93% AND 95% 2-STAGE VARIABLE SPEED GAS FURNACE INSTALLATION INSTRUCTIONS 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.
Table of Contents GAS FURNACE SAFETY PRECAUTIONS ....................................3 PRODUCT DESCRIPTION AND APPLICATION ..........................4 Shipping Inspection .....................................................................4 Electrostatic Discharge (ESD) ......................................................4 To The Installer.............................................................................4 Important Note to the Owner Regarding Product Warranty .......4 Product Application......
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. WARNING Hazards or unsafe practices could result in property damage, product damage, severe personal injury or death.
WARNING Should overheating occur or the gas supply fail to shut off, turn off the manual gas shutoff valve external to the furnace before turning off the electrical supply. WARNING Possible property damage, personal injury or death due to fire, explosion, smoke, soot, condensation, electrical shock or carbon monoxide may result from improper installation, repair, operation or maintenance of this product.
Product limited warranty certificates can be viewed at www.goodmanmfg.com or www.amana-hac.com. Each product overview page contains a Product Warranty link. By clicking on the link, you will be able to view the limited warranty coverage for that specific product. To view warranty registration information, click on the Product Warranty link on the left navigation panel on the home page of each website. The Online Product Registration pages are located in this same section.
LOCATION REQUIREMENTS AND CONSIDERATIONS Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in “Combustion and Ventilation Air Requirements.” ■ WARNING Goodman 50 To prevent possible equipment damage, property damage, personal injury or death, the following bullet points must be observed when installing the unit.
Clearances and Accessibility Existing Furnace Removal Installations must adhere to the clearances to combustible materials to which this furnace has been design-certified. The minimum clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently maintained. Clearances must also accommodate an installation’s gas, electrical, drain trap and drain line connections.
Combustion and Ventilation Air Requirements WARNING To avoid property damage, personal injury or death, sufficient fresh air for proper combustion and ventilation of flue gases must be supplied. Most homes require outside air be supplied into the furnace area. Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows.
Recommended Installation Positions—Upright Upflow Drain Trap and Lines A 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. Refer to “Condensate Drain Trap and Lines” for further details.
PROPANE GAS/HIGH ALTITUDE INSTALLATIONS WARNING Possible property damage, personal injury or death may occur if the correct conversion kits are not installed. The appropriate kits must be applied to ensure safe and proper furnace operation. All conversions must be performed by a qualified installer or service agency. For installations above 7,000 ft (2,133.6 m), refer to your distributor for required kit(s).
The vent termination of a nondirect vent application must terminate at least 4 ft (121.9 cm) below, 4 ft (121.9 cm) horizontally from or 12" (30.5 cm) above any door, window or gravity air inlet into any building. ■ The vent termination of a direct vent application must terminate at least 12" (30.5 cm) from any opening through which flue gases may enter a building (door, window or gravity air inlet). ■ The vent termination of vent pipe run vertically through a roof must terminate at least 12" (30.
Vent Termination Clearances NOTE: Because of probable material conflicts, do not use other commercially available “no hub connectors.” The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling. A B Combustion Air Pipe—Nondirect Vent Installations C J D E I A minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage. D Standard Connection—Upflow E H D E G E B B F C A.
Vent/Flue Pipe Cuts Alternate Furnace Connections If the standard locations are undesirable for a specific installation, alternate side panel locations are available for both combustion air inlet and vent/flue pipe connections.
Alternate Vent/Flue Location—Upflow Alternate Combustion Air Intake Location A B C D E A. Vent/flue pipe B. Screw locations (4) C. Plastic plug—alternate vent/flue location D. Rubber elbow E. Induced draft blower Alternate Vent/Flue Location—Counterflow/Upright (Upflow Similar) A B C The alternate combustion air intake location consists of a large, unobstructed hole (alternate vent connection is aligned with the induced draft blower).
Nondirect Vent (Single Pipe) Piping Nondirect vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12" (30.5 cm) above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosionresistant flashing.
Vent/Flue Pipe Terminations ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall. Vertical vent/flue pipe terminations should be as shown in “Vertical Vent Termination (Single Pipe)” illustration. Refer to “Termination Locations” in this section for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.
