Grandaire WFAR, WFAR080B048 Installation Instructions Manual

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Page 1

INSTALLATION INSTRUCTIONS

Single--Stage, PSC Blower Motor

35” Tall, High Efficiency Condensing Gas Furnace

WFAR080B048 (B Series Only)

WFAR (All C Series)

These instructions must be read and understood completely before attempting installation.

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE

The signal words DANGER, WARNING, CAUTION, and NOTE areused to identify levels of

hazard seriousness. The signal word DANGER is only used on product labelsto signifyan immediate hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product.

DANGER -- Immediate hazards which will result in severe personal injury or death.

WARNING -- Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION -- Hazards or unsafe practices which may result in minor personal injury or product or property damage.

NOTE -- Used to highlight suggestions which will result in enhanced installation, reliability, or operation.

Signal Words in Manuals

The signal word WARNING is used throughout this manual in the following manner:

WARNING

The signal word CAUTION is used throughout this manual in the following manner:

CAUTION

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures or product labels.

Safety--alert symbol

When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS 3..............................

INTRODUCTION 4.........................................

CODES AND STANDARDS 4................................

ELECTROSTATIC DISCHARGE

PRECAUTIONS PROCEDURE 5............................

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS 5...

DIMENSIONAL DRAWING 7................................

LOCATION 8..............................................

GENERAL 8...............................................

AIR FOR COMBUSTION AND VENTILATION 9................

MINIMUM FREE AREA REQUIRED 11........................

MINIMUM SPACE VOLUMES 11..............................

CONDENSATE TRAP 12.....................................

INSTALLATION 20..........................................

FILTER AND RETURN DUCT SIZING 22.......................

AIR DUCTS 28.............................................

GAS PIPING 29.............................................

ELECTRICAL CONNECTIONS 30.............................

J--BOX INSTALLATION 31...................................

VENTING 35...............................................

SPECIAL VENTING REQUIREMENTS

FOR INSTALLATIONS IN CANADA 35........................

VENTING SYSTEMS 36.....................................

INSTALLING THE VENT TERMINATION 42....................

VENTING SYSTEM LENGTH CALCULATIONS 46..............

Portions of thetextand tables arereprinted from NFPA 54/ANSI Z223.1--2012, with permissionof National FireProtection Association,Quincy,MA 02269 andAmericanGas Association, Washington,DC

20001. This reprinted material is not the complete and official position of the NFPA or ANSI, on the referenced subject, which is represented only by the standard in its entirety.

INSTALLER: Affix these instructions on or adjacent to the furnace. CONSUMER: Retain these instructions for future reference.

Use of the AHRI CertifiedTM Mark indicates a manufacturer’s participation in the program. For verification of certification for individual products, go to www.ahridirectory.org .

Printed in U.S.A. 44001710402 12/9/2014

Page 2

Required Notice for Massachusetts Installations

Important

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:

5.08: Modifications to NFPA--54, Chapter 10

2) Revise 10.8.3 by adding the following additional requirements:

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential

purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back--up is installed on the floor level where the gas equipment is to be installed. in addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified license professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon

monoxide detector with alarm and battery back--up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of

thirty (30) days to comply with the above requirement; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one--half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state of local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR

5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall

horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side

wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists

for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers and Gas

Fitters, 239 Causeway Street, Boston, MA 02114. 617--727--9952

2 44001710402

Specifications are subject to change without notice.

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INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation, personal injury, death, or property damage.

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factory--authorized and listed kits or accessories when modifying this product.

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Solvent cements and primers are combustible. Keep away from heat, sparks and open flame. Use only in well--ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and

qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic

maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with furnace and other safety precautions that may apply.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with

440 01 7104 02 3

WARNING

CAUTION

changing residential construction practices. We require these instructions as a minimum for a safe installation.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing furnaces.

This is the safety--alert symbol . When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and

CAUTION. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result

in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify hazards which may result in minor personal injury or product and property damage. NOTE and NOTICE are used to highlight suggestions which will result in enhanced installation, reliability, or operation.

1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified in “Air for Combustion and Ventilation” section.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.

5. 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 “Gas Piping” section.

6. 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 “Start--Up, Adjustments, and Safety Check” section. See furnace rating plate.

7. 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. See “Air Ducts” section.

8. A gas--fired furnace for installation in a residential garage must be installed as specified in the warning box in the “Location” section.

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

10. These Multipoise Gas--Fired Furnaces are CSA design--certified for use with natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory--shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to convert furnace for use with propane gas.

Specifications subject to change without notice.

CAUTION

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INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

11. See Table 2 for required clearances to combustible construction.

12. Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on carpeting, combustible tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly or when Coil Box is used. See Table 2 for clearance to combustible construction information.

NOTICE

IMPORTANT INSTALLATION AND START--UP PROCEDURES

Failure to follow thisprocedure mayresult ina nuisancesmoke or odor complaint.

The manifold pressure, gas rate by meter clocking,temperature rise and operation must be checked after installation. Minor smoke andodor maybe present temporarily after start--up from the manufacturing process. Some occupants are more sensitive to thisminor smoke and odor. It is recommendedthat doors and windows be open during the first heat cycle.

INTRODUCTION

This 4--way multipoise Category IV condensing furnace is CSA design--certified as a direct vent (2-pipe) or non-direct vent (1-pipe) furnace. (See Figure 2.) The furnace is factory--shipped for use with natural gas. The furnace can be converted in the field for use with propane gas when a factory-supplied conversion kit is used. Refer to the furnace rating plate for conversion kit information.

This furnace is approved for installation in a mobile home when a factory-supplied accessory mobile home conversion kit is used. The conversion kit is required for use with both natural and propane gas. The furnace must also be installed on a factory-supplied accessory combustible floor base or evaporator coil casing.

This furnace is designed for minimum continuous return--air temperature of 60_F(15_C) db or intermittent operation down to 55_F(13_C) db such as when used with a night setback thermostat. Return-air temperature must not exceed 80_F (27_C) db. Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Figure 3). The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. None of the furnace model sizes can be used if the heating load is 20,000 BTU or lower. Use Air Conditioning Contractors of America (Manual J and S); American Society of Heating, Refrigerating, and Air--Conditioning Engineers; or other approved engineering method to calculate heating load estimates and select the furnace. Excessive oversizing of the furnace may cause the furnace and/or vent to fail prematurely, customer discomfort and/or vent freezing. Failure to follow these guidelines is considered faulty installation and/or misapplication of the furnace; and resulting failure, damage, or repairs may impact warranty coverage.

For accessory installation details, refer to the applicable instruction literature. NOTE: Remove all shipping materials, loose parts bag, and literature before operating the furnace. (See Table 1).

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply

with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction. In the United States and Canada, follow all codes and standards for the following:

Safety

S US: National Fuel Gas Code (NFGC) NFPA

54--2012/ANSI Z223.1--2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

S A manufactured (Mobile) home installation must

conform with the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or when this standard is not applicable, the Standard for Manufactured Home Installation (Manufactured Home Sites, Communities, and Set-Ups),ANSI/NCS A225.1, and/or CAN/CSA-Z240, MH Series Mobile Homes

S CANADA: National Standard of Canada, Natural Gas

and Propane Installation Code (NSCNGPIC) CAN/CSA B149.1--2010

General Installation

S US: NFGC and the NFPA 90B. For copies, contact the

National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC contact the American Gas Association, 400 N. Capitol, N.W., Washington DC 20001

S CANADA: NSCNGPIC. For a copy, contact Standard

Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada

Combustion and Ventilation Air

S US: Section 9.3 of the NFPA54/ANSI Z223.1--2012 Air

for Combustion and Ventilation

S CANADA: Part 8 of the CAN/CSA B149.1--2010,

Venting Systems and Air Supply for Appliances

Duct Systems

S US and CANADA: Air Conditioning Contractors

Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2005 Fundamentals Handbook Chapter 35

Acoustical Lining and Fibrous Glass Duct

S US and CANADA: current edition of SMACNA, NFPA

90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Gas Piping and Gas Pipe Pressure Testing

S US: NFPA 54/ANSI Z223.1--2012 NFGC; Chapters 5,

6, 7, and 8 and national plumbing codes. CANADA: CAN/CSA--B149.1--2010, Parts 4, 5, 6, and

In the state of Massachusetts:

S This product must be installed by a licensed plumber or

gas fitter.

S When flexible connectors are used, the maximum

length shall not exceed 36 in. (914 mm).

4 440 01 7104 02

Specifications subject to change without notice.

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INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

S When lever type gas shutoffs are used they shall be

T--handle type.

S The use of copper tubing for gas piping is not

approved by the state of Massachusetts.

Electrical Connections

S US: National Electrical Code (NEC) NFPA 70--2011 S CANADA: Canadian Electrical Code CSA C22.1

Condensate Drain Connection

 US: National Standard Plumbing Code2009, Section8.7.  Canada: National Plumbing Code of Canada 2010 in

Canada.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

PROCEDURE

CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR

ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity (for example; DO NOT move or shuffle your feet, do not touch ungrounded objects, etc.).

4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

ACCESSORIES

See Specification Sheets for a list of accessories for this product.

Table1–Factory--Supplied Installation Parts

DESCRIPTION QUANTITY

Outlet Choke Plate (provided with 40K BTUH furnaces only; see Note) 1

AirIntakePipeFlange 1

Vent Pipe Flange 1

Pipe Flange Gaskets 2

Sharp Tip Screws (Vent and Inlet Flanges) 10

Vent Pipe Coupling 1

Vent Pipe Coupling Clamps 2

Pressure Switch Tube 1

Rubber Drain Elbow 1

Drain Elbow Clamps 4

1 / 2 --- i n . C P V C to 3/ 4 --- i n . P V C Pi p e A d a p t e r 1

Gas Line Grommet 1

Junction Box Cover 1

Junction Box Base 1

Green Ground Screw 1

Blunt Tip Screws (Junction Box) 3

Thermostat Wire Grommet 1

Drain Extension Tube (Z--- pipe) (Provided separately in furnace) 1

NOTE: Only used for 40K BTUH furnaces from 0--2000 ft. (0 to 610 M) above sea level for total equivalent vent lengths under 10 ft. (3 M)

440 01 7104 02 5

Specifications subject to change without notice.

Page 6

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Table2–MinimumClearancestoCombustibleMaterialsforAllUnits

POSITION

REAR 0

FRONT (Combustion air openings in furnace and in structure) 1in.(25mm)

Recommended for service *24 in. (610 mm)

All Sides of Supply Plenum *1 in. (25 mm)

Sides 0

Vent 0

Top of Furnace 1in.(25mm)

*Consult local building codes

CLEARANCE

6 440 01 7104 02

SD5060--4 Rev F

Specifications subject to change without notice.

Page 7

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

FURNACE SIZE

A B C D

CABINET

WIDTH

OUTLET WIDTH

BOTTOM

INLET WIDTH

AIR INTAKE

SHIP WT.

LB (KG)

040A030C 14--3/16 (361) 12--1/2 (319) 12--9/16 (322) 7--1/8 (181) 123 (55) 060B048C 17--1/2 (445) 15--7/8 (403) 16 (406) 8--3/4 (222) 144 (65) 080B048B 17--1/2 (445) 15--7/8 (403) 16 (406) 8--3/4 (222) 154 (69) 080B048C 17--1/2 (445) 15--7/8 (403) 16 (406) 8--3/4 (222) 154 (69) 080C060C 21 (533) 19--3/8 (492) 19--1/2 (495) 10--1/2 (267) 162 (73) 100C048C 21 (533) 19--3/8 (492) 19--1/2 (495) 10--1/2 (267) 169 (76) 100C060C 21 (533) 19--3/8 (492) 19--1/2 (495) 10--1/2 (267) 169 (76) 120D060C 24--1/2 (622) 22--7/8 (581) 23 (584) 12--1/4 (311) 186 (84)

Figure 1 -- Dimensional Drawing

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

THEBLOWERISLOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD.

Figure 2 -- Multipoise Orientations

SUPPLY AIR

Figure 3 -- Freeze Protection and Return Air Temperature

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

80 / 27˚C

/ 16˚C

L12F010

A10490

440 01 7104 02 7

Specifications subject to change without notice.

Page 8

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

LOCATION

CAUTION

PERSONAL INJURY AND/OR PROPERTY

BACK POSI-

TIONED DOWN-

WARD

BACK POSI-

TIONED UPWARD

Figure 4 -- Prohibited Installations

Figure 5 -- Installation in a Garage

TURN

CUT IN

BACK

18-IN. (457.2 mm)

MINIMUM TO BURNERS

AIR RE-

L12F011

A93044

DAMAGE HAZARD

Improper use or installation of this furnace may result in premature furnace component failure. This gas furnace may be used for heating buildings under construction provided that:

--The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

--The furnace is controlled by a thermostat. It may not be “hot wired” to provide heat continuously to the structure without thermostatic control.

--Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

--The temperature of the return air to the furnace is maintained between 55_F(13_C) and 80_F(27_C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

--The air temperature rise is within the rated rise range on the furnace rating plate, and the gas input rate has been set to the nameplate value.

--The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

--The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

--Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting according to these installation instructions.

8 440 01 7104 02

General

These furnaces are shipped with materials to assist in proper furnace installation. These materials are shipped in the main blower compartment.

Specifications subject to change without notice.

Page 9

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

See Table 1 for loose parts bag contents. This furnace must:

S be installed so the electrical components are

protected from water.

S not be installed directly on any combustible material

other than wood flooring (refer to SAFETY CONSIDERATIONS).

S be located close to the chimney or vent and attached

to an air distribution system. Refer to Air Ducts section.

S be provided ample space for servicing and cleaning.

Always comply with minimum fire protection clearances shown in Table 2 or on the furnace clearance to combustible construction label.

CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD

Failure to follow this warning could result in personal injury or death and unit component damage.

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.

WARNING

S Masonry acid washing materials

All fuel--burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return--air duct to prevent pulling air from the burner area.

FIRE, INJURY OR DEATH HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 in. (457 mm) above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFPA 54/ANSI Z223.1--2012 or CAN/CSA B149.2--2010. (See Figure 5.)

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect return--air ducts to the back of the furnace. (See Figure 4.)

WARNING

The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:

S Commercial buildings S Buildings with indoor pools S Laundry rooms S Hobby or craft rooms S Chemical storage areas

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for combustion:

S Permanent wave solutions S Chlorinated waxes and cleaners S Chlorine based swimming pool chemicals S Water softening chemicals S De--icing salts or chemicals S Carbon tetrachloride S Halogen type refrigerants S Cleaning solvents (such as perchloroethylene) S Printing inks, paint removers, varnishes, etc. S Hydrochloric acid S Cements and glues S Antistatic fabric softeners for clothes dryers

440 01 7104 02 9

Location Relative to Cooling Equipment

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full--heat or full--cool position.

AIR FOR COMBUSTION AND VENTILATION

Introduction

Direct Vent (2--pipe) Applications

When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required. However, other gas appliances installed in the space with the furnace may require outside air for combustion. Follow the guidelines below to insure that other gas appliances have sufficient air for combustion.

Non--Direct Vent (1--pipe) Applications

When the furnace is installed as a non-direct vent (1-pipe) furnace, it will be necessary to insure there is adequate air for combustion. Other gas appliances installed with the furnace may also require air for combustion and ventilation in addition to the amount of combustion air and ventilation air required for

Specifications subject to change without notice.

Page 10

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

the furnace. Follow the guidelines below to insure that the furnace and other gas appliances have sufficient air for combustion.

Ventilated Combustion Air Applications

When the furnace is installed using the ventilated combustion air option, the attic or crawlspace must freely communicate with the outdoor to provide sufficient air for combustion. The combustion air pipe cannot be terminated in attics or crawlspaces that use ventilation fans designed to operate during the heating season. If ventilation fans are present in these areas, the combustion air pipe must terminate outdoors as a Direct Vent/ 2-Pipe system.

All air for combustion is piped directly to the furnace from a space that is well ventilated with outdoor air (such as an attic, crawlspace, or equipment closet) and the space is well isolated from the living space or garage. In addition, other gas appliances installed in the space with the furnace may require outside air for combustion. Follow the guidelines below to insure that the roof or crawlspace walls have sufficient free area to provide sufficient air for combustion and ventilation for the furnaces. The guidelines below can be used to insure that other gas appliances have sufficient air for combustion.

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

S U.S.A. Installations: Section 9.3 of the NFPA 54/ANSI

Z223.1--2012 , Air for Combustion and Ventilation and applicable provisions of the local building codes.

