Specifications

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93% CONVERTIBLE MULTISPEED GAS FURNACE

INSTALLATION INSTRUCTIONS

Table of Contents

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

Install Condensate Condensate Drain Lines and Drain Trap—

Standard Vent/Flue Drain Hose Connections............................23

Install Condensate Condensate Drain Lines and Drain Trap—

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

Complete Installation..................................................................34

Furnace Shut Down....................................................................34

SEQUENCE OF OPERATION ......................................................35

Power Up....................................................................................35

Heating Mode—Mode DIP Switch Set to 1 STG Position.........35

Heating Mode—Mode DIP Switch Set to 2 STG Position.........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

115-Volt Line Connection of Accessories—

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

WPIO-299F

Whirlpool

Home Cooling and Heating

14610 Breakers Drive

Jacksonville, Florida 32258

Whirlpool Gold

Model

WFD193

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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Summary of content (44 pages)

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93% CONVERTIBLE MULTISPEED GAS FURNACE INSTALLATION INSTRUCTIONS Table of Contents GAS FURNACE SAFETY................................................................2 INSTALLATION REQUIREMENTS ................................................3 Tools and Parts ............................................................................4 Component Identification.............................................................4 Electrostatic Discharge (ESD) ......................................................
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GAS FURNACE SAFETY CAUTION Goodman 9 in property Hazards or unsafe practices may result Recognize this symbol as a safety precaution. WARNING 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 damage, product damage, personal injury or death. IMPORTANT SAFETY INSTRUCTIONS ■ ■ Use only with type of gas approved for this furnace.
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WARNING If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — WHAT TO DO IF YOU SMELL GAS Goodman 42 WARNING Should overheating occur or the gas43 supply fail to shut Goodman off, turn off the manual gas shutoff valve external to the furnace before turning off the electrical supply.
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The installation of the furnace, wiring, warm air ducts, venting, etc., must conform to the requirements of the National Fire Protection Association; the National Fuel Gas Code, ANSI Z223.1/NFPA No. 54 (latest edition) and the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States, and any state laws, local ordinances (including plumbing or wastewater codes), or local gas utility requirements. Local authorities having jurisdiction should be consulted before installation is made.
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Electrostatic Discharge (ESD) 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 avoid damage to the integrated control module. 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.
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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 furnace from airborne contaminants. To ensure that the enclosed nondirect vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to “Combustion and Ventilation Air Requirements.
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For installations above 7,000 ft (2,133.6 m), refer to your local distributor for required kit(s). Recommended Installation Positions—Horizontal Upflow—Left Side Panel Discharge Manifold Pressure Gas Altitude Kit B Pressure High Low Switch Orifice Stage Stage Change Natural None #43 0 to 7,000 ft Propane (2,133.6 m) LPM- #55 05 3.5" W.C. 1.9" W.C. None 10.0" W.C. 6.0" W.C. None A A. Air discharge B. Alternate flue pipe location C.
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Drain Trap and Lines Alternate Electrical and Gas Line Connections In horizontal applications, the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 4³⁄₄" (12.1 cm) below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. See “Condensate Drain Trap and Lines.
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■ ■ ■ ■ ■ Do not attach ductwork to the back of the furnace. Flexible joints may be used for supply and return connections to reduce noise transmission. A connecting duct must be installed between the furnace and the utility room wall to keep the blower from interfering with combustion air or draft when a central return is used. Do not use a room, closet or alcove as a return air chamber. For models with airflow over 1,800 CFM, install a bottom return, 2 side returns or 1 side and 1 bottom return.
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Existing Venting Systems When an existing furnace is removed or replaced, the original 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. See the “Carbon Monoxide Poisoning Hazard” for proper test procedure.
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It is the responsibility of the installer to follow the manufacturers’ 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 piping and connections possess adequate structural integrity and support to avoid flue pipe separation, shifting or sagging during furnace operation.
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Plan Vent System WARNING Goodman 53 Failure to follow these instructions can result in bodily injury or death. Carefully read and follow all instructions given in this section. WARNING Upon completion of the furnace installation, carefully inspect the entire flue system both inside and outside of Goodman 54 the furnace to assure it is properly sealed. Leaks in the flue system can result in serious personal injury or death due to exposure to flue products, including carbon monoxide.
