Whirlpool Gold WFD195 Installation Instructions Manual Download

Page: 41 / 48

■

Induced draft
blower runs
continuously
with no further
furnace
operation.

■

Integrated
control module
diagnostic LED
is flashing
3 flashes.

3 flashes

■

Pressure switch
circuit is not
closed.

■

Induced draft
blower is
operating.

■

Pressure switch hose
blocked, pinched or
connected improperly.

■

Blocked flue and/or inlet
air pipe, blocked drain
system or weak induced
draft blower.

■

Incorrect pressure
switch setpoint or
malfunctioning switch
contacts.

■

Loose or improperly
connected wiring.

■

Inspect pressure
switch hose. Repair/
replace, if necessary,

■

Inspect flue and/or
inlet air piping for
blockage, proper
length, elbows and
termination.

■

Check drain system.
Correct as necessary.

■

Correct pressure
switch setpoint or
contact motion.

■

Tighten or correct
wiring connection.

■

Turn off power
prior to repair.

■

Replace pressure
switch with
correct
replacement part.

■

Replace induced
draft blower with
correct
replacement part.

■

Circulator
blower runs
continuously.
No furnace
operation.

■

Integrated
control module
diagnostic LED
is flashing
4 flashes.

4 flashes

■

Primary limit or
auxiliary limit
circuit is open.

■

Insufficient conditioned
air over the heat
exchanger. Blocked
filters, restrictive
ductwork, improper
circulator blower speed,
or failed circulator
blower.

■

Faulty primary limit
switch.

■

Loose or improperly
connected wiring.

■

Check primary limit
switch. Replace if
necessary.

■

Check filters and
ductwork for blockage.
Clean filters or remove
obstruction.

■

Check circulator
blower speed and
performance. Correct
speed or replace
blower if necessary.

■

Tighten or correct
wiring connection.

■

Turn off power
prior to repair.

■

Replace primary
switch with
correct
replacement part.

■

Replace
circulator blower
with correct
replacement part.

■

Induced draft
blower and
circulator
blower runs
continuously.
No furnace
operation.

■

Integrated
control module
diagnostic LED
is flashing
5 flashes.

5 flashes

■

Flame sensed
with no call for
heat.

■

Short to ground in flame
sense circuit.

■

Correct short at flame
sensor or in flame
sensor wiring.

■

Turn off power
prior to repair.

■

No furnace
operation.

■

Integrated
control module
diagnostic LED
is flashing
6 flashes.

6 flashes

■

Rollout limit
switch open.

■

Integrated
control module
fuse is blown.

■

Flame rollout.

■

Misaligned burners,
blocked flue and/or air
inlet pipe or failed
induced draft blower.

■

Loose or improperly
connected wiring.

■

Short in 24-volt AC
control circuits or safety
circuits.

■

Faulty rollout limit
switch.

■

Check burners for
proper alignment.

■

Check flue and air inlet
piping for blockage,
proper length, elbows
and termination.
Correct as necessary.

■

Check rollout limit
switch. Replace if
necessary.

■

Check induced draft
blower for proper
performance. Replace
if necessary.

■

Tighten or correct
wiring connection.

■

Repair short in 24-volt
AC control/safety
circuit(s).

■

Replace integrated
control module fuse
(3A).

■

Turn off power
prior to repair.

■

Replace induced
draft blower with
correct
replacement part.

■

Replace
integrated control
module fuse with
3A automotive
fuse.

■

Read precautions
in “Electrostatic
Discharge”
section of
manual.

■

Replace rollout
limit switch with
correct
replacement part.

■

See “Vent/Fluie
Pipe” section for
piping details.

Symptoms of
Abnormal
Operation

Associated
LED Code

Fault Description Possible Causes

Corrective Actions

Notes and
Cautions

Summary of Contents for Gold WFD195

Page 1: ...afety 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 e...

Page 2: ...nel 23 Horizontal Installations Right Side Down 23 Horizontal Installations Left Side Down 23 Horizontal Drain Trap Mounting Left or Right Side Panel 24 ELECTRICAL CONNECTIONS 24 Wiring Harness 24 115 Volt Line Connections 24 Junction Box Relocation 25 24 Volt Thermostat Wiring 25 115 Volt Line Connection of Accessories Humidifier and Electronic Air Cleaner 25 GAS SUPPLY AND PIPING 26 High Altitud...