S Canada: Part 8 of the CAN/CSA--B149.1--2010,

Venting Systems and Air Supply for Appliances.

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make--up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to the Carbon Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount of make--up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

WARNING

S Spaces having less than 50 cubic feet per 1,000 Btuh

(4.8 cubic meters per kW) require the Outdoor Combustion Air Method.

S Spaces having at least 50 cubic feet per 1,000 Btuh

(4.8 cubic meters per kW) may use the Indoor Combustion Air, Standard or Known Air Infiltration Method.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Figure 6 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

a. One opening MUST commence within 12 in. (300

mm) of the ceiling and the second opening MUST

commence within 12 in. (300 mm) of the floor. b. Size openings and ducts per Figure 6 and Table 3. c. TWO HORIZONTAL DUCTS require 1 sq. in. (645

sq. mm) of free area per 2,000 Btuh (1,100 mm

of combined input for all gas appliances in the space

per Figure 6 and Table 3. d. TWO OPENINGS OR VERTICAL DUCTS require 1

sq. in. (645 sq. mm) of free area per 4,000 Btuh (550

/kW) for combined input of all gas appliances in

the space per Figure 6 and Table 3.

3. ONE OUTDOOR OPENING requires: a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh

(734 mm appliances in the space per Figure 6 and Table 3.

b. Not less than the sum of the areas of all vent

connectors in the space.

The opening shall commence within 12 in. (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

/kW) for combined input of all gas

/kW)

Indoor Combustion AirE NFPA&AGA Standard and Known--Air--Infiltration Rate

Methods

Indoor air is permitted for combustion, ventilation, and dilution,

if the Standard or Known--Air--Infiltration Method is used.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in accordance with this instruction manual.

WARNING

10 440 01 7104 02

Specifications subject to change without notice.

Page 11

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Standard Method

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 4 or Equations 1 and

2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space.

Table 4 -- Minimum Space Volumes were determined by using the following equations from the current edition of the National

Fuel Gas Code ANSI Z223.1/NFPA 54, 9.3.2.2:

1. For other than fan--assisted appliances, such as a draft hood--equipped water heater:

other

1000 Btu/hr

fan

/1,000 Btuh

A04002

A04003

Volume

Other

21ft ACH

2. For fan--assisted appliances such as this furnace:

Volume

Fan

15ft ACH

If: Iother = combined input of all other than fan--assisted appliances in Btuh/hr

Ifan = combined input of all fan--assisted appliances in Btuh/hr ACH = air changes per hour (ACH shall not exceed 0.60.) The following requirements apply to the Standard Method and

to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if: a. There are no closeable doors between rooms. b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in. (2,000 mm

/kW) of the total input rating of all gas appliances in the space, but not less than 100 in. (0.06 m2). One opening shall commence within 12 in. (300 mm) of the ceiling and the second opening shall commence within 12 in. (300 mm) of the floor. The

minimum dimension of air openings shall be at least 3in.(80mm).(SeeFigure7.)

c. Combining space on different floor levels. The

volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors havingfreeareaofatleast2in.

/kW) of total input rating of all gas appliances.

/1,000 Btuh (4,400

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1--in.

/4,000 Btuh of

total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section.

4. Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a

continuous, sealed vapor barrier. Openings are gasketed or sealed and

b. Doors and openable windows are weatherstripped

and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole plates and floors, between wall--ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combustion Air Method below and,

2. Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows: a. Calculate the Ratio of all Indoor Space volume

divided by required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80 mm).

Table3–MinimumFreeAreaRequiredforEachCombustionAirOpeningorDucttoOutdoors

TWO HORIZONTAL DUCTS

(1 SQ. IN./2,000 BTUH)

FURNACE

INPUT (BTUH)

(1,100 SQ. MM/KW)

Free Area of

Opening and

Duct

Sq. In (Sq.

Round Duct

In. (mm) Dia

mm)

40,000

60,000

80,000

100,000

120,000

20 (12904) 5 (127) 14 (8696) 5 (127) 10 (6452) 4 (102) 30 (19355) 6 (152) 20 (13043) 5 (127) 15 (9678) 5 (127) 40 (25807) 7 (178) 27 (17391) 6 (152) 20 (12904) 5 (127) 50 (32258) 8 (203) 34 (21739) 7 (178) 25 (16130) 6 (152) 60 (38709) 9 (229) 40 (26087) 7 (178) 30 (19355) 6 (152)

440 01 7104 02 11

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH)

(734 SQ. MM/KW)

Free Area of

Opening and

Duct

Sq. In (Sq.

Round Duct

In. (mm) Dia

mm)

Specifications subject to change without notice.

TWO OPENINGS OR

VERTICAL DUCTS

(1 SQ. IN./4,000 BTUH)

(550 SQ. MM/KW)

Free Area of

Opening and

Duct

In. (mm) Dia.

Sq. In (mm)

Round Duct

Page 12

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

100,000 + 30,000 =

60,000 + 40,000 =

80,000 + 30,000 =

Table4–MinimumSpaceVolumesfor100% Combustion, Ventilation and Dilution Air from Outdoors

OTHER THAN FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

ACH

0.60

0.50

0.40

0.30

0.20

0.10

0.00

NP = Not Permitted

30 40 50 40 60 80 100 120 140

1,050 (29.7)

1,260 (35.6)

1,575 (44.5)

2,100 (59.4)

3,150 (89.1)

6,300

(178.0)

1,400 (39.6)

1,680 (47.5)

2,100 (59.4)

2,800 (79.2)

4,200

(118.9)

8,400

(237.8)

NP NP NP NP NP NP NP NP NP

(130,000 divided by

4,000)

(100,000 divided by

3,000)

(110,000 divided by

2,000)

1,750

(49.5)

2,100 (59.4)

2,625 (74.3)

3,500 (99.1)

5,250

(148.6) 10,500

(297.3)

1,400 (39.6)

1,680 (47.5)

2,100 (59.4)

2,800 (79.2)

4,200

(118.9)

8,400

(237.8)

Space Volume Ft3(M3)

32.5 Sq. In. for each two Vertical Ducts or Open-

ings

= 33.3 Sq. In. for each Single Duct or Opening

= 55.0 Sq. In. for each two Horizontal Ducts

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

1,500 (42.5)

1,800 (51.0)

2,250 (63.7)

3,000 (84.9)

4,500

(127.3)

9,000

(254.6)

2,000

(56.6) 2,400

(67.9) 3,000

(84.9) 4,000

(113.2)

6,000

(169.8) 12,000

(339.5)

2,500 (70.8)

3,000 (84.9)

3,750

(106.1)

5,000

(141.5)

7,500

(212.2) 15,000

(424.4)

3,000 (84.9)

3,600

(101.9)

4,500

(127.3)

6,000

(169.8)

9,000

(254.6) 18,000

(509.2)

3,500 (99.1)

4,200

(118.9)

5,250

(148.6)

7,000

(198.1) 10,500

(297.1) 21,000

(594.1)

*Minimum dimensions of 3-in. (76mm)

NOTE Use any of the following combinations of openings:

A&B, C&D, D&E, F&G

Figure 6 -- Air for Combustion, Ventilation, and Dilution for

Outdoors

12 440 01 7104 02

* Minimum opening size is 100 sq in. (64516 sq. mm) with

minimum dimensions of 3-in. (76mm)

{ Minimum of 3-in. (76mm) when type-B1 vent is used.

L12F012

Specifications subject to change without notice.

Figure 7 -- Air for Combustion, Ventilation, and Dilution

L12F013

from Indoors

Page 13

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

CONDENSATE TRAP

Condensate Trap -- Upflow Orientation

When the furnace is installed in the upflow position, it is not necessary to relocate the condensate trap or associated tubing. Refer to Figure 8 for upflow condensate trap information. Refer to Condensate Drain section for information how to install the condensate drain.

Condensate Trap -- Downflow Orientation.

When the furnace is installed in the downflow position, the condensate trap will be initially located at the upper left corner of the collector box, as received from the factory. See the top image in Figure 9. When the furnace is installed in the downflow orientation, the condensate trap must be relocated for proper condensate drainage. See the bottom image in Figure 9.

To Relocate the Condensate Trap:

S Orient the furnace in the downflow position. S Figure 9 shows the condensate trap and tubing before

and after relocation. Refer to Figure 9 to begin the trap conversion.

S Refer to Condensate Drain section for information how

to install the condensate drain.

Condensate Trap -- Horizontal Orientation.

When the furnace is installed in the horizontal right position, the condensate trap will be initially located at the bottom of the collector box, as received from the factory. See the top image in Figure 10. When the furnace is installed in the horizontal left position, the condensate trap will be initially located at the top of the collector box, as received from the factory. See the top image in Figure 11. In both cases, the trap must be repositioned on the collector box for proper condensate drainage. See bottom images in Figure 10 and Figure 11.

A field--supplied, accessory Horizontal Installation Kit (trap grommet) is required for all direct--vent horizontal installations (only). The kit contains a rubber casing grommet designed to seal between the furnace casing and the condensate trap. (See Figure 17.)

Condensate Trap

Relief Port

NOTICE

The field-supplied, accessory horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. It is NOT required for applications using single-pipe or ventilated combustion air venting.

NOTICE

The condensate trap extends below the side of the casing in the horizontal position. A minimum of 2-in. (51 mm) of clearance is required between the casing side and the furnace platform for the trap to extend out of the casing in the horizontal position. Allow at least 1/4-in. per foot (20mm per meter) of slope down and away from the furnace in horizontal sections of drain line.

To Relocate the Condensate Trap:

S Remove the knockout in the casing for the

condensate trap.

S Install the grommet in the casing when required for

direct--vent horizontal applications.

S Orient the furnace in the desired position. S Allow for 2 in. (51 mm) of clearance underneath the

furnace for the condensate trap and drain line.

S Figure 10 shows the condensate trap and tubing

before and after relocation in the horizontal right position.

S Figure 11 shows the condensate trap and tubing

before and after relocation in the horizontal left position.

S Refer to the appropriate figure to begin the trap

conversion.

S Refer to Condensate Drain section for information how

to install the condensate drain.

Vent Pipe Clamp

Vent Elbow Clamp

Collector Box

Plugs

440 01 7104 02 13

Pressure Switch

Port

UPFLOW TRAP CONFIGURATION

1 & 2 Stage Units

Figure 8 -- Upflow Trap Configuration

(Appearance may vary)

Specifications subject to change without notice.

Vent Elbow

Collector Box

Plug

Condensate Trap

Relief Port

Condensate Trap

Outlet

A11307

Page 14

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Remove pressure switch tube from front pressure switch and discard. A new tube is shipped in the loose parts bag.

Remove relief tube from relief port on condensate trap.

Remove the screw that secures the trap to the collector box and remove trap.

Loosen clamp on inlet to vent elbow.

Unconverted Factory Configuration as

Viewed in the Downflow Orientation

Connect the new pressure switch tube from Loose Parts bag to port on front pressure switch.

Remove tube from relief port.

Remove middle and bottom plugs. DO NOT DISCARD.

Route tube through inducer standïoffs to adjust position of the tube.

Install the two plugs previously removed on the open ports of the collector box.

Connect relief tube to port on collector box.

Rotate elbow to desired position and tighten clamp to 15 lb.ïin.

Slide tube in standïoffs

to adjust length.

Align condensate trap over middle and bottom ports of collector box.

Downflow Trap Configuration

Figure 9 -- Downflow Trap Configuration

(Appearance may vary)

Trim excess tube. Connect pressure switch tube to port on collector box.

Attach condensate trap with screw to collector box.

Connect relief tube to

relief port on condensate trap.

A11587

14 440 01 7104 02

Specifications subject to change without notice.

Page 15

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Remove plug from collector box. DO NOT DISCARD.

As Viewed in the Horizontal Right Orientation

NOTE: Remove knockout in casing before reïinstalling the condensate trap.

If alternate vent position is required, loosen clamp on inlet of vent elbow.

Remove the screw that secures the trap to the collector box and remove trap.

Unconverted Factory Configuration

Slide relief tube in standïoffs to adjust length.

Attach condensate trap with screw to collector box.

Install plug on open port of collector box

Vent elbow shown in alternate orientation. Tighten clamp on inlet to vent elbow 15 lb.ïin.

Align trap over middle and rightïhand port on collector box.

Horizontal Right Trap Configuration

A11573

Figure 10 -- Horizontal Right Trap Configuration

(Appearance may vary)

440 01 7104 02 15

Specifications subject to change without notice.

Page 16

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Remove the screw that secures the condensate trap to the collector box

If alternate vent position

is required, loosen clamp on vent elbow inlet.

Remove relief tube from port on collector box.

and remove trap.

Remove relief tube from relief port on condensate trap.

Remove middle and right

plug from collector box. DO NOT DISCARD.

Remove front pressure switch tube and discard. A new tube is shipped in the Loose Parts bag.

NOTE: Remove knockout in casing before re-installing the condensate trap.

Rotate elbow to

desired position and torque clamp on inlet 15 lb.-in.

Slide relief tube in stand-offs to adjust length.

Attach condensate trap with screw to collector box.

Align trap over middle and right-hand port on collector box.

Unconverted Factory Trap Configuration

As Viewed in the Horizontal Left Orientation

Install two plugs previously removed in open ports on collector box.

Connect relief tube to port on collector box.

Connect the new pressure switch

tube from Loose Parts bag to port on front pressure switch.

Route pressure switch tube underneath relief tube and

connect to port on collector box.

Connect relief tube to relief port on condensate trap.

16 440 01 7104 02

Horizontal Left Trap Configuration

A11574

Figure 11 -- Horizontal Left Configuration

(Appearance may vary)

Specifications subject to change without notice.

Page 17

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

CONDENSATE DRAIN CONNECTION

FROZEN AND BURST WATER PIPE HAZARD

Failure to protect against the risk of freezing may result in property damage.

Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper operation or damage to equipment. If furnace environment has the potential of freezing, the drain trap and drain line must be protected. The use of accessory drain trap heaters, electric heat tape and/or RV antifreeze is recommended for these installations.

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in burst water pipes and/or property damage.

If a condensate pump is installed, a plugged condensate drain or a failed pump may cause the furnace to shut down. Do not leave the home unattended during freezing weather without turning off water supply and draining water pipes or otherwise protecting against the risk of frozen pipes.

DO NOT trap the drain line in any other location than at the condensate drain trap supplied with the furnace. If possible, DO NOT route the drain line where it may freeze. The drain line must terminate at an inside drain to prevent freezing of the condensate and possible property damage.

Special precautions MUST be made if installing furnace in an area which may drop below 32°F(0°C). This can cause improper operation or damage to the equipment. If the furnace environment has the potential of freezing, the drain trap and drain line must be protected. In areas where the temperature may be below 32°F(0°C), a Condensate Freeze Protection kit is required. The kit includes a condensate trap with heat pad and replaces the factory--installed condensate trap. Refer to the accessory section of the Specification Sheets for current kit number. A self--regulating, shielded and waterproof heat tape rated at 3 to 6 watt per foot (10 to 20 watt per meter) at 115 volt, 40° F(4° C) may be used to provide freeze protection of the remaining condensate drain line. Wrap the drain trap and the drain line with the heat tape and secure with appropriate plastic ties. Follow the heat tape manufacturer’s recommendations. Prime the trap before furnace operation.

The condensate drain line must be supported and/or secured per local codes. Supports and clamps should be spaced to prevent the drain line from sagging or being dislocated from the furnace or termination point. In the absence of local codes, consult the edition of the National Standard Plumbing Code 2009, in the US or the National Plumbing Code of Canada 2010 in Canada.

Upflow/Downflow Orientation

In the Upflow or Downflow orientation, the condensate trap is inside the furnace casing. The condensate drain must be routed from the trap through the furnace casing. The condensate drain can be routed through the left or right side of

CAUTION

the casing. (The left or right side is as you are viewing/facing the furnace from the front.)

An indoor coil condensate drain or humidifier drain can be connected to the external furnace condensate drain provided:

a. The drains are not hard piped together, and b. There is an air gap at the point where the two drain

lines meet or

c. All condensate piping is at least 1/2 in. PVC and

there is a relief tee at the top of condensate drain

piping as shown below: NOTE: On narrower casings, it may be easier to remove the condensate trap, connect the drain line components and re-install the condensate trap. Read the steps thoroughly to familiarize yourself with the required steps.

For Right Side Condensate Drain:

1. Remove the 7/8--in. knock--out from the right side of the casing. (See Figure 12 for suggested knockout removal technique.)

