95% 2-STAGE VARIABLE SPEED GAS FURNACE INSTALLATION INSTRUCTIONS Table of Contents

95% 2-STAGE VARIABLE SPEED GAS FURNACE INSTALLATION INSTRUCTIONS Table of Contents
95% 2-STAGE VARIABLE SPEED GAS FURNACE
INSTALLATION INSTRUCTIONS
Table of Contents
GAS FURNACE SAFETY................................................................1
INSTALLATION REQUIREMENTS ................................................3
Tools and Parts ............................................................................3
Location Requirements ................................................................3
Installation Configurations ...........................................................4
Ductwork Requirements ..............................................................5
Electrical Requirements ...............................................................5
Gas Supply Requirements ...........................................................5
Venting Requirements..................................................................5
INSTALLATION INSTRUCTIONS ..................................................7
Inspect Shipment .........................................................................7
Plan Vent System .........................................................................8
Determine Vent Pipe Direction...................................................10
Connect Venting.........................................................................18
Install Condensate Disposal.......................................................19
Connection to Pressure Switch .................................................22
Install Ductwork..........................................................................23
Filter Specifications ....................................................................23
Make Electrical Connections .....................................................24
Make Gas Connections..............................................................24
Check the Furnace Input Rate ...................................................25
Adjust the Furnace Input Rate ...................................................25
Complete Installation..................................................................26
Shut Down the Furnace .............................................................27
Sequence of Operation ..............................................................28
Controls ......................................................................................28
TROUBLESHOOTING ..................................................................29
ASSISTANCE OR SERVICE .........................................................32
Accessories ................................................................................32
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:
DANGER
WARNING
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.
Whirlpool Gold™ Models
WGFEU, WGFEC, WGFET
47905K005
Whirlpool® Home Cooling and Heating
14610 Breakers Drive
Jacksonville, Florida 32258
IMPORTANT SAFETY 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.
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.
■
■
■
■
■
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.
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.
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:
■
■
■
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.
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 is design certified by CSA 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.
Location Requirements
WARNING
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.
WARNING
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
■
Noncorrosive leak check solution
■
Screwdriver
■
■
Tape measure
Test gauge with ¹⁄₈" NPT connection
(for measuring gas supply pressure)
■
Thread sealant
■
Allen wrench
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.
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 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.
■
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.
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 Configurations
WGFEU models must be installed only as upflow furnaces.
WGFEC 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
Installation Clearances
■
A 2" 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" 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.
WARNING
Fire Hazard
Minimum Clearance to Combustibles Chart
Before installing counterflow (downflow) furnace on
combustible surface, such as wood, install one of the
following kits:
Upflow
Horizontal
Unit Sides
0"
0"
Rear of Unit
0"
0"
Front of Unit
2"
18"
WABASE 511 (14.5" cabinets)
WABASE 512 (17.5" cabinets)
WABASE 568 (21" cabinets)
WABASE 569 (24.5" cabinets)
Flue Pipe
0"
0"
Contact your local dealer.
Plenum Top (upflow)
1"
1"
Failure to do so can result in death or fire.
Supply Duct (counterflow)
1"
1"
High Altitude Installations
IMPORTANT:
■ The furnace may be installed directly on the supply plenum or
coil cabinet if the furnace is installed on a noncombustible
floor.
■
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. Altitude Chart.
1. Cut, size and frame opening in floor to fit the combustible
floor base and provide a minimum 1" clearance between the
supply duct and combustible materials. The 4 legs on the
base assembly should recess into the floor and the base
should rest on all 4 outside flanges.
2. Construct duct connections with 1" to 1³⁄₄" 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. Position the furnace over the right angle duct flanges.
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 ft 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.
Combustible Floor Installation (Counterflow Models only)
Electrical Requirements
WARNING
A
B
C
D
E
1" min.
Electrical Shock Hazard
F
Electrically ground furnace.
Connect ground wire to green ground screw.
Failure to do so can result in death or electrical shock.
F
■
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).
■
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. 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 be sure that safety controls
provide the protection intended.
B
D
A. Furnace
B. Woven glass tape (between
flanges of outlet duct and
base assembly)
C. Base assembly
D. Combustible flooring
E. Leg
F. Supply plenum or coil cabinet
(not provided—accessory)
Gas Supply Requirements
Ductwork 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.
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 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
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/NFPA 54 (latest edition), or applicable provisions
of the local building codes.
5
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 the spilling of flue products into the living space, the
formation of condensate, leakage, etc. See the “Carbon
Monoxide Poisoning Hazard” for proper test procedure.
Venting Options
The furnace can be installed as either direct vent or nondirect
vent units.
For either type of installation, special venting considerations
must be followed. See “Determine Vent Pipe Direction” for the
type of furnace and venting being installed.
Direct Vent
WARNING:
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.
CARBON MONOXIDE POISONING HAZARD
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.
A 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. 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 (nondirect
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
nondirect vent systems.
Flue Pipe Screen
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.
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.
6. Follow the lighting instructions. Place the appliance being
inspected into operation. Adjust the thermostat so
appliance is operating continuously.
Flue Pipe Screen
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
appliances to their previous conditions of use.
6
Nondirect Vent
The flue pipe screen
should be installed at the
termination of the flue pipe
in all installations.
Unconfined Space
An unconfined space is defined as “a space whose volume is
more than 50 cu. ft per 1,000 Btu/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.
Confined Space
A confined space is defined as “a space whose volume is less
than 50 cu. ft per 1,000 Btu/h of the combined input rating of all
appliances installed in that space.” Use direct vent method. See
“Plan Vent System.”
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.