Page 3: ...formed by a qualified installer service agency or the gas supplier WARNING This product contains or produces a chemical or chemicals which may cause serious illness or death and which are known to the State of California to cause cancer birth defects or other reproductive harm WARNING Heating unit should not be utilized without reasonable routine inspection maintenance and supervision If the build...

Page 4: ...statute of limitations Original or certified copy of the Bill of Lading or indemnity bond Original paid freight bill or indemnity in lieu thereof Original or certified copy of the invoice showing trade and other discounts or reductions Copy of the inspection report issued by carrier s representative at the time damage is reported to carrier The carrier is responsible for making prompt inspection o...

Page 5: ...L dual certified appliance and is appropriate for use with Natural or propane gas NOTE If you are using propane a propane conversion kit is required A Gas control valve B Gas line entrance alternate C Pressure switch D Gas manifold E Combustion air intake connection coupling F Hot surface igniter G Rollout limit switch H Burners I Flame sensor J Flue pipe connection coupling K Flue pipe L Primary ...

Page 6: ... edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CSA B149 Installation Codes local plumbing or waste water codes and other applicable codes A copy of the National Fuel Gas Code NFPA 54 ANSI Z223 1 can be obtained from any of the following American National Standards Institute 1430 Broadway New York NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy MA 022...

Page 7: ...ers fire horizontally into the heat exchanger Do not connect the furnace to a chimney flue that serves a separate appliance designed to burn solid fuel On counterflow installations the air conditioning coil must be downstream on the supply positive side of the furnace heat exchanger Counterflow Installation Over a Noncombustible Floor Before setting the furnace over the plenum opening ensure that ...

Page 8: ...cation The thermostat should be placed approximately 5 ft 1 5 m from the floor on a vibration free inside wall in an area having good air circulation NOTE Do not install the thermostat where it may be influenced by any of the following Drafts or dead spots behind doors in corners or under cabinets Hot or cold air from registers Radiant heat from the sun Light fixtures or other appliances Radiant h...

Page 9: ...d to be provided using the methods described in 5 3 3 b or 5 3 4 Space Unconfined For purposes of this Code a space whose volume is not less than 50 cu ft per 1 000 Btu h of the aggregate input rating of all appliances installed in that space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered a part of the unco...

Page 10: ...reas of all vent connectors in the confined space 5 When directly communicating with the outdoors the single opening shall have a minimum free area of 1 sq in 6 5 cm2 per 3 000 Btu h of total input rating of all equipment in the enclosure 5 3 4 Specially Engineered Installations The requirements of 5 3 3 shall not necessarily govern when special engineering approved by the authority having jurisdi...

Page 11: ...on Refer to Condensate Drain Trap and Lines for further details If the drain trap and drain line will be exposed to temperatures near or below freezing adequate measures must be taken to avoid condensate from freezing Leveling Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower For proper flue pipe drainage the furnace must be level lengthwise from end to e...

Page 12: ...e DrainPan A drain pan must be provided if the furnace is installed above a conditioned area The drain pan must cover the entire area under the furnace and air conditioning coil if applicable FreezeProtection Refer to Horizontal Applications and Conditions Drain Trap and Lines FurnaceSuspension If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a...

Page 13: ...y be installed as a nondirect vent single pipe or direct vent dual pipe appliance A nondirect vent installation requires only a vent flue pipe while a direct vent installation requires both a vent flue pipe and a combustion air intake pipe Refer to the appropriate section for details concerning piping size length number of elbows furnace connections and terminations MaterialsandJoiningMethods 2 or...

Page 14: ...minationLocations NOTE Refer to Location Requirements and Considerations for combustion air contaminant restrictions The following bullets and illustration describe the restrictions concerning the appropriate location of vent flue pipe and combustion air intake pipe when applicable terminations Refer to Nondirect Vent Single Pipe Piping and Direct Vent Dual Pipe Piping located in this section for ...

