Whirlpool WGFD28 Installation Instructions Manual

Text of Whirlpool WGFD28 User Guide:

• Whirlpool WGFD28, 26 Profile D ■ 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. 6. Select the heating speed from the heating speed chart in the Specification Sheet for your model. The Adjust Taps setting (already established by the cooling speed selection) determines which set of speeds are available. The selected speed must provide a temperature rise within the rise range listed with the particular model. Example: The WGF

• 22 Gas Supply Pressure Measurement The line pressure supplied to the gas control valve must be within the range specified below. The supply pressure can be measured at the gas control valve inlet pressure boss or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use the following p

• 25 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 WGFM28070V4BX furnace installed with a 2.5 ton air conditioning system. The airflow needed is 1,000 CFM. Looking at the cooling speed

• Whirlpool WGFD28, 15 Thermostat Wiring Diagram—2-Stage Heating with Single-Stage Cooling Thermostat Wiring Diagram—2-Stage Heating with 2-Stage Cooling A single-stage thermostat with only one heating stage may be used to control this furnace. The application of a single-stage thermostat does not offer true thermostat-driven 2-stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat.

• Whirlpool WGFD28, 29 MAINTENANCE Annual Inspection The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair or service as necessary. ■ Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the con

• Whirlpool WGFD28, 10 Typical Multiple Flue Clay Tile Chimney Checklist Summary This checklist serves as a summary of the items to be checked before venting an 80+ furnace into a masonry chimney. In addition, we recommend that a qualified serviceman use this checklist to perform a yearly inspection of the furnace venting system. This checklist is only a summary. For detailed information on each of the procedures mentioned, see the paragraph referenced with each item. This inspection is based upon a draft topical report, “Masonry Chimney Inspection and Relining,” issued by the Gas Research Inst

• Whirlpool WGFD28, 80% 2-STAGE VARIABLE SPEED GAS FURNACE INSTALLATION INSTRUCTIONS Keep this literature in a safe place for future reference. WPIO-369 Whirlpool ® Home Cooling and Heating 14610 Breakers Drive Jacksonville, Florida 32258 Whirlpool Gold ® Models WGFD28, WGFM28 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 o

• Whirlpool WGFD28, 37 ■ Furnace fails to operate. ■ Integrated control module LED display provides “b5” error code. b5 ■ Circulator blower motor fails to start 10 consecutive times. ■ Obstruction in circulator blower housing. ■ Seized circulator blower motor bearings. ■ Failed circulator blower motor. ■ Check circulator blower for obstructions. Remove and repair/replace wheel/motor, if necessary. ■ Check circulator blower motor shaft rotation and motor. Replace motor if necessary. ■ Turn off power prior to rep

• Whirlpool WGFD28, 12 The surfaces of the liner must be physically sound. If gaps or holes are present, the metal liner must be removed and replaced (Fix 4—Relining). Finally, confirm that the metal liner is the correct size for the appliances to be installed. Use the GAMA tables and rules. NOTE: If a metal liner is not present, a clay tile liner must be present, or the chimney must be lined (Fix 4—Relining). Use a flashlight and small mirror at the cleanout or vent connector to inspect the clay tile liner. If any of the following problems are present, reline (Fix 4—Reli

• Whirlpool WGFD28, 14 Junction Box Relocation Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the left side prior to making electrical connections. To relocate the junction box, perform the following steps. 1. Remove both doors from the furnace. 2. Remove and save the screws securing the junction box to t

• Whirlpool WGFD28, 33 ■ Induced draft blower runs continuously with no further furnace operation. ■ Integrated control module LED display provides “E2” error code. E2 ■ Low-stage pressure switch circuit is not closed. ■ 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 syst

• Whirlpool WGFD28, 20 Sizing Between 2 nd Stage and Appliance Regulator* Maximum Propane Capacities Listed are Based on ¹⁄₂" W.C. pressure drop at 10.0" W.C. setting. Capacities in 1,000 Btu/h. Data in accordance with NFPA pamphlet Number 54. CIRCULATING AIR AND FILTERS Ductwork—Airflow ■ Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Design the ductwork in accordance with the recommended methods of “Air Conditioning Contractors of America” Manual D. ■ Install the duct syst

• Whirlpool WGFD28, 38 WIRING DIAGRAM Check codes for proper wiring and circuit protection before installation. NOTES: 1. Set heat anticipator on room thermostat at 0.7 amps. 2. Manufacturer’s specified replacement parts must be used when servicing. 3. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105ºC. Use copper conductors only. 4. Furnace must be permanently grounded and conform to NEC and local

• Whirlpool WGFD28, 30 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. Remove the induced draft blower, drain hose and pressure tap hoses from the recuperator coil front cover. 5. Remove the recuperator coil front cover to

• Whirlpool WGFD28, 17 NOTE: Adjusting the minimum supply pressure below the limits in the above table could lead to unreliable ignition. Gas input to the burners must not exceed the rated input shown on the rating plate. Overfiring of the furnace can result in premature heat exchanger failure. Gas pressures in excess of 13" W.C. can also cause permanent damage to the gas control valve. At all altitudes, the manifold pressure must be within 0.3" W.C. of that listed in the Specification Sheet applicable to your model for the fuel used. At all altitudes and with either fuel, the air temperature rise must be within the range listed on the fu

• Whirlpool WGFD28, 35 ■ Furnace fails to operate. ■ Integrated control module LED display provides “EA” error code. EA ■ Polarity of 115-volt AC is reversed. ■ Polarity of 115-volt AC power to furnace or integrated module is reversed. ■ Poor furnace ground. ■ Review wiring diagram to correct polarity. ■ Verify proper ground. Correct if necessary. ■ Check and correct wiring. ■ Turn off power prior to repair. ■ Furnace fails to operate. ■ Integrated control module LED display provides “d0” error code. d0 ■ Data not yet on network. ■ Furnace does not contain any shared data. ■ Po

• Whirlpool WGFD28, 24 foot dial, divide the number of seconds recorded in Step 2 by one. If the dial is a 2 cubic foot dial, divide the number of seconds 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/ft 3 (Obtained from gas supplier) Installation’s seconds per cubic

• 8 3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. 4. Close fireplace dampers. 5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts

• Whirlpool WGFD28, 23 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. Reinstall plug before turning on gas supply to furnace. 9. Turn off any unnecessary gas appliances that were turned on in Step 4. Measuring Inlet Gas Pressure—Alternate Method Gas Manifold Pressure Measurement and Adjustment Only 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 measur

• Whirlpool WGFD28, 32 Symptoms of Abnormal Operation Diagnostic/ Staus LED Code Fault Description Possible Causes Corrective Actions Notes and Cautions ■ Furnace fails to operate. ■ Integrated control module diagnostic LED display provides no signal. 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. ■ Blown fuse or circuit breaker ■ Integrated control module has an internal fault. ■ Assure 115-vo

• Whirlpool WGFD28, 34 ■ Furnace not operating. ■ Integrated control module LED display provides “E6” error code. E6 ■ Flame sense microamp signal is low. ■ Flame sensor is coated/oxidized. ■ Flame sensor incorrectly positioned in burner flame. ■ Lazy burner flame due to improper gas pressure or combustion air. ■ Sand flame sensor if coated/oxidized. ■ Inspect for proper sensor alignment. ■ Check inlet air piping for blockage, proper length, elbows and termination. ■ Compare current gas pressure to rating plate info. Adjust as needed. ■ Turn off power prior to repair. ■ Sand flame sensor with emery cloth. ■ See “Vent/Flue P

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