■
Contaminated Combustion Air
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
If indoor combustion air is used, the air supply to the furnace
should not be exposed to the following substances:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine-based swimming pool chemicals
Water softening chemicals
Deicing salts or chemicals
Carbon tetrachloride
Halogen-type refrigerants
Cleaning solvents (such as perchloroethylene)
■
Furnaces installed in buildings with indoor pools
Printing inks, paint removers, varnishes, etc.
■
Furnaces installed in hobby or craft rooms
Cements and glues
■
Furnaces installed near chemical storage areas
Antistatic fabric softeners for clothes dryers
■
Furnaces installed in laundry rooms
Masonry acid washing materials
■
Furnaces installed in hair salons
Chlorinated laundry products
Hydrochloric acid
INSTALLATION INSTRUCTIONS
WARNING
Inspect Shipment
WARNING
Excessive Weight Hazard
Use two or more people to move and install furnace.
Explosion Hazard
Furnace must be installed and serviced by a
qualified person.
Examples of a qualified person include:
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.
Failure to do so can result in back or other injury.
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.
■
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.
NOTE: If any damages are discovered and reported to the
carrier, do not install the unit as your claim may be denied.
7
Plan Vent System
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.
■
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.
Materials
■
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 chart for
approved piping and fitting materials.
8
Vent Pipe Size and Length
Piping and Fitting Material
ASTM Specification
The vent pipe and air intake pipe (in direct vent installations)
should be sized in accordance with the information found in the
Vent Table charts. 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.
Schedule 40 PVC (Pipe)
D1785
Vent Table—40,000 - 80,000 Btu/h Models
Schedule 40 PVC (Cellular Core Pipe)
F891
Piping and Fitting Specifications
■
NOTE: Do not use cement.
Number of 90º Elbows
Schedule 40 PVC (Fittings)
D2466
Vent Pipe
Length (ft)
SDR-26 (Pipe)
D2241
5
1.5 1.5 2
2
2
2
2
2
2
2
Schedule 40 ABS (Pipe)
D1527
10
1.5 2
2
2
2
2
2
2
2
2
Schedule 40 ABS (Fittings)
D2468
20
2
2
2
2
2
2
2
2
2
2.5
Schedule 40 & 80 CPVC (Pipe)
F441
30
2
2
2
2
2
2
2
2.5 2.5 2.5
ABS-DWV Drain Waste & Vent
(Pipe & Fittings)
D2661
40
2
2
2
2
2
2.5 2.5 2.5 2.5 2.5
50
2
2
2.5 2.5 2.5 2.5 2.5 2.5 2.5 3
PVC-DWV Drain Waste & Vent
(Pipe & Fittings)
D2665
60
2
2.5 2.5 2.5 2.5 2.5 2.5 3
70
2.5 2.5 2.5 2.5 2.5 3
3
80
2.5 2.5 2.5 3
3
3
90
2.5 2.5 3
3
3
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.
0
1
2
3
4
5
6
7
8
9
NR = Not Recommended
3
3
3
3
3
NR
3
3
NR NR
3
NR NR NR
Vent Table—90,000 - 100,000 Btu/h Models
Vent Table—112,000 - 125,000 Btu/h Models
Vent Pipe
Length (ft)
Minimum Pipe Diameter (in.)
Vent Pipe
Length (ft)
Minimum Pipe Diameter (in.)
5
NR 2
2
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
10
2
2
2
2
2
2
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 3
20
2
2
2
2
2
2.5 2.5 2.5 2.5 3
20
2.5 2.5 2.5 2.5 2.5 2.5 2.5 3
30
2
2
2
2.5 2.5 2.5 2.5 3
40
2
2
2.5 2.5 2.5 3
50
2.5 2.5 2.5 3
3
60
2.5 3
3
3
70
3
3
3
3
80
3
3
3
NR NR NR NR NR NR NR
90
3
3
NR NR NR NR NR NR NR NR
Number of 90°
Elbows
0
1
2
2.5 2.5 2.5
3
3
30
2.5 2.5 2.5 2.5 2.5 3
3
3
NR
NR NR NR
3
3
3
3
40
2.5 2.5 2.5 2.5 3
NR NR NR NR NR
3
3
3
3
NR
50
2.5 3
3
3
3
3
NR NR NR
60
3
3
NR NR NR NR NR NR NR NR
3
NR NR NR NR NR
Number of 90°
Elbows
0
1
2
NR NR NR NR NR NR NR
3
4
5
6
7
8
9
NR = Not Recommended
NR = Not Recommended
3
4
5
6
7
8
9
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 “Plan Vent System” for the
unit model and type of installation.
9
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.
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.
Combustion Air Sources
Horizontal Venting
There are 2 sources for combustion air:
1. From outside the building (direct vent)
2. From inside the building (nondirect vent)
Please read the information provided here about vertical and
horizontal venting, then find and follow the instructions for your
venting configuration.
The vent terminal location shall comply with the National Fuel
Gas Code (ANSI Z223.1) or local requirements. For informational
purposes, the side wall terminal vent clearances are shown in the
Sidewall Vent Terminal Clearances tables.
