Whirlpool WGFDU Specifications

90+ GAS FURNACE INSTALLATION INSTRUCTIONS
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
GAS FURNACE SAFETY
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:
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.
Models WFCU, WFCC, WGFDC, WGFDU
46948D003
Whirlpool® Home Cooling and Heating
7901 S.W. 6th Court
Plantation, Florida 33324
IMPORTANT SAFETY INSTRUCTIONS
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■
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■
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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.
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.
■
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.
■
A 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.
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.
Adequate clearance must be provided around the
vent-air intake terminals.
Always 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.
■
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.
SAVE THESE INSTRUCTIONS
The California Safe Drinking Water and Toxic Enforcement Act 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.
WARNING: 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.
ADDITIONAL SAFETY INFORMATION
In the State of Massachusetts, the following installation instructions apply:
■
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2
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.
A flexible gas connector, when used, must not exceed 3 feet.
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.
The installation of the furnace, wiring, warm air ducts, venting,
etc. must conform to the requirements of the National Fire
Protection Association; the National Fuel Gas Code, ANSI
Z223.1/NFPA No. 54 (latest edition) and the National Electrical
Code, ANSI/NFPA 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 design is certified by CSA International as a
Category IV furnace in compliance with the latest edition of
American National Standard Z21.47/CSA Standard 2.3 for GasFired Central Furnaces, for operation with natural gas or propane.
Consult the rating plate on the furnace for gas type before
installing.
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.
Tools and Parts
Assemble the required tools before starting installation. Read and
follow the instructions provided with any tools listed here.
Tools Needed:
■
Pipe wrench
■
Non-corrosive leak check solution
■
Screwdriver
■
■
Tape measure
Test gauge with ¹⁄₈ in. NPT
connection
(for measuring gas supply pressure)
■
Thread sealant
Parts Needed:
Check local codes and with gas supplier. Check existing gas
supply, electrical supply, and venting, and read “Duct Work
Requirements,” “Electrical Requirements,” “Gas Supply
Requirements” and “Venting Requirements” before purchasing
parts.
Parts Supplied
■ Inlet air restrictor plate
■
Flue pipe screen
Explosion Hazard
Do not install this furnace in a mobile home.
Doing so can result in death, explosion, fire, or
carbon monoxide poisoning.
IMPORTANT: 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 condensate drain on this furnace is incorporated within
the furnace and must be primed before start-up. The
condensate system must not be exposed to temperatures
under 32°F.
■
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.
3
■
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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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 in. above the floor. The furnace is to be located or
protected to avoid physical damage by vehicles.
Installation Configurations
WGFDU and WFCU models must be installed only as upflow
furnaces.
WGFDC and WFCC models must be installed only as
counterflow (downflow) furnaces.
IMPORTANT: To ensure access to parts for servicing, install
upflow and counterflow furnaces so that the burner and blower
access panels are readily accessible.
Installation for Counterflow (Downflow) Models
If the furnace is to be installed in an attic or other insulated
space, it must be kept free and clear of insulating materials.
WARNING
Installation Clearances
■
A 2 in. minimum clearance is required in front for air openings
into the combustion chamber.
■
All servicing and cleaning of the furnace can be performed
from the front. If installed in a closet or utility room, provide 24
in. 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.
Fire Hazard
Before installing counterflow (downflow) furnace on
combustible surface, such as wood, install one of the
following kits:
Minimum Clearance to Combustibles Chart
Unit Sides
0"
Rear of Unit
0"
WABASE 511 (14.5" cabinets)
WABASE 512 (17.5" cabinets)
WABASE 568 (21" cabinets)
WABASE 569 (24.5" cabinets)
Front of Unit
2"
Contact your local dealer.
Flue Pipe
0"
Plenum Top (upflow)
1"
Supply Duct (counterflow)
1"
Failure to do so can result in death or fire.
IMPORTANT:
■ The furnace may be installed directly on the supply plenum or
coil cabinet if the furnace is installed on a non-combustible
floor.
■
High Altitude Installations
■
This furnace is approved for operation at altitudes from 0 to
4,500 feet 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. Altitude charts.
IMPORTANT:
For installations above 7,500 ft, the furnace input rate is to be
reduced per the requirements of the National Fuel Gas Code
(ANSI Z223.1/NFPA 54, latest edition), at the rate of 4 percent for
each 1,000 feet above sea level.
The furnace is not recommended for installation above 10,000 ft.
4
For installations on combustible flooring, a special base must
be ordered and used. See the “Accessories” section.
1. Cut, size and frame opening in floor to fit the Combustible
floor base and provide a minimum 1 in. clearance between
the Supply Duct and combustible materials. The four legs on
the base assembly should recess into the floor and the base
should rest on all four outside flanges.
2. Construct duct connections with 1 in. to 1³⁄₄ in. right angle
flanges, and long enough to extend below the floor joists.
3. Drop the duct connections through the top of the base
assembly with the right angle flanges in good contact with
the glass tape on top of the base assembly.
4. Carefully position the furnace over the right angle duct
flanges.
Combustible Floor Installation (Counterflow Models only)
1
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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. See the furnace wiring diagram for
specific connection information.
■
Proper polarity of the supply connections (“HOT” and
“NEUTRAL”) must be observed to ensure that safety controls
provide the protection intended.
2
3
4
5
6
Gas Supply Requirements
This furnace is equipped for use with natural gas. A conversion
kit is required for use with propane. To order the correct
conversion kit, see “Accessories.”