Direct Vent (Dual Pipe) Piping Vent/Flue and Combustion Air Pipe Lengths and Diameters The inlet air screens provided in the installation instruction packet are available for the installer to use in the inlet of the combustion air pipe to prevent animals from building nests in the combustion air pipe. Installation of screens, while strongly recommended, is not required and will not affect performance of the furnace. Direct vent installations require both a combustion air intake and a vent/flue pipe.
Counterflow Direct Vent (Dual Pipe) Maximum Allowable Length of Vent/Flue and Combustion Air Intake Pipe—ft (m) Number of Elbows Unit Input (Btu) Termination Style Pipe— in. (cm) 70,000 Standard Alternate 90,000 Standard Alternate 1 2 3 2 or 2¹⁄₂ (5.12 or 6.4) 49 (14.9) 46 (14) 43 (13.1) 40 (12.2) 37 (11.3) 34 (10.4) 31 (9.5) 28 (8.5) 3 (7.6) 71 (21.6) 68 (20.7) 65 (19.8) 62 (18.9) 59 (18) 2 or 2¹⁄₂ (5.12 or 6.4) 36 (11) 33 (10.1) 30 (9.2) 3 (7.6) 57 (17.4) 54 (16.5) 51 (15.
Horizontal terminations should be as shown in “Standard Horizontal Vent Terminations (Dual Pipe)” illustration. Refer to “Termination Locations” in this section for location restrictions. ■ A 2³⁄₈" (6.1 cm) diameter wall penetration is required for 2" (5.1 cm) diameter 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.
Horizontal Venting of Multiple Furnaces Concentric Vent Termination A B Refer to the directions provided with the Concentric Vent Kit (DCVK) for installation specifications. B F C GF D H E A. 90º medium radius elbows B. Flue/vent pipes C. 12" (30.5 cm) minimum to roof or highest anticipated snow level D. 12" (30.5 cm) minimum to roof or highest anticipated snow level E. Screens F. 24" (61 cm) maximum, 3" (7.6 cm) minimum G. 3" (7.6 cm) minimum H.
6. Cut 17³⁄₄" (45.1 cm) from the long end of Hose B and discard. 7. Secure the remaining Hose B to Tube 1 with a green hose clamp. 8. Route the other end of Hose B to the front right side panel grommet hole. NOTE: For details concerning the mounting of the drain trap, refer to “Horizontal Drain Trap Mounting.” 9. Insert the short end of each Tube 2 through the side panel grommet holes. 10. Secure the tubes to Hose A and Hose B with the green hose clamps.
Upright Standard Connections—Left Side Upflow (Counterflow Similar) A M B C D E F L K J I H A. Left side panel B. Rubber elbow C. Rubber elbow drain port D. Silver hose clamp F G E. Tube 1 I. Tubes 2 F. Green hose clamps (3) J. Side panel drain holes K. Hose A G. Hose B H. Drain trap L. Front cover drain port Cabinet Width Models (kBtu/Tons) X Length to Cut from Long End of Hose B 17¹⁄₂" (44.5 cm) 45_30 7" (17.8 cm) 21" (53.4 cm) 70_40 3¹⁄₂" (8.89 cm) 24¹⁄₂" (62.
Horizontal Installations—Left Side Down Horizontal installations with the left side panel down will require the drain hoses to be connected to the left side front cover drain port and the side drain port on the rubber elbow. 1. Remove the rubber plug from the front cover left (down) side drain port. 2. Relocate the front cover pressure switch hose connection from the right side (as shipped) pressure tap to the left (down) side tap.
115-Volt Line Connections Before proceeding with electrical connections, ensure that the supply voltage, frequency and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be NEC Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.
Thermostat Wiring Diagram—Single-Stage Thermostat Application A Y R R B NEU Y C C D A. Thermostat—single-stage heating and single-stage cooling B. Furnace integrated control module C. Dehumidistat (optional) D. Remote condensing unit (single-stage cooling) NOTE: To apply a single-stage heating thermostat, the thermostat selector switch on the integrated control module must be set on single-stage. A single-stage thermostat with only one heating stage may be used to control this furnace.
■ Fossil Fuel Applications This furnace can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump or gas furnace). A heat pump thermostat with 3 stages of heat is required to properly use a 2-stage furnace in conjunction with a heat pump.
High Altitude Derate When this furnace is installed at high altitude, the appropriate high altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design-certified input rate within the specified altitude range. High altitude kits are purchased according to the installation altitude and usage of either Natural or propane gas.