Sidewall Vent Terminal Clearances—Direct Vented Furnaces (Horizontal Venting)
V Vent Terminal
X Air Supply Inlet
Area Where Terminal Is
Not Permitted
A
B
Clearance above grade, veranda, porch, deck, or balcony
Clearance to window or door that may be opened
C
D
Clearance to permanently closed window
Vertical clearance to ventilated soffit located above the
terminal within a horizontal distance of 2 ft from the center
line of the terminal
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
Clearance to each side of center line extended above
meter/regulator assembly
Clearance to service regulator vent outlet
Clearance to nonmechanical air supply inlet to building or
the combustion air inlet to any other appliance
E
F
G
H
I
J
K
L
U.S. Installations1
12"
6" for appliances less than 10,000 Btu/h, 9" for appliances
greater than 10,000 Btu/h, and less than or equal to
50,000 Btu/h, 12" for appliances greater than 50,000 Btu/h
*
*
*
*
*
*
*
6" for appliances less than or equal to 10,000 Btu/h, 9" for
appliances greater than 10,000 Btu/h, and less than or equal to
50,000 Btu/h, 12" for appliances greater than 50,000 Btu/h
3 ft above if within 10 ft horizontally
*
Clearance to a mechanical air supply inlet
Clearance above paved sidewalk or paved driveway
located on public property
M
Clearance under veranda, porch, deck, or balcony
*
1
In accordance with the current ANSI Z2223.1/NFPA 54, National Fuel Gas Code.
*Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's installation
instructions.
10
Sidewall Vent Terminal Clearances—Nondirect Vented Furnaces (Horizontal Venting)
V Vent Terminal
X Air Supply Inlet
Area Where Terminal Is
Not Permitted
A
B
C
D
U.S. Installations1
12"
4 ft below or to side of opening; 12" above opening
*
*
Clearance above grade, veranda, porch, deck, or balcony
Clearance to window or door that may be opened
Clearance to permanently closed window
Vertical clearance to ventilated soffit located above the terminal within a
horizontal distance of 2 ft from the center line of the terminal
E
Clearance to unventilated soffit
*
F
Clearance to outside corner
*
G
Clearance to inside corner
*
H
Clearance to each side of center line extended above meter/regulator
*
assembly
I
Clearance to service regulator vent outlet
*
J
Clearance to nonmechanical air supply inlet to building or the
4 ft below or to side of opening; 12" above opening
combustion air inlet to any other appliance
K
Clearance to a mechanical air supply inlet
3 ft above if within 10 ft horizontally
L
Clearance above paved sidewalk or paved driveway located on public
7 ft
property
M
Clearance under veranda, porch, deck, or balcony
*
1
In accordance with the current ANSI Z2223.1/NFPA 54, National Fuel Gas Code.
*Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's installation
instructions.
11
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”) supplied with this furnace is to be used only
in nondirect vent applications.
■
The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen”), should be installed at the
termination of the flue pipe.
■
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" 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". Height may be
increased as needed provided total length of pipe to furnace
is not exceeded.
NOTE: Do not place an additional flue pipe screen in the
intake termination because the air intake may freeze shut.
Direct Vent—Upflow (Horizontal Venting)
Run Pitch =
¹⁄₄" Per Ft
Minimum
Direct Vent—Upflow (Vertical Venting)
C
D
E
18"
6.5" Min. - 24" Max.
C
D
Height to Provide 6" Minimum to Roof.
Adjust Height to Expected Snow
Level Based on Local Conditions.
E
F
6"
Height to Provide 12"
Clearance to Expected
Snow Level Based on
Local Conditions.
THRU.
A
B
(CLOSED)
DRAIN
HOLE
59.69/56.64
G
A
Run Pitch =
¹⁄₄" Per Ft
Minimum
F
Overhead View
G
E
C
B
F
3" Min. - 48" Max.
A. Air intake pipe
B. Condensate collar
C. Optional piece
12
D. Flue pipe screen (inside flue pipe)
E. Flue pipe
F. Air intake pipe
G. Wall
A. Flue pipe
B. Condensate collar
C. Flue pipe screen (inside flue pipe)
D. Storm collars
E. Flashing
F. Air intake pipe
Nondirect 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 nondirect vent installations.
■
Nondirect Vent—Upflow (Horizontal Venting)
See “Inlet Air Restrictor Plate.” 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”), should be installed at the
termination of the flue pipe.
Nondirect Vent—Upflow (Vertical Venting)
Run Pitch =
¹⁄₄" Per Ft
Minimum
A
A
D
Height to Provide 6" Minimum to Roof.
Adjust Height to Expected Snow
Level Based on Local Conditions.
C
6"
Height to Provide 12"
Clearance to Expected
Snow Level Based on
Local Conditions.
B
B
E
DRAIN
(CLOSED)
HOLE
59.69/56.64
THRU.
C
A. Flue pipe
B. Air intake pipe
C. Condensate collar
Run Pitch =
¹⁄₄" Per Ft
Minimum
D. Flue pipe screen (inside flue pipe)
E. Inlet air restrictor plate
(inside intake pipe or elbow)
D
E
F
G
A. Flue pipe screen
(inside flue pipe)
B. Storm collar
C. Flashing
D. Flue pipe
E. Inlet air restrictor plate
(inside intake pipe or elbow)
F. Air intake pipe
G. Condensate collar
13
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.
■
Direct Vent—Counterflow (Vertical Venting)
A
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”) supplied with this furnace is to be used only
in nondirect vent applications.
■
The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen”), should be installed at the
termination of the flue pipe.
6.5" Min. - 24" Max.
F
G
Height to Provide 6" Minimum to Roof.
Adjust Height to Expected Snow
Level Based on Local Conditions.
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.
■
E
B
H
NOTE: The 18" 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". Height may be
increased as needed provided total length is not exceeded.
C
59.69/56.64
THRU.
D
Direct Vent—Counterflow (Horizontal Venting)
Run Pitch =
¹⁄₄" Per Ft
Minimum
D
E
A. Flue pipe screen (inside flue pipe)
B. Flue pipe
C. PVC collars
D. Condensate collar
18"
F
6"
A
Height to Provide 12"
Clearance to Expected
Snow Level Based on
Local Conditions.
Some 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.
THRU.