2. Remove the pre--formed rubber drain elbow and two spring clamps from the loose parts bag.

3. Slide a spring clamp 1 inch (25 mm) down the plain end (the end without the formed grommet) of the drain elbow.

4. From inside the casing, insert the formed grommet end of the elbow through the 7/8--in. knockout in the casing.

5. Pull the grommet through the casing from the outside until it is seated in the knockout

6. Attach the plain end of the drain elbow to the outlet stub on the drain trap. Secure the drain elbow to the trap with thespringclamp.

The remaining drain line can be constructed from field supplied 1/2--in. CPVC or 3/4--in. PVC pipe, in compliance with local building codes. A factory--supplied 1/2--in. CPVC to 3/4--in. PVC adapter is supplied in the loose parts bag for use as required.

7. Install the adapter or connect the 1/2--in. CPVC pipe by sliding a spring clamp over the open end of the grommet on the outside the furnace casing.

8. Open the spring clamp and insert the long end of the adapter or the 1/2--in. CPVC pipe into the outlet stub on the drain elbow.

9. Connect additional condensate piping to a code--approved drain, or to a condensate pump approved for use with acidic furnace condensate and compatible with mineral and vegetable oils, such as canola oil.

Allow at least 1/4-in. per foot (20 mm per meter) of slope down and away from the furnace in horizontal sections of drain line.

TIPS FROM CONTRACTORS: Contractors have found that temporarily removing the inducer assembly in upflow applications while performing the steps below, makes upflow left--side drain connections easier.

For Left Side Condensate Drain Connection:

1. For left side condensate drainage, the drain line is routed from the condensate trap, behind the inducer (upflow) or gas valve (downflow) and out through the left side of the furnace casing. A pre-formed 1/2--in. CPVC “Z-pipe” is provided with the furnace. The “Z-pipe” is long enough to extend across the casing for drain connections.

2. Locate the “Z-pipe”. Remove the pre-formed drain elbow and four spring clamps from the loose parts bag.

3. The“Z-pipe” is connected to the condensate trap and the outside of the furnace by modifying the formed rubber drain elbow as shown in Figure 18.

440 01 7104 02 17

Specifications subject to change without notice.

Page 18

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

4. Remove the formed grommet from the rubber drain elbow by cutting the elbow along the vertical line located about 1--3/8 in. (35 mm) away from the formed grommet. See Figure 16. DO NOT DISCARD THE FORMED GROMMET OR THE RUBBER ELBOW. Both of these pieces will be used.

Assemble and route the drain line to the opposite side of the furnace as detailed below:

5. Remove the knock--out from the left side of the casing. (See Figure 12 for suggested knockout removal technique.)

6. From the outside of the casing, insert the angled end of the“Z-pipe” through drain hole in the left side of the casing and behind the inducer or gas valve. Allow the“Z-pipe” to temporarily rest on the blower shelf (upflow) or burner box (downflow). (NOTE: When the inducer housing has been removed to ease installation in upflow applications, this step is not needed.)

7. After inserting the “Z-pipe” through the casing, slide a spring clamp over each end of the “Z-pipe”.

8. From inside the casing, insert the short end of the formed grommet cut from the rubber drain elbow through the 7/8-in. drain knockout in the casing.

9. Pull the grommet through the casing from the outside until it is seated in the knockout.

10. Align the “Z-pipe” with the long end of the grommet inside the furnace and insert slightly. The angled end of the tube at the other side of the casing should be facing the front of the furnace.

11. Slide a spring clamp over the end of the remaining rubber drain elbow.

12. Attach the drain elbow to the angled end of “Z-pipe” and the drain trap outlet stub. Adjust the length of “Z-pipe” inserted into the grommet at the opposite side of the furnace as necessary for proper fit and positioning. In both upflow and downflow orientations, the “Z-pipe” should NOT be resting on any sheet metal parts.

13. Secure the rubber elbow to the drain trap and the “Z-pipe” with spring clamps.

14. Secure the grommet to the “Z-pipe” with the spring clamp. The remaining drain line can be constructed from field supplied 1/2--in. CPVC or 3/4--in. PVC pipe, in compliance with local building codes. A factory-supplied 1/2--in. CPVC to 3/4--in. PVC adapter is supplied in the loose parts bag for use as required.

15. Install the adapter or connect the 1/2--in. CPVC pipe by sliding a spring clamp over the open end of the grommet on the outside the furnace casing.

16. Open the spring clamp and insert the long end of the adapter or the 1/2--in. CPVC pipe into the outlet stub on the drain elbow.

17. Connect additional condensate piping to a code-approved drain, or to a condensate pump approved for use with acidic furnace condensate and compatible with mineral and vegetable oils, such as canola oil.

Allow at least 1/4-in. per foot (20 mm per meter) of slope down and away from the furnace in horizontal sections of drain line.

NOTICE

The field-supplied, accessory horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. It is NOT required for applications using single-pipe or ventilated combustion air venting.

TIPS FROM CONTRACTORS: When installing the furnace horizontally, use the entire drain elbow (that is, do NOT cut as shown in Figure 16) to connect the trap to the drain line. This helps to prevent bumps and shocks to the drain line from damaging the furnace drain trap. Avoid misalignment of the drain pipe which may cause kinks in the elbow.

Horizontal Orientation

1. The condensate trap outlet extends 2--in. (51 mm) below the furnace casing. Leave enough clearance between the furnace and the furnace platform for the trap.

2. To allow for servicing the trap, the condensate drain elbow in the loose parts bag can be used to make a coupler to allow for future service of the condensate trap and drain line.

3. Remove the knock-out for the condensate trap in the side of the casing.

4. Install the drain trap grommet in the casing if required for direct vent applications. If necessary, remove the trap, install the grommet and re-install the trap.

5. Remove the pre-formed rubber drain elbow, and two spring clamps from the loose parts bag.

6. Connect the full or modified elbow and/or grommet to the outlet of the condensate trap with one spring clamp. Avoid misalignment of the drain pipe which may cause kinks in the elbow or grommet.

7. The remaining drain line can be constructed from field--supplied 1/2--in. CPVC or 3/4--in. PVC pipe, in compliance with local building codes. A factory--supplied 1/2--in. CPVC to 3/4--in. PVC adapter is supplied in the loose parts bag for use as required.

8. Install the adapter or connect the 1/2--in. CPVC pipe by sliding a spring clamp over the open end of the elbow or grommet on the outside the furnace casing.

9. Open the spring clamp and insert the long end of the adapter or the 1/2--in. CPVC pipe into the outlet stub on the drain elbow.

10. Connect additional condensate piping to a code--approved drain, or to a condensate pump approved for use with acidic furnace condensate and compatible with mineral and vegetable oils, such as canola oil.

Allow at least 1/4-in. per foot (20 mm per meter) of slope down and away from the furnace in horizontal sections of drain line.

L12F019

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheetmetal parts mayhave sharp edgesorburrs.Use care and wearappropriateprotectiveclothing,safety glasses andgloves when handling parts, and servicing furnaces.

CAUTION

Figure 12 -- Knockout Removal

18 440 01 7104 02

Specifications subject to change without notice.

Page 19

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Evaporator Coil

AIRFLOW

DIRECTION

AIRFLOW

DIRECTION

AIRFLOW

DIRECTION

Condensing

Furnace

Blower

< +

Evaporator Coil

Condensing

Furnace

Blower

+ = Positive pressure < + = Pressure lower than areas with +

ï = Negative pressure

Evaporator Coil

Condensing

Furnace

Blower

+ = Positive pressure < + = Pressure lower than areas with +

ï = Negative pressure

+ = Positive pressure < + = Pressure lower than areas with +

ï = Negative pressure

Blower creates positive pressure.

Positive pressure extends into coil condensate drain (no trap).

Furnace condensate does not flow consistently when drain is at positive pressure.

3/4” PVC

3/4

3/4” PVC

3/4

1/2” CPVC or larger*

3/4

< +

3/4

3/4” PVC

< +

3/4

1/2

Open standpipe

3/4” PVC

1/2” CPVC or larger*

3/4

< +

Figure 13 -- Example of Field Drain Attachment

(NOT ALLOWED)

L14F021

L14F022

L14F023

Open standpipe for coil or humidifier drain

Air gap here

TEE (1/2” CPVC to 3/4” PVC adapter from loose parts bag.)

To open drain

Evaporator Coil

3/4” PVC

AIRFLOW

DIRECTION

+ = Positive pressure < + = Pressure lower than areas with +

ï = Negative pressure

AIRFLOW

DIRECTION

Condensing

Furnace

Blower

Evaporator Coil

Condensing

Furnace

3/4

3/4” PVC

3/4

Open standpipe Air gap required when

another drain is connected

to furnace drain.

3/4

TEE

< +

3/4

(1/2” CPVC to 3/4” PVC adapter from loose parts bag.)

< +

3/4

Open standpipe (Optional when coil drain is

3/4

not connected to furnace drain.)

3/4” PVC

1/2” CPVC or larger*

3/4

< +

< + < +

3/4” PVC

Blower

+ = Positive pressure < + = Pressure lower than areas with +

ï = Negative pressure

Figure 14 -- Example of Field Drain Attachment

3/4

L14F024

L14F025

L14F026

440 01 7104 02 19

Specifications subject to change without notice.

Page 20

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Evaporator Coil

3/4

< +

3/4

Open standpipe (Optional when coil drain is not connected to furnace drain.)

3/4” PVC

TEE (1/2” CPVC to 3/4” PVC adapter from loose parts bag.)

Condensing

AIRFLOW

DIRECTION

Furnace

3/4” PVC

3/4

< +

Blower

+ = Positive pressure < + = Pressure lower than areas with +

ï = Negative pressure

Example of Field Drain Attachment (continued)

INSTALL CLAMPS ON DRAIN ELBOW ATTACH DRAIN ELBOW TO CONDENSATE DRAIN TRAP

PULL DRAIN STUB THROUGH CASING

3/4

L14F027

NOTE: Trap grommet is required only for direct-vent applications.

Remove knockout. Install grommet before relocating condensate trap.

Figure 17 -- Accessory Horizontal Drain Trap Grommet

Attach elbow to condensate trap

Cut formed end off condensate drain elbow

Formed end of grommet

Connect short end of “Z” pipe to modified drain elbow

A11582

OPEN SPRING CLAMP INSERT FACTORY-- SUPPLIED 1/2--IN. CPVC

TO 3/4--IN. PVC ADAPTER OR 1/2--IN. CPVC PIPE *CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN ELBOW

Figure 15 -- Formed Rubber Drain Grommet

L12F022

Factory supplied 1/2--in. CPVC to 3/4--in. PVC adapter

TRAP, DRAIN ELBOW WITH DISCHARGE PIPE

Formed end of grommet Open spring clamp. Insert 1/2--in. to 3/4--in. CPVCto PVC adapter or 1/2--in.

Modified drain elbowconnect to condensate trap and “Z” pipe

CPVC pipe

NOTE: Remove Inducer Housing for easier access, if desired.

LEFT SIDE DRAIN ROUTED BEHIND INDUCER

Figure 18 -- Drain Trap Connection and Routing

(Appearance May Vary)

L12F015

Figure 16 -- Modify Rubber Drain Elbow

20 440 01 7104 02

A11581

Specifications subject to change without notice.

Page 21

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

INSTALLATION

NOTICE

This furnace is certified to leak 2% or less of nominal air conditioning CFM delivered when pressurized to 1-inch water column (250 Pa) with all present air inlets (including bottom closure in upflow and horizontal applications), air outlets, and plumbing and electrical ports sealed.

Upflow Installation

NOTE: The furnace must be pitched as shown in Figure 25 for

proper condensate drainage.

Supply Air Connections

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

Connect supply--air duct to flanges on furnace supply--air outlet. Bend flange upward to 90_ with wide duct pliers. (See Figure 22.) The supply--air duct must be connected to ONLY the furnace supply--outlet--air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing side to attach supply air duct, humidifier, or other accessories. All supply--side accessories MUST be connected to duct external to furnace main casing.

Return Air Connections

FIRE HAZARD

A failure to follow this warning could cause personal injury, death and/or property damage.

Never connect return--air ducts to the back of the furnace. Follow instructions below.

The return--air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing. Bypass humidifier may be attached into unused return air side of the furnace casing. (See Figure 26, Figure 27, Figure 28.)

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 4 screws holding bottom plate. (See Figure 24.)

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate and screws.

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when only side return air is used.

NOTE: Side return--air openings can be used in UPFLOW and some HORIZONTAL configurations. Do not use side return--air openings in DOWNFLOW configuration. (See Figure 26, Figure 27, Figure 28.)

440 01 7104 02 21

WARNING

Leveling Legs (If Desired)

In upflow position with side return inlet(s), leveling legs may be used. (See Figure 23.) Install field--supplied, 5/16 x 1--1/2 in. (8 x 38 mm) (max) corrosion--resistant machine bolts, washers and nuts.

NOTE: Bottom closure must be used when leveling legs are used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see Item 1 in Bottom Return Air Inlet section in Step 1 above.

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace.

2. For each leg, install nut on bolt and then install bolt with nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

Downflow Installation

NOTE: The furnace must be forward as shown in Figure 25 for

proper condensate drainage.

Supply Air Connections

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the following two accessories are used:

S Special Base, NAHA01101SB S Cased Coil Assembly -- WENC, WTNC, WENW,

WTNW, WLNC, WLNW, WLAM

1. Determine application being installed from Table 8.

2. Construct hole in floor per Table 8 and Figure 21.

3. Construct plenum to dimensions specified in Table 8 and Figure 21.

4. Install special base coil assembly or coil box as shown in Figure 21.

NOTE: It is recommended that the perforated supply--air duct flanges be completely removed from furnace when installing the furnace on a factory--supplied cased coil or coil box. To remove the supply--air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Figure 22.)

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing furnaces.

Connect supply--air duct to supply--air outlet on furnace. Bend flange inward past 90_ with wide duct pliers (See Figure 22.) The supply--air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing (when used). When installed on combustible material, supply--air duct must be connected to ONLY the factory--approved accessory subbase, or a factory--approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All supply--side accessories MUST be connected to duct external to furnace casing.

Specifications subject to change without notice.

CAUTION

Page 22

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Return Air Connections

FIRE HAZARD

A failure to follow this warning could cause personal injury, death and/or property damage.

Never connect return--air ducts to the back of the furnace. Follow instructions below.

The return--air duct must be connected to return--air opening (bottom inlet). DO NOT cut into casing sides (left or right). Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. (See Figure 27.)

Bottom Return Air Inlet

1. Tilt or raise furnace and remove 4 screws holding bottom plate. (See Figure 24.)

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate and screws.

WARNING

Horizontal Installation

NOTE: The furnace must be pitched forward as shown in

Figure 25 for proper condensate drainage.

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

MINOR PROPERTY HAZARD

Failure to follow this caution may result in minor property damage.

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling.

The furnace can be installed horizontally in an attic or crawlspace on either the left--hand (LH) or right--hand (RH) side. The furnace can be hung from floor joists, rafters or trusses or installed on a non--combustible platform, blocks, bricks or pad.

WARNING

CAUTION

Platform Furnace Support

Construct working platform at location where all required furnace clearances are met. (See Table 2 and Figure 29.) For furnaces with 1--in. (25 mm) clearance requirement on side, set furnace on non--combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

Suspended Furnace Support

The furnace must be supported under the entire length of the furnace with threaded rod and angle iron. (See Figure 30.) Secure angle iron to bottom of furnace as shown.

Roll--Out Protection

Provide a minimum 12--in. x 22--in. (305 x 559 mm) piece of sheet metal for flame roll--out protection in front of burner area for furnaces closer than 12--in. (305 mm) above the combustible deck or suspended furnaces closer than 12--in. (305 mm) to joists. The sheet metal MUST extend underneath the furnace casing by 1--in. (25 mm) with the door removed.

The bottom closure panel on furnaces of widths 17--1/2--in. (445 mm) and larger may be used for flame roll--out protection when bottom of furnace is used for return air connection. See Figure 29 for proper orientation of roll--out shield.

Supply Air Connections

Return Air Connections

The return--air duct may be connected to bottom of the furnace. The side of casing that faces downward may also be used for return air connection. A combination of the bottom and downward facing side may also be used. The upward facing side of the casing cannot be used as a return air connection. (See Figure 28.)

Bottom Return Air Inlet

1. Tilt or raise furnace and remove 4 screws holding bottom plate. (See Figure 24.)

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate and screws.

