Instructions Manual

80% 2-stage variable speed gas furnace.
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80% 2-STAGE VARIABLE SPEED GAS FURNACE
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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Keep this literature in a safe place for future reference.
Whirlpool Gold
®
Models
WGFD295, WGFM295
WPIO-369B

INSTALLATION INSTRUCTIONS

Tradewinds Distributing Company, LLC
14610 Breakers Drive
Jacksonville, Florida 32258
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.

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Table of Contents

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   Summary of Contents for Whirlpool Gold WGFD295

  • Page 1: Installation Instructions

    These furnaces comply with requirements embodied in the American National Standard/National Standard of Canada ANSI Keep this literature in a safe place for future reference. Z21.47-CSA-2.3 Gas Fired Central Furnaces. Tradewinds Distributing Company, LLC Whirlpool Gold ® Models 14610 Breakers Drive WGFD295, WGFM295 Jacksonville, Florida 32258 WPIO-369B...
  • Page 2: Table Of Contents

    TABLE OF CONTENTS GAS FURNACE SAFETY PRECAUTIONS ........3 Gas Supply Pressure Measurement ..........22 Additional Safety Considerations..........4 Gas Manifold Pressure Measurement and Adjustment.....23 Gas Input Rate Measurement—Natural Gas Only.....24 PRODUCT DESCRIPTION AND APPLICATION ......4 Temperature Rise ...............24 Shipping Inspection ..............4 Circulator Blower Speeds ............25 Electrostatic Discharge (ESD) Precautions........4 Blower Heat Off Delay Timings ..........27 To the Installer................4...
  • Page 3: Gas Furnace Safety Precautions

    GAS FURNACE SAFETY PRECAUTIONS Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. Recognize this symbol as a safety precaution.
  • Page 4: Additional Safety Considerations

    The furnace must be carefully inspected on arrival for damage WARNING and bolts or screws which may have come loose in transit. In the event of damage, the consignee should: Goodman 46 To prevent possible property damage, personal injury or 1.
  • Page 5: Important Note To The Owner Regarding Product Warranty

    The vent system is permanently installed according to these installation instructions. Important Note to the Owner Regarding A room thermostat is used to control the furnace. Fixed Product Warranty jumpers that provide continuous heating cannot be used. Your warranty certificate is supplied as a separate document with Return air ducts are provided and sealed to the furnace.
  • Page 6: Location Requirements And Considerations

    The rated heating capacity of the furnace should be greater than All venting shall be in accordance with PART 7, Venting of or equal to the total heat loss of the area to be heated. The total Equipment, of the National Fuel Gas Code, ANSI Z223.1, or heat loss should be calculated by an approved method or in applicable local building and/or air conditioning codes.
  • Page 7: Clearances And Accessibility

    Counterflow Installation Over a Noncombustible Floor Adequate combustion/ventilation air must be supplied to the closet or enclosure. Before setting the furnace over the plenum opening, ensure that the surface around the opening is smooth and level. A Furnace must be completely sealed to the floor or base. tight seal should be made between the furnace base and Combustion/ventilation air supply pipes must terminate 12"...
  • Page 8: Existing Furnace Removal

    8. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined Existing Furnace Removal above, return doors, windows, exhaust fans, fireplace NOTE: When an existing furnace is removed from a venting dampers and any other gas-burning appliance to their system serving other appliances, the venting system may be too previous conditions of use.
  • Page 9: Category I Furnaces Only-exterior Masonry Chimneys

    All installations must be vented in accordance with National Fuel 6. Remove and save the 4 screws that fasten the chimney top to Gas Code NFPA 54/ANSI Z223.1—latest edition. In Canada, the the chimney bottom. furnaces must be vented in accordance with the National 7.
  • Page 10 WARNING Checklist Summary This checklist serves as a summary of the items to be checked Possiblility of property damage, personal injury or death. before venting an 80+ furnace into a masonry chimney. In Damaging condensation can occur inside masonry Goodman 69 addition, we recommend that a qualified serviceman use this chimneys when a single fan-assisted Category I appliance checklist to perform a yearly inspection of the furnace venting...
  • Page 11 If the chimney does not meet these termination requirements, but Check 2—Any Solid or Liquid Fuel Appliances Vented into all other requirements in the checklist can be met, it may be This Chimney Channel possible for a mason to extend the chimney. If this will not be Solid fuel appliances include fireplaces, wood stoves, coal practical, see “Fix 1—Liner Termination.”...
  • Page 12 Flexible liners should be hung straight or nearly straight. If it is Fix 1—Liner Termination spiraled in the chimney and in good condition, it should be Any cap or roof assembly used with a liner must be approved by rehung. To do this, break the top seal. Pull up and cut off the the liner manufacturer for such use.
  • Page 13: Electrical Connections