B
C
■
E. Run pitch = ¹⁄₄" per ft min.
F. Storm collars
G. Flashing
H. Air intake pipe
59.69/56.64
Inlet Air Assembly (on some models)
A
B
Overhead
View
G
D
E
A. Straight inlet pipe
B. 22.5° elbows
F
3" Min. - 48" Max.
A. PVC collars
B. Flue pipe
C. Condensate collar
14
C
D. Optional piece
E. Flue pipe screen
(inside flue pipe)
F. Air intake pipe
G. Wall
C. Burner box
NOTE: The vent for this appliance shall not terminate over public
walkways, or near soffit vents or crawl space vents or other areas
where condensate or vapor could create a nuisance or hazard or
cause property damage, or where condensate vapor could cause
damage or could be detrimental to the operation of regulators,
relief valves, or other equipment.
Nondirect 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 nondirect vent installations. See “Inlet
Air Restrictor Plate.” 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”), should be installed at the
termination of the flue pipe.
Nondirect Vent—Counterflow (Vertical Venting)
E
F
Height to Provide 6" Minimum to Roof.
Adjust Height to Expected Snow
Level Based on Local Conditions.
G
Nondirect Vent—Counterflow (Horizontal Venting)
Run Pitch =
¹⁄₄" Per Ft
Minimum
A
D
E
A
H
I
6"
Height to Provide 12"
Clearance to Expected
Snow Level Based on
Local Conditions.
B
B
C
F
C
59.69/56.64
THRU.
D
A. Inlet coupler
B. PVC collars
C. Flue pipe
D. Condensate collar
E. Flue pipe screen (inside flue pipe)
F. Inlet air restrictor plate
(inside intake pipe or elbow)
A. Flue pipe
B. PVC collars
C. Condensate collar
D. Run pitch = ¹⁄₄" per ft min.
E. Flue pipe screen (inside flue pipe)
■
F. Storm collar
G. Flashing
H. Inlet air restrictor plate
(inside intake pipe or elbow)
I. Air intake pipe
Some 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 (on some models)
A
B
C
A. Straight inlet pipe
B. 22.5° elbows
C. Burner box
15
Direct Vent Installation—Horizontal Installations
■
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 nondirect 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.
■
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" 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". Height may be
increased as needed provided total length of pipe to furnace
is not exceeded.
NOTE: Do not place an additional flue pipe screen in the
intake termination because the air intake may freeze shut.
Direct Vent—Horizontal (Horizontal Venting—Horizontal
Right to Left)
Direct Vent—Horizontal (Horizontal Venting—Horizontal
Left to Right Alternate Venting for Low Clearance
Installations)
A
B
C
18"
6"
D
A B
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
Direct Vent—Horizontal (Horizontal Venting—Horizontal
Left to Right)
A
B
18"
6"
C
A. 3" long piece of 2" diameter pipe
B. Drain tee (in kit)
C. Height to provide 12" minimum clearance. Adjust height
to expected snow level based on local conditions.
16
A. 3" long piece of 2" diameter pipe
B. 2 each of 2" 90º street elbows
C. Drain tee (in kit)
D. Height to provide 12" minimum clearance. Adjust height
to expected snow level based on local conditions.
Direct Vent—Horizontal (Vertical Venting—Horizontal Right
to Left)
Direct Vent—Horizontal (Vertical Venting—Horizontal Left
to Right)
6.5" Min. - 24" Max.
6.5" Min. - 24" Max.
C
C
B
A
A
B
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
C. Height to provide 6" minimum to roof. Adjust height to
expected snow level based on local conditions.
A. Height to provide 6" minimum to roof. Adjust height to
expected snow level based on local conditions.
B. Drain tee (in kit)
C. 3" long piece of 2" diameter pipe
Nondirect Vent Installation—Horizontal Installations
■
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 nondirect vent installations.
Nondirect Vent—Horizontal (Horizontal Venting—
Horizontal Right to Left)
See the “Inlet Air Restrictor Plate” section. Install the inlet air
restrictor plate inside the inlet coupler. Attach a 90° elbow
(not supplied) to the inlet coupler.
■
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.
Nondirect Vent—Horizontal (Horizontal Venting—
Horizontal Left to Right)
A
B
6"
C
C
A
B
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
C. Inlet air restrictor plate (inside inlet coupler)
A. 3" long piece of 2" diameter pipe
B. Drain tee (in kit)
C. Inlet air restrictor plate (inside inlet coupler)
17
Nondirect Vent—Horizontal (Vertical Venting—Horizontal
Right to Left)
Nondirect Vent—Horizontal (Vertical Venting—Horizontal
Left to Right)
A
C
B
C
D
A
B
A. Height to provide 6" minimum to roof. Adjust height
to expected snow level based on local conditions.
B. 3" long piece of 2" diameter pipe
C. Drain tee (in kit)
D. Inlet air restrictor plate (inside inlet coupler)
D
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
C. Height to provide 6" minimum to roof. Adjust height
to expected snow level based on local conditions.
D. Inlet air restrictor plate (inside inlet coupler)
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.
3. For nondirect vent installations only, install the inlet air
restrictor plate in the air inlet pipe. See Nondirect vents in
“Venting Options” for details.
4. Install tee assembly for condensate drain as shown
(horizontal applications only).
5. Attach the flue pipe connector to the furnace.
18
6. For both direct and nondirect vent installations, install the flue
pipe screen at the outside end of the flue pipe.
7. Make sure all vent connections do not leak.
8. Check that the exhaust vent pipe terminates outside the
building.
9. After the condensate disposal system has been installed,
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" 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.