■ Gas supply piping should be installed in accordance with
local codes and the regulations of the utility. Piping must be
of adequate size to prevent undue pressure drop. Consult the
local utility or gas supplier for complete details on special
requirements for sizing gas piping.
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1. Furnace
2. Woven glass tape (between
flanges of outlet duct and
base assembly)
3. Base assembly
4. Combustible flooring
5. Leg
6. Supply plenum or coil cabinet
(not provided - accessory)
Duct Work Requirements
Install the conditioned air plenum, ducts and air filters (if not
provided on the furnace) in accordance with NFPA 90B Standard
for the Installation of Warm Air Heating and Air-Conditioning
Systems (latest edition).
The furnace is provided with flanges for the connection of the
plenum and ducts.
All air filters must be listed as Class 2 furnace air filters.
Electrical Requirements
WARNING
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
Adequate provisions for combustion air and ventilation of furnace
must be made. Refer to Section 5.3, “Air for Combustion and
Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA54
(latest edition), or applicable provisions of the local building
codes.
Unconfined Space
An unconfined space is defined as “a space whose volume is
more than 50 cubic feet per 1000 BTU per hour 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.
Confined Space
A confined space is defined as “a space whose volume is less
than 50 cubic feet per 1000 BTU per hour of the combined input
rating of all appliances installed in that space.” Use Direct Vent
method. See “Plan Ventilation System.”
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 ANSI/NFPA No. 70 (latest edition).
5
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.
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
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Furnaces installed in buildings with indoor pools
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Furnaces installed in hobby or craft rooms
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Furnaces installed near chemical storage areas
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Furnaces installed in laundry rooms
Furnace must be installed and serviced by a
qualified person.
■
Furnaces installed in hair salons
Examples of a qualified person include:
Explosion Hazard
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:
■ All provisions for indoor combustion air must meet the
requirements for combustion air indicated in the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 (latest edition), and/or any
applicable local codes.
■
licensed heating personnel,
authorized gas company personnel.
Read and follow all instructions provided for
installation, adjustment, service, alteration, or
maintenance.
Failure to follow these instructions can result in death,
explosion, fire, or carbon monoxide poisoning.
If indoor combustion air is used, the air supply to the furnace
should not be exposed to the following substances:
Permanent wave solutions
Inspect Shipment
Chlorinated waxes and cleaners
Chlorine-based swimming pool chemicals
WARNING
Water softening chemicals
Deicing salts or chemicals
Excessive Weight Hazard
Carbon tetrachloride
Use two or more people to move and install furnace.
Halogen-type refrigerants
Failure to do so can result in back or other injury.
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Masonry acid washing materials
This furnace is shipped in one package, completely assembled
and wired. The thermostat is shipped in a separate carton when
ordered.
■ Check the unit rating plate to confirm specifications are as
ordered.
Chlorinated laundry products
■
Upon receipt of equipment, carefully inspect it for possible
shipping damage. Take special care to examine the unit
inside the carton if the carton is damaged.
■
If damage is found, it should be noted on the carrier’s freight
bill. Damage claims should be filed with the carrier
immediately. Claims of shortages should be filed with the
seller within 5 days.
Cements and glues
Antistatic fabric softeners for clothes dryers
Hydrochloric acid
NOTE: If any damages are discovered and reported to the
carrier, do not install the unit, as your claim may be denied.
6
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. All venting must be in
accordance with the codes having jurisdiction in the area and
these instructions.
IMPORTANT:
■ The venting system must be supported with mounting straps
to prevent any weight load from being applied to the vent
blower. Horizontal vent pipe must be supported every 5 ft and
vertical pipe should be supported every 10 ft to prevent
sagging and provide rigid support.
■
This furnace must not be connected to any Type B, BW, or L
vent or vent connector and must not be connected to any
portion of a factory-built or masonry chimney.
■
This furnace is not to be common vented with any other
appliance. The vent pipe must not be connected to a
chimney flue serving a separate appliance designed to burn
solid fuel.
Venting Options
WFCU, WFCC, WGFDC and WGFDU models can be installed as
either direct vent or non-direct vent units.
For either type of installation, special venting considerations
must be followed. See “Determine Vent Pipe Direction” section
for the type of furnace and venting being installed.
Direct Vent
A direct vent (two pipe) installation requires that all the air
necessary for combustion be supplied from outside the dwelling
through an air intake pipe.
■ All vents passing through floors, ceilings, and walls must be
installed in accordance with National Fuel Gas Code, ANSI
Z223.1/NFPA 54 (latest edition). In all applications where the
flue pipe is run through an unconditioned space, ¹⁄₂ in.
insulation must be used over the pipe. In extremely cold
climates, ³⁄₄ in. insulation is recommended.
Non-Direct Vent
A non-direct 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. An 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 (non-direct
vent), attach a 90° elbow (not supplied) to the inlet coupler
and install the restrictor plate inside the elbow (see “NonDirect Vent Installation”).
Inlet Air Restrictor Plate
The inlet air restrictor plate
must be installed in all
installations using inside air
for combustion (non-direct
vent).
Flue Pipe Screen
A flue pipe screen designed to keep objects out of the flue pipe is
included in the plastic bag.
In all installations, this screen should be installed at the
termination of the flue pipe.
Flue Pipe Screen
The flue pipe screen
should be installed at the
termination of the flue pipe
in all installations.
7
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. See “Piping and Fitting Specifications” for approved
piping and fitting materials.