Page 15: ...hould be installed on the combustion air intake coupling to guard against inadvertent blockage CombustionAirPipe DirectVentInstallations On upflow units secure the combustion air intake pipe directly to the air intake coupling On counterflow units secure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit The counterf...

Page 16: ...astic plug from the alternate vent flue location Relocate and install the plastic plug in the standard vent flue location base pan Plug remaining hole in the blower deck with the plastic plug included in the drain kit bag Upflow and Counterflow Units 8 Insert the cut section of the vent flue pipe and coupling into the alternate vent flue location 9 Attach the vent flue pipe and coupling to the ind...

Page 17: ...n be used in place of 2 5 1 cm diameter pipe Increased clearance configurations using two 45º long sweep elbows should be considered equivalent to one 90º elbow Vent FluePipeTerminations 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 illustratio...

Page 18: ... on termination constructions For details concerning connection of pipes to the furnace refer to the Standard Furnace Connections or Alternate Furnace Connections in this section Vent FlueandCombustionAirPipe Lengthsand Diameters Refer to the following chart for applicable length elbows and pipe diameter for construction of the vent flue and combustion air intake pipe systems of a direct vent dual...

Page 19: ...o a length of pipe connecting the 2 couplings The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall The wall penetration should be sealed with silicone caulking material Direct Vent Dual Pipe Maximum Allowable Length of Vent Flue and Combustion Air Intake Pipe ft m Number of Elbows Unit Input Btu Termination Styl...

Page 20: ...kes at the same elevation Horizontal Venting of Multiple Furnaces ConcentricVentTermination Refer to the directions provided with the Concentric Vent Kit DCVK for installation specifications A 24 61 cm maximum 3 7 6 cm minimum B 12 30 5 cm minimum from wall C Vent flue tee D 12 30 5 cm minimum to roof or highest anticipated snow level E Combustion air intake F Screen G 90º medium radius elbow A 90...

Page 21: ...ioning coil is installed with the furnace a common drain may be used An open tee must be installed in the drain line near the cooling coil to relieve positive air pressure from the coil s plenum This is necessary to prohibit any interference with the function of the furnace s drain trap StandardRightorLeftSide Drain Hose Connections All installation positions require the use of the drain trap hose...

Page 22: ... left side trap installation grommets must be moved to the left side of the furnace and the plugs installed on the right side of the furnace 1 Remove the rubber plug cap from the left side of the front cover drain port 2 Secure Hose A to the front cover drain port with a red hose clamp 3 Route Hose A to the rear side panel grommet hole 4 Cut and remove 6 4 cm from the end of the drain port on the ...

Page 23: ...r drainage and are not kinked or bound For details concerning the mounting of the drain trap refer to Horizontal Drain Trap Mounting in Condensate Drain Lines and Drain Trap Horizontal Upflow Connections Right Side Down Counterflow Similar HorizontalInstallations LeftSideDown Horizontal installations with the left side panel down will require the drain hoses to be connected to the left side front ...

Page 24: ... or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate An electrical disconnect must be provided at the furnace location NOTE Line polarity must be observed when making field connections Connect hot neutral and ground wires as shown in the wiring diagram located on the unit s blower door For direct vent applications the cabinet op...

Page 25: ...ils of 115 volt and 24 volt wiring NOTE To apply a single stage heating thermostat the thermostat selector switch on the integrated control module must be set on single stage 115 VoltLineConnectionofAccessories Humidifier andElectronicAirCleaner The furnace integrated control module is equipped with line voltage accessory terminals for controlling power to an optional field supplied electronic air...

Page 26: ...e 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 Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer s high altitude Natural propane gas and or pressure switch kits NOTE Do not derate the furnace by a...

Page 27: ...joint unions Install a drip leg to trap dirt and moisture before it can enter the gas control valve The drip leg must be a minimum of 3 7 6 cm long Install a 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 orienta...