Horizontal Right to Left
Horizontal Left to Right
A
B
C
D
D
A
B
C
A. 2" x 2" x ¹⁄₂" ppt supplied in kit
B. To vent pipe
C. 3" nipple supplied in kit
D. Flue pipe
A. 2" x 2" x ¹⁄₂" ppt supplied in kit
B. To vent pipe
C. 3" nipple supplied in kit
D. Flue pipe
Install Condensate Disposal
Upflow Installation
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
THRU.
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" NPT x ³⁄₄" 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.
B
C
59.69/56.64
2. Connect the plastic pipe plug opposite of the drain.
3. Connect ³⁄₄" PVC pipe, make a connection from the adapter
just installed to extend just outside the unit. Install a ³⁄₄" PVC
tee as shown.
A
A. ¹⁄₂" NPT plug (supplied)
B. ³⁄₄" PVC
D
C. Tee (must remain open)
D. ¹⁄₂" NPT x ³⁄₄" PVC adapter (supplied)
Horizontal Installation—Left to Right Airflow
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.
■
Furnace must be mounted such that the side through which
the condensate will drain is elevated a minimum of 9" above a
surface such as a floor.
19
Install furnace at a slight pitch forward with shims or adjusting
screws.
■
3. Insert trap assembly supplied in kit into flue pan.
A
¹/₄" Max
B
1. Relocate ¹⁄₂" NPT plug from the flue pan to the internal trap
assembly.
2. Connect the ¹⁄₂" NPT plug (supplied in kit) to the opposite side
of the internal trap assembly from the NPT plug installed in
Step 1.
A. Flue pan
B. Condensate drain and trap assembly with ³⁄₄" PVC pipe outlet
4. Connect a length of ³⁄₄" PVC pipe (3 ft minimum) to the trap
assembly.
5. Install a ³⁄₄" PVC tee as shown.
A
B
C
A. ¹⁄₂" NPT plug (supplied in kit)
B. Internal trap assembly on flue pan
C. ¹⁄₂" NPT plug
C
A
B
A. ³⁄₄" tee
B. 72" piece of ³⁄₈" vinyl hose
C. ³⁄₄" PVC pipe
6. From the ³⁄₄" 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.
7. Connect one end of vinyl hose (supplied in kit) to the ³⁄₈"
barbed fittings of the 2" x 2" x ¹⁄₂" tee in vent and the other
end to the ³⁄₈" barbed fitting on the drain trap assembly.
IMPORTANT: Be sure to avoid double-trapping the vinyl hose.
Hose must be installed as shown above.
20
Horizontal Installation—Right to Left Airflow
2. Connect the ¹⁄₂" NPT plug (supplied in kit) to the opposite side
of the internal trap assembly from the NPT plug installed in
Step 1.
A
B
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.
■
Furnace must be mounted such that the side through which
the condensate will drain is elevated a minimum of 9" above a
surface such as a floor.
■
Install furnace at a slight pitch forward with shims or adjusting
screws.
C
A. ¹⁄₂" NPT plug
B. Internal trap assembly on flue pan
C. ¹⁄₂" NPT plug (supplied in kit)
¹/₄" Max
3. Insert trap assembly (supplied in kit) into the flue pan.
A
B
1. Relocate ¹⁄₂" NPT plug from the flue pan to the internal trap
assembly.
A. Flue pan
B. Condensate drain and trap assembly with ³⁄₄" PVC pipe outlet
4. Connect a length of ³⁄₄" PVC pipe (3 ft minimum) to the trap
assembly.
21
5. Install a ³⁄₄" PVC tee as shown.
Horizontal Installation—Tight Clearance Below Unit
In certain horizontal installations, clearance between unit and
drain pan beneath unit may be limited. In these applications, an
alternate method may be used to install the condensate drain
trap assembly. Using two 90º elbows (field supplied), bring
condensate trap out to side of unit beyond drain pan. See figure
below. After trap assembly has been attached using this method,
follow instructions on the previous pages for completing
condensate drain installation.
A
B
C
Two ³/₄" 90 Elbows
A. ³⁄₄" tee
B. 36" piece of ³⁄₈" vinyl tubing
C. ³⁄₄" PVC pipe
6. From the ³⁄₄" 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.
7. Remove vinyl hose from kit and cut in half. Connect one end
of the hose to the ³⁄₈" barbed fitting on the vent tee. Connect
the other end of the vinyl hose to the ³⁄₈" barbed fitting on the
drain trap assembly.
IMPORTANT: Be sure to avoid double-trapping the vinyl hose.
Hose must be installed as shown above.
A
B
¹/₂" NPT x ¹/₂" PVC
Adapter and Trap Assembly
(supplied)
A. Drain pan
B. Field-supplied fittings
Connection to Pressure Switch
Horizontal Left to Right Installation
NOTE: Black hose is factory connected to the 0.10" W.C.
pressure switch. Other end of hose must be connected to
external drain trap. Route hose through gas line access hole in
cabinet. Then connect to ¹⁄₄" barbed fitting on drain trap
assembly.
A
B
A. 0.10" W.C. pressure switch
B. Black hose
22
Upflow Installation
Installation with Return Ducts
The furnace is shipped from the manufacturer with a black hose
connected to the 0.10" W.C. pressure switch and the other end
hanging loose. Remove and discard the yellow cap from the tee
on the low-fire—high-fire pressure switch hose and connect the
hose from the 0.10" W.C. pressure switch hose to the tee.
IMPORTANT: Be sure that the pressure switch hoses do not
form a trap to hold condensation that could result from the flue
gas. Hose may be cut shorter to avoid forming a trap, if required.
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 a condensing 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.
A
B
C
G
D
F
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.