    If a flexible liner is to be used, it must be made of the proper Do not spiral excess liner inside of the chimney. materials, such as: Support the liner as recommended by the liner manufacturer. For most residential applications, an aluminum liner should Some manufacturers of flexible liners offer an insulation sleeve be acceptable.
  • Page 14: Junction Box Relocation

    To make electrical connections through the opposite side of the IMPORTANT: To avoid possible equipment malfunction, route the furnace, the junction box must be relocated to the other side of low voltage wires to avoid interference with filter removal or other the burner or blower compartment prior to making electrical maintenance.
  • Page 15 NOTES: Thermostat Wiring Diagram—2-Stage Heating with 2-Stage Cooling For single-stage cooling applications, a jumper may be NOTE: Place jumper between Y1 and O for proper required between Y1 and Y2 at the furnace control in order to dehumidification operation and proper ramping profile operation. achieve the desired single-stage cooling airflow.
  • Page 16: 24-volt Dehumidistat Wiring

    24-Volt Dehumidistat Wiring 115-Volt Line Connection of Accessories (Humidifier and Electronic Air Cleaner) The optional usage of a dehumidistat allows the furnace’s circulator blower to operate at a slightly lower speed (82% of desired speed) during a combined thermostat call for cooling and WARNING dehumidistat call for dehumidification.
  • Page 17: Gas Supply And Piping

    If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all High Altitude Derate local codes, and have a minimum temperature rating of 105°C. NOTE: The furnace will naturally derate itself with altitude. Do not All line voltage wire splices must be made inside the furnace attempt to increase the firing rate by changing orifices or junction box.
  • Page 18: Gas Piping Connections

    Gas Piping Connections Use 2 pipe wrenches when making the connection to the gas CAUTION control valve to keep it from turning. NOTE: The orientation of the gas control valve on the To avoid possible unsatisfactory operation or equipment manifold must be maintained as shipped from the factory. damage due to underfiring of equipment, use the proper Install a manual shutoff valve between the gas meter and the Goodman 62...
  • Page 19: Gas Piping Checks

    Drip leg Propane Gas Tanks and Piping Manual shutoff valve Transition piece from ¹⁄₂" to another pipe size, if needed WARNING 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): If the gas furnace is installed in a basement, and Goodman 64...
  • Page 20 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 21: Circulating Air And Filters

    CIRCULATING AIR AND FILTERS When the furnace is heating, the temperature of the return air Ductwork—Airflow entering the furnace must be between 55°F and 100°F (13ºC and 38ºC). When a furnace is installed so that supply ducts carry air WARNING circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct sealed Goodman 68...
  • Page 22: Start-up Procedure And Adjustment

    START-UP PROCEDURE AND ADJUSTMENT This furnace must have a 115 VAC power supply properly 2. Remove the burner compartment door and move the furnace connected and grounded. Proper polarity must be maintained for gas control valve manual control to the Off position. correct operation.
  • Page 23: Gas Manifold Pressure Measurement And Adjustment

    Gas Control Valve—Honeywell 2-Stage VR9205 5. Measure the furnace gas supply pressure with burners firing. NOTE: Supply pressure must be within the range specified in the Inlet Gas Supply Pressure chart. Inlet Gas Supply Pressure Natural Gas Minimum: 5.0" W.C. Maximum: 10.0" W.C. Propane Gas Minimum: 11.0"...
  • Page 24: Gas Input Rate Measurement-natural Gas Only

    3. Outlet pressure tap connections: Gas Input Rate Measurement—Natural Gas Only Honeywell VR9205 valve: Remove the outlet pressure boss plug. Install an ¹⁄₈" NPT hose barb fitting into the The gas input rate to the furnace must never be greater than that outlet pressure tap.
  • Page 25: Circulator Blower Speeds

    Temperature Rise Measurement 2. Determine the proper airflow for the cooling system. Most cooling systems are designed to work with airflows between Rise = Supply air temperature - Return air temperature 350 and 450 CFM per ton. Most manufacturers recommend an airflow of about 400 CFM per ton.
  • Page 26 Speed Taps—Adjust Provides a 1-minute Off delay at 100% of the cooling demand airflow. Switch Bank: S3 DIP Switch Number 85% CFM 100% CFM 100% CFM Adjust Tap 7¹⁄₂ min 1 min Cooling Demand Normal* Profile D +10% Adjust Ramps up to 50% of the full cooling demand airflow for -10% Adjust 30 seconds.
  • Page 27: Blower Heat Off Delay Timings

