80% 2-STAGE VARIABLE SPEED GAS FURNACE INSTALLATION INSTRUCTIONS - PDF

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80% 2-STGE VRILE SPEED GS FURNCE INSTLLTION INSTRUCTIONS GS FURNCE SFETY...1 INSTLLTION REQUIREMENTS...3 Tools and Parts...3 Location Requirements...3 Installation Configurations...4 Ductwork Requirements...4
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80% 2-STGE VRILE SPEED GS FURNCE INSTLLTION INSTRUCTIONS GS FURNCE SFETY...1 INSTLLTION REQUIREMENTS...3 Tools and Parts...3 Location Requirements...3 Installation Configurations...4 Ductwork Requirements...4 Electrical Requirements...5 Gas Supply Requirements...5 Venting Requirements...5 INSTLLTION INSTRUCTIONS...7 Inspect Shipment...7 Plan Vent System...7 Determine Vent Pipe Direction...12 Connect Venting...13 Table of Contents GS FURNCE SFETY Install Ductwork...13 Filter Specifications...14 Make Electrical Connections...14 Make Gas Connections...15 Check the Furnace Input Rate...16 djust the Furnace Input Rate...16 Complete Installation...17 Shut Down...18 Sequence of Operation...19 Controls...20 TROULESHOOTING...21 SSISTNCE OR SERVICE...24 ccessories...24 WRRNTY...25 Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on your appliance. lways 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. ll safety messages will follow the safety alert symbol and either the word DNGER or WRNING. These words mean: DNGER You can be killed or seriously injured if you don't immediately follow instructions. WRNING You can be killed or seriously injured if you don't follow instructions. ll 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. Whirlpool Gold Models WGFT, WGFLT 47724K005 Whirlpool Home Cooling and Heating reakers Drive Jacksonville, FL 32258 IMPORTNT SFETY 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. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the Venting Requirements section of these instructions. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the Make Gas Connections section of these instructions. lways install furnace to operate within the furnace s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified in the Complete Installation section of these instructions. See furnace rating plate. SVE THESE INSTRUCTIONS When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. gas-fired furnace for installation in a residential garage must be installed as specified in the Location Requirements section of these instructions. The furnace is not to be used for temporary heating of buildings or structures under construction. The furnace shall be installed so the electrical components are protected from water. Furnaces for indoor installation on combustible flooring shall not be installed directly on carpeting, tile or other combustible material other than wood flooring. The California Safe Drinking Water and Toxic Enforcement ct requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances. WRNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This appliance can cause low-level exposure to some of the substances listed, including benzene, formaldehyde, carbon monoxide, toluene, and soot. DDITIONL SFETY INFORMTION In the State of Massachusetts, the following installation instructions apply: Installations and repairs must be performed by a qualified or licensed contractor, plumber, or gasfitter qualified or licensed by the State of Massachusetts. If using a ball valve, it shall be a T-handle type. flexible gas connector, when used, must not exceed 3 feet. 2 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. The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of the National Fire Protection ssociation; the National Fuel Gas Code, NSI Z223.1/NFP No. 54 (latest edition) and the National Electrical Code, NSI/NFP 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. Such applicable regulations or requirements take precedence over the general instructions in this manual. This furnace is design certified by CS International as a Category I furnace using air from inside the structure for combustion. The combustion system is fan assisted, which means it is equipped with an integral mechanical means to draw products of combustion through the heat exchanger. Tools and Parts Gather the required tools and parts before starting installation. Read and follow the instructions provided with any tools listed here. Tools needed Pipe wrench Screwdriver Tape measure Thread sealant Parts needed Check local codes and with gas supplier. Check existing gas supply, electrical supply, and venting, and read Ductwork Requirements, Electrical Requirements, Gas Supply Requirements and Venting Requirements before purchasing parts. INSTLLTION REQUIREMENTS Noncorrosive leak check solution Test gauge with ¹ ₈ NPT connection (for measuring gas supply pressure) llen wrench Location Requirements WRNING Explosion Hazard Keep flammable materials and vapors, such as gasoline, away from furnace. Place furnace so that burners are at least 18 inches (46 cm) above the floor for a garage installation. Failure to follow these instructions can result in death, explosion, or fire. WRNING Explosion Hazard Do not install this furnace in a mobile home. Doing so can result in death, explosion, fire, or carbon monoxide poisoning. IMPORTNT: Do not use the furnace as a heater in a building under construction. The furnace can be severely damaged due to the abnormal environment caused by construction. Chlorides from sources such as paint, stain, or