■ ■ Install a ¹⁄₈" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace. Always use a backup wrench when making the connection to the gas control valve to keep it from turning. NOTE: The orientation of the gas control valve on the manifold must be maintained as shipped from the factory. ■ Maximum torque for the gas control valve connection is 375 in-lbs. NOTE: Excessive overtightening may damage the gas control valve.
Gas Piping Connections—Horizontal Counterflow Gas Piping Checks C Before placing the furnace in operation, leak test the furnace and gas connections. D A B WARNING E To avoid the possibility of explosion or fire, never use a match or open flame to test for leaks. J I F H G A. Gas control valve B. Ground joint pipe union C. Manual shutoff valve (upstream from ground joint pipe union) D. Drip leg E. Grommet in standard gas line hole F. Drain trap G. Plug in alternate gas line hole H.
Propane Gas Installation—Typical Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers 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.
Propane Gas Piping Chart II 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" 1" 1¹⁄₄" 1¹⁄₂" 150 (45.7) 9 21 43 72 109 63 132 252 511 787 200 (61) 8 19 39 66 100 54 112 209 439 665 250 (76.2) 8 17 36 60 93 48 100 185 390 590 Data in accordance with NFPA pamphlet Number 54. CIRCULATING AIR AND FILTERS Ductwork—Airflow WARNING 4.
Filters—Read This Section Before Installing the Return Air Ductwork ■ ■ ■ Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided, sized and installed externally by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. If the furnace is installed without filters, the warranty will be voided. ■ On upflow units, guide dimples locate the side return cutout locations.
Filter Locations—Possible Upright Counterflow Upright Installations 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. The following illustrations show possible filter locations. Filter Locations—Possible Upright Upflow C A A B B F B C E B B D A. Central return grille B. Filter C.
Honeywell 2-Stage Gas Control Valve—Model VR9205 Furnace Shutdown 1. Set the thermostat to the lowest setting. The integrated control will close the gas control valve and extinguish the flame. Following a 15-second delay, the induced draft blower will be de-energized. After a 120-, 150-, 180- or 210-second delay period (field-selectable delay Off [90, 120, 150, 180] plus a 30-second ramp down), the circulator blower de-energizes. 2.
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" W.C. Maximum: 13.0" W.C. If the supply pressure differs from chart, make the necessary adjustments to the pressure regulator, gas piping size, etc., and/ or consult with local gas utility. 6. Turn off the gas supply to the furnace at the manual shutoff valve. 7. Disconnect the manometer. 8.
Temperature Rise Measurement Gas Input Rate Measurement—Natural Gas Only The gas input rate to the furnace must never be greater than that specified on the unit rating plate. To measure Natural gas input using the gas meter, use the following procedure. 1. Turn off the gas supply to all other gas-burning appliances except the furnace. 2. While the furnace is operating, time and record one complete revolution of the smallest gas meter dial. 3.
3. Knowing the furnace model, locate the high-stage cooling airflow charts in the Specification Sheet applicable to your model. Look up the cooling airflow determined in Step 2 and find the required cooling speed and adjustment setting. Example: A WGFM295070V4C furnace installed with a 2.5 ton air conditioning system. The airflow needed is 1,000 CFM. Looking at the cooling speed chart for WGFM295070V4C, find the airflow closest to 1,000 CFM.
Profile D To Set Airflow Ramps up to 50% of the full cooling demand airflow for 30 seconds. Then ramps to 82% of the full cooling demand airflow for approximately 7¹⁄₂ minutes. The motor then ramps to 100% of the required airflow. Provides a 30-second Off delay at 50% of the cooling demand airflow. ■ ■ ■ ■ 50% CFM Off 82% CFM 30 sec 50% CFM 100% CFM Off 30 sec 7¹⁄₂ min Cooling Demand 6. Select the heating speed from the heating speed chart in the Specification Sheet for your model.
Blower Heat Off Delay Timings The integrated control module provides a selectable heat-off delay function. The heat off delay period may be set to 90, 120, 150 or 180 seconds using the DIP switches or jumper provided on the control module. The delay is factory-shipped at 150 seconds, but may be changed to suit the installation requirements and/or homeowner preference. Refer to the following chart for DIP switch positions and corresponding delay times.
■ ■ ■ Circulator blower continues running during a cool-off delay period. The Off delay time and airflow level are determined by the selected ramping profile. Electronic air cleaner terminal and circulator blower are de-energized. Furnace awaits next call from thermostat. 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.