Piping and Fitting Specifications
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■
■
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Piping and Fitting Material
ASTM Specification
Schedule 40 PVC (Pipe)
D1785
Schedule 40 PVC (Cellular Core Pipe)
F891
Schedule 40 PVC (Fittings)
D2466
SDR-26 (Pipe)
D2241
Schedule 40 ABS (Pipe)
D1527
Schedule 40 ABS (Fittings)
D2468
Schedule 40 & 80 CPVC (Pipe)
F441
ABS-DWV Drain Waste & Vent
(Pipe & Fittings)
D2661
PVC-DWV Drain Waste & Vent
(Pipe & Fittings)
D2665
The primers and solvents used must also meet ASTM
specifications. PVC primer is specified in ASTM F656. Use
PVC solvent as specified in ASTM D2564 and ABS solvent
cement as specified ASTM D2235. Low temperature solvent
cement is recommended. Metal or plastic strapping may be
used for vent pipe hangers.
When making ABS joints, pieces can be prepared with a
cleaner. When joining ABS to PVC materials, use PVC solvent
cement as specified in ASTM D3138.
Preferred fittings are DWV style or long sweep. Seal all joints
gas tight with appropriate cement. In areas where vent and air
intake pipes are exposed to abnormal stress or are subject to
damage, schedule 80 pipe should be used.
Use high temperature RTV silicone sealant to attach the air
intake pipe into the connector on the burner box so the air
intake pipe can be removed if service is required.
The vent pipe and air intake pipe (in direct vent installations)
should be sized in accordance with the information found in the
“Vent Tables.” One 90° elbow is equivalent to 5 ft of pipe.Two 45°
elbows are equivalent to one 90° elbow.The minimum length
certified for use with this furnace is 5 ft and one elbow, not
including the vent and air intake terminals.
Vent Table - 40,000 - 80,000 BTU/HR Models
Vent Pipe
Length (ft)
Minimum Pipe Diameter (in.)
5
1.5 1.5
2
2
2
2
2
2
2
2
10
1.5
2
2
2
2
2
2
2
2
2
20
2
2
2
2
2
2
2
2
2
2.5
30
2
2
2
2
2
2
2
40
2
2
2
2
2
50
2
2
60
2
2.5 2.5 2.5
2.5 2.5 2.5 2.5 2.5
2.5 2.5 2.5 2.5 2.5 2.5 2.5 NR
2.5 2.5 2.5 2.5 2.5 2.5 NR NR NR
70
2.5 2.5 2.5 2.5 2.5 NR NR NR NR NR
80
2.5 2.5 2.5 NR NR NR NR NR NR NR
90
2.5 2.5 NR NR NR NR NR NR NR NR
Number of 90°
Elbows
0
1
2
3
4
5
6
7
8
9
NR = Not Recommended
Vent Table- 90,000 - 100,000 BTU/HR Models
Vent Pipe
Length (ft)
Minimum Pipe Diameter (in.)
5
NR
2
2
2
2
2
10
2
2
2
2
2
2
20
2
2
2
2
2
30
2
2
2
40
2
2
2
2.5 2.5 2.5 2.5
2.5 2.5 2.5 2.5
2.5 2.5 2.5 2.5
2.5 2.5 2.5
2.5 2.5 2.5
3
3
3
3
3
3
3
3
3
3
3
NR
50
2.5 2.5 2.5
3
3
3
3
60
2.5
3
3
3
3
3
3
70
3
3
3
3
3
80
3
3
3
90
3
3
Number of 90°
Elbows
0
1
NOTE: Do not use cement.
NR = Not Recommended
8
NR NR NR
NR NR NR NR NR
NR NR NR NR NR NR NR
NR NR NR NR NR NR NR NR
2
3
4
5
6
7
8
9
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. For example, if a
length of pipe needed to install the furnace is 27 ft, use the
diameter values for the 30 ft row in the tables.
For direct vent installations, if the vent and air intake pipe are not
equal in length and number of elbows, then determine the
minimum pipe diameter for both the vent and air intake. If the
results indicate different diameters, use the larger of the two for
both the vent and air intake.
NOTE: Under no circumstances should the vent and air intake
pipe size be different in diameter. See “Install Vent System” for
the unit model and type of installation.
NR NR NR NR NR
NR NR NR NR NR NR NR
NR NR NR NR NR NR NR NR
2
3
4
5
6
7
8
9
NR = Not Recommended
Determine Vent Pipe Direction
The vent system of the furnace must be self-supporting and must not apply any weight load to the combustion blower.
Combustion Air Sources
There are 2 sources for combustion air:
1. From outside the building (Direct Vent)
2. From inside the building (Non-Direct Vent)
Please read the information provided here about Vertical and
Horizontal Venting, then find and follow the instructions for your
venting configuration.
Vertical Venting
A vertical vent should extend through the roof a minimum of 2 ft
and not be obstructed a minimum of 10 ft in any direction.
Horizontal Venting
The vent terminal location shall comply with Section 7.8 of the
National Fuel Gas Code (ANSI Z223.1) or local requirement,
whichever takes precedence. For informational purposes, the
applicable sections of Section 7.8 are reprinted here:
The venting system shall terminate at least 3 feet (0.9 m)
above any forced air inlet located within 10 feet (3.1 m).This
provision shall not apply to the combustion air inlet of a direct
vent appliance or to the separation of the circulating air inlet
and vent discharge of a listed outdoor appliance.
For non-direct vent installation, the vent system shall
terminate at least 4 feet (1.2 m) below, 4 feet (1.2 m)
horizontally from, or 12 inches (30 cm) above any door,
window, or gravity inlet into any building.The bottom of the
vent terminal shall be located at least 12 inches (30 cm)
above grade or maximum expected snow depth.