varnish; tile and counter cements; adhesives; and foam insulation are abundant in a structure under construction and can be highly corrosive. Low return air temperature can cause condensation in the furnace and other damage that can shorten the life of the furnace. The furnace is suitable for installation in buildings constructed on site. The furnace should be centralized in respect to the heat distribution system as much as practicable. ll models are suitable for closet or utility room installation. Utility room installation requires: door opening large enough for the widest part of the furnace. door opening large enough to remove/replace any other appliance located in the utility room, such as a water heater. ny other appliances arranged so that each appliance can be removed/replaced without disturbing the furnace. 3 In a residential garage, a gas-fired furnace must be installed so the burner(s) and the ignition source are located not less than 18 above the floor. The furnace is to be located or protected to avoid physical damage by vehicles. Furnaces may be installed as suspended units in the horizontal position. These furnaces are not designed for direct attachment of suspension rods to the furnace casing. See Installation Configurations. If the furnace is to be installed in an attic or other insulated space, it must be kept free and clear of insulating materials. Installation Clearances 2 minimum clearance is required in front for air openings into the combustion chamber. ll servicing and cleaning of the furnace can be performed from the front. If installed in a closet or utility room, provide 24 clearance in front for service if the door to the room is not in line with the front of the furnace. Where servicing clearances are greater than clearances to combustibles, servicing clearances take precedence. Minimum Clearance to Combustibles Chart (all measurements in inches) Upflow Installations Upflow Installations Installation Configurations Furnaces can be installed with either a side or bottom air return. For bottom air return the bottom air return knockout plate must be removed. For units that do not include a side or bottom return filter rack, kit no. FILT524-1 (side return) or kit no. FILT529-1 (bottom return) can be used. To provide sufficient filter area for installations requiring more than 1,600 CFM nominal air delivery, return air will have to be brought through both sides of the furnace, or through one side and the bottom. Horizontal Installations Furnaces can be horizontally installed for airflow right to left or left to right. To ensure access to parts for servicing, install upflow and counterflow furnaces so that the burner and blower access panels are readily accessible. NOTE: When installed horizontally, the installer must install a sheet metal screw to retain the upper door as shown following, in either Position or, depending on installation configuration. Horizontal Installation Sides Cabinet Width Front ack Top Vent Left Right Horizontal Installations Supply Return Cabinet Width Front ack Vent irflow R to L L to R Top ottom Top ottom. Screw placement for Right to Left airflow. Screw placement for Left to Right airflow May be 2 when Type -1 vent pipe is used. 2 May be 1 when Type -1 vent pipe is used. 3 Where values greater than 0 are shown, may be 0 when Type -1 vent pipe is used. High ltitude Installations This furnace is approved for operation at altitudes from 0 to 4,500 ft above sea level without any required modifications. From 4,500 to 7,500 ft, the gas manifold pressure needs to be adjusted according to the information shown in the Manifold Pressure vs. ltitude Chart. IMPORTNT: For installations above 7,500 ft, the furnace input rate is to be reduced per the requirements of the National Fuel Gas Code (NSI Z223.1/NFP 54, latest edition), at the rate of 4 percent for each 1,000 ft above sea level. The furnace is not recommended for installation above 10,000 ft. Horizontal Installation Suspended Furnaces may be installed as suspended units in the horizontal position. These furnaces are not designed for direct attachment of suspension rods to the furnace casing. The suspending means must be field fabricated, and should consist of 2 cradles made by attaching 2 rods to a length of angle iron or suitable gauge steel. Locate the cradles so that they are as close as possible to the ends of the furnace (this will provide access for removal of major components such as the blower assembly). Provide enough clearance between the suspension rods and the furnace to allow removal of access panels. Ductwork Requirements Install the conditioned air plenum, ducts and air filters (if not provided on the furnace) in accordance with NFP 90 Standard for the Installation of Warm ir Heating and ir-conditioning Systems (latest edition). The furnace is provided with flanges for the connection of the plenum and ducts. ll air filters must be listed as Class 2 furnace air filters. 4 Electrical Requirements WRNING 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. n 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. Electrical Shock Hazard Electrically ground furnace. Connect ground wire to green ground screw. Failure to do so can result in death or electrical shock. The furnace must be grounded and wired in accordance with local codes or, in the absence of local codes, with the National Electrical Code NSI/NFP No. 70 (latest edition). 