22 440 01 7104 02

Specifications subject to change without notice.

Page 23

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) are used without a bottom return air inlet.

Not all horizontal furnaces are approved for side return air connections (See Figure 28.)

Filter Arrangement

FIRE, CARBON MONOXIDE AND POISONING HAZARD

Failure to follow this warning could result in fire, personal injury or death.

Never operate a furnace without a filter or filtration device installed. Never operate a furnace with filter or filtration device access doors removed.

WARNING

Furnaces shipped without a filter rack:

There are no provisions for an internal filter rack in these furnaces. An external filter is required and is purchased separately. A field supplied accessory air cleaner may also be used in place of the filter rack.

For upflow applications, the filter can be installed on either side of the furnace, the bottom of the furnace or any combination of side and bottom of the furnace. See Figure 19, Figure 20, Figure 26.

For downflow applications, the filter rack (or field supplied accessory air cleaner) must only be connected to the bottom opening on the furnace. See Figure 20 and Figure 27.

For horizontal applications, the filter rack (or field supplied accessory air cleaner) can be connected to the bottom opening on the furnace. For side return use in the horizontal position, refer to Figure 28. If both side and bottom openings are used in Figure 28, each opening used will require a filter.

A filter rack or any field supplied accessory air cleaner can also be installed in the common return duct prior to entering the return air opening in any orientation.

Refer to the instructions supplied with filter rack or accessory air filter for additional assembly and installation options.

See Table 5 for filter size details.

Filter and Return Duct Sizing

Pressure drop must be taken into account when sizing filters, filter racks, IAQ devices, and associated system ductwork. See Table 6 for a comparison of Pressure Drop (initial/clean resistance to airflow) versus Airflow for a variety of filter media types and sizes. These are representative numbers. Consult the filter or IAQ device manufacturers’ specification sheet for performance data for a particular filter media or IAQ device.

Design the filter and associated ductwork for the best match of pressure drop versus filter size. Best practice usually chooses filter systems with pressure drops under 0.2 in. w.c. (50 Pa), with the best blower electrical efficiency and system airflow performance occurring with filter pressure drops under 0.1 in. w.c. (25 Pa).

Due to the relatively high pressure drops of 1-in (25 mm) thick after-market filter media, it is recommended that the filtration system be designed for at least 2-in (51 mm) thick media.

TIPS FROM CONTRACTORS: Install a media cabinet capable

of incorporating a 4-in (102 mm) thick media filter. This allows room for future upgrades to other IAQ devices.

NOTICE

Design the duct system FIRST to determine how much pressure drop may be allowed in the filter system. See the AIR DUCTS section. Excessive filter pressure drop often compromises system airflow and duct performance, causes inadequate airflow to the furthest ends of the duct system, as well as causes excess noise and higher than anticipated electrical consumption.

Provide duct transitions, as required, to smoothly transition airflow from the return duct system to the filter (or IAQ device) to the furnace when the dimensions of the ductwork or furnace return air opening do not match the required filter or IAQ device dimensions. See the instructions supplied with factory-accessory duct adapters.

Table5–FilterSizeInformation--in.(mm)

FURNACE

CASING

WIDTH

14--3/16{

(360)

17--1/2

(445)

21 (533)

24--1/2

(622)

* Recommended to maintain air filter face velocity. See Product Data for part number. { Not all families have these models.

16 x 25 x 3/4

(406 x 635 x

16 x 25 x 3/4

(406 x 635 x

16 x 25 x 3/4

(406 x 635 x

16 x 25 x 3/4

(406 x 635 x

FILTER SIZE

SIDE

RETURN

19)

BOTTOM RETURN

14 x 25 x 3/4

(356 x 635 x

19)

16 x 25 x 3/4

(406 x 635 x

19)

20 x 25 x 3/4

(508 x 635 x

19)

24 x 25 x 3/4

(610 x 635 x

19)

440 01 7104 02 23

FILTER

TYPE

Wash-

able*

Wash-

able*

Wash-

able*

Wash-

able*

Specifications subject to change without notice.

Page 24

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Table 6 Filter Media Pressure Drop (Clean) Versus Airflow - in. w.c. (Pa)

Factory-Accy

14x25Filter

Washable

CFM L/s (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

600 (283) 0.04 (12) 0.07 (17) 0.10 (26) 0.24 (60) 0.16 (40)

800 (378) 0.06 (15) 0.10 (25) 0.15 (39) 0.34 (85) 0.23 (59) 1000 (472) 0.07 (18) 0.13 (34) 0.21 (52) - - 0.32 (81) 1200 (566) 0.08 (20) 0.17 (43) 0.27 (68) - - - -

Representative After-Market Filter Media*

Fiberglass* Pleated*

Factory-Accy

16x 25 Filter

Washable

CFM L/s (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

600 (283) 0.04 (10) 0.06 (15) 0.09 (22) 0.20 (51) 0.13 (34)

800 (378) 0.05 (13) 0.08 (21) 0.13 (32) 0.29 (72) 0.20 (49) 1000 (472) 0.06 (16) 0.11 (28) 0.17 (43) - - 0.27 (67) 1200 (566) 0.07 (18) 0.14 (36) 0.22 (56) - - - 1400 (661) 0.08 (21) 0.18 (45) 0.28 (70) - - - 1600 (755) 0.09 (23) 0.21 (54) - - - - - 1800 (850) 0.10 (25) 0.26 (64) - - - - - -

Factory-Accy

20x25Filter

Washable

CFM (L/s) (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

800 (378) 0.04 (11) 0.06 (16) 0.09 (24) 0.22 (55) 0.15 (37) 1000 (472) 0.05 (13) 0.08 (21) 0.13 (32) 0.29 (72) 0.20 (49) 1200 (566) 0.06 (15) 0.11 (27) 0.16 (41) - - 0.25 (63) 1400 (661) 0.07 (17) 0.13 (33) 0.20 (51) - - 0.31 (79) 1600 (755) 0.08 (19) 0.16 (40) 0.24 (61) - - - 1800 (850) 0.08 (21) 0.18 (47) 0.29 (73) - - - 2000 (944) 0.09 (23) 0.21 (54) - - - - - 2200 (1038) 0.09 (24) 0.25 (62) - - - - - -

Factory-Accy

25x25Filter

Washable

CFM L/s (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

800 (378) 0.03 (9) 0.05 (12) 0.07 (18) 0.17 (43) 0.11 (28) 1000 (472) 0.04 (11) 0.06 (16) 0.09 (24) 0.22 (55) 0.15 (37) 1200 (566) 0.05 (13) 0.08 (20) 0.12 (31) 0.27 (68) 0.18 (47) 1400 (661) 0.06 (15) 0.10 (24) 0.15 (38) - - 0.23 (58) 1600 (755) 0.06 (16) 0.11 (29) 0.18 (45) - - 0.28 (69) 1800 (850) 0.07 (18) 0.13 (34) 0.21 (53) - - - 2000 (944) 0.08 (19) 0.16 (39) 0.24 (61) - - - 2200 (1038) 0.08 (21) 0.18 (45) 0.28 (70) - - - -

* Representative estimates from filter manufacturer data sheets.

See manufacturers’ specifications for pressure drop versus airflow data for specific filter media.

If the filter size that you are looking for is not contained in Table 6, refer to Table 7 for a comparison of Pressure Drop (initial/clean resistance to airflow) versus Face Velocity for a variety of filter media types.

The following equations relate Face Velocity (FPM), Filter Area and Airflow (CFM):

Filter Face Velocity = Airflow / Filter Area Minimum Filter Area = Rated System Airflow / Maximum Filter Face Velocity

Table 7

Filter Media Pressure Drop (Clean) Versus Velocity - in. w.c. (Pa)

Face Velocity Factory-Accy

Washable

FPM (m/s) (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

200 (1) 0.04 (10) 0.05 (13) 0.08 (20) 0.18 (47) 0.12 (31) 300 (1.5) 0.05 (14) 0.09 (22) 0.13 (34) 0.30 (75) 0.21 (52) 400 (2) 0.07 (17) 0.13 (32) 0.20 (50) - - 0.31 (78) 500 (2.5) 0.08 (21) 0.18 (44) 0.27 (69) - - - 600 (3) 0.09 (23) 0.23 - - - - - - 700 (3.6) 0.10 (26) 0.29 - - - - - - -

* Representative estimates from filter manufacturer data sheets.

See manufacturers’ specifications for pressure drop versus airflow data for specific filter media.

24 440 01 7104 02

Representative After-Market Filter Media*

Fiberglass* Pleated*

Representative After-Market Filter Media*

Fiberglass* Pleated*

Representative After-Market Filter Media*

Fiberglass* Pleated*

Representative After-Market Filter Media*

Fiberglass* Pleated*

Specifications subject to change without notice.

Page 25

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

)

FURNACE

FILTER FRAME

17 ⅛” (43.5 cm)

1 ¼” (3 cm)

(TYP.)

4”

(3 cm)

DOOR

FILTER

⅜” (1 cm)

TABS

25 ⅛” (64 cm)

23 ⅛” (59 cm)

OPENING

TABS

½” (1.3 cm)

(2 cm)

14 ½” (37 cm)

OPENING

L12F023

¾”

16 ⅛” (41 cm

Figure 19 -- Accessory Side Filter Rack

2 ⅜” (6 cm

L12F023

FURNACE

(OR COIL CASING

WHEN USED)

Figure 20 -- Accessory Bottom Filter

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

A11095

PLENUM

OPENING

FLOOR

OPENING

Figure 21 -- Installation on Combustible Flooring

440 01 7104 02 25

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Specifications subject to change without notice.

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A10491

Page 26

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Table8–OpeningDimensions--In.(mm)

FURNACE

CASING

WIDTH

IN. (mm)

Upflow Applications on Combustible or Noncombus-

Downflow Applications on Noncombustible Flooring

14–3/16{

(360)

Downflow applications on combustible flooring

Downflow Applications on Combustible Flooring with

Assembly or coil box (subbase not required)

Upflow Applications on Combustible or Noncombus-

Downflow Applications on Noncombustible Flooring

17–1/2

(445)

Downflow applications on combustible flooring

Downflow Applications on Combustible Flooring with

Assembly or coil box (subbase not required)

Upflow Applications on Combustible or Noncombus-

Downflow Applications on Noncombustible Flooring

(533)

Downflow applications on combustible flooring

Downflow Applications on Combustible Flooring with

Assembly or coil box (subbase not required)

Upflow Applications on Combustible or Noncombus-

Downflow Applications on Noncombustible Flooring

24--1/2

(622)

Downflow applications on Combustible flooring

Downflow Applications on Combustible Flooring with

Assembly or coil box (subbase not required)

{ Not all families have these models.

APPLICATION

tible

Flooring (subbase not required)

(subbase not required)

(subbase required)

Coil

tible

Flooring (subbase not required)

(subbase not required)

(subbase required)

Coil

tible

Flooring (subbase not required)

(subbase not required)

(subbase required)

Coil

tible

Flooring (subbase not required)

(subbase not required)

(subbase required)

Coil

PLENUM OPENING FLOOR OPENING

A B C D

12--11/16

(322)

12--9/16

(319)

11--13/16

(284)

12--5/16

(319)

(406)

15--7/8

(403)

15--1/8

(384)

15--1/2

(394)

19--1/2

(495)

19--3/8

(492)

18--5/8

(473)

(483)

(584)

22--7/8

(581)

22--1/8

(562)

22--1/2

(572)

21--5/8

(549)

(483)

21--5/8

(549)

(483)

21--5/8

(549)

(483)

21--1/8

(537)

(483)

13--5/16

(338)

13--3/16

(335)

13--7/16

(341)

13--5/16

(338)

16--5/8

(422)

16--1/2

(419)

16--3/4

(425)

16--1/2

(419)

20--1/8

(511)

(508)

20--1/4

(514)

(508)

23--5/8

(600)

23--1/2

(597)

23--3/4

(603)

23--1/2

(597)

22--1/4

(565)

19--5/8

(498)

20--5/8

(600)

(508)

22--1/4

(565)

19--5/8

(498)

20--5/8

(600)

(508)

22--1/4

(565)

19--5/8

(498)

20--5/8

(600)

(508)

22--1/4

(565)

19--5/8

(498)

20--5/8

(600)

(508)

UPFLOW DOWNFLOW HORIZONTAL

PERFORATED DISCHARGE DUCT FLANGE

90°

26 440 01 7104 02

YES

120° MIN

YES

Figure 22 -- Duct Flanges

Specifications subject to change without notice.

120°

MIN

YES

120°

MIN

YES

A10493

Page 27

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR



(8mm)



1 3 / 4 

(44mm)

/ 4 

1 (44mm)

(8mm)



(8mm)



(44mm)

4 

Figure 23 -- Leveling Legs

LEVEL 0-IN. (0 MM) TO 1/2-IN. (13 MM) MAX

BOTTOM PLA TE

A89014

Figure 24 -- Removing Bottom Closure Panel

BOTTOM CLOSURE PAN EL

A11092

UPFLOW OR DOWNFLOW

Figure 25 -- Furnace Pitch Requirements

MIN 1/4-IN. (6 MM) TO 1/2-IN. (13 MM) MAX

HORIZONTAL

A11237

ANY COMBINATION OF 1, 2, OR 3 PERMITTED.

Figure 26 -- Upflow Return Air Configurations and

Restrictions

440 01 7104 02 27

A11036

Figure 27 -- Downflow Return Air Configurations

Specifications subject to change without notice.

A11037

and Restrictions

Page 28

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

CASING

WIDTH

COMBINA

TION

CASING

WIDTH

COMBINA

TION

HORIZONTAL TOP RETURN NOT PERMITTED FOR

HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL

ANY MODEL

SUPPLY

AIR

RETURN

AIR

A11038

Figure 28 -- Horizontal Return Air Configurations and Restrictions

HORIZONTAL LEFT

RETURN AIR CONNECTIONS

INPUT*

40,000

60,000

80,000

WIDTH

INCHES

CONNECTION

1ONLY 2ONLY 3ONLY

14 3/16 YES YES NO YES

17 1/2 YES YES NO YES

14 3/16 YES YES NO YES

17 1/2 YES NO NO YES 17 1/2 YES YES NO YES

21 YES YES NO YES

COMBINATION

OF 1 & 2

100,000 21 YES YES NO YES 120,000 24 1/2 YES YES NO YES

*NOTE: Not all models may be available in all casing sizes shown in the table above

COMBUSTION - AIR PIPE (SEE VENTING SECTION)

*RETURN

AIR

*HORIZONTAL LEFT BOTTOM RETURN NOT PERMITTED FOR ALL MODELS. SEE TABLE BELOW.

A14006

HORIZONTAL RIGHT

RETURN AIR CONNECTIONS

INPUT*

40,000

60,000

80,000

WIDTH

INCHES

CONNECTION

1ONLY 2ONLY 3ONLY

14 3/16 YES YES NO YES

17 1/2 YES YES NO YES

14 3/16 YES YES NO YES

17 1/2 YES YES NO YES 17 1/2 YES YES NO YES

21 YES YES NO YES

COMBINATION

OF 1 & 2

100,000 21 YES YES NO YES 120,000 24 1/2 YES YES NO YES

*NOTE: Not all models may be available in all casing sizes shown in the table above

NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.

28 440 01 7104 02

30 IN. (762 mm)

2-IN.

(51 mm)

MIN. WORK AREA

ROLLOUT PROTECTION REQUIRED

Install 12” x 22” (305 x 559 mm) sheet metal in front of burner compartment area.

Figure 29 -- Working Platform for Attic Installation

Specifications subject to change without notice.

A11154

Page 29

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

COMBUSTION-AIR PIPE (SEE VENTING SECTION)

2-IN.

(51 mm)

A11155

Figure 30 -- Suspended Furnace Installation

NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.

AIR DUCTS

NOTICE

Many states, provinces and localities are considering or have implemented standards and/or restrictions on duct sizing practices, ductwork leakage, and/or ductwork thermal, airflow and electrical efficiencies. CONSULT LOCAL CODE OFFICIALS for ductwork design and performance requirements in your area.

General Requirements

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA Manual D), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Service and Technical Support Manual. When a furnace is installed so that the 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. Secure ductwork with proper fasteners for type of ductwork used. Seal supply-- and return--duct connections to furnace with code approved tape or duct sealer. NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration.

Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36--in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

Return Duct Sizing

Refer to the Filter Selection and Duct Sizing section for information on the proper selection of filter sizes and the associated ductwork and duct transitions. Improperly designed filtering systems and return ductwork are the most common causes of airflow and/or noise complaints in HVAC systems.