MAINTENANCE WARNING HIGH VOLTAGE! To avoid personal injury or death due to electrical shock, disconnect electrical power before performing any maintenance. If you must handle the igniter, handle with care. Touching the igniter element with bare fingers, rough handling or vibration could damage the igniter resulting in premature failure. Only a qualified servicer should ever handle the igniter.
Flue Passages (Qualified Servicer Only) The heat exchanger flue passageways should be inspected at the beginning of each heating season. If necessary, clean the passageways as outlined below. 1. Turn off the electrical power and gas supply to the furnace. 2. Disconnect the gas line and remove the burner/manifold assembly by removing the screws securing the assembly to the partition panel. 3. Disconnect the flue pipe system from the induced draft blower. 4.
Resetting from Lockout Furnace lockout results when a furnace is unable to achieve ignition after 3 attempts during a single call for heat. It is characterized by a nonfunctioning furnace and a “E0” code displayed on the dual 7-segment display. If the furnace is in “lockout,” it will (or can be) reset in any of the following ways. 1. Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal operations following a 1-hour lockout period. 2.
Symptoms of Abnormal Operation ■ ■ Furnace fails to operate. Integrated control module diagnostic LED display provides no signal. Diagnostic/ Staus LED Code Fault Description Possible Causes None ■ ■ ■ No 115-volt power to furnace, or no 24-volt power to integrated control module. Blown fuse or circuit breaker. Internal fault in Integrated control module. ■ ■ ■ Manual disconnect switch Off, door switch open or 24-volt wire improperly connected or loose.
Symptoms of Abnormal Operation ■ ■ Induced draft blower runs continuously with no further furnace operation. Integrated control module LED display provides “E2” error code. Diagnostic/ Staus LED Code Fault Description Possible Causes E2 ■ Low-stage pressure switch circuit is not closed. ■ ■ ■ ■ ■ ■ Circulator blower runs continuously. No furnace operation. Integrated control module LED display provides “E3” error code. E3 ■ ■ Primary limit or auxiliary limit circuit is open.
Symptoms of Abnormal Operation ■ ■ ■ ■ ■ ■ ■ ■ ■ Furnace not operating. Integrated control module LED display provides “E6” error code. Diagnostic/ Staus LED Code Fault Description Possible Causes E6 ■ Flame sense microamp signal is low. ■ ■ ■ Furnace operating on low stage gas with high stage induced draft blower High stage circulator blower (temperature, of conditioned air, lower than typical). Integrated control module LED display provides “E7” error code.
Symptoms of Abnormal Operation ■ ■ ■ ■ Diagnostic/ Staus LED Code Fault Description Possible Causes Furnace fails to operate. Integrated control module LED display provides “EA” error code. EA Furnace fails to operate. Integrated control module LED display provides “d0” error code. d0 ■ Polarity of 115volt AC is reversed. ■ ■ ■ Data not yet on network. ■ Corrective Actions Polarity of 115-volt AC power to furnace or integrated module is reversed. Poor furnace ground.
Symptoms of Abnormal Operation ■ ■ ■ ■ Diagnostic/ Staus LED Code Fault Description Possible Causes Furnace fails to operate. Integrated control module LED display provides “b1” error code. b1 Furnace fails to operate. Integrated control module LED display provides “b2” error code. b2 ■ Integrated control module has lost communication s with circulator blower motor. ■ ■ ■ ■ Circulator blower motor horse power in shared data set does not match circulator blower motor horse power.
Symptoms of Abnormal Operation ■ ■ ■ ■ ■ ■ Diagnostic/ Staus LED Code Fault Description Possible Causes Furnace fails to operate. Integrated control module LED display provides “b5” error code. b5 Furnace fails to operate. Integrated control module LED display provides “b6” error code. b6 Furnace fails to operate. Integrated control module LED display provides “b7” error code. b7 ■ ■ Furnace operates at reduced performance or operates on low stage when high stage is expected.
WIRING DIAGRAM WARNING 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 GND Junction Box Induced Draft Blower 2-Stage Pressure Switch Assembly Equipment GND 24V Humidifier Field GND Hot Surface Igniter Field Splice OR Low-Fire Pressure Switch C C NO Switch (Temp.
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.
WPIO-368 © 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.
