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90+ GAS FURNACE INSTALLATION INSTRUCTIONS

GAS FURNACE SAFETY

Table of Contents

GAS FURNACE SAFETY................................................................1

INSTALLATION REQUIREMENTS................................................3

Tools and Parts ............................................................................3

Location Requirements................................................................3

Installation Configurations ...........................................................4

Duct Work Requirements.............................................................5

Electrical Requirements ...............................................................5

Gas Supply Requirements...........................................................5

Venting Requirements..................................................................5

INSTALLATION INSTRUCTIONS..................................................6

Inspect Shipment .........................................................................6

Plan Vent System.........................................................................7

Determine Vent Pipe Direction.....................................................9

Connect Venting.........................................................................14

Install Condensate Disposal.......................................................14

Install Duct Work ........................................................................15

Filter Specifications....................................................................15

Make Electrical Connections .....................................................16

Make Gas Connections..............................................................17

Check the Furnace Input Rate ...................................................17

Adjust the Furnace Input Rate ...................................................18

Complete Installation..................................................................19

Sequence of Operation ..............................................................20

Controls ......................................................................................20

TROUBLESHOOTING ..................................................................21

ASSISTANCE OR SERVICE.........................................................24

Accessories ................................................................................24

46948D003

Whirlpool

Home Cooling and Heating

7901 S.W. 6th Court

Plantation, Florida 33324

Models WFCU, WFCC, WGFDC, WGFDU

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.

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.

Your safety and the safety of others are very important.

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:

Summary of content (24 pages)