For direct vent installation of models with an input rating of
50,000 BTUH or less, the vent system shall terminate at least
9 inches (23 cm) from any opening through which flue gases
could enter a building. For direct vent installation of models
with an input greater than 50,000 BTUH, the vent system
shall terminate at least 12 inches (30 cm) from any opening
through which flue gases could enter a building.
Regardless of input, the vent terminal and air intake shall
terminate at least 12 inches (30 cm) above grade or maximum
expected snow depth.
The vent system, regardless of installation type, shall
terminate a minimum horizontal clearance of 4 ft from electric
meters, gas meters, regulators, and relief equipment.
9
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.
■ The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen” section), should be installed at
the termination of the flue pipe.
NOTE: Do not place an additional flue pipe screen in the
intake termination because the air intake may freeze shut.
■ For proper operation, the vent and air intake pipe must be
installed in the same pressure zone. Therefore, in horizontal
venting applications they must be on the same side of the
house within the parameters as shown.
NOTE: The 18 in. dimension shown below is the minimum
recommended height for extremely cold areas. In these
areas, moisture in the flue gases may condense and freeze on
the air intake if this height is reduced. In milder climates, this
may be reduced to a minimum of 6 in. Height may be
increased as needed provided total length of pipe to furnace
is not exceeded.
Direct Vent-Upflow (Horizontal Venting)
■
Run Ptich = 1/4"
Per Foot Min.
3
4
5
18"
Direct Vent - Upflow (Vertical Venting)
10 Ft.
Min.
6.5" Min. - 24" Max.
3
4
2 Ft.
Min.
1
5
Run Pitch = 1/4"
Per Foot Min.
6
2
6
6"
Height to Provide
12" Clearance to
Max. Snow Level.
THRU.
1
2
(CLOSED)
DRAIN
HOLE
59.69/56.64
7
Overhead View
7
3
5
6
3" Min. - 48" Max.
1. Air intake pipe
2. Condensate collar
3. Optional piece
10
4. Flue pipe screen (inside flue pipe)
5. Flue pipe
6. Air intake pipe
7. Wall
1. Flue pipe
2. Condensate collar
3. Flue pipe screen (inside flue pipe)
4. Storm collars
5. Flashing
6. Air intake pipe
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. Attach a 90° elbow
(not supplied) to the inlet coupler and install the inlet air
restrictor plate inside the elbow.
■
Non-Direct Vent Upflow - Vertical Venting
10 Ft.
Min.
2 Ft.
Min.
1
2
3
The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen” section), should be installed at
the termination of the flue pipe.
Non-Direct Vent Upflow - Horizontal Venting
Run Ptich = 1/4"
Per Foot Min.
1
4
Run Pitch = 1/4"
Per Foot Min.
6"
2
Height to Provide
12" Clearance to
Max. Snow Level.
4
5
6
5
59.69/56.64
THRU.
3
1. Flue pipe
2. Air intake pipe
3. Condensate collar
(CLOSED)
DRAIN
HOLE
7
4. Flue pipe screen (inside flue pipe)
5. Inlet air restrictor plate
(inside intake pipe or elbow)
1. Flue pipe screen
(inside flue pipe)
2. Storm collar
3. Flashing
4. Flue pipe
5. Inlet air restrictor plate
(inside intake pipe or elbow)
6. Air intake pipe
7. Condensate collar
11
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.
■ The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen” section), should be installed at
the termination of the flue pipe.
NOTE: Do not place an additional flue pipe screen in the
intake termination because the air intake may freeze shut.
■ For proper operation, the vent and air intake pipe must be
installed in the same pressure zone. Therefore, in horizontal
venting applications they must be on the same side of the
house within the parameters as shown.
NOTE: The 18 in. dimension shown in “Direct Vent
Counterflow - Horizontal Venting” is the minimum
recommended height for extremely cold areas. In these
areas, moisture in the flue gases may condense and freeze on
the air intake if this height is reduced. In milder climates, this
may be reduced to a minimum of 6 in. Height may be
increased as needed provided total length is not exceeded.
Direct Vent Counterflow - Horizontal Venting
■
Run Ptich = 1/4"
Per Foot Min.
Direct Vent Counterflow- Vertical Venting
1
10 Ft.
Min.
6.5" Min. - 24" Max.
5
2 Ft.
Min.
6
Run Pitch = 1/4"
Per Foot Min.
2
7
4
3
5
18"
6
4
THRU.
6"
1
59.69/56.64
Height to Provide
12" Clearance to
Max. Snow Level.
2
THRU.
3
59.69/56.64
1. Flue pipe screen
(inside flue pipe)
2. Flue pipe
3. PVC collars
4. Condensate collar
■
Overhead View
7
4
5
5. Storm collars
6. Flashing
7. Air intake pipe
The 45,000 and 67,000 BTU per hour models contain an inlet
air assembly that uses two 22.5° elbows that attach
separately from the straight inlet pipe, as shown. This allows
the inlet pipe assembly to be removed if needed for service.
Inlet Air Assembly- 45,000 & 67,000 BTU/HR Units
1
2
6
3" Min. - 48" Max.
1. PVC collars
2. Flue pipe
3. Condensate collar
4. Optional piece
12
5. Flue pipe screen
(inside flue pipe)
6. Air intake pipe
7. Wall
3
1. Straight inlet pipe
2. 22.5° Elbows
3. Burner box
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. Attach a 90° elbow (not
supplied) to the inlet coupler and install the inlet air restrictor
plate inside the elbow.