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow

and 10 ft. (3 M) of main duct to the first branch take--off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

NOTE: For horizontal applications, the top most flange may be bent past 90_ to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed.

440 01 7104 02 29

Specifications subject to change without notice.

Page 30

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

GAS PIPING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Never purge a gas line into a combustion chamber. 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.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Use proper length of pipe to avoid stress on gas control manifold and gas valve.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Gas valve inlet and/or inlet pipe must remain capped until gas supply line is permanently installed to protect the valve from moisture and debris. Also, install a sediment trap in the gas supply piping at the inlet to the gas valve.

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S.A. Refer to current edition of NSCNGPIC in Canada.

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.

NOTE: Use a back--up wrench on the inlet of the gas valve when connecting the gas line to the gas valve.

WARNING

NOTICE

In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36--in. (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T--handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

Refer to Table 9 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of

one hanger every 6 ft. (1.8 M). Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas.

FIRE OR EXPLOSION HAZARD

A failure to follow this warning could result in personal injury, death, and/or property damage.

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 served another gas appliance. Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2--in. (51 mm) outside the furnace.

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace damage.

Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls and burner misalignment.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. (1.8 M) of furnace.

Install a sediment trap in riser leading to furnace as shown in Figure 33. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve.

A 1/8--in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve. Piping should be pressure and leak tested in accordance with the current addition of the NFGC in the United States, local, and national plumbing and gas codes before the furnace has been connected. Refer to current edition of NSCNGPIC in Canada. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace. NOTE: The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14--in. w.c.) stated on gas control valve. (See Figure 31.) If pressure exceeds 0.5 psig (14--in. w.c.), gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than 0.5 psig (14--in. w.c.), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace. The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF. Some installations require gas entry on right side of furnace (as viewed in upflow). (See Figure 32.)

WARNING

CAUTION

30 440 01 7104 02

Specifications subject to change without notice.

Page 31

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

SINGLE-STAGE

ON/OFF Switch

GAS

SUPPLY

1/2” NPT Inlet

1/8” NPT Inlet Pressure Tap

Regulator Seal Cap

Regulator Adjustment Regulator Seal Cap under Cap

1/8” NPT Manifold Pressure Tap

1/2” NPT Outlet

A11153

Figure 31 -- Gas Valve

Gas Pipe Grommet

For direct vent (2-pipe) applications, the knockout for the gas pipe must be sealed to prevent air leakage. Remove the knockout, install the grommet in the knockout, then insert the gas pipe. The grommet is included in the loose parts bag. See Figure 32.

Table9–MaximumCapacityofPipe

NOMINAL

IRON

PIPE SIZE

IN. (MM)

(3.0)

1/2 (13) 175 120 97 82 73 3/4 (19) 360 250 200 170 151

1 (25) 680 465 375 320 285 1-1/4 (32) 1400 950 770 660 580 1-1/2 (39) 2100 1460 1180 990 900

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14 --- in. w.c.) or less and a pressure drop of 0.5 --- in. w.c. (based on a 0.60 specific gravity gas). Ref: Table 9 above and 6.2 of NFPA54/ANSI Z223.1---2012.

Left Side Gas Entry. Gas Pipe Grommet Required For Direct Vent Applications.

LENGTH OF PIPE -- FT (M)

(6.0)

(9.1)40(12.1)50(15.2)

Gas Pipe Grommet Required For Direct Vent Applications

FRONT

MANUAL SHUT OFF VALV E (REQUIRED)

SEDIMENT TRAP

UNION

NOTE: Union may be inside the vestibule where permitted by local codes.

Figure 33 -- Typical Gas Pipe Arrangement

ELECTRICAL CONNECTIONS

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death or property damage.

S Before servicing, disconnect all electrical

power to furnace.

S When servicing controls, label all wires prior

to disconnecting. Reconnect wires correctly.

S Verify proper operation after servicing.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower door switch opens 115--v power to control. No component operation can occur. Do not bypass or close switch with blower door removed.

WARNING

A11035

Figure 32 -- Gas Entry

440 01 7104 02 31

See Figure 37 for field wiring diagram showing typical field 115--v wiring. Check all factory and field electrical connections for tightness.

Field--supplied wiring shall conform with the limitations of 63_F (33_C) rise.

A11338

Specifications subject to change without notice.

Page 32

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

The cabinet MUST have an uninterrupted or unbroken ground according to NEC NFPA 70--2011 or local codes to minimize personal injury if an electrical fault should occur. In Canada, refer to Canadian Electrical Code CSA C22.1. This may consist of electrical wire, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer’s ratings for proper wire gauge. Do not use gas piping as an electrical ground.

CAUTION

FURNACE MAY NOT OPERATE HAZARD

Failure to follow this caution may result in intermittent furnace operation.

Furnace control must be grounded for proper operation or else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw.

115--V Wiring

Furnace must have a 115-v power supply properly connected and grounded.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 10 for equipment electrical specifications.

U.S.A. Installations: Make all electrical connections in accordance with the current edition of the National Electrical Code (NEC) NFPA 70 and any local codes or ordinances that might apply.

Canada Installations: Make all electrical connections in accordance with the current edition of the Canadian Electrical Code CSA C22.1 and any local codes or ordinances that might apply.

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. See Figure 35.

Use a separate, fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 10 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

32 440 01 7104 02

WARNING

J--Box Installation

FIRE OR ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

If field--supplied manual disconnect switch is to be mounted on furnace casing side, select a location where a drill or fastener cannot damage electrical or gas components.

The J-Box is used when field line voltage electrical connections are made to the furnace wiring harness inside the furnace casing. The J-Box is not required if a field-supplied electrical box is attached to the outside of the furnace casing and the box is grounded to the green ground wire of the main wiring harness and the earth ground of the field electrical supply.

The J--Box cover, mounting bracket and screws are shipped in the loose parts bag included with the furnace. The J--Box can be mounted on the left or right side of the casing, as viewed from the upflow position. (See Figure 34)

Remove the J--Box cover and mounting bracket from the loose parts bag. Select a 7/8--in. (22 mm) knock-out on the desired side of the casing. Remove the knock-out from the casing. Drill two (2) 1/8--in. (3 mm) pilot holes in the casing dimples by the desired 7/8--in. (22 mm) knock-out.

Align the J--Box mounting bracket against the inside of the casing and secure the mounting bracket with the screws. (See Figure 34.)

Electrical Box on Furnace Casing Side

NOTE: Check that duct on side of furnace will not interfere with

installed electrical box.

1. Fasten a field-supplied external electrical box to the outside of the casing by driving two field-supplied screws from inside electrical box into casing. (See Figure 35.)

2. Route field power wiring into external electrical box.

3. Pull furnace power wires through 1/2-in. (12 mm) diameter hole in J-Box. If necessary, loosen power wires from strain--relief wire-tie on furnace wiring harness.

4. Connect any code required external disconnect(s) to field power wiring.

5. Route external field power wires through holes in electrical box and casing.

6. Connect field ground wire and factory ground wire to green ground screw on J--Box mounting bracket as shown in Figure 34.

7. Connect field power and neutral leads to furnace power leads as shown in Figure 37.

8. Attach furnace J-Box cover to mounting bracket with screws supplied in loose parts bag. Do not pinch wires between cover and bracket.

9. Complete external disconnect wiring and installation. Connect line voltage leads as shown in Figure 35. Use best practices (NEC) NFPA 70 in U.S.A. for wire bushings, strain relief, etc., CANADA: Canadian Electrical Code CSA C22.1)

Power Cord Installation in Furnace J--Box

NOTE: Power cords must be able to handle the electrical

requirements listed in Table 10. Refer to power cord manufacturer’s listings.

1. Install J--Box mounting bracket to inside of furnace casing. (See Figure 34.)

Specifications subject to change without notice.

WARNING

Page 33

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

2. Route listed power cord through 7/8--in. (22 mm) diameter hole in casing and J--Box bracket.

3. Secure power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used.

4. Pull furnace power wires through 1/2--in. (12 mm) diameter hole in J--Box. If necessary, loosen power wires from strain—relief wire--tie on furnace wiring harness.

5. Connect field ground wire and factory ground wire to green ground screw on J--Box mounting bracket as shown in Figure 34.

6. Connect power cord power and neutral leads to furnace power leads as shown in Figure 37.

7. Attach furnace J--Box cover to mounting bracket with screws supplied in loose parts bag. Do not pinch wires between cover and bracket. (See Figure 34).

BX Cable Installation in Furnace J--Box

1. Install J--Box mounting bracket to inside of furnace casing. See Figure 34.

2. Route BX connector through 7/8--in. (22 mm) diameter hole in casing and J--Box bracket.

3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.

4. Connect field ground wire and factory ground wire to green ground screw on J--Box mounting bracket as shown in Figure 34.

5. Connect field power and neutral leads to furnace power leads. as shown in Figure 37.

6. Attach furnace J--Box cover to mounting bracket with screws supplied in loose parts bag. Do not pinch wires between cover and bracket.

! WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation, personal injury, death, or property damage.

Do no drill into blower shelf of furnace to route control wiring. Route any control or accessory wiring to the blower compartment through external knockouts on the casing.

24--V Wiring

Make field 24--v connections at the 24--v terminal strip. (See Figure 38.) Use only AWG No. 18, color--coded, copper thermostat wire.

NOTE: Use AWG No. 18 color-coded copper thermostat wire for lengths up to 100 ft. (30.5 M). For wire lengths over 100 ft., useAWGNo.16wire.

The 24--v circuit contains an automotive--type, 3--amp. fuse located on the control. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3--amp. fuse of identical size. See Figure 38.

Accessories (See Figure 36 and Figure 38.)

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using 1/4--in. female quick connect terminals to the two male 1/4--in. quick--connect terminals on the control board marked EAC--1 and EAC--2. The terminals are rated for 115VAC, 1.0 amps maximum and are energized during blower motor operation.

2. Humidifier (HUM) The HUM terminal is a 24 VAC output, energized when the LPS closes during a call for heat. Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the ¼--in. male quick--connect HUM terminal and COM--24V screw terminal on the control board thermostat strip. (See Figure 38.)

NOTE: If the humidifier has its own 24 VAC power supply, an isolation relay may be required. Connect the 24 VAC coil of the isolation relay to the HUM and COM/24V screw terminal on the control board thermostat strip. (See Figure 36.)

Alternate Power Supplies

This furnace is designed to operate on utility generated power which has a smooth sinusoidal waveform. If the furnace is to be operated on a generator or other alternate power supply, the alternate power supply must produce a smooth sinusoidal waveform for compatibility with the furnace electronics. The alternate power supply must generate the same voltage, phase, and frequency (Hz) as shown in Table 10 or the furnace rating plate.

Power from an alternate power supply that is non-sinusoidal may damage the furnace electronics or cause erratic operation.

Contact the alternate power supply manufacturer for specifications and details.

VOLTS--

UNIT SIZE

040A030C 115--60--1 127 104 5.2 7.5 14 49 (14.9) 15 060B048C 115--60--1 127 104 8.6 11.7 14 31 (9.4) 15 080B048B 115--60--1 127 104 8.1 11.1 14 33 (10.1) 15 080B048C 115--60--1 127 104 8.1 11.1 14 33 (10.1) 15 080C060C 115--60--1 127 104 8.6 11.7 14 31 (9.4) 15 100C048C 115--60--1 127 104 7.3 10.1 14 36(11.0) 15 100C060C 115--60--1 127 104 11.9 15.8 12 36(11.0) 20 120D060C 115--60--1 127 104 11.9 15.8 12 36(11.0) 20

* Permissible limits of the voltage range at which the unit operates satisfactorily. # Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load

amps.

{Time--delay type is recommended. }Length shown is as measured one way along wire path between furnace and service panel for maximum 2 percent voltage drop.

HERTZ--

PHASE

OPERATING VOLTAGE

RANGE*

Maximum* Minimum*

440 01 7104 02 33

Table 10 – Electrical Data

MAXIMUM

UNIT

AMPS

Specifications subject to change without notice.

UNIT

AMPACITY#

MINIMUM

WIRE

SIZE

AWG

MAXIMUM

WIRE

LENGTH

FT (M)}

MAXIMUM

FUSE OR CKT BKR

AMPS{

Page 34

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

OPTIONAL J--BOX LOCATIONS

Representative drawing only, some models may vary in appearance.

L12F024

J--BOX MOUNTING SCREWS

J--BOX MOUNTING BRACKET

GROUND

NEUTRAL

LINE VOLTAGE

ELECTRIC

DISCONNECT

SWITCH

COPPER

WIRE ONLY

ALUMINUM

WIRE

Figure 35 -- Field--Supplied Electrical Box on Furnace

Casing

A11146

GROUND SCREW

J--BOX COVER

Figure 34 -- Installing J--Box (When Used)

To Humidifier Leads

Figure 36 -- Field--supplied Isolation Relay for Humidifiers with Internal Power Supply

L12F025

To HUM Terminal On

Furnace Control Board

24 V

Coil

To Com/24V Screw Terminal

on Thermostat Strip

A11157

34 440 01 7104 02

Specifications subject to change without notice.

Page 35

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING

FIVE WIRE

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

BLK

WHT

115-V FIELD-

SUPPLIED

BLK

WHT

GND

AUXILIARY J-BOX

DISCONNECT

GND

FURNACE

NOTE 2

WCR GY

N T

COM

24-V

TERMINAL

NOTE 1

BLOCK

NOTES: Connect Y-terminal in furnace as shown for proper blower operation.

1. Some thermostats require a "C" terminal connection as shown.

2. If any of the original wire, as supplied, must be replaced, use

3. same type or equivalent wire.

Figure 37 -- Typical Single--Stage Wiring Diagram

THERMOSTAT TERMINALS

CONDENSING UNIT

TWO WIRE

FIELD-SUPPLIED DISCONNECT

GND

208/230- OR 460-V THREE PHASE

208/230-V SINGLE PHASE

A11387

BLOWER OFF-DELAY

J2 JUMPER

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

COOL

HEAT

BLOWER SPEED

SELECTION TERMINALS

G Com W Y R

24V

STATUS CODE LED

NUETRAL

BLW

COOL HEAT

SPARE-1

SPARE-2

BLOWER OFF-DELAY

TEST/TWIN

0.5 AMP@24VAC

FUSE 3-AMP

SEC-2 SEC-1

EAC-2 L2

SPARE-1 SPARE-2

90 150

HUM

ARE-3

TWINNING AND/OR COMPONENT TEST

TERMINAL

120 180

PLT

PL1

(115-VAC 1.0 AMP MAX.)

SPARE-3

EAC-1 TERMINAL

PR-1

PL2 1

115 VAC (L1) LINE

VOLTAGE CONNECTION

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLTAGE MAIN

HARNESS CONNECTOR

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

Figure 38 -- Example of Single Stage Furnace Control

440 01 7104 02 35

A11619

Specifications subject to change without notice.

Page 36

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

VENTING

NOTE: Planning for the venting system should be done in

conjunction with planning for the ductwork, drainage, and furnace accessories, such as air cleaners and humidifiers. Begin assembling the venting system AFTER the furnace is set in place in the required orientation.

Venting for this furnace shall follow all Local codes for category IV venting systems. This furnace is CSA approved for venting with PVC/ABS DWV venting systems. This furnace is also CSA approved for venting the M&G DuraVentr PolyPror polyproplylene venting systems.

NOTE: THESE INSTRUCTIONS DO NOT CONTAIN DETAILED INSTALLATION INSTRUCTIONS FOR POLYPROPYLENE VENTING SYSTEMS. Refer to the polyproplylene venting system manufacturer’s installation instructions for the polyproplylene venting system installation.

NOTE: When using polypropylene venting systems, all venting materials used, including the vent terminations, must be from the same manufacturer.

Special Venting Requirements for Installations in Canada

Installation in Canada must conform to the requirements of CAN/CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC S636. The special vent fittings, accessory concentric vent termination kits, and accessory external drain trap available from the furnace manufacturer have been certified to ULC S636 for use with those Royal Pipe and IPEX PVC vent components which have been certified to this standard. In Canada, the primer and cement must be of the same manufacturer as the vent system – GVS-65 Primer (Purple) for Royal Pipe or IPEX System 636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and GVS-65 PVC Solvent Cement for Royal Pipe or IPEX System

t, PVC Cement for Flue Gas Venting, rated Class IIA, 65

636

(1)

deg C. must be used with this venting system - do not mix primers and cements from one manufacturer with a vent system from a different manufacturer. Follow the manufacturer’s instructions in the use of primer and cement and never use primer or cement beyond its expiration date.