PAGE 1
90+ GAS FURNACE INSTALLATION INSTRUCTIONS Table of Contents GAS FURNACE SAFETY................................................................1 INSTALLATION REQUIREMENTS ................................................3 Tools and Parts ............................................................................3 Location Requirements................................................................3 Installation Configurations ...........................................................
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IMPORTANT SAFETY INSTRUCTIONS ■ ■ ■ ■ ■ ■ ■ Use only with type of gas approved for this furnace. Refer to the furnace rating plate. Install this furnace only in a location and position as specified in the Location Requirements section of these instructions. ■ Provide adequate combustion and ventilation air to the furnace space as specified in the “Venting Requirements” section of these instructions.
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Location Requirements INSTALLATION REQUIREMENTS These instructions are intended as a general guide only for use by qualified persons and do not supersede any national or local codes in any way. Compliance with all local, state, or national codes pertaining to this type of equipment should be determined prior to installation. Read this entire instruction manual, as well as the instructions supplied in separate equipment, before starting the installation.
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■ All models are suitable for closet or utility room installation. 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.
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Combustible Floor Installation (Counterflow Models only) 1 ■ In all instances, other than wiring for the thermostat, the wiring to be done and any replacement of wire shall conform with the temperature limitation for Type T wire – 63°F (35°C) rise. ■ The line voltage supply should be routed through a readily accessible disconnect located within sight of the furnace. A junction box on the furnace side panel is provided for line voltage connections.
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Contaminated Combustion Air INSTALLATION INSTRUCTIONS Excessive exposure to contaminated combustion air will result in performance related problems. The recommended source of combustion air is outdoor air. Outdoor air as the source of combustion air If the furnace is installed in a confined space, it is recommended that the necessary combustion air come from the outdoors by way of an attic, crawl space, air duct, or direct opening.
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Plan Vent System The high efficiency of this furnace is accomplished by the removal of both sensible and latent heat from the flue gases. The removal of latent heat results in the condensation of moisture in the flue gases. This condensation occurs in the secondary heat exchanger and in the vent system. Therefore, this furnace requires special venting considerations and the instructions must be followed to ensure proper operation.
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Materials ■ Vent Pipe Size and Length All pipe, fittings, primer, and solvent cement must conform with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM) standards. The solvent shall be free flowing and contain no lumps, undissolved particles, or any foreign matter that adversely affects the joint strength or chemical resistance of the cement. The cement shall show no gelatinization, stratification, or separation that cannot be removed by stirring.
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Vent Table - 112,000 - 125,000 BTU/HR Models Vent Pipe Length (ft) Minimum Pipe Diameter (in.) 5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 10 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 20 2.5 2.5 2.5 2.5 2.5 2.5 2.5 30 2.5 2.5 2.5 2.5 2.5 40 2.5 2.5 2.5 2.5 50 2.5 3 60 3 3 Number of 90° Elbows 0 1 3 3 3 3 3 3 3 NR NR NR NR In the event that the pipe length is in between the lengths listed in the Vent Table, use the next larger length listed.
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Direct Vent Installation Upflow Models Refer to the appropriate vent table for proper pipe size, vent length and the number of elbows allowed, and air intake length and the number of elbows allowed. ■ Refer to the “Materials” section for the proper venting material. ■ Do not install the inlet air restrictor plate in any direct vent installation. The inlet air restrictor plate (see “Inlet Air Restrictor Plate” section) supplied with this furnace is to be used only in non-direct vent applications.
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Non-Direct Vent Installation - Upflow Models ■ Refer to appropriate tables for proper pipe size, vent length and the number of elbows allowed. ■ Refer to the “Materials” section for the proper venting material. ■ An inlet air restrictor plate found in the plastic bag containing these Installation Instructions and the User’s Information Manual must be installed in all non-direct vent installations. See the “Inlet Air Restrictor Plate” section.
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Direct Vent Installation - Counterflow Models Refer to appropriate tables for proper pipe size, vent length and the number of elbows allowed, and air intake length and the number of elbows allowed. ■ Refer to the “Materials” section for the proper venting material. ■ Do not install the inlet air restrictor plate in any direct vent installation. The inlet air restrictor plate (see “Inlet Air Restrictor Plate” section) supplied with this furnace is to be used only in non-direct vent applications.
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Non-Direct Vent Installation- Counterflow Models ■ Refer to appropriate tables for proper pipe size, vent length and the number of elbows allowed. ■ Refer to the “Materials” section for the proper venting material. ■ An inlet air restrictor plate found in the plastic bag containing these Installation Instructions and the Use and Care Guide must be installed in all non-direct vent installations. See the “Inlet Air Restrictor Plate” section.
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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 spillage of flue products into the living space, the formation of condensate, leakage, etc. See the “Carbon Monoxide Poisoning Hazard” for proper test procedure. Connect Venting 1. Run venting to the furnace, see “Plan Vent System.” 2. Attach the air intake pipe to the furnace connector.
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Counterflow Models Install Duct Work IMPORTANT: ■ Install duct work in accordance with NFPA 90B and any local codes. ■ If there is no complete return air duct system, the return air connection must be sealed to the furnace casing and run full size to a location outside the utility room or space housing the furnace to prevent a negative pressure on the venting system. Installation with Return Ducts A return air duct system is recommended.
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Make Electrical Connections 5. Using UL listed wire nuts, connect the field supply wires to the furnace (black to black and white to white). WARNING Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. Thermostat Install a room thermostat according to the instructions furnished with it. Select a location on an inside wall that is not subject to drafts, direct sunshine, or other heat sources.
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Make Gas Connections IMPORTANT: This furnace requires conversion for use with propane. To order the correct conversion kit, see “Accessories.” 1. Install the field gas supply as shown. 2. Provide a sediment trap on the outside of the furnace. 3. Install a manual gas shutoff valve in the gas line, outside the unit, 5 ft above the floor, or in accordance with any local codes. 4. Install a test gauge connection with a ¹⁄₈ in. NPT plugged tapping immediately upstream of the manual gas shutoff valve as shown. 5.
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Adjust the Furnace Input Rate (if required) For altitudes 4,500 to 7,500 feet above sea level. 1. Remove the burner access door. 2. Move the gas control switch to the OFF position. Use only your hand to move the gas control switch; tools are not required. 3. Remove the outlet pressure tap plug on the gas control valve and connect pressure gauge to the ¹⁄₈ in. NPT outlet pressure tap. Gas Control Valve C3 C2 3 9. Refer to the Manifold Pressure vs. Altitude chart for the correct manifold pressure.
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Adjust Blower Speed 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 to be sure you have all of your tools. 2. Dispose of 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 Primary Limit Control This is a normally closed control that opens if abnormally high circulating air temperatures occur. It is an automatic reset control. Heating A call for heat from the thermostat closes R to W on the blower control board, which begins the ignition sequence. The induced draft blower output energizes. The pressure switch senses normal combustion air flow and closes. After a 15-second prepurge, the control energizes the hot surface igniter.
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Failure Codes TROUBLESHOOTING Furnace Fails to Operate Properly Review “Sequence of Operation” and visually inspect the following before troubleshooting: Is the power to the furnace on? Is the blower compartment door securely closed? Are the manual shutoff valves in the gas line to the furnace open? LED Status (Flash Codes) Fault Description Off No Power to the System Control Steady Flash (11 or more flashes without a pause) Normal Operation (Standby or call for heat) 2 Flashes Pressure switch clos
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Wiring Connection Diagram - Honeywell® SmartValve II® Ignition System BRN LINE VOLTAGE - FACTORY LINE VOLTAGE - FIELD LOW VOLTAGE - FACTORY LOW VOLTAGE - FIELD WHT INDUCED DRAFT BLOWER C1 WHT SMARTVALVE IGNITION CONTROL BLK/WHT 1 6 2 7 3 8 4 HIGH LIMIT VLT VLT PRESSURE SWITCH ORG RED BLU 4 3 2 1 VLT AUX AUX LIMIT LIMIT (IF USED) (IF USED) C2 4 BLK WHT/BLK P1 5 BRN WHT ROLLOUT SWITCH ROLLOUT SWITCH (IF USED) S1 3 2 1 C3 GRN 120/1/60 WHT YEL HOT SURFACE IGNITER P2 S2
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Wiring Schematic - Honeywell® SmartValve II® Ignition System N H N EAC(S) (IF USED) INTERLOCK SWITCH CONSTANT K1 MED M1 COOL LOW CIRCULATION FAN HI K2 SMVII IGNITION CONTROL NEUTRALS NEUTRALS HEAT K2 K1 AIR CLEANER NEUTRALS INDUCED DRAFT BLOWER HUMIDIFIER HUM (IF USED) IGNITER (120 VAC) NEUTRALS 120 VAC TRANSFORMER 24 VAC BLOWER CONTROL CENTER R C W T’STAT Y G 1 2 3 4 5 6 (IF USED) (IF USED) ROLLOUT SWITCH ROLLOUT SWITCH (IF USED) PRESSURE SWITCH C R AUX LIMIT DATA AUX LI
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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 7901 S.W. 6th Court Plantation, Florida 33324 Please include a daytime phone number in your correspondence. Accessories To order accessories ask for the appropriate part number listed below or contact your Whirlpool® Home Cooling and Heating dealer.