    To Set Airflow Blower Heat Off Delay Timings The integrated control module provides a selectable heat-off 1. Select the model and desired high-stage cooling airflow. delay function. The heat off delay period may be set to 90, 120, 2. Determine the corresponding tap (A, B, C, or D). 150 or 180 seconds using the DIP switches or jumper provided 3.
  • Page 28: Cooling Mode

    If the thermostat call is for low heat, the gas control valve and Electronic air cleaner terminal and circulator blower are induced draft blower will continue on low stage. If the call is de-energized. for high heat, the gas control valve and induced draft blower Furnace awaits next call from thermostat.
  • Page 29: Primary Limit Control

    Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to Primary Limit Control the furnace. The primary limit control is located on the partition panel and Heat exchanger. Check for corrosion and/or buildup within monitors heat exchanger compartment temperatures.
  • Page 30: Burners

    6. Remove the recuperator coil turbulators individually by slowly pulling each turbulator forward firmly. Burners 7. Clean the recuperator coil tubes using a long handle wire brush, such as a gun cleaning brush. WARNING 8. Clean the primary heat exchanger tubes using a wire brush attached to a length of high grade stainless steel cable, such To avoid personal injury or death due to electrical shock, as drain cleanout cable.
  • Page 31: Troubleshooting

    TROUBLESHOOTING Electrostatic Discharge (ESD) Precautions Fault Recall NOTE: Discharge static electricity accumulated in the body The ignition control is equipped with a momentary pushbutton before touching the unit. An electrostatic discharge can adversely switch that can be used to display the last 6 faults on the dual affect electrical components.
  • Page 32: Diagnostic Chart

    Diagnostic Chart WARNING Goodman 118 Long HIGH VOLTAGE! To avoid personal injury or death due to electrical shock, disconnect electrical power before performing any service or maintenance. The dual 7-segment LED display will display an error code that may contain a letter and number. The error code may be used to assist in troubleshooting the unit.
  • Page 33 Symptoms of Diagnostic/ Abnormal Status LED Operation Code Fault Description Possible Causes Corrective Actions Notes and Cautions Furnace fails to Low-stage Low-stage Replace low-stage Turn off power prior to operate. pressure switch pressure switch pressure switch. repair. circuit is closed contacts sticking.
  • Page 34 Symptoms of Diagnostic/ Abnormal Status LED Operation Code Fault Description Possible Causes Corrective Actions Notes and Cautions No furnace Open fuse. Short in low voltage Locate and correct Turn off power prior to operation. wiring. short in low voltage repair. wiring.
  • Page 35 Symptoms of Diagnostic/ Abnormal Status LED Operation Code Fault Description Possible Causes Corrective Actions Notes and Cautions Furnace fails to High-stage Pressure switch Inspect pressure Turn off power prior to operate on high pressure switch hose blocked, switch hose. Repair, if repair.
  • Page 36 Symptoms of Diagnostic/ Abnormal Status LED Operation Code Fault Description Possible Causes Corrective Actions Notes and Cautions Furnace fails to Circulator Loose wiring Tighten or correct Turn off power prior to operate. blower motor is connection at wiring connection. repair. not running circulator motor Integrated...
  • Page 37 Symptoms of Diagnostic/ Abnormal Status LED Operation Code Fault Description Possible Causes Corrective Actions Notes and Cautions Furnace fails to Circulator Abnormal motor Check filters, filter Turn off power prior to operate. blower motor loading, sudden grills/registers, duct repair. senses a loss of change in speed or system and furnace air Integrated...
  • Page 38: Dip Switch Chart

    DIP Switch Chart WARNING Goodman 118 Long HIGH VOLTAGE! To avoid personal injury or death due to electrical shock, disconnect electrical power before performing any service or maintenance. Switch DIP Switch Number Bank Purpose Function Heat Off 90 Seconds Delay 120 Seconds 150 Seconds* 180 Seconds...
  • Page 39: Wiring Diagram

    WIRING DIAGRAM WARNING Goodman 6 Long HIGH VOLTAGE! Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. To 115 VAC/10/60 Hz Power Supply with Overcurrent Protection Device Induced Draft Blower 2-Stage Pressure Switch Assembly Equipment GND WARNING:...
  • Page 40: Assistance Or Service

    Tradewinds Distributing Company, LLC 14610 Breakers Drive Jacksonville, FL 32258 ®Registered Trademark/TM Trademark of Whirlpool, U.S.A., Manufactured under license by Tradewinds Distributing Company, LLC, Jacksonville, Florida. WPIO-369B Warranty provided by manufacturer. All other trademarks are owned by their respective companies.

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