The safe operation, as defined by ULC S636, of the vent system is based on following these installation instructions, the vent system manufacturer’s installation instructions, and proper use of primer and cement. All fire stop and roof flashing used with this system must be UL listed material. Acceptability under

Canadian standard CAN/CSA B149 is dependent upon full compliance with all installation instructions. Under this standard, it is recommended that the vent system be checked once a year by qualified service personnel.

The authority having jurisdiction (gas inspection authority, municipal building department, fire department, etc) should be consulted before installation to determine the need to obtain a permit.

*IPEX System 636™ is a trademark of IPEX Inc.

Consignes spéciales pour l’installation de ventilation au Canada

L’installation faite au Canada doit se conformer aux exigences du code CAN/CSA B149--2010. Ce systême de ventillation doit se composer de tuyaux, raccords, ciments et apprêts conformes au ULC S636. La tuyauterie de ventilation des gaz, ses accessoires, le terminal concentrique mural ainsi que l’ensemble du drain de condensation extérieur fourni par le fabricant de cette fournaise ont été certifiés ULC S636 pour l’application des composantes Royal Pipe, IPEX PVC qui sont certifiées à ce standard. Au Canada, l’apprêt et le ciment doivent être du même fabricant que le système d’évacuation. L’apprêt GVS-65 (Purple) et le ciment-solvant GVS-65 doivent être utilisé avec les Royal Pipe. Système IPEX 636, apprêt PVC/CPVC, Purple pour évacuation des gaz de combustion et système IPEX 636(1)t, ciment PVC pour évacuation des gaz de combustion, coté classe IIA, 65 deg C. doivent être utilisés avec le système d’évacuation IPEX 636 – Ne pas combiner l ’apprêt et le ciment d’un manufacturier avec un système d’évacuation d’un manufacturier différent.

Bien suivre les indications du manufacturier lors de l’utilisation de l’apprêt et du ciment et ne pas utiliser ceux-ci si la date d’expiration est atteinte.

L’opération sécuritaire, tel que définit par ULC S636, du système de ventilation est basé sur les instructions d’installation suivantes, ainsi que l’usage approprié de l’apprêt et ciment. Tout arrët feu et solin de toit utilisés avec ce système doivent être des matériaux listés UL. L’acceptation du standard Canadien CAN/CSA B149 est directement relié à l’installation conforme aux instructions ci- haut mentionnées. Le standard Canadien recommande l’ inspection par un personel qualifié et ce, une fois par année.

Les autoritées ayant juridiction (inspecteurs de gas, inspecteurs en bâtiments, département des incendies, etc) devraient être consultées avant l’installation afin de déterminer si un permis est requis.

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INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

system, or Figure 54 for single--pipe or ventilated combustion

WARNING

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.

1. Seal any unused openings in 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 Code 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 betweenthe space in which theappliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryersand anyappliance notconnected to the venting system. Turn on any exhaust fans, such asrange 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 hoodrelief openingafter 5 minutesof main burner operation. Usethe 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 CSAB149.1 Natural Gasand Propane Installation Code.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaustfans, fireplacedampers andany othergas--fired burning appliance to their previous conditions of use.

General

If this furnace replaces a furnace that was connected to a vent system or chimney, the vent or vent connectors of other remaining appliances may need to be re--sized. Vent systems or vent connectors of other appliances must be sized to the minimum size as determined using appropriate table found in the current edition of National Fuel Gas Code NFPA 54/ANSI Z--223.1. In Canada, refer to CAN/CSA--B149.1.

An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion--air (when applicable) and vent pipes. Each furnace must have its own set of combustion--air and vent pipes and be terminated individually, as shown in Figure 53 for Direct Vent (2--Pipe)

air option. A furnace shall not be connected to a chimney flue serving a

separate appliance designed to burn solid fuel. Other gas appliances with their own venting system may also use the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code, and the vent or liner manufacturer’s installation instructions. Care must be taken to prevent the exhaust gases from one appliance from contaminating the combustion air of other gas appliances.

Do not take combustion air from inside the chimney when using ventilated combustion air or single--pipe vent option.

These furnaces can be vented as direct--vent (two--pipe), ventilated combustion air, or non-direct (single--pipe) vent system. Each type of venting system is described below. Common venting between these furnaces or other appliances is prohibited.

Materials

U.S.A.

Combustion air and vent pipe, fittings, primers, and solvents must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards. See Table 12 for approved materials for use in the U.S.A. This furnace is also CSA approved for venting with M&G DuraVent® PolyPro® polyproplylene venting systems.

Canada

Special Venting Requirements for Installations in Canada Installation in Canada must conform to the requirements of CAN/CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC S636. M&G DuraVent PolyPro polyproplylene venting systems are ULC S636 listed.

NOTE: When using polypropylene venting systems, all venting materials used, including the vent terminations, must be from the same manufacturer.

Venting Systems

CARBON MONOXIDE POISONING HAZARD

Failure to follow the instructions outlined below for each appliance being placed into operation could result in carbon monoxide poisoning or death.

For allventing configurations for this appliance and other gas appliances placed into operation for the structure, provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

U.S.A. Installations: Section 9.3 NFPA 54/ANSI Z223.1 1--2012, Air for Combustion and Ventilation and applicable provisions of the local building codes.

Canadian Installations: Part 8 of CAN/CSA--B149.1--10. Venting Systems and Air Supply for Appliances and all authorities having

WARNING

jurisdiction.

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NOTICE

RECOMMENDED SUPPORT FOR VENT TERMINATIONS

It is recommended that sidewall vent terminations of over 24 inches (0.6 M) in length or rooftop vent terminations of over 36 inches (1 M) in length be supported by EITHER the factory accessory vent termination kit or field-supplied brackets or supports attached to the structure. A factory accessory vent termination kit may be used for direct vent terminations. Termination kits are available for 2-in. or 3-in. pipe. See Table 11 for available options.

Table 11 – Vent Termination for Direct Vent (2--pipe)

Systems

Direct Vent (2--Pipe)

Termination Kit

2--in (51 mm)

Concentric Vent Kit

3--in (76 mm)

Concentric Vent Kit

2--in (51 mm)

Termination Bracket

Kit

3--in (76 mm)

Termination Bracket

Termination System

Single Penetration of

Wall or Roof

Single Penetration of

Wall or Roof

2--Pipe Termination

System

2--Pipe Termination

System

Diam. Of

Combustion Air and

Vent Pipes

in.(mm)

1,1--1/2,2,or2--1/2

(25, 38, 51, 64 mm)

2--1/2, 3 or 4

(64, 76, 102 mm)

1,1--1/2,2,or2--1/2

(25, 38, 51, 64 mm)

2--1/2, 3 or 4

(64, 76, 102 mm)

Direct Vent / 2-Pipe System

In a direct--vent (2--pipe) system, all air for combustion is taken directly from outdoor atmosphere, and all flue products are discharged to outdoor atmosphere. Combustion-air and vent pipes must terminate together in the same atmospheric pressure zone, either through the roof (preferred) or a sidewall. See Figure 51 for references to clearances required by National code authorities.

NOTICE

OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

When sizing venting systems, the equivalent length of the optional inlet pipe moisture trap must be taken into account.

Ventilated Combustion Air Systems

In a ventilated combustion air option, the vent terminates and discharges the flue products directly to the outdoors similar to a direct vent system. See Figure 52 for references to clearances required by National code authorities.

All air for combustion is piped directly to the furnace from a space that is well ventilated with outdoor air (such as an attic or crawl space) and the space is well isolated from the living space or garage. Combustion air requirements for this option are the same as the requirements for providing outside air for combustion for a single pipe vent system. Refer to the “Air For Combustion and Ventilation Section.

Non-Direct Vent (1-pipe) System

In a non direct-vent (1-pipe) system, all air for combustion is taken from the area adjacent to furnace, and all flue products are discharged to outdoor atmosphere. Air for combustion must be supplied as described in the Air For Combustion and Ventilation Section. Do not use an abandoned chimney to supply outside air to the furnace. See Figure 52 for references to clearances required by National code authorities.

A combustion air pipe to the outdoors is not required for a single pipe vent system. A 12-in. (304 mm) long pipe with a 2--in. (50 mm Nominal Dimension-- ND) tight radius 90 degree elbow is required to be attached to the combustion air pipe adapter on the furnace. (See Figure 50) This short inlet air pipe helps to ensure stable combustion, as well as allow for sound attenuation. To aid sound attenuation, point the inlet air pipe away from occupants. An extra elbow and/or five feet (1.5 M) of pipe may be used to accomplish the sound attenuation function.

NOTICE

OPTIONAL VENTING BELOW THE FURNACE

The venting system may be positioned below the furnace ONLY IF the factory accessory External Vent Trap Kit is used. The External Vent Trap Kit is only approved for PVC/ABS DWV venting systems.

CAREFULLY FOLLOW THE INSTRUCTIONS PROVIDED WITH THE EXTERNAL VENT TRAP KIT FOR LAYING OUT THE VENTING SYSTEM AND THE DRAIN SYSTEM. The instructions included with

this furnace DO NOT APPLY to vent systems that are located below the furnace.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the instructions outlined in Locating the Vent Termination for each appliance being placed into operation could result in carbon monoxide poisoning or death.

The instructions included with this furnace DO NOT APPLY to vent systems that are located below the furnace.

CAREFULLY FOLLOW THE INSTRUCTIONS PROVIDED WITH THE EXTERNAL VENT TRAP KIT FOR LAYING OUT THE VENTING SYSTEM AND THE DRAIN SYSTEM when all or part of the venting system is placed below the furnace.

Proper configuration of the venting and drain system is critical when placing all or part of the venting system below the level of the furnace. VENT GASSES COULD BE RELEASED FROM THEDRAINAGE SYSTEM, ifthe instructions provided with the External Vent Trap Kit are not followed.

Locating the Vent Termination

General

NOTE: Termination Requirements for the Provinces of Alberta and Saskatchewan are located at the end of this section.

Combustion--air inlet pipe (direct vent/2--pipe system only) and vent pipe must terminate outside structure, either through sidewall or roof.

WARNING

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INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

For vent termination clearance, references to National codes are shown in Figure 51 for Direct Vent/2--Pipe system and Figure 52 for Ventilated Combustion Air/Non--direct Vent/1--Pipe system. For exterior termination arrangements, refer to Figure 53 for Direct Vent/2--Pipe system and Figure 54 for Ventilated Combustion Air/Non-- Direct/1--Pipe system. Contact Local code authorities for other requirements to and/or exemptions from the National codes shown in the figures.

Roof termination is the recommended termination location. Roof terminations provide better performance against sustained prevailing winds. The roof location is preferred since the vent and combustion air system is less susceptible to damage or contamination. The termination is usually located away from adjacent structures or other obstacles such as inside corners, windows, doors or other appliances. It is less prone to icing conditions, and it often has less visible vent vapors.

Sidewall terminations may require sealing or shielding of building surfaces with a corrosive resistance material due to the corrosive properties of combustion products from the vent system, as well as protection of adjacent structures.

NOTE: (Direct Vent/2--Pipe system ONLY) A factory accessory termination kit MUST be used. See Table 11 for available options.

NOTICE

RECOMMENDED SUPPORT FOR VENT TERMINATIONS

It is recommended thatsidewall vent terminations ofover 24 inches (0.6 M) in length or rooftop vent terminations of over 36 inches (1 M) in vertical length be supported by EITHER the Direct Vent Termination Kit shown in Table 11 or by field-supplied brackets or supports fastened to the structure.

When determining appropriate location for termination, consider the following guidelines:

1. Comply with all clearance requirements stated in Figure 51 or Figure 52 per application.

2. Termination or termination kit should be positioned where vent vapors will not damage plants/shrubs, air conditioning equipment or utility meters.

3. Do not locate termination directly into prevailing winds. Termination should be positioned so that it will not be affected by sustained prevailing winds over 30 mph, wind eddy, such as inside building corners, or by recirculation of flue gases, airborne leaves, or light snow.

4. Termination or termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones, balls, etc.

5. Termination or termination kit should be positioned where vent vapors are not objectionable.

INSIDE CORNER TERMINATIONS

Corner terminations for Direct Vent (2--pipe) terminations are permitted provided that:

1. The Direct Vent termination is located on the longer of the two walls.

2. The Direct Vent termination is located at a distance farther away from the inside corner than the length of the adjacent wall

3. All other clearance requirements are met

Example:

1. The length of wall “A” is 15--ft and the length of wall “B” is 6--ft.

2. Therefore, the Direct Vent termination must be located on wall “A”.

3. The Direct Vent termination must be located at least 6--ft. away from the inside corner.

L14F028

Figure 39 -- Inside Corner Termination

Direct Vent / 2-Pipe System

Direct vent (2--pipe) vent and combustion air pipes must terminate outside the structure. See Figure 51 for references to vent clearances required by National code authorities. Allowable vent and combustion air terminations are shown in Figure 53.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the instructions outlined below for each appliance being placed into operation could result in carbon monoxide poisoning or death.

For all venting configurations for this appliance and other gas appliances placed into operation for the structure, provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

U.S.A. Installations: Section 9.3 NFPA 54/ANSI Z223.1 1--2012, Air for Combustion and Ventilation and applicable provisions of the local building codes.

Canadian Installations: Part 8 of CAN/CSA--B149.1--10. Venting Systems and Air Supply for Appliances and all authorities having jurisdiction.

Ventilated Combustion Air

The vent pipe for a Ventilated Combustion Air System must terminate outdoors. See Figure 52 for references to vent clearances required by National code authorities. Allowable vent terminations are shown in Figure 54 The combustion air pipe terminates in a well--ventilated attic or crawl space. Follow the clearances as shown in Figure 56.

The combustion air pipe cannot terminate in attics or crawl spaces that use ventilation fans designed to operate in the heating season. If ventilation fans are present in these areas, the combustion air pipe must terminate outdoors as a Direct Vent System.

Non-Direct Vent / 1-Pipe System

The vent pipe for a Non Direct Vent (1--pipe) system must terminate outdoors. See Figure 52 for references to vent

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INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

clearances required by National code authorities. Allowable vent terminations are shown in Figure 54.

A combustion inlet air pipe to the outdoors is not required for a Non--Direct Vent System. A 12--in. long section of pipe with a tight radius 2--in. (51 mm) 90 degree elbow is required to be attached to the furnace. See Figure 55. This short inlet air pipe helps to ensure inlet air pipe away from occupants. An extra elbow and/or five fee (1.5 M) of pipe may be used to accomplish the sound attenuation function.

Termination Requirements for the Provinces of Alberta and Saskatchewan

The Provinces of Alberta and Saskatchewan require a minimum unobstructed distance of 4 ft. (1.2 M) from the foundation to the property line of the adjacent lot for vent termination of any appliance with an input over 35,000 btuh. If there is less than 4 ft. (1.2 M) of unobstructed distance to the property line of the adjacent lot, no type of vent termination is permitted for appliances with inputs greater than 35,000 btuh.

There are no additional restrictions on unobstructed distances greater than 8 ft. (2.4 M). All single, two-pipe and concentric vents may be used, providing all other Code and manufacturer’s requirements in these instructions are adhered to. Refer to the appropriate Vent Termination section above for locating the vent termination

If the unobstructed distance from the foundation to the property line of the adjacent lot is no less than 4 ft. (1.2 M) and no greater than 8 ft. (2.4 M), it will be necessary to re-direct the flue gas plume. In this situation, a concentric vent kit cannot be used. A 2-pipe termination (or single pipe termination when permitted) that re-directs the flue gas away by use of an elbow or tee, certified to ULC S636 from the adjacent property line must be used. See Figure 55.

The concentric vent kit currently cannot be modified to attach an elbow to the vent portion of the rain cap. A tee attached to the rain cap could potentially direct the flue gas plume toward the intake air stream and contaminate the incoming combustion air for the furnace.

Refer to Figure 55 for terminations approved for use in Alberta and Saskatchewan.

Size the Vent and Combustion Air Pipes

General

Approved 2--pipe

Vent or Combustion Air

Pipe Diameters

1 1/2--in. X N/A N/A

2--in. X N/A N/A

2 1/2--in. N/A X N/A

3--in. N/A X N/A 4--in. N/A X X

Note: Optional accessory 2--pipe termination brackets are

sized for 2--in. and 3--in. Pipe. If a termination bracket is required for a 4--in. termination, field fabricate the necessary brackets and clamps.