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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, ULCS636 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” on the pipe and fittings. Follow the manufacturer’s instructions for cutting, cleaning and solvent cementing PVC and/or ABS.
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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. The tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.
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Sidewall Vent Terminal Clearances—Direct Vented Furnaces (Horizontal Venting) V Vent Terminal Air Supply Intake X Inside Corner Detail Area Where Terminal Is Not Permitted G V D A V L H Fixed Closed E V Operable B C B B V F V V I V B X V B A X V K J B M Fixed Closed Operable U.S. Installations1 A Clearance above grade, veranda, porch, deck, or balcony 12" (30.5 cm) B Clearance to window or door that may be opened 6" (15.2 cm) for appliances less than 10,000 Btu/h, 9" (22.
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Sidewall Vent Terminal Clearances—Nondirect Vented Furnaces (Horizontal Venting) V Vent Terminal Air Supply Intake X Inside Corner Detail Area Where Terminal Is Not Permitted G V D A V L H Fixed Closed E V Operable B C B B V F V V I V B B X V A M X V K J Fixed Closed B Operable U.S. Installations1 A Clearance above grade, veranda, porch, deck, or balcony 12" (30.5 cm) B Clearance to window or door that may be opened 48" (121.9 cm) below or to side of opening; 12" (30.
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Standard Connection—Counterflow Vent Pipe Installation—Standard Furnace Connections B 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).
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3. Remove the vent/flue pipe from the furnace. 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. Alternate Vent/Flue Location—Upflow A B 5. Discard remaining pipe and elbows. C D E Vent/Flue Pipe Cuts A B C A. Vent/flue pipe B. Screw locations (4) C. Plastic plug—alternate vent/flue location D. Rubber elbow E.
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Alternate Vent/Flue Location—Counterflow Vent/Flue Pipe Cuts A A B B C C D E F A. Flange B. Cut location C. 3³⁄₄" (9.5 cm) 8. Remove the plastic plug from the alternate vent/flue location. 9. Relocate and install the plastic plug in the standard vent/flue location (base pan). 10. Insert the plastic plug (included in the drain kit bag) into the remaining hole in induced draft blower deck. 11. Insert the cut section of the vent/flue pipe and rubber coupling into the alternate vent/flue location. 12.
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Alternate Combustion Air Intake Location—Counterflow ■ B A Vent/Flue Pipe Terminations ■ C F E ■ D ■ ■ ■ A. Section of pipe to be cut B. Screw locations (4) C. 2" (5.1 cm) minimum D. Plastic plug—alternate combustion air intake location E. Screw locations (3) F. Plastic plug from drain kit bag 8.
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Standard Horizontal Vent Termination (Single Pipe) B ■ ■ C A ■ D G ■ F H E ■ A. Inside building B. Wall C. Outside building D. Tee or 90º elbow turned down E. 12" (30.5 cm) minimum to roof or highest anticipated snow level F. 12" (30.5 cm) minimum from wall G. Coupling H. Elbow or coupling Standard Horizontal Vent Termination (Single Pipe)— Above Highest Anticipated Snow Level ■ A 3" (7.6 cm) diameter hole is required for a 2¹⁄₂" (6.4 cm) pipe. A 3¹⁄₂" (8.
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Alternate Horizontal Vent Terminations (Dual Pipe) 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.
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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 extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. The condensate which is generated must be piped to an appropriate drain location. In upright installations, the furnace’s drain hoses may exit either the right or left side of the furnace.
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9. For left side drains, cut 0" to 7" (17.8 cm) from the long end of Hose B and discard. See the following chart. 10. Secure the remaining Hose B to Tube 1 with a green hose clamp. 11. Route other end of Hose B to the front left side panel grommet hole. 15. Ensure that the hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding.
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8. Route Hose B to the front right (down) side panel grommet holes. 9. Cut 5¹⁄₂" (14 cm) straight length from the long end of each Tube 2. Alternate Horizontal Upflow Connections—Left Side Down (Counterflow Similar) A Alternate Horizontal Upflow Connections—Right Side Down (Counterflow Similar) B B A C F M D L E J I K D I H G C DE F C I HG F E J A. Front cover drain port B. Front cover pressure tap C. Right side panel D. Rubber elbow E. Rubber elbow drain port F. Red hose clamps G.
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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 air circulated by the furnace to areas outside the space containing the furnace, the return air shall be handled by a duct or ducts sealed to the furnace casing and terminated outsides the space containing the furnace.
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Upright Installations Make Electrical Connections Depending on the installation and/or customer preference, filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Filter Locations—Possible Upright Upflow WARNING Goodman 70 To avoid the risk of electrical shock, wiring to the unit must be polarized and grounded.
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3. Remove the cover from the furnace electrical connection box. 4. Route the field supply wires to the furnace electrical connection box. 5. Using UL listed wire connectors, connect the field supply wires to the furnace (black to black and white to white). Make Gas Connections The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied.
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When connecting gas piping: Gas Piping Connections WARNING Goodman Edges of sheet metal holes may be56 sharp. Use gloves as WARNING Goodman 52injury or death may Possible property damage, personal occur if the correct conversion kits are not installed. The appropriate kits must be applied to insure safe and proper furnace operation. All conversions must be performed by a qualified installer or service agency.