■
The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen” section), should be installed at
the termination of the flue pipe.
Non-Direct Vent Counterflow - Vertical Venting
10 Ft.
Min.
4
5
2 Ft.
Min.
6
Non-Direct Vent Counterflow - Horizontal Venting
Run Ptich = 1/4"
Per Foot Min.
5
1
Run Pitch = 1/4"
Per Foot Min.
1
6"
Height to Provide
12" Clearance to
Max. Snow Level.
2
7
8
6
3
2
59.69/56.64
THRU.
4
3
1. Inlet coupler
2. PVC collars
3. Flue pipe
4. Condensate collar
5. Flue pipe screen (inside flue pipe)
6. Inlet air restrictor plate
(inside intake pipe or elbow)
1. Flue pipe
2. PVC collars
3. Condensate collar
4. Flue pipe screen
(inside flue pipe)
■
5. Storm collar
6. Flashing
7. Inlet air restrictor plate
(inside intake pipe or elbow)
8. Air intake pipe
The 45,000 and 67,000 BTU per hour models contain an inlet
air assembly that uses two 22.5° elbows that attach
separately from the straight inlet pipe, as shown. This allows
the inlet pipe assembly to be removed if needed for service.
Inlet Air Assembly - 45,000 & 67,000 BTU/HR Units
1
2
3
1. Straight inlet pipe
2. 22.5° Elbows
3. Burner box
13
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.
Use high temperature RTV silicone sealant to attach the air
intake pipe into the connector on the burner box so the air
intake pipe can be removed if service is required.
NOTE: Do not use cement.
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,
ANSI Z223.1/NFPA 54 or the CSA B149.1, 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. 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, 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. Adjust 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, ANSI Z223.1/NFPA 54
and/or CSA B149.1, Natural Gas and Propane Installation
Codes.
9. After 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
appliance to their previous conditions of use.
14
Install Condensate Disposal
IMPORTANT: The condensate drain should be routed directly to
a locally acceptable disposal area. The condensate drain line
should not be run directly to the outdoors especially in colder
climates where temperatures may cause the condensate to
freeze in the drain line.
1. Connect the ¹⁄₂ in. NPT x ³⁄₄ in. PVC adapter (supplied) in the
drain on the side that the draining will occur.
NOTE: The condensate can be drained from either the right
or left side of the furnace.
2. Connect the plastic pipe plug opposite of the drain.
3. Connect ³⁄₄ in. PVC pipe, make a connection from the adapter
just installed to extend just outside the unit. Install a ³⁄₄ in.
PVC tee as shown.
4. From the tee, connect the drain to the disposal area.
NOTE: The top of the tee must be left open for proper
condensate drainage. The open end of the tee must be
oriented so that the condensate does not run out of this
opening.
Condensate Disposal
TH R U .
CARBON MONOXIDE POISONING HAZARD
2
3
59.69/56.64
WARNING:
3. For non-direct vent installations only, install the inlet air
restrictor plate in the air inlet pipe.
4. Attach the flue pipe connector to the furnace.
5. For both direct and non-direct vent installations, install the
flue pipe screen at the outside end of the flue pipe.
6. Make sure all vent connections do not leak.
7. Check that the exhaust vent pipe terminates outside the
building.
8. Prime the trap system by slowly pouring 1 cup of water down
the vent pipe. The vent pipe on horizontal runs must slope
upward, away from the furnace, at a minimum pitch of ¹⁄₄ in.
per foot of run, to prevent accumulation of condensate.
NOTE: On initial start-up of the unit, some of the water used
to prime the trap system may run down into the combustion
blower and cause noise.
1
1. ¹⁄₂ in. NPT plug
(supplied)
2. ³⁄₄ in.PVC
4
3. Tee (must remain open)
4. ¹⁄₂ in.NPT x ³⁄₄ in.PVC adapter
(supplied)
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. If the unit is installed in
a confined space or closet, a return connection must be run, full
size, to a location outside the closet. The air duct in the closet
must be tight to prevent any entrance of air from the closet into
the circulating air.
Installation with an Evaporator Coil
When an air conditioning unit is used in conjunction with the
furnace, the evaporator coil must be installed in the discharge
(supply) air. Do not install an evaporator coil in the return air;
excessive condensation will occur within the furnace.
Filters are not supplied with these furnaces; however, filters must
be used. It is the installer’s responsibility to install a filter rack with
the ductwork and to install properly sized filters in accordance
with the “Minimum Filter Requirements Chart.”
■ The Airflow Descriptor is the 2 digits immediately preceding
the hyphen (-) in the furnace model number. Example: 16 is
the Airflow Descriptor for furnace model WFAT075B16-1A.
The model number is located on the rating plate inside the
access panel.
■
Areas and dimensions shown for cleanable filters are based
on filters rated at 600 ft per minute face velocity.
■
Typical filter sizes are shown; however, any combination of
filers whose area equals or exceeds the minimum area shown
is satisfactory.
Minimum Filter Requirements Chart
Disposable Filters
Cleanable Filters
Airflow
Size
Qty. Min. Area
Size
Qty.
Descriptor Min. Area
(sq. in.)
(in.)
(sq. in.)
(in.)
Installation without an Evaporator Coil
If a cooling coil is not installed with the furnace, then a removable
access panel should be provided in the supply plenum for
purposes of inspecting the heat exchanger. This opening must be
accessible when the furnace is installed. It must be large enough
that the heat exchanger can be viewed for possible openings
using light assistance or so that a probe can be inserted for
sampling the airstream. The cover for the opening must be leak
tight.