E
A. Low-fire—high-fire pressure
switch assembly
B. 0.10" W.C. pressure switch
C. Black hose
D. Trap
E. Yellow cap
F. Tee (supplied)
G. Blower housing trap
Horizontal Right to Left Installation
NOTE: Black hose is factory connected to the 0.10" W.C.
pressure switch. Other end of hose must be connected to
external drain trap. Route hose through gas line access hole in
cabinet. Then connect to ¹⁄₄" barbed fitting on drain trap
assembly.
Filter Specifications
Filters are not supplied with these furnaces. It is the furnace
installer’s responsibility 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. 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
filters whose area equals or exceeds the minimum area
shown is satisfactory.
Minimum Filter Requirements Chart
A
Disposable Filters
B
A. 0.10" W.C. pressure switch
B. Black hose
IMPORTANT: Be sure that the pressure switch hoses do not
form a trap to hold condensation that could result from the flue
gas. Hose may be cut shorter to avoid forming a trap, if required.
Install Ductwork
IMPORTANT:
■ Install ductwork 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.
Cleanable Filters
Min.
Airflow
Area
Descriptor (sq. in.)
Min.
Area
Size (in.) Qty. (sq. in.)
Size
(in.)
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, 22
960
20 x 25
2
480
20 x 25 1
Qty.
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.
23
6. Connect ground wire to green ground screw.
Make Electrical Connections
WARNING
A
B
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 ignition
control board as indicated on the Wiring Connection Diagram in
the “Troubleshooting” section.
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.
5. Using UL listed wire nuts, connect the field supply wires to
the furnace (black to black and white to white).
A. Connect white to white and black to black
B. Green ground screw
7. Replace the furnace electrical connection box cover and
screw.
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
furnace, 5 ft above the floor, or in accordance with any local
codes.
4. Install a test gauge connection with a ¹⁄₈" NPT plugged tap
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.
A
B
C
D
WARNING
E
F
G
A. ¹⁄₈" NPT plugged tap
B. Manual gas shutoff valve
C. Ground joint union
D. Tee
E. Sediment trap
F. Cap
G. Gas control valve
(inside furnace)
Electrical Shock Hazard
Electrically ground furnace.
Connect ground wire to green ground screw.
Failure to do so can result in death or electrical shock.
®Teflon is a registered trademark of E.I. Dupont de Nemours and
Company.
24
■
This furnace is equipped for rated input at manifold pressures
of 1.7" W.C. (1st stage) and 3.5" W.C. (2nd stage) for Natural
gas. When an LP conversion kit is used, it is equipped for
rated input at manifold pressures of 4.9" W.C. (1st stage) and
10.0" W.C. (2nd stage) for propane gas.
■
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.
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.
BTU/H =
Cu. ft per Revolution
x 3600 x Heating
INPUT
Value
# Seconds per Revolution
NOTE: The actual heating value of your gas can be obtained from
your local utility company.
6. Turn off the gas supply at the manual gas shutoff valve.
Adjust the Furnace Input Rate
A
(if required)
B
For Altitudes 4,500 to 7,500 ft Above Sea Level
A. Closed valve
B. Open valve
7. Remove the inlet pressure tap plug on the gas control valve
and connect pressure gauge to the ¹⁄₈" 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" W.C. for Natural
gas and 11" W.C. for propane gas.
1. Remove the burner access door.
2. Turn 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" NPT outlet
pressure tap.
Gas Control Valve
G
A
The maximum inlet gas supply pressure is 10.5" W.C. for
Natural gas and 13" 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" 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.
■
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.
Check the Furnace Input Rate
(if required)
IMPORTANT:
■ The furnace input rate must not exceed the input rating on
the furnace rating plate.
■
At altitudes from 4,500 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 in the
“Adjust the Furnace Input Rate” section.
B
F
C
E
A. Regulator adjusting cap—LO
B. ¹⁄₂" NPT outlet
C. ¹⁄₈" NPT outlet pressure tap
(OUT P)
D
D. Gas control switch
E. ¹⁄₂" NPT inlet
F. ¹⁄₈" NPT inlet pressure tap (IN P)
G. Regulator adjusting cap—HI
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.
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.
9. Refer to the Manifold Pressure vs. Altitude Chart later in this
section for the correct manifold pressure. If necessary, turn
the regulator adjusting screw clockwise to increase pressure
and input, or counterclockwise to decrease pressure and
input. The gas control valve has 2 separate adjusting screws
for first-stage marked “LO” and the second-stage marked
“HI.”
25
NOTE: The pressure regulator adjustment is sensitive; one
turn of the adjusting screw will result in a large change in
manifold pressure.
NOTE: If more than one run of return or heated air ducts are
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.
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" NPT outlet
pressure tap.
12. Replace outlet pressure tap plug and the regulator adjusting
cap on the gas control 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.
Warm Air
B
A
Manifold Pressure vs. Altitude Chart
Return Air
Natural Gas
Altitude (ft)
Manifold
Heating Value Pressure High
(Btu/ft3)
Fire (in. W.C.)
Manifold
Pressure Low
Fire (in. W.C.)
2,000
948
3.5
1.7
3,000
914
3.5
1.7
4,000
881
3.5
1.7
4,500
865
3.5
1.7
5,000
849
3.29
1.61
5,500
833
3.27
1.6
6,000
818
3.25
1.59
6,500
802
3.23
1.58
7,000
787
3.21
1.57
7,500
771
3.19
1.56
For Altitudes 7,500 to 10,000 ft 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).
A. Measure return air here.
B. Measure supply temperature here.
3. If furnace doesn't maintain temperature rise within the range
shown on the furnace rating plate, adjust the blower speed.