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Gas Piping Connections—Upflow B C Gas Piping Connections—Horizontal Upflow D C E D A A B E J F I J H G I H A. Alternate gas line location B. Manifold C. Gas control valve D. Burners E. Manual shutoff valve (upstream from ground joint pipe union F. Height required by local codes G. Drip leg H. Grommet in standard gas line hole I. Ground joint pipe union J. Plug in alternate gas line hole Gas Piping Connections—Counterflow G A. Gas control valve B. Ground joint pipe union C.
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Direct/Standard Inlet Piping When gas piping enters directly to the gas control valve through the standard inlet hole, the installer must supply straight pipe 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 cabinet to seal the grommet cabinet penetration. A semirigid connector to the gas piping can be used outside the cabinet per local codes.
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Sizing Between 1st and 2nd 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 ¹⁄₂ ⁵⁄₈ ³⁄₄ ⁷⁄₈ ¹⁄₂ ³⁄₄ 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.
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Check the Furnace Input Rate (if required) CAUTION To prevent unreliable operation or equipment damage, Goodman 61 the inlet gas supply pressure must be as specified on the ■ unit rating plate with all other household gas-fired appliances operating. (12.45 cm) W.C. (1st stage) and 10.0" (25.4 cm) W.C. (2nd stage) for propane gas. For Natural gas, check the furnace rate by observing the gas meter, making sure all other gas appliances are turned off.
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Complete Installation IMPORTANT: Do not use this furnace if any part has been under water. Immediately call a qualified person to inspect the furnace and to replace any part of the control system and gas control which has been under water. 1. Check that you have all of your tools. 2. Dispose of/recycle all packaging materials. 3. Check the furnace in its final location. Be sure the vent is not blocked.
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SEQUENCE OF OPERATION ■ Power Up The normal power up sequence is as follows: ■ 115 VAC power applied to furnace. ■ Integrated control module performs internal checks. ■ Integrated control module LED will light. ■ Integrated control module monitors safety circuits continuously. ■ Furnace awaits call from thermostat. ■ ■ ■ ■ Heating Mode—Mode DIP Switch Set to 1 STG Position The normal operational sequence in heating mode is as follows: ■ R and W thermostat contacts close, initiating a call for heat.
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■ Fan Only Mode The normal operational sequence in fan only mode is as follows: ■ R and G thermostat contacts close, initiating a call for fan. ■ Integrated control module performs safety circuit checks. ■ Circulator blower is energized on low-heat speed. Electronic air cleaner terminals are energized. ■ ■ ■ Circulator blower runs; integrated control module monitors safety circuits continuously. R and G thermostat contacts open, completing the call for fan. Circulator blower is de-energized.
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■ 115-Volt Line Connection of Accessories—Electronic Air Cleaner All field wiring must conform to applicable codes. Optional Accessories Wiring Connections should be made as shown below. WARNING A HIGH VOLTAGE! Goodman 6 Disconnect ALL power before servicing. Multiple power sources may be present. B Failure to do so may cause property damage, personal injury or death.
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To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit. Horizontal Furnace Filter Removal Filters in horizontal installations are located in the central return register or the ductwork near the furnace. To remove: 1. Disconnect power to the furnace. 2. Remove the filter(s) from the central return register or ductwork. 3. Replace the filter(s) by reversing the procedure for removal. 4. Reconnect power to the furnace.
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TROUBLESHOOTING See “Electrostatic Discharge (ESD)” before touching any electronic part on this furnace. Furnace Fails to Operate Properly Review “Sequence of Operation” and visually inspect the following before troubleshooting: WARNING Fault Recall 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.
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Problem ■ ■ LED Code Induced draft blower runs 3 flashes continuously with no further furnace operation. Integrated control module diagnostic LED is flashing 3 flashes. Fault/Cause ■ ■ ■ ■ ■ ■ ■ ■ Circulator blower runs 4 flashes continuously. No furnace operation. Integrated control module diagnostic LED is flashing 4 flashes. ■ ■ ■ ■ ■ ■ ■ Induced draft blower and 5 flashes circulator blower runs continuously. No furnace operation.
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Wiring Diagram 0 Steady On = Normal Operation 1 1 Flash = System Lockout (Retries/Recycles Exceeded 2 24 VAC Humidifier 2 Flashes = Low Fire Pressure Switch Stuck Closed 3 3 Flashes = Low Fire Pressure Switch Stuck Open 4 4 Flashes = Thermal Protective Device Open 5 Flashes = Flame Sensed With Gas Control Valve De-energized 7 7 Flashes = Low Flame Sense Signal 8 8 Flashes = Check Igniter Or Improper Grounding Continuous Flashes = 115-Volt AC Power Reversed 115 VAC 24V Thermostat Connections
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ASSISTANCE OR SERVICE If you 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. 42 Accessories to order accessories, contact your Whirlpool® Home Cooling and Heating dealer.
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Notes 43
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WPIO-299F © 2009. All rights reserved. ®Registered Trademark/TM Trademark of Whirlpool, U.S.A., Manufactured under license by Tradewinds Distributing Company, LLC., Jacksonville, Florida 8/09 Printed in U.S.A.