Page 28: ...ve upstream from ground joint pipe union B Alternate gas line location C Plug in alternate gas line hole D Gas control valve E Manifold F Burners G Grommet in standard gas line hole H Ground joint pipe union I Drip leg J Height required by local codes A B C D E G H I J F A B C D E F G H I J A Gas control valve B Ground joint pipe union C Manual shutoff valve upstream from ground joint pipe union D...

Page 29: ...ant in propane gas Do not rely on your sense of smell Contact a local propane gas supplier about installing a gas detecting warning system All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters NBFU Manual 58 For satisfactory operation propane gas pressure must be 11 W C at the furnace manifold with all gas appliances in operation Maintaining prop...

Page 30: ... 3 400 60 18 3 300 700 1 300 2 200 3 300 1 300 3 100 80 24 4 260 610 1 200 1 900 2 900 1 200 2 600 100 30 5 220 540 1 000 1 700 2 600 1 000 2 300 125 38 1 200 490 900 1 400 2 300 900 2 100 150 45 7 190 430 830 1 300 2 100 830 1 900 175 53 3 170 400 780 1 200 1 900 770 1 700 200 61 160 380 730 1 100 1 800 720 1 500 Propane Gas Piping Chart II Tubing Size O D Type L Nominal Pipe Size Schedule 40 Pip...

Page 31: ... inspection or such that a sampling probe can be inserted into the airstream The access panel must be made to prevent air leaks when the furnace is in operation When the furnace is heating the temperature of the return air entering the furnace must be between 55 F and 100 F 13ºC and 38ºC BottomReturnAirOpening UpflowModels The bottom return air opening on upflow models utilizes a lance and cut met...

Page 32: ... return air ductwork Minimum Filter Requirements Chart Cooling Airflow Requirement CFM Permanent Minimum Filter Area sq in Based On 600 ft 182 9 m Per Minute Filter Face Velocity Input Airflow 600 800 1 000 1 200 1 400 1 600 2 000 0453BXA 194 194 240 288 0703BXA 324 324 324 336 0704CXA 291 291 336 384 0904CXA 432 432 432 432 0905DXA 388 388 388 480 1155DXA 486 486 486 486 Cooling Airflow Requireme...

Page 33: ...e instructions in Gas Furnace Safety Precautions in this manual 8 If no gas odor is detected move the furnace gas control valve manual control to the On position 9 Replace the burner compartment door 10 Open the manual gas shutoff valve external to the furnace 11 Turn on the electrical power to the furnace 12 Adjust the thermostat to a setting above room temperature 13 After the burners are lit se...

Page 34: ...y small variations in gas pressure should be made by adjusting the gas control valve pressure regulator The manifold pressure must be measured with the burners operating To measure and adjust the manifold pressure use the following procedure 1 Turn off the gas supply to furnace at the manual gas shutoff valve external to the furnace 2 Turn off all electrical power to the system 3 Outlet pressure t...

Page 35: ... recorded in Step 2 by 2 4 Calculate the furnace input in Btu per hour Btu h Input equals the sum of the installation s gas heating value and a conversion factor hours to seconds divided by the number of seconds per cubic foot The measured input must not be greater than the input indicated on the unit rating plate Example Installation s gas heating HTG value 1 000 Btu ft3 Obtained from gas supplie...

Page 36: ...en only if flame is detected Circulator blower is energized on high heat speed following a fixed 30 second blower on delay Electronic air cleaner terminals are energized with circulator blower Furnace operates integrated control module monitors safety circuits continuously R and W thermostat contacts open completing the call for heat Gas control valve closes extinguishing flame Induced draft blowe...

Page 37: ... may cause orange tips but must not be yellow The flames should extend directly outward from the burner without curling floating or lifting off Flames must not impinge on the sides of the heat exchanger firing tubes Burner Flame Check the burner flames for good adjustment a stable soft and blue flame that is not curling floating or lifting off SAFETY CIRCUIT DESCRIPTION General A number of circuit...

Page 38: ...lter or Electronic Air Cleaner Removal Follow the manufacturer s directions for service Burners Visually inspect the burner flames periodically during the heating season Turn on the furnace at the thermostat and allow several minutes for flames to stabilize since any dislodged dust will alter the flames normal appearance Flames should be stable quiet soft and blue dust may cause orange tips but th...