Filter Specifications
Upflow Models
A filter rack and cleanable 16 in. x 25 in. x 1/2 in. filter are
supplied with model WGFDU only. Filter rack and filters are not
supplied with models WFCU, WFCC, or WGFDC. (Models
designed for more than 1600 CFM nominal air delivery include
two of each.)
Some model 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. AFILT524-1 (side return) or
kit no. AFILT529-1 (bottom return) can be used.
To provide sufficient filter area for installations requiring more
than 1600 CFM nominal air delivery, return air will have to be
brought through both sides of the furnace, or through one side
and the bottom, or an optional filter rack WAFILTHA7 may be
used.
09
480
20 x 25
1
240
16 x 20
1
10
480
20 x 25
1
240
16 x 20
1
12
576
16 x 20
2
288
16 x 20
1
14
672
20 x 20
2
336
20 x 20
1
16
768
20 x 20
2
384
20 x 20
1
20
960
20 x 25
2
480
20 x 25
1
If a central return air filter-grille is used, the furnace does not
require a filter.
To install a filter at the furnace only, use the following kits:
■ AFILT524 for side return on upflow installations.
■
AFILT529 for bottom return on upflow furnace installations.
■
WAFILTHA7 for single side return in installations requiring
more than 1600 CFM nominal air delivery.
15
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.
Make the low voltage thermostat connections to the blower
control board as indicated on the Wiring Connection Diagram.
Continuous Low Speed Blower
If continuous blower operation on low speed is desired, connect
the low speed motor tap to the CONT (constant) air terminal on
the blower control board. See the Wiring Connection Diagram.
The blower will operate on low speed whenever the main power
is connected to the furnace, except when it operates on heating
or cooling speed during thermostat call for heat or cooling.
NOTE: The constant air terminal is to be connected to the low
speed motor tap only. If a motor is wired for a higher speed, the
increased amp draw could cause the board control to fail and
void the warranty.
1. Disconnect power.
2. Remove the screw from the furnace electrical connection
box.
3. Remove the cover from the furnace electrical connection box.
4. Route the field supply wires to the furnace electrical
connection box.
WARNING
Electrical Shock Hazard
Electrically ground furnace.
Connect ground wire to green ground screw.
Failure to do so can result in death or electrical shock.
6. Connect ground wire to green ground screw.
1
2
1. Connect white to white and black to black
2. Green ground screw
7. Replace the furnace electrical connection box cover and
screw.
16
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. Connect the gas pipe to the furnace controls providing a
ground joint union as close to the controls as possible to
facilitate removal of controls and manifold.
Pipe-joint compounds suitable for use with natural and LP
gas must be used. Do not use Teflon® tape.
1
2
3
7. Remove the inlet pressure tap plug on the gas control valve
and connect pressure gauge to the ¹⁄₈ in. NPT inlet
pressure tap.
8. Turn on the gas supply at the manual gas shutoff valve.
9. Observe the inlet pressure.
The minimum inlet gas supply pressure is 5 in. W.C. for
natural gas and 11 in. W.C. for propane gas.
The maximum inlet gas supply pressure is 10.5 in. W.C. for
natural gas and 13 in. W.C. for propane gas.
10. Turn off the gas supply at the manual gas shutoff valve.
IMPORTANT: If the inlet gas supply pressure is not within the
minimum and maximum range as shown on the rating plate,
contact your gas supplier.
11. Disconnect the pressure gauge from the ¹⁄₈ in. NPT inlet
pressure tap.
12. Replace the inlet pressure tap plug on the gas control valve.
13. Turn on the gas supply at the manual gas shutoff valve.
14. Test all connections by brushing on an approved noncorrosive leak-detection solution. Bubbles will show a leak.
Correct any leak found.
■ At test pressures greater than ¹⁄₂ psig (3.5 kPa), the
furnace and the manual gas shutoff valve must be
disconnected from the gas supply piping system.
■
4
At test pressures less than or equal to ¹⁄₂ psig (3.5 kPa),
the furnace must be isolated from the gas supply piping
system by closing the manual gas shutoff valve.
15. Replace the burner access door.
5
6
7
Check the Furnace Input Rate
1. ¹⁄₈ in. NPT plugged tapping
2. Manual gas shutoff valve
3. Ground joint union
4. Tee
5. Sediment trap
6. Cap
7. Gas control valve
(inside furnace)
(if required)
IMPORTANT:
■ The furnace input rate must not exceed the input rating on
the furnace rating plate.
■
At altitudes from 2,000 to 7,500 ft the furnace input rate must
not exceed that on the rating plate multiplied by the Input
Factor in the Manifold Pressure vs. Altitude chart.
■
This furnace is equipped for rated input at manifold pressures
of 3.5 in. W.C. for natural gas and 10.0 in. W.C. for propane
gas.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result
in serious injury, death or property damage.
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. A fire
or explosion may result causing property damage,
personal injury or loss of life.
6. Turn off the gas supply at the manual gas shutoff valve.
1. For natural gas, check the furnace rate by observing the gas
meter, making sure all other gas appliances are turned off.
The test hand on the meter should be timed for at least one
revolution.
BTU/HR = Cubic feet per Revolution x 3600 x Heating
INPUT
Value
# Seconds per Revolution
2. The actual heating value of your gas can be obtained from
your local utility company.
1. Closed valve
2. Open valve
®Teflon is a registered trademark of E.I. Dupont de Nemours and
Company.