Furnace combustion air and vent pipe connections are sized for 2-in. (50 mm ND) PVC/ABS DWV pipe. The combustion air and vent pipe connections also accommodate 60mm polypropylene venting systems with outside diameters of approximately 60 mm (2--3/8 inches). Any pipe diameter change should be made outside furnace casing in vertical pipe. Any change in diameter to the pipe must be made as close to the furnace as reasonably possible. See Figure 40.

termination fittings

2--in. 3--in. 4--in.

The Maximum Vent Length for the vent and combustion air pipe (when used) is determined from the Maximum Equivalent Vent Length in Table 14, minus the number of fittings multiplied by the deduction for each type of fitting used from Table 15.

FURNACE

NOT IN HORIZONTAL SECTION

PIPE DIAMENTER TRANSITION IN SECTION

A93034

Figure 40 -- Combustion--Air and Vent Pipe

Diameter Transition Location and Elbow

Configuration

NOTICE

OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

In applications where there is a risk of excessive moisture entering the combustion air inlet pipe, a moisture trap may be added to the inlet pipe to help prevent moisture from entering the furnace from the combustion air inlet pipe. See Figure 57. When sizing venting systems, the equivalent length of the optional moisture trap (15 feet/5 M) must be taken into account.

Combustion Air Inlet Moisture Trap

To prevent moisture from trickling into the furnace vestibule, a trap can be installed in the intake air pipe near the furnace. Connecting a drain line to the trap is recommended as trace amounts of moisture will evaporate into the intake air stream. If the combustion air inlet is located near a moisture exhaust duct, or there are other concerns of excessive moisture being drawn into the combustion air inlet, it is encouraged to connect adrainlinetothetrap.

The trap can be constructed from a running tee of the same diameter of the intake air pipe with EITHER a removable cap attached to a 6-inch long pipe connected to the tee or the External vent Trap Kit to help prevent contaminants from entering the furnace. See

The External Vent Trap Kit accessory may be used as a trap for the combustion air inlet pipe if a large amount of moisture must be removed. The drain line may be connected to the same drain as the furnace condensate and the evaporator coil condensate line ONLY if the inlet air trap drain and the evaporator coil drain empty into an open segment of pipe above the drain, See Trap Kit, refer to those instructions for proper drain connections.

The tee may also be connected to the intake air pipe on the side of the casing. See

In any configuration, it will be necessary to add the equivalent length of the tee (15 feet/5 M) to the Total Equivalent Vent Length of the venting system.

Figure 57.

Figure 13. When using the External Vent

Figure 57.

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INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

7. Select a diameter of vent pipe from Table 14 and note

NOTICE

ADDITIONAL INFORMATION FOR POLYPROPYLENE VENTING SYSTEMS

Polypropylene venting systems include flexible vent pipe. These flexible vent pipes have a different equivalent vent length than straight sections of PVC/ABS DWV vent pipe. Be sure to make the appropriate deductions from the Maximum Equivalent Vent Length (MEVL), or additions to the Total Equivalent Vent Length (TEVL), when applying flexible vent pipes in polypropylene venting systems. See the polypropylene vent system manufacturer’s installation instructions for details.

When using metric-sized venting systems, use these equivalencies for obtaining the proper MEVL from the Tables:

Use 2” Vent Tables for 60mm (o.d.) vent systems Use 3” Vent Tables for 80mm (o.d.) vent systems Use 4” Vent Tables for 100mm (o.d.) vent systems

The measured length of pipe used in a single or 2--pipe termination is included in the total vent length. Include deductions from the Maximum Equivalent Vent Length (MEVL) contained in the Venting Tables for elbows and flexible vent pipe. Factory accessory concentric vent terminations, or pipe lengths and elbows used for “standard” vent terminations (see vent termination figures associated with Table 14 do not require a deduction from the Maximum Equivalent Vent Length. Include a deduction for a Tee when used for Alberta and Saskatchewan terminations.

NOTE: Polypropylene venting systems MAY require additional deductions from the MEVL, or additions to the TEVL, for vent terminations and flexible pipe sections. See the polypropylene venting system manufacturer’s instructions for details on equivalent lengths of vent terminations and flexible vent pipes, and for calculating total vent lengths.

To calculate the Total Equivalent Vent Length (TEVL) of the venting system:

1. Measure the individual distance from the furnace to the termination for each pipe.

2. Count the number of elbows for each pipe.

3. For each pipe, multiply the number of elbows by the equivalent length for the type of elbow used. Record the equivalent length of all the elbows for each pipe.

4. If a Tee is used on the termination (Alberta and Saskatchewan, when required), record the equivalent length of the Tee used.

5. Calculate Total Equivalent Vent Length by adding the equivalent lengths of the fittings to the lengths of the individual vent and combustion air pipes.

6. When using polypropylene venting systems with flexible vent pipes, perform adjustments for the equivalent length of the flexible vent pipe to the calculated total equivalent venting system length. See the polypropylene vent system manufacturer’s instructions for details.

the Maximum Equivalent Vent Length (MEVL) shown for that application for that specific furnace input size. Compare the Total Equivalent Vent Length (TEVL) to the MEVL:

a. If the Total Equivalent Vent Length is shorter than the

Maximum Equivalent Vent Length for the diameter of pipe chosen, then that diameter of pipe selected may be used.

b. If the Total Vent Length is longer than the Maximum

Equivalent Vent Length for the diameter of pipe chosen, that diameter pipe MAY MOT be used for

venting the furnace. Try the next larger diameter pipe. NOTE: If the calculated Total Equivalent Vent Lengths results in different diameter pipes for the vent and combustion air, select the larger diameter for both pipes. NOTE: If the Maximum Vent Length for diameter of the pipe selected is longer than the measured length and the equivalent length of all the fittings and terminations, recalculate Total Equivalent Vent Length using the next smaller diameter. If the Maximum Vent Length is still longer than the longer TEVL of the vent pipe or combustion air pipe, then that diameter of pipe selected may be used. When installing vent systems with pipe lengths of 10 ft. (3.0 M)

or less, use the smallest allowable pipe diameter. Using pipe size greater than required for short venting systems may result in loss of efficiency, incomplete combustion, flame disturbance, or flame sense lockout.

For vent systems longer than 10 ft. (3.0 M), any larger diameter show in Table 14 may be used.

Combustion Air and Vent Piping Insulation Guidelines

NOTE: Use closed cell, neoprene insulation or equivalent.

The vent pipe may pass through unconditioned areas. The amount of exposed pipe allowed is shown in Table 13.

1. Using winter design temperature (used in load calculations), find appropriate temperature for your application and furnace model.

2. Determine the amount of total and exposed vent pipe.

3. Determine required insulation thickness for exposed pipe length(s).

4. When combustion air inlet piping is installed above a suspended ceiling, the pipe MUST be insulated with moisture resistant insulation such as Armaflex or other equivalent type of insulation.

5. Insulate combustion air inlet piping when run in warm, humid spaces.

6. Install the insulation per the insulation manufacturer’s installation instructions.

NOTE: Pipe length (ft. / M) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as calculated from Table 14.

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Configure the Furnace

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

To route the vent pipe and combustion air pipe through the furnace, the manufacturer supplied kit must be used. Failure to properly seal the blower compartment from the furnace vestibule could result in the circulation of carbon monoxide throughout the structure. The vent pipe and combustion air pipe must be a continuous pipe while passing through the blower compartment. Seals supplied in this kit must be installed per the instructions provided. Follow all procedures outlined in these instructions.

Near Furnace Vent Connections

Offsets in the vertical portion of the vent pipe should be made with 45 degree elbows instead of 90 degree elbows. Short horizontal runs of vent pipe are difficult to pitch correctly and may trap water in the vent pipe. Trapped water in the vent pipe may result in nuisance pressure switch tripping.

Avoid short horizontal offsets with 90 deg. Elbows. Short offsets can be difficult to slope and may trap condensate.

Slope vent pipe back to the furnace at least ¼” per foot

Use 45 deg. Elbows where possible, to ensure condensate drainage.

L14F020A

Install the Vent and Combustion Air Pipe

With the furnace installed in the required position, remove the desired knockouts from the casing. It will be necessary to remove one knockout for the vent pipe and the other knockout for the combustion air connection. (See Figure 12.)

Use a flat blade screwdriver and tap on the knockout on opposite sides, where the knockout meets the casing. Fold the knockout down with duct pliers and work the knockout back and forth until it is removed. Trim any excess metal from the knockout with tin snips.

The vent elbow can be rotated to the required location on the casing if necessary. See Figure 43. To rotate the vent elbow:

1. Loosen the clamp on the inlet of the vent elbow attached to the inducer.

2. Rotate the vent elbow to the required position. There are rounded notches on the vent elbow to align it with the inducer housing for each orientation.

3. Tighten the clamp around the vent elbow. Torque the clamp to 15 lb--in. See Figure 45--Figure 48.

Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

DO NOT use cement to join polypropylene venting systems. Follow the polypropylene venting system manufacturer’s instructions for installing polypropylene venting systems.

WARNING

Figure 41 -- Combustion--Air and Vent Pipe Diameter

Transition Location and Elbow Configuration

42 440 01 7104 02

NOTE: The rubber coupling that attaches to the vent pipe adapter must be used. The adapter seals the vent pipe to the casing and reduces the strain on the vent elbow attached to the inducer.

1. Apply the gaskets to the vent pipe and combustion air pipe adapters. If supplied, remove and discard round center “slug” from interior of gasket. See Figure 42.

NOTE: The vent pipe adapter can be distinguished from the

L14F020B

Specifications subject to change without notice.

inlet pipe adapter by the absence of an internal pipe-stopping ring. The vent pipe can pass through the vent pipe adapter; it cannot pass through the inlet pipe adapter.

2. Align the screw holes in the plastic vent pipe adapter with the dimples in the casing.

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INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

3. Pilot drill the screw holes for the adapter in the casing and attach the vent pipe adapter to the furnace with sheet metal screws

4. Slide the end of the rubber vent coupling with notches in it over the standoffs on the vent pipe adapter.

5. Insert a length of vent pipe through the coupling into the outlet of the vent elbow.

6. Tighten the clamp around the outlet of the vent elbow. Torque the clamp to 15 lb-- in.

NOTICE

The following instructions are for PVC/ABS DWV vent piping, only. DO NOT USE THESE TECHNIQUES FOR POLYPROPYLENE VENT PIPING SYSTEMS. See the polypropylene vent system manufacturer’s instructions for installing polypropylene venting systems.

Install the remaining vent and combustion air pipes as shown below. It is recommended that all pipes be cut, prepared, and preassembled before permanently cementing any joint.

1. Working from furnace to outside, cut pipe to required length(s).

2. De--burr inside and outside of pipe.

3. Chamfer outside edge of pipe for better distribution of primer and cement.

4. Clean and dry all surfaces to be joined.

5. Check dry fit of pipe and mark insertion depth on pipe.

6. Insert the vent pipe into the vent elbow.

7. Torque clamp on vent elbow 15 lb--in.

8. Torque clamp on vent coupling 15 lb--in.

9. Insert the combustion air pipe into the adapter.

10. Pilot drill a screw hole through the adapter into the combustion air pipe and secure the pipe to the adapter with sheet metal screws. DO NOT DRILL INTO POLYPROPYLENE VENT PIPES. Use an optional accessory vent coupling, if needed.

11. Seal around the combustion air pipe with silicone or foil tape. SILICONE SEALERS MAY NOT BE APPROPRIATE FOR POLYPROPYLENE VENT SYSTEMS. SEE POLYPROPYLENE VENT SYSTEM MANUFACTRUER’S INSTRUCTIONS.

12. After pipes have been cut and preassembled, apply generous layer of cement primer to pipe fitting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat. DO NOT CEMENT POLYPROPYLENE FITTINGS.

13. While cement is still wet, twist pipe into socket with 1/4--in. turn. Be sure pipe is fully inserted into fitting socket.

14. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint.

15. Handle pipe joints carefully until cement sets.

16. Horizontal portions of the venting system shall be supported to prevent sagging. Space combustion air piping and vent piping hangars as shown in the table below. Support pipes using perforated metal hanging strap or commercially available hangars or straps designed to support plastic pipe.

Hangar Spacing

Material

PVC Sch

CPVC

ABS

Polypr op

ylene

SDR 21

&26

1½-in.

(38-mm)

(914-mm)

30-in.

(762-mm)

(51-mm)

36-in.

2-in.

Pipe Diameter

2½-in.

(64-mm)

42-in.

(1067-mm)

42-in.

(1067-mm)

42-in.

(1067-mm)

40-in.

(1000-mm)

36-in.

(914-mm)

3-in.

(76-mm)

4-in.

(102-mm)

48-in.

(1219-mm)

48-in.

(1219-mm)

48-in.

(1219-mm)

42-in.

(1067-mm)

! CAUTION

FURNACE RELIABILITY HAZARD Failure to follow this caution may result in nuisance short

cycling, frozen vent termination, and/or no heat. Slope the vent and combustion air piping downward towards

furnace at a minimum of 1/4--in. per linear ft. of pipe.

17. Slope the vent and combustion air piping and downward towards furnace. A minimum slope of at least 1/4 in. per linear ft.(1 in. per 4 ft.) with no sags between hangers is required. See Caution Box below

18. Complete the vent and combustion air pipe installation by connecting the concentric vent or by installing the required termination elbows as shown in Figs. Figure 53, Figure 54 and Figure 55.

19. For Ventilated Combustion Air Termination, See Figure 56.

20. Use appropriate methods to seal openings where combustion air pipe and vent pipe pass through roof or sidewall.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

DO NOT use cement to join polypropylene venting systems. Follow the polypropylene venting system manufacturer’s instructions for installing polypropylene venting systems.

Optional Installation of the vent pipe

NOTE: DO NOT USE THIS TECHNIQUE FOR

POLYPROPYLENE VENTING SYSTEMS. This option provides a disconnect point for the vent pipe. The

vent pipe must be cemented to the plastic vent pipe adapter to maintain a sealed vestibule. See Figure 49.

1. Insert a length of vent pipe through the casing into the outlet of the vent elbow.

2. Slide the plastic vent pipe adapter over the length of the vent pipe down to the furnace casing. Mark the pipe where it is flush with the outlet of the adapter.

3. Remove the pipe from the furnace and the adapter and cut off any excess pipe.

4. Clean and prime the end of the pipe that is flush with the vent adapter with a primer that is appropriate for the type of pipe being used.

5. Re--insert the pipe through the casing into the vent elbow.

WARNING

440 01 7104 02 43

Specifications subject to change without notice.

Page 44

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

6. Tighten the clamp around the outlet of the vent elbow. Torque the clamp to 15 lb-- in.

7. Apply cement to the end of the pipe and to the inside of the plastic vent adapter.

8. Slide the adapter over the vent pipe and align the screw holes in the adapter with the dimples in the furnace casing.

9. Pilot drill 1/8--in. screw holes for the adapter in the casing and secure the adapter to the furnace with sheet metal screws.

10. Loosen the clamps on the rubber vent coupling.

11. Slide the end of the coupling with notches in it over the standoffs in the vent pipe adapter.

12. Tighten the clamp of the coupling over the vent pipe adapter. Torque the lower clamp around the vent pipe adapter to 15 lb--in.

13. Pilot drill a 1/8--in. hole in the combustion air pipe adapter.

14. Complete the vent and combustion air pipe as shown in “Install the Vent and Combustion Air Pipe”

NOTICE

FOR POLYPROPYLENE VENTING SYSTEMS

When using polypropylene venting systems, all venting materials used, including the vent terminations, must be from the same manufacturer.

! WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

DO NOT use cement to join polypropylene venting systems. Follow the polypropylene venting system manufacturer’s instructions for installing polypropylene venting systems.

NOTE: Follow the instructions of the vent terminal manufacturer. These instructions are provided as a reference only.

Cut one 4--in. (102 mm) diameter hole for 2--in. (50 mm ND) kit, or one 5--in. (127 mm) diameter hole for 3--in. (80 mm ND) kit in the desired location.

Loosely assemble concentric vent/combustion air termination components together using instructions in kit.

Slide assembled kit with rain shield REMOVED through hole in wall or roof flashing.

NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.

Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. DO NOT CEMENT POLYPROPYLENE FITTINGS.

Two--Pipe and Single--Pipe Terminations

Single and two pipe vent must be installed as shown in Figure 53 and Figure 54. Maintain the required separation distance between vents or pairs of vents as shown in Figure 53 and Figure 54. and all clearance shown in Figure 51 and Figure 52 .