Passive and Active Dehumidification
For situations in which condensation is a problem, a
dehumidification feature has been built into the variable speed
motor. At the start of each cooling cycle, the variable speed
motor will run at 82% of the rated airflow for 7.5 minutes. After
7.5 minutes has elapsed, the motor will increase to 100% of the
rated airflow. If this feature is not desired, clip the jumper wire
between R and O on the integrated ignition/blower control board.
With R and O not connected by the jumper wire, the variable
speed motor will reach 100% of the rated airflow within
10 seconds of a call for cooling.
Additional dehumidification can be achieved by connecting a
humidistat to the DEHUM and R terminals on the integrated
ignition/blower control board. In this setup, the variable speed
motor will operate at a 10% reduction in the normal cooling
airflow rate when there is a call for dehumidification.
Both the passive and active dehumidification methods described
above can be utilized on the same furnace.
Variable Speed Features
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/recycle all packaging materials.
3. Check the furnace in its final location. Be sure the vent is not
blocked.
The furnace is equipped with a variable speed circulation air
blower motor that will deliver a constant airflow within a wide
range of external static pressures. Other features of this variable
speed motor include:
Start
The variable speed motor will slowly ramp up to normal operating
speed. This minimizes noise and increases comfort by
eliminating the initial blasts of air encountered with standard
motors.
Stop
Measure Temperature Rise
1. Adjust room thermostat to the highest temperature setting
possible.
2. 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.
26
At the end of a cooling or heating cycle, the variable speed motor
will slowly ramp down after a short blower “off” delay. If
continuous blower operation has been selected, the variable
speed motor will slowly ramp down until it reaches the airflow for
that mode.
control board flashes. Each flash signifies 100 CFM; count the
flashes and multiply by 100 to determine the actual CFM
delivered (for example: 10 flashes x 100 = 1,000 CFM).
Single Stage Thermostat Operation
The automatic heat staging option allows a single stage
thermostat to be used with a two-stage WGFE furnace. To
activate this option, move the jumper pin to desired setting
(5 minutes or 10 minutes). The furnace will start on first stage
heat and stay at first stage heat for the duration of the selected
time before switching to second stage heat.
W1 on the control board must be connected to W1 on the
thermostat.
Heating Mode
The unit as shipped is factory set to run at the middle of the
heating rise range as shown on the unit rating plate. If higher or
lower rise is desired, change the rise 15% up or down by moving
the ADJUST jumper plug from NORM position to the (+) or (-)
position. This adjustment will also cause the cooling airflow to be
raised or lowered by 15%.
The TEST position on the ADJUST tap is not used.
Control Board Taps
Circulating Airflow Adjustments
Cooling Mode
The units are factory set for the highest airflow for each model.
Adjustments can be made to the cooling airflow by repositioning
the jumper plug marked COOL - A, B, C, D based on the
information found in the Application Table For Cooling Airflow
Adjustments. To determine what CFM the motor is delivering at
any time, count the number of times the amber LED on the
Application Table For Cooling Airflow Adjustments
Heating CFM @ .5 Static
Cooling CFM @ .5 Static
Model #*
Motor HP
ADJUST Setting
HEAT Setting
High Fire
Low Fire
A
B
C
D
40V12
¹⁄₂
NORM
A
750
500
1,200
1,000
800
600
60V14
¹⁄₂
NORM
A
1,000
650
1,400
1,200
1,000
800
80V16
³⁄₄
NORM
A
1,500
950
1,600
1,400
1,200
1,000
80V20
1
NORM
C, D
1,500
950
2,000
1,800
1,600
1,400
100V20
1
NORM
B
1,700
1,150
2,000
1,800
1,600
1,400
125V20
1
NORM
A
2,100
1,450
2,000
1,800
1,600
1,400
For heating airflow adjustments (all models): Moving the ADJUST tap from NORM to (+) will increase airflow by 10%. Moving the
ADJUST tap from NORM to (-) will decrease the airflow by 12%.
*Only the portion of the model number (#) that indicates furnace input is shown.
Shut Down the Furnace
1. Set the room thermostat to the lowest setting.
2. Disconnect power.
3. Remove burner access door.
4. Shut off the gas by moving the gas control switch to the Off
position.
5. Replace the burner access door.
27
Sequence of Operation
Heating
On a call for first stage heat (W1) from the room thermostat, the
ignition control performs a 1-second self-check. Upon
confirmation that the pressure switch contacts are in an open
condition, the ignition control energizes the combustion blower to
high speed. The control then checks for adequate combustion air
by making sure the low-fire pressure switch contacts are closed.
The igniter energizes and is allowed to warm up for 7 seconds
before the gas control valve energizes on first stage and main
burners ignite. 45 seconds after the control confirms ignition has
occurred, the control drops the combustion blower to low speed.
The circulating blower ramps up to 50% of 1st stage heat speed
for one minute (including ramp up time), then at 75% of 1st stage
heat speed for an additional minute. After that, the circulating
blower operates at full 1st stage heat speed until either the heat
call is satisfied or the thermostat initiates a call for 2nd stage
heat. On a call for 2nd stage heat, the control energizes the
circulating air blower on full CFM 2nd stage heat.
If the automatic heat staging option is being used, the furnace
does not switch to 2nd stage heat in response to a call from the
thermostat, but instead operates at 1st stage heat for the
duration of the selected time before automatically switching to
2nd stage heat.
If first stage heating operation is not sufficient to satisfy the
heating demand, the room thermostat initiates a call for second
stage heat (W1 and W2). The control energizes the combustion
blower to high speed and energizes the W1 and W2. When the
high-fire pressure switch contacts close, the gas control valve
energizes on second stage and the circulating blower ramps up
to second stage heat speed.
When the second stage call for heat is satisfied, the ignition
control closes the gas control valve and runs the combustion
blower for an additional 15 seconds. The circulating air blower
continues to run for approximately 120 seconds at 82% of the
selected heating speed, then ramps down to the off mode.