Page 39: ...nace the control and the person at the same electrostatic potential these steps will help avoid exposing the integrated control module to electrostatic discharge This procedure is applicable to both installed and uninstalled ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s elec...

Page 40: ... flash Furnace lockout due to an excessive number of ignition retries 3 total Failure to establish flame No gas to burners front cover pressure switch stuck open bad igniter or igniter alignment improper orifices or coated oxidized or improperly connected flame sensor Loss of flame after establishment Interrupted gas supply lazy burner flames improper gas pressure or restriction in flue and or com...

Page 41: ...ghten or correct wiring connection Turn off power prior to repair Replace primary switch with correct replacement part Replace circulator blower with correct replacement part Induced draft blower and circulator blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing 5 flashes 5 flashes Flame sensed with no call for heat Short to ground in flame sense circ...

Page 42: ...er runs continuously No furnace operation Integrated control module diagnostic LED is flashing continuously Continuous flashes Polarity of 115 volt or 24 volt power is reversed Polarity of 115 volt AC power to furnace or integrated control module is reversed Red and blue wires to transformer are reversed Poor unit ground Review wiring diagram to correct polarity Verify proper ground Correct if nec...

Page 43: ... 1 118 1 082 1 015 WFD1950453BXA MED HI High 3 0 1 415 28 1 352 30 1 290 31 1 196 34 1 127 36 1 035 936 825 Med 2 5 1 221 33 1 178 34 1 127 36 1 073 38 1 007 40 932 834 733 Med Lo 2 0 1 034 39 1 000 40 976 41 935 43 881 46 818 733 662 Low 1 5 860 47 845 48 812 50 783 51 740 54 682 619 534 WFD1950703BXA MED HI High 3 0 1 431 42 1 368 44 1 296 47 1 228 49 1 150 53 1 055 962 860 Med 2 5 1 212 50 1 18...

Page 44: ...witch Overcurrent Prot Device High Voltage Field Gray GY White W Black BK Red R Blue BU Orange OR Yellow Y Green G Pink PK Azure A Violet V Brown BR Color Symbol 40 VA Transformer 24V Thermostat Connections Integrated Control Module Factory Settings Shown Fuse Diagnostic LED See Note 6 See Note 4 HEAT H COOL H Circulator Blower Low Voltage Field Humidifier Blower Compartment Burner Compartment Man...

Page 45: ...reen G Pink PK Azure A Violet V Brown BR Color Symbol Low Voltage Field 0 C 7 6 5 4 3 2 1 8 Steady On Off 1 Flash 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes 8 Flashes Continuous Rapid Flashes Normal Operation Control Failure System Lockout Retries Exceeded Pressure Switch Stuck Closed Pressure Switch Stuck Open Open High Limit Switch Flame Sense without Gas Control Valve Open Roll...

Page 46: ... Limits 1 In upflow blower deck 2 In counterflow blower housing OR To 115 VAC 10 60 Hz Power Supply with Overcurrent Protection Device OR Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring Low Voltage 24V High Voltage 115V Junction Terminal Internal To Integrated Control Plug Connection Equipment GND Field GND Field Splice Switch Temperature I...

Page 47: ...ot Device High Voltage Field Color Gray White Black Red Blue Orange Yellow Green Pink Azure Violet Brown Symbol GY W BK R BU OR Y G PK A V BR Low Voltage Field 0 C 7 6 5 4 3 2 1 8 Steady On Off 1 Flash 2 Flashes 3 Flashes 4 Flashes 5 Flashes 6 Flashes 7 Flashes 8 Flashes Continuous Rapid Flashes Normal Operation Control Failure System Lockout Retries Exceeded Pressure Switch Stuck Closed Pressure ...

Page 48: ... and conform to NEC and local codes 6 To recall the last 5 faults most recent to least recent depress switch for more than 2 seconds in standby no thermostat inputs ASSISTANCE OR SERVICE If you need further assistance you can write to the below address with any questions or concerns Tradewinds Distributing Company LLC 14610 Breakers Drive Jacksonville FL 32258 Please include a daytime phone number...

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