17
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. If necessary, remove the regulator
adjusting cap on the gas valve and turn the regulator
adjusting screw clockwise to increase pressure and input, or
counterclockwise to decrease pressure and input.
IMPORTANT: If the manifold pressure cannot be adjusted to
the correct value, contact your gas supplier.
10. Move the gas control switch to the OFF position.
11. Disconnect the pressure gauge from the ¹⁄₈ in. NPT outlet
pressure tap.
12. Replace outlet pressure tap plug and the regulator adjusting
cap on the gas valve.
13. Move the gas control switch to the ON position.
14. Replace the burner access door.
15. Set the room thermostat to the desired temperature
necessary to achieve optimum temperature rise.
Manifold Pressure vs. Altitude Chart
2
1
C1
1/2" NPT Inlet
OFF
ON
4
1/2" NPT Outlet
Natural Gas
Altitude (ft)
Heating Value
(BTU/ft3)
Manifold
Pressure
(in. W.C.)
Input
Factor
1. ¹⁄₈ ” NPT Inlet pressure tap
2. Regulator adjusting cap
3. Diagnostic LED
4. ¹⁄₈ ” NPT Outlet pressure tap
5. Gas control switch
2000
948
3.50
0.9666
3000
914
3.50
0.9499
4000
881
3.50
0.9332
4. Be sure the gas control switch has been in the OFF position
for at least 5 minutes before starting the unit.
5. Move the gas control switch to the ON position.
NOTE: This furnace is equipped with an ignition device which
automatically lights the burner. This furnace cannot be lighted
manually. Do not try to light the burner by hand.
4500
865
3.50
0.9249
5000
849
3.29
0.8900
5500
833
3.27
0.8790
6000
818
3.25
0.8680
6500
802
3.23
0.8570
7000
787
3.21
0.8460
7500
771
3.19
0.8350
5
6. Turn on the electrical power to the furnace.
7. Set the room thermostat to a point above room temperature
to light the main burners.
8. Observe the pressure reading on the pressure gauge.
For Altitudes 7,500 to 10,000 feet above sea level.
Do not adjust manifold pressure. An orifice change is required.
For the correct orifice size, see Table F.4 in Appendix F of the
National Fuel Gas Code (ANSI Z223.1/NFPA 54, latest edition).
18
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.
WARNING
Electrical Shock Hazard
Measure Temperature Rise
Disconnect power before servicing.
1. After 20 minutes of heating operation, measure the furnace
temperature rise. Take air temperature readings in both the
return air ducts and the heated air ducts (about 6 ft from the
furnace where they will not be affected by radiant heat) as
shown.
NOTE: If more than one run of return or heated air ducts is
used, air temperature measurements should be taken in each
duct. These measurements can be converted to an average
to obtain the temperature rise of the whole system.
Warm Air
2
1
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
NOTE: See the Wiring Connection Diagram while performing the
following procedure.
1. Disconnect power.
2. For heating speed, check the temperature rise and make the
necessary adjustments to the blower speed tap. See Wiring
Diagram.
3. Reconnect power.
4. Recheck the temperature rise. Repeat the procedure as
necessary to achieve optimum temperature rise.
5. If the furnace does not begin to heat the room, see the
“Troubleshooting” section.
Shut Down the Furnace
Return Air
1. Measure return air here.
2. Measure supply temperature here.
1.
2.
3.
4.
Set the room thermostat to the lowest setting.
Disconnect power.
Remove burner access door.
Shut off the gas by moving the gas control switch to the OFF
position.
5. Replace the burner access door.
2. If furnace doesn't maintain temperature rise within the range
shown on the furnace rating plate, adjust the blower speed.
19
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. After an
igniter warm-up period, the main gas valve energizes. Upon main
burner ignition, the circulating air blower energizes following a
30-second delay.
When the call for heat is satisfied, R to W opens and the gas to
the burners shuts off. The control turns off the inducer after a 5second post-purge delay and the heating speed blower output
turns off following the blower “off” delay.
Fan On
Auxiliary Limit Control (on some models)
This is a normally closed control, located on the circulating air
blower housing, that opens under abnormal “reverse air flow”
conditions that could occur in a counterflow or horizontal
installation if the circulating air blower fails. It is an automatic
reset control.
Safety Interlock Switch
When the blower door is removed, the safety interlock switch
breaks the power supply to the burner controls and blower motor.
Blower Control Board
A call for fan from the thermostat closes R to G on the control
board. The control waits for a 1-second thermostat debounce
delay before responding by energizing the heat speed blower.
When the call for fan is turned off, the control de-energizes the
heating speed blower after a 60-second delay.
WARNING
Cooling
A call for cooling from the thermostat closes R to Y and R to G on
the blower control board. The control waits for a 1-second
thermostat debounce delay before energizing the cool speed
blower. When the call for cooling is satisfied, the control
de-energizes the cooling speed blower after a 60-second delay.
Controls
Pressure Switch
The pressure switch is a normally open switch that monitors
combustion airflow. Inadequate airflow resulting from excessive
venting system restriction or a failed combustion blower will
cause the switch to remain open.
Rollout Switch(es)
The rollout switch(es) are normally closed switch(es) that open
when abnormal temperatures exist in the burner area. This can
be caused by a restricted heat exchanger causing main burner
flame to “roll out” into the vestibule area or burner box.
The rollout switch(es) must be manually reset by pushing the
button on top to restore furnace operation.
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.
The blower control board operates the circulating air blower, the
combustion blower and any accessories connected to it.
