Westinghouse Gas Furnace Manual

The Westinghouse Gas Furnace is a high-efficiency residential heating system designed for reliable performance and energy savings. It features advanced combustion technology, multiple heating stages, variable-speed blower motors, integrated diagnostic controls, and compatibility with various thermostat systems. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation Requirements 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Thermostat 7. Operating the Furnace 8. Safety Features 9. Maintenance & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Heat exchanger, burners, inducer motor, blower assembly, gas valve, control board, pressure switches, flame sensor, filter rack.

Feature	Description
Heat Exchanger	Stainless steel primary and secondary for high efficiency
Burners	Multi-port inshot burners for quiet, efficient combustion
Inducer Motor	Draft inducer for proper venting and safety
Blower Assembly	Variable-speed ECM motor for consistent airflow
Gas Valve	Modulating or two-stage for precise gas flow control
Control Board	Integrated diagnostics with LED status codes
Pressure Switches	Verify proper venting before ignition
Flame Sensor	Confirms burner ignition for safety shutdown
Filter Rack	Standard 1-inch or 4-inch media filter compatibility
Thermostat Connections	Compatible with single-stage, two-stage, and smart thermostats

Installation Requirements

Unpack and inspect all components. Ensure proper clearances and venting.

Location: Install in approved area (closet, basement, utility room) with adequate combustion air.
Venting: Use approved PVC or metal vent pipe per local codes; maintain proper slope.
Gas Supply: Connect to gas line with shutoff valve; pressure test for leaks.
Electrical: Connect to 120V AC power with dedicated circuit; proper grounding required.
Drain Line: Connect condensate drain to suitable drain or pump.

WARNING! Installation must be performed by qualified technician in accordance with all local codes. Gas leaks can cause explosion or fire.

First-Time Setup

After installation, perform initial startup and configuration.

Gas pressure check: Verify inlet and manifold pressures match specifications.
Vent verification: Confirm inducer motor creates proper draft; pressure switches close.
Thermostat wiring: Connect R, W, G, C terminals per wiring diagram.
System test: Set thermostat to heat mode; observe ignition sequence.
Airflow adjustment: Set blower speeds for heating per installation manual.

CAUTION! Never bypass safety controls. Ensure proper ventilation to prevent carbon monoxide buildup.

Specifications

Input BTU/h: 40,000 to 120,000 (varies by model).
AFUE Rating: Up to 96% efficiency.
Gas Type: Natural gas (LP conversion kit available).
Electrical: 120V AC, 60Hz, less than 12 amps.
Venting: 2" or 3" PVC/CPVC for direct vent (sidewall or roof).
Airflow: 600 to 2000 CFM (blower dependent).
Operating Temp: Minimum return air 60°F, maximum 120°F.
Dimensions: Varies by model (typical: 45"H x 21"W x 26"D).
Warranty: Limited lifetime heat exchanger, 10-year parts.

Controls and Settings

Access control board via front panel. LED status light indicates system mode and fault codes.

Control Board: POWER switch, LED indicator, DIP switches for configuration, test terminals.

DIP Switch Settings: Heat staging (1-stage/2-stage), blower off delay, thermostat type. LED Codes: Steady = normal operation; flashing = fault (count flashes for code). Manual Override: Jumper test terminals for manual operation during service. Gas Valve Adjustment: Requires manometer; do not adjust unless qualified.

Connecting Thermostat

Compatible with most 24V thermostats. Wiring: R (24V power), W (heat), G (fan), C (common), Y (cooling if AC connected).

Turn off power at furnace and thermostat.
Remove thermostat cover; label existing wires.
Connect wires to control board terminals matching labels.
Restore power; configure thermostat for gas furnace with appropriate stages.

Tip: Use 18-gauge thermostat wire. Ensure C wire is connected for smart thermostats.

Operating the Furnace

Normal heating cycle sequence:

Thermostat calls for heat: Sends 24V signal to control board.
Inducer motor starts: Creates draft; pressure switches close.
Ignition sequence: Hot surface igniter glows; gas valve opens.
Flame verification: Flame sensor confirms ignition; igniter shuts off.
Blower starts: After heat exchanger warm-up delay, blower circulates warm air.
Cycle complete: When thermostat satisfied, gas valve closes, inducer runs post-purge, blower runs cool-down.

WARNING! If you smell gas, turn off gas supply immediately, evacuate, and call gas company. Do not operate furnace until leak is repaired.

Safety Features

Flame Rollout Switches: Detect improper burner combustion; shut off gas if triggered. Limit Switches: Prevent overheating by shutting off burners if temperature excessive. Pressure Switches: Ensure proper venting before allowing ignition. Flame Sensor: Confirms burner ignition; shuts off gas if no flame detected. Carbon Monoxide: Install CO detectors near sleeping areas as additional safety measure.

Maintenance & Cleaning

Annual professional maintenance recommended. Monthly homeowner tasks:

Filter: Check monthly; replace when dirty (typically 1-3 months).
Vent pipes: Visually inspect for obstructions or damage.
Drain line: Flush with water/vinegar solution if clogged.
Burners: Professional cleaning of burners and heat exchanger annually.
Blower: Vacuum blower wheel and compartment annually.

CAUTION! Turn off power and gas before any maintenance. Never operate without filter installed.

Regulatory Information

ANSI Z21.47/CSA 2.3: Certified for safety standards. UL Listed: Electrical components. For installation in USA and Canada. Efficiency certified to DOE standards. Copyright © Westinghouse; trademarks of Westinghouse Electric Corporation. For support, visit www.westinghousehvac.com or contact 1-800-422-4328.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, switch	Check circuit breaker, thermostat setting, furnace switch, door safety switch.
No heat (blower runs)	Gas, ignition	Verify gas valve on; check for ignition attempts; LED fault code.
Short cycling	Filter, limit switch	Replace dirty filter; check for blocked vents/registers; professional check limit switch.
Blower won't stop	Thermostat, control	Check thermostat fan setting; possible control board failure.
Unusual odors	Dust, overheating	First few cycles may have dust smell; persistent gas smell requires immediate shutdown.
LED flashing code	System fault	Count flashes; refer to fault code chart in manual.

Reset: Power cycle (turn off for 30 seconds, then on). Some faults require professional reset.

Service: 1-800-422-4328; www.westinghousehvac.com