In the event the unit loses ignition, the control will attempt to
recycle up to 5 times before it goes into a 1-hour lockout.
Lockout may be manually reset by removing power from the
control for more than 1 second or removing the thermostat call
for heat for more than 3 seconds.
If during a heating cycle the limit control senses an abnormally
high temperature and opens, the ignition control de-energizes the
gas control valve and the combustion blower while the circulating
blower ramps up to second stage heat speed. The circulating
blower remains energized until the limits are closed.
Fan On
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 circulating blower at
50% of the cooling speed. When the call for fan is turned off, the
control de-energizes the circulating blower.
Cooling
A call for cooling from the thermostat closes R to Y and R to G on
the integrated ignition/blower control board. The control waits for
a 1-second thermostat debounce delay before energizing the
circulating blower to 82% of the cooling speed. After 7.5 minutes,
the circulating blower automatically ramps up to 100% of the
cooling speed. When the call for cooling is satisfied, the
circulating blower ramps back down to 82% of the cooling speed
for 60 seconds, then turns off.
Controls
Following is a description of the operation of some of the controls
used in this furnace. All models use one of each control, except
as noted.
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
The rollout switch is a normally closed switch that opens 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.
These units have 2 rollout switches.
Primary Limit Control
This is a normally closed control that opens if abnormally high
circulating air temperatures occur. It is an automatic reset control.
Auxiliary Limit Control
This is a normally closed control that opens under abnormal
“reverse airflow” conditions that could occur in a counterflow or
horizontal installation if the circulating blower fails. It is an
automatic reset control.
Interlock (Blower Door) Switch
When the blower door is removed, the interlock switch breaks the
power supply to the burner controls and blower motor. The
switch operation must be checked to confirm it is operating
correctly.
Gas Control Valve
The gas control valve regulates the manifold gas pressure and
provides gas flow.
28
TROUBLESHOOTING
Furnace Fails to Operate Properly
Review “Sequence of Operation” and visually inspect the
following before troubleshooting:
WARNING
CFM LED
On these models, an amber LED is provided on the control board
to display CFM. To determine what CFM the motor is delivering at
any time, count the number of times the amber LED flashes. Each
flash signifies 100 CFM; count the flashes and multiply by 100 to
determine the actual CFM delivered (for example: 10 flashes x
100 = 1,000 CFM).
Failure Codes
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 furnace has a built-in, self-diagnostic capability. If a system
problem occurs, a fault code is shown by a red LED on the
control board. The control continuously monitors its own
operation and the operation of the system. If a failure occurs, the
LED will indicate the failure code.
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.
■
Is the integrated ignition/blower control board and 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?
Failure Codes Chart
Are all wiring connections secure?
LED Status
Fault Description
LED Off
No power to control or control hardware
fault detected
LED On
Normal operation
1 flash
Flame present with gas control valve off
2 flashes
Pressure switch closed with inducer off
3 flashes
Low-fire pressure, rollout, drain pressure,
or auxiliary limit open
4 flashes
High limit switch open
5 flashes
Not used
6 flashes
Pressure switch cycle lockout
7 flashes
Lockout due to no ignition
8 flashes
Lockout due to too many flame dropouts
9 flashes
Incorrect polarity and phasing
■
Start the system by setting thermostat above room temperature.
Observe system response. Then use the information provided in
this section to check the system operation.
Fault Code History Button
The control stores the last 5 fault codes in memory. A pushbutton switch is located on the control. When the push-button
switch is pressed and released, the control flashes the stored
fault codes. The most recent fault code is flashed first; the oldest
fault code is flashed last. To clear the fault code history, press
and hold the push-button switch for more than 5 seconds before
releasing.
High Heat State LED
On these models, a green LED is provided on the control board to
indicate high heat state.
High Heat State—Green LED
LED Status
Description
LED Off
LED On
LED Flashing
No demand for high heat
High heat demand, operating normally
High heat demand, high pressure switch not
closed
29
Wiring Connection Diagram
Check codes for proper wiring and circuit protection before installation.
NOTES:
1. Press and release fault code history button to display fault
4.
codes. To erase codes, press and hold button in for more
than 5 seconds.
2. If any of the original wire as supplied with the furnace must be
5.
replaced, it must be replaced with wiring material having a
temperature rating of at least 194ºF (90ºC).
3. Proper polarity must be observed for field line voltage supply;
ignition control will lock out if polarity is reversed.
30
For temporary service replacement of circulating blower
motor with a PSC motor, connect desired speed tap to EAC
terminal and neutral tap to neutral terminal on ignition control.
Do not connect C (common) between the thermostat and the
furnace unless required by the thermostat manufacturer.
Refer to the thermostat installation instructions.
Wiring Schematic
(LOW)
(DRAIN)
31
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
14610 Breakers Drive
Jacksonville, FL 32258
Please include a daytime phone number in your correspondence.
47905K005
© 2005. All rights reserved.
Accessories
To order accessories ask for the appropriate part number listed
below or contact your Whirlpool® Home Cooling and Heating
dealer.
ALPKT582-1
Natural Gas to Propane Conversion Kit
AFILT524-1
Side Return Filter Kit
AFILT529-2
Bottom Return Filter Kit
WABASE511
Combustible Floor Base (14.5" cabinets)
WABASE512
Combustible Floor Base (17.5" cabinets)
WABASE568
Combustible Floor Base (21.0" cabinets)
WABASE569
Combustible Floor Base (24.5" cabinets)
®Registered Trademark/TM Trademark of Whirlpool, U.S.A.,
Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida
11/05
Printed in U.S.A.
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