WGFDC and WGFDU models
Feature user-selectable blower “off” delay times (60, 90, 120, and
150 seconds) that are factory set to provide a 120-second blower
“off” delay on heating.
WFCU and WFCC models
Feature a fixed blower “off” delay of 90 seconds which is onetime adjustable to 150 seconds. See the “Wiring Connection”
diagram.
In the event the limit control senses an abnormally high
temperature and opens, the ignition control de-energizes, and the
combustion blower and circulating air blower heating speed
continue to energize.
Gas Control Valve
The gas control valve contains control logic to sense proper
operating conditions and provides gas flow and ignition only
when all conditions are properly met. The gas control valve also
regulates the manifold gas pressure.
20
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 closed when it should be
open
Failure Codes
The system has a built-in, self-diagnostic capability. The control
continuously monitors its own operation and the operation of the
system. If a system problem occurs, a failure code is indicated by
the LED on the gas control valve. See the Failure Codes chart for
a description of the flash codes.
IMPORTANT: Do not remove the blower compartment door or
turn off the power to the furnace because either action will clear
the control’s memory of the failure.
1. Start the system by setting the thermostat above the room
temperature.
2. Observe the system’s response.
3. Use the information provided in this section to check the
system’s operation.
3 Flashes
Pressure switch stuck open 30 seconds or
longer after call for heat (system in 5-minute
delay mode before next call for heat). On/off
switch in OFF position during a call for heat
will generate this code.
4 Flashes
Open Limit Switch or Limit Switch Circuit
5 Flashes
Flame Sense Signal sensed out of proper
sequence
*6 Flashes
pause
1 Flash
Soft Lockout Type 1
Failure to light within 4 trials for ignition
(See Note 1)
*6 Flashes
pause
2 Flashes
Soft Lockout Type 2
Flame sense lost during run
(See Notes 1 & 2)
*6 Flashes
pause
3 Flashes
Soft Lockout Type 3
Pressure switch opened during run
(See Notes 1 & 2)
*6 Flashes
pause
4 Flashes
Soft Lockout Type 4
Limit or limit circuit opened during run
(See Notes 1 & 2)
*6 Flashes
pause
5 Flashes
Soft Lockout Type 5
Flame has gone away after Error Code 5
(See Note 1)
*6 Flashes
pause
7 Flashes
Soft Lockout Type 7
Self-check failure
(See Note 1)
*10 Flashes
Line Input Voltage Polarity Reversed
*On some models
Note 1: The 6 + X designation indicates a combination of flash
codes. Six flashes shows the control is in soft lock-out,
followed by X flashes to indicate the reason the control went
into soft lockout. When the 6 + X code is flashed, the control
will attempt a new ignition sequence after 1 hour (if the call for
heat is still present). Reset of the thermostat will initiate a new
ignition sequence immediately.
Note 2: Any combination of 5 “abnormal events” during a
single call for heat will result in a soft lockout. An abnormal
event is an occurrence of any of the following: flame sense
failure during run, airflow proving circuit open during run, or
limit circuit open during run. The flash code will indicate which
was the last abnormal event that put the system into the soft
lockout state (see above).
21
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
YEL
BLK
WHT
FLAME
SENSOR
GRY
INTERLOCK
SWITCH
WHT
BLK
WHT
2
6
3
ORG
BLU
2
TWIN
BLOWER
CONTROL
R
C W Y
*
WHT (NEUT)
RED (LO)
ORN (MED/LO)
BLU (MED)
YEL (MED/HI)
BLK (HIGH)
CIRCULATION
BLOWER
*
NOT USED ON ALL MODELS
HUM
1
24VAC COM
BLU
or
YEL
5
RED
TRANSFORMER
YEL
1
M1 M2
WHT
4
HEAT
BLK
HUM
SEE NOTE 2
WHT
EAC
CONT COOL
NEUTRAL
G
EAC
SEE NOTE 2
CONDENSER
SEE NOTE 2
SEE NOTE 3
JUMPER
1 2
60 SEC
FIG. 1
1 2
1 2
90 SEC
120 SEC
2 1
150 SEC
THERMOSTAT & SUB-BASE
HEAT ANTICIPATOR
.75 AMP
DELAY OFF SWITCH SETTINGS
HONEYWELL
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.
Check codes for proper wiring and circuit protection before
installation.
22
NOTES:
1. 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 90°C.
2. Not used on all models
3. For a fixed blower off delay of 90 seconds see “Blower
Control Board” section. Jumper can be cut for a 150 second
off delay.
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
LIMIT
CONDENSER
HIGH
LIMIT
12345678
1234
C1
C3
C2
SMARTVALVE II
IGNITION CONTROL
1
2
3
4
FLAME
SENSOR
(24 VAC)
23
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.
ALPKT572-2
Natural Gas to Propane Conversion Kit
ALPKT574-2
Natural Gas to Propane Conversion Kit
WAFILTHA7-2
Filter Frame Kit
AFILT524-1
Side Return Filter Kit
AFILT529-1
Bottom Return Filter Kit
WABASE512
Combustible Floor Base (17.5" cabinets)
WABASE568
Combustible Floor Base (21.0" cabinets)
WABASE569
Combustible Floor Base (24.5" cabinets)
46948D003
© 2003. All rights reserved.
Honeywell and SmartValve are trademarks of Honeywell International, Inc.
®/TM Whirlpool and all other trademarks are owned by Whirlpool, U.S.A.,
used under license by Tradewinds Distributing Company, LLC.
4/03
Printed in U.S.A.