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 rise). The line voltage supply should be routed through a readily accessible disconnect located within sight of the furnace. junction box on the furnace side panel is provided for line voltage connections. See the Wiring Connection Diagram in the Troubleshooting section for specific connection information. Proper polarity of the supply connections ( HOT and NEUTRL ) must be observed to be sure that safety controls provide the protection intended. Gas Supply Requirements This furnace is equipped for use with Natural gas. conversion kit is required for use with propane. To order the correct conversion kit, see ccessories. Gas supply piping should be installed in accordance with local codes and the regulations of the utility. Piping must be of adequate size to avoid undue pressure drop. Consult the local utility or gas supplier for complete details on special requirements for sizing gas piping. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance. Venting Requirements dequate provisions for combustion air and ventilation of furnace must be made. Refer to Section 5.3, ir for Combustion and Ventilation, of the National Fuel Gas Code, NSI Z223.1/NFP 54 (latest edition), or applicable provisions of the local building codes. For Category 1 furnaces, vent installations shall be in accordance with parts 7 and 11 of the National Fuel Gas Code, NSI Z223.1/NFP 54, the local building codes, and the furnace and vent manufacturer s instructions. WRNING: CRON MONOXIDE POISONING HZRD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1. Seal any unused openings in the venting system. 2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, NSI Z223.1/NFP 54 or the CS 149.1, Natural Gas and Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. 3. s 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, so they are operating at maximum speed. Do not operate a summer exhaust fan. 6. Follow the lighting instructions. Place the appliance being inspected into operation. djust the thermostat so appliance is operating continuously. 7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. 8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, NSI Z223.1/NFP 54 and/or CS 149.1, Natural Gas and Propane Installation Codes. 9. fter it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliances to their previous conditions of use. 5 Venting Options The furnace can be installed as either direct vent or nondirect vent unit. For either type of installation, special venting considerations must be followed. See Plan Vent System and Determine Vent Pipe Direction for the type of furnace and venting being installed. Direct Vent direct vent (two pipe) installation requires that all the air necessary for combustion be supplied from outside the dwelling through an air intake pipe. ll vents passing through floors, ceilings, and walls must be installed in accordance with National Fuel Gas Code, NSI Z223.1/NFP 54 (latest edition). In all applications in which the flue pipe is run through an unconditioned space, ¹ ₂ insulation must be used over the pipe. In extremely cold climates, ³ ₄ insulation is recommended. Nondirect Vent nondirect vent (one pipe) installation uses air from inside the dwelling for combustion. The furnace is shipped with the air inlet pipe terminated to the top panel for either inside or outside combustion air. n inlet air restrictor plate is supplied with this furnace and can be found in the plastic bag containing these Installation Instructions and the User s Information Manual. For installations using inside air for combustion (nondirect vent), attach a 90 elbow (not supplied) to the inlet coupler and install the restrictor plate inside the elbow. See Plan Vent System. Inlet ir Restrictor Plate The inlet air restrictor plate must be installed in all installations that are nondirect vent. Unconfined Space n unconfined space is defined as a space whose volume is more than 50 cu. ft per 1,000 tu/h of the combined input rating of all appliances installed in that space. When a furnace is installed in an unconfined space in a building, it can be assumed that the infiltration will be sufficient to supply the required air. If the furnace is installed in a ventilated attic or crawl space, it is assumed that the air infiltration is sufficient to supply the required combustion air. However, in a building of unusually tight construction, additional outdoor air should be provided. Contaminated Combustion ir 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. Outdoor air is required as the source of combustion air when the indoor air is contaminated with chemical substances and in the following types of installations: Furnaces installed in commercial buildings Furnaces installed in buildings with indoor pools Furnaces installed in hobby or craft rooms Furnaces installed near chemical storage areas Furnaces installed in laundry rooms Furnaces installed in hair salons Indoor air as the source of combustion air Indoor air as the source of combustion air is acceptable in most applications if the following guidelines are met: ll provisions for indoor combustion air must meet the requirements for combustion air indicated in the National Fuel Gas Code, NSI Z223.1/NFP 54 (latest edition), and/or any applicable local codes. If indoor combustion air is used, the air supply to the furnace should not be exposed to the following substances: Permanent wave solutions Chlorinated wa
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