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

DO NOT use cement to join polypropylene venting systems. Follow the polypropylene venting system manufacturer’s instructions for installing polypropylene venting systems.

Installing the Vent Termination

Roof Terminations

A roof termination of any type will require a 4-in. (102 mm) flashing for a 2--in. (50 mm ND) concentric vent or a 5--in. (127 mm) diameter flashing for a 3-in. (80 mm ND) concentric vent kit. For two-pipe or single pipe vent systems, a flashing for each pipe of the required diameter will be necessary.

It is recommended that the flashing be installed by a roofer or competent professional prior to installing the concentric vent. The terminations can be installed on a flat or pitched roof.

Concentric Vent

Single or multiple concentric vent must be installed as shown in Figure 53. Maintain the required separation distance between vents or pairs of vents as shown in Figure 53 and all clearance shown in Figure 51.

NOTICE

RECOMMENDED SUPPORT FOR VENT TERMINATIONS

It is recommended that rooftop vent terminations in excess of 36 inches (1.0 M) in vertical length be supported by EITHER the Direct Vent Termination Kit shown in Table 11 or by field-supplied brackets or supports fastened to the structure.

Cut the required number of holes in the roof or sidewall for vent and (when used) combustion air pipes. Sidewall holes for two-pipe vent terminations should be side-by-side, allowing space between the pipes for the elbows to fit on the pipes.

Holes in the roof for direct--vent (two--pipe) terminations should be spaced no more than 18--in. (457 mm) apart to help avoid vent gas recirculation into combustion air intake.

Termination elbows will be installed after the vent and (if used) combustion air pipe is installed.

Sidewall Terminations Concentric Vent

NOTE: Follow the instructions of the vent terminal

manufacturer. These instructions are provided as a reference, only.

Determine an appropriate location for termination kit using the guidelines provided in section “Locating The Vent Termination” in this instruction.

1. Cut one 4--in. diameter hole for 2--in. kit, or one 5--in. diameter hole for 3--in. kit.

2. Loosely assemble concentric vent/combustion air termination components together using instructions in kit.

44 440 01 7104 02

Specifications subject to change without notice.

Page 45

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

3. Slide assembled kit with rain shield REMOVED through hole.

NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.

4. Locate assembly through sidewall with rain shield positioned no more than 1--in. (25 mm) from wall as shown in Figure 53.

5. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. DO NOT CEMENT POLYPROPYLENE FITTINGS.

Two-Pipe and Single-Pipe Vent Termination

NOTE: Follow the instructions of the vent terminal

manufacturer. These instructions are provided as a reference, only.

NOTICE

RECOMMENDED SUPPORT FOR VENT TERMINATIONS

It is recommended that side--wall vent terminations in excess of 24 inches (0.6 M) in vertical length be supported by EITHER the Direct Vent Termination Kit in Table 12 or by field-supplied brackets or supports fastened to the structure.

Determine an appropriate location for termination kit using the guidelines provided in section “Locating The Vent Termination”

in this instruction.

1. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size being used.

2. Loosely install elbow in bracket (if used) and place assembly on combustion--air pipe.

3. Install bracket as shown in Figure 53 and Figure 55. NOTE: For applications using vent pipe option indicated by dashed lines in Figure 53 and Figure 54, rotate vent elbow 90_

from position.

4. Disassemble loose pipe fittings. Clean and cement using

same procedures as used for system piping. DO NOT CEMENT POLYPROPYLENE FITTINGS.

(Direct Vent / Two-Pipe System ONLY)

When two or more furnaces are vented near each other, two vent terminations may be installed as shown in Figure 53, but next vent termination, or pair of vent terminations, must be at least 36--in. (914 mm) away from first two terminations. It is important that vent terminations be made as shown in Figure 53 to avoid recirculation of gases.

Inducer Outlet Restrictor

To improve efficiency and operation of 40,000 BTUH input models on very short vent systems, an inducer outlet restrictor is required to be installed on the outlet of the inducer assembly. The outlet restrictor is shipped in the loose parts bag.

To determine if the outlet restrictor is required, see Table 13.

Failure to use an outlet choke when required may result in flame disturbance or flame sense lockout.

To install the outlet restrictor:

1. Remove the vent elbow from the inducer outlet.

2. Align the lock tabs on the outlet restrictor with the slots

on inside outlet of the inducer assembly.

3. Snap the outlet restrictor in place.

4. Re-install the vent elbow.

5. Torque vent elbow clamp 15-lb. in.

Table 12 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A. Installations)

ASTM SPECIFICATION

(MARKED ON MATERIAL)

D1527 ABS Pipe — — Schedule--40 D1785 PVC Pipe — — Schedule--40 D2235 For ABS — — Solvent Cement For ABS D2241 PVC Pipe — — SDR--21 & SDR--26 D2466 PVC — Fittings — Schedule--40 D2468 ABS — Fittings — Schedule--40 D2564 For PVC — — Solvent Cement For PVC D2661 ABS Pipe Fittings — DWV at Schedule--40 IPS sizes D2665 PVC Pipe Fittings — DWV

F438 CPVC — Fittings — Schedule--40 F441 CPVC Pipe — — Schedule--40 F442 CPVC Pipe — — SDR F493 For CPVC — — Solvent Cement For CPVC

F628 ABS Pipe — —

F656 For PVC — — Primer For PVC

F891 PVC Pipe — —

MATERI-

PIPE FITTINGS

SOLVENT CEMENT

AND PRIMERS

DESCRIPTION

Cellular Core DWV at

Schedule--40 IPS sizes

Cellular Core Schedule--40 &

DWV

440 01 7104 02 45

Specifications subject to change without notice.

Page 46

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Table 13 – Maximum Allowable Exposed Vent Length Table -- Ft. / M

Maximum Allowable Exposed Vent Length in Unconditioned Space (Feet)

Unit Size 40,000* BTUH 60,000 BTUH

Pipe Dia.

in.

Winter

Design

Temp

°F

Winter

Design

Temp

°F

Winter

Design

Temp

°F

Winter

Design

Temp

°F

* Not all families have these models

Winter

Design

Temp

°C

Winter

Design

Temp

°C

Winter

Design

Temp

°C

Winter

Design

Temp

°C

* Not all families have these models

20 20 20 20 20 50 45 20 60 50 20 30 30 25 20 75 65 60 20 85 75 65

0 10 5 5 20 25 20 20 30 25 15 15 10 10 20 40 30 25 20 45 40 30

-20 5 20 15 10 20 20 15 10 5 20 25 20 15 20 30 25 20

-40 15 10 5 15 15 10 5 20 15 15 10 20 20 15 10

Unit Size 80,000 BTUH

Pipe Dia.

in.

20 15 40 40 35 30 15 50 90 75 65 15 50 70 70 70

0 15 20 15 10 5 15 50 45 35 30 15 50 50 40 35

-20 15 10 5 15 35 30 20 15 15 40 30 25 15

-40 10 5 15 25 20 15 5 15 30 25 20 10

Unit Size 100,000 BTUH

Pipe Dia.

in.

20 20 50 40 35 20 80 95 80 20 80 105 90

0 20 20 15 10 20 55 45 35 20 65 55 45

-20 15 10 5 20 35 30 20 20 45 35 25

-40 10 5 20 25 20 10 20 30 25 15

Unit Size

Pipe Dia.

in.

20 10 50 40 10 75 95 10 75 105 5 55 50 5 65 105 5 65 125

0 10 20 15 10 55 45 10 65 50 5 25 15 5 65 50 5 65 60

-20 10 10 10 35 25 10 45 30 5 10 5 5 45 30 5 50 40

-40 10 5 10 25 15 10 30 20 5 5 5 30 20 5 35 25

Unit Size 40,000* BTUH 60,000 BTUH

Pipe Dia.

-7 6.1 6.1 6.1 6.1 15.2 13.7 6.1 18.3 15.2 6.1 9.1 9.1 7.6 6.1 22.9 19.8 18.3 6.1 25.9 22.9 19.8

-18 3.0 1.5 1.5 6.1 7.6 6.1 6.1 9.1 7.6 4.6 4.6 3.0 3.0 6.1 12.2 9.1 7.6 6.1 13.7 12.2 9.1

-29 1.5 6.1 4.6 3.0 6.1 6.1 4.6 3.0 1.5 6.1 7.6 6.1 4.6 6.1 9.1 7.6 6.1

-40 4.6 3.0 1.5 4.6 4.6 3.0 1.5 6.1 4.6 4.6 3.0 6.1 6.1 4.6 3.0

Unit Size 80,000 BTUH

Pipe Dia.

-7 4.6 12.2 12.2 10.7 9.1 4.6 15.2 27.4 22.9 19.8 4.6 15.2 21.3 21.3 21.3

-18 4.6 6.1 4.6 3.0 1.5 4.6 15.2 13.7 10.7 9.1 4.6 15.2 15.2 12.2 10.7

-29 4.6 3.0 1.5 4.6 10.7 9.1 6.1 4.6 4.6 12.2 9.1 7.6 4.6

-40 3.0 1.5 4.6 7.6 6.1 4.6 1.5 4.6 9.1 7.6 6.1 3.0

Unit Size 100,000 BTUH

Pipe Dia.

-7 6.1 15.2 12.2 10.7 6.1 24.4 28.9 24.4 6.1 24.4 32.0 27.4

-18 6.1 6.1 4.6 3.0 6.1 16.8 13.7 10.7 6.1 19.8 16.7 13.7

-29 4.6 3.0 1.5 6.1 10.7 9.1 6.1 6.1 13.7 10.7 7.6

-40 3.0 1.5 6.1 7.6 6.1 3.0 6.1 9.1 7.6 4.6

Unit Size 120,000 BTUH 140,000* BTUH

Pipe Dia.

-7 3.0 15.2 12.2 3.0 22.9 28.9 3.0 22.9 32.0 1.5 16.7 15.2 1.5 19.8 32.0 1.5 19.8 38.1

-18 3.0 6.1 4.6 3.0 16.8 13.7 3.0 19.8 15.2 1.5 7.6 4.6 1.5 19.8 15.2 1.5 19.8 18.3

-29 3.0 3.0 3.0 10.7 7.6 3.0 13.7 9.1 1.5 3.0 1.5 1.5 13.7 9.1 1.5 15.2 12.2

-40 3.0 1.5 3.0 7.6 4.6 3.0 9.1 6.1 1.5 1.5 1.5 9.1 6.1 1.5 35 7.6

Uninsulated

1½ 2 2½ 1½ 2 2½ 1½ 2 2½ 1½ 2 2½ 3 1½ 2 2½ 3 1½ 2 2½ 3

1½ 2 2½ 3 4 1½ 2 2½ 3 4 1½ 2 2½ 3 4

2 2½ 3 4 2 2½ 3 4 2 2½ 3 4

Uninsulated

2½ 3 4 2½ 3 4 2½ 3 4 2½ 3 4 2½ 3 4 2½ 3 4

3/8-in. Insulation 1/2-in. Insulation

Uninsulated 3/8-in. Insulation 1/2-in. Insulation

120,000 BTUH 140,000* BTUH

3/8-in. Insulation 1/2-in. Insulation

Uninsulated 3/8-in. Insulation 1/2-in. Insulation

Maximum Allowable Exposed Vent Length in Unconditioned Space (Metric)

Uninsulated

38 51 64 38 51 64 38 51 64 38 51 64 76 38 51 64 76 38 51 64 76

38 51 64 76 102 38 51 64 76 102 38 51 64 76 102

Uninsulated 3/8-in. Insulation 1/2-in. Insulation

51 64 76 102 51 64 76 102 51 64 76 102

Uninsulated

64 76 102 64 76 102 64 76 102 64 76 102 64 76 102 64 76 102

3/8-in. Insulation 1/2-in. Insulation

Uninsulated 3/8-in. Insulation 1/2-in. Insulation

3/8-in. Insulation 1/2-in. Insulation

Uninsulated 3/8-in. Insulation 1/2-in. Insulation

46 440 01 7104 02

Specifications subject to change without notice.

Page 47

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Table 14 – Maximum Equivalent Vent Length Table -- Ft. / M

40,000

Unit Size

Pipe Dia.

(in)

0-2000 20 85 185 2001-3000 3001-4000 70 160 4001-4500 4501-5000 60 145 80 165 145 160 5001-6000 55 130 75 140 155 35 100 135 150 140 155 155 35 80 6001-7000

Altitude (feet)

7001-8000 40 110 65 120 135 120 125 8001-9000

9001-10000 25 85 N/A 55 105 115 20 75 100 105 45 100 115 30 115 10 15

Unit Size

Pipe Dia.

(mm)

0-610 6 26 57

611-914

915-1219 22 49 1220-1370 1371-1524 19 45 24 51 45 50 1525-1829 17 41 82 43 47 11 31 42 46 43 48 48 11 25 1830-2134

Altitude (meters)

2135-2438 12 34 20 37 42 36 39 2439-2743 2744-3048 8 26 N/A 17 33 36 7 24 31 33 14 34 36 12 35 3.5 5

*Not all families have these models.

Outlet choke

required under 10

ft. TEVL

1½ 2 2½ 1½ 2 2½ 3 1½ 2 2½ 3 4 2 2½ 3 4 2½ 3 4 2½ 3 4

80 175 95 165 185

65 155 85

45 120

30 95 5 60 115 125 25 80 110 115 50 115 125 40 120 15 30

N/A

40,000

Outlet choke

required under 10 ft.

TEVL

38 51 64 38 5 64 76 38 51 64 76 102 51 64 76 102 64 76 102 64 76 102

4.5

1.5

N/A

24 53 29 51 57

20 47 26

15 37

10 30 1.5 19 35 38 8 26 34 36 15 36 39 13 38 5 10

60,000 80,000 100,000 120,000 140,000

100 175 200 15 50 130 175 200 20 80 175 200

90 155 175 115 155 175

150

70 130 145

60,000 80,000 100,000 120,000 140,000

31 54 61 2 16 40 54 61 6 25 54 61

6.5 27 48 54 36 48 53

22 40 44

Single Stage feet/inches

170

40 110

30 90

N/A

Single Stage - Meters/mm

N/A

75 185 5 65 155

125 165 185

150 165

125 140 60 135 145 50 140 30 65

38 51 57

13 34

10 27

46 51

39 42 19 41 45 16 43 9 20

15 75

N/A

165 185 70 175 155

70 170

150 165 45 100

55 125 135 45 130 25 45

5 23

51 57 21 54 48

22 52

46 51 14 31

18 38 42 14 40 7 15

175 5 65 165 120

160

N/A

23 57 1.5 21 48

54 1.5 20 51 36

N/A

Table 15 – Deductions from Maximum Equivalent Vent Length -- Ft. (M)

Pipe Diameter (in):

Mitered 90º Elbow 8 (2.4) 8 (2.4) 8 (2.4) 8 (2.4) 8 (2.4)

Medium Radius 90º Elbow 5 (1.5) 5 (1.5) 5 (1.5) 5 (1.5) 5 (1.5)

Long Radius 90º Elbow 3 (0.9) 3 (0.9) 3 (0.9) 3 (0.9) 3 (0.9)

Mitered 45º Elbow 4 (1.2) 4 (1.2) 4 (1.2) 4 (1.2) 4 (1.2)

Medium Radius 45º Elbow 2.5 (0.8) 2.5 (0.8) 2.5 (0.8) 2.5 (0.8) 2.5 (0.8)

Long Radius 45º Elbow 1.5 (0.5) 1.5 (0.5) 1.5 (0.5) 1.5 (0.5) 1.5 (0.5)

Tee 16 (4.9) 16 (4.9) 16 (4.9) 16 (4.9) 16 (4.9)

Concentric Vent Termination NA 0 (0.0) NA 0 (0.0) NA

Standard Vent Termination 0 (0.0) 0 (0.0) 0 (0.0) 0 (0.0) 0 (0.0)

1-1/2 2 2-1/2 3 4

NOTES:

1. Use only thesmallest diameter pipe possible forventing. Over--sizing maycause flame disturbance orexcessive ventterminal icing or freeze--up.

2. NA = Not allowed. Pressure switch will not close, or flame disturbance may result.

3. Total equivalent vent lengths under 10 ft. for 40k BTUH furnaces from 0 to 2000 ft (0 to 610m) above sea level require use of an inducer outlet choke. Failure to use an outlet choke may result in flame disturbance or flame sense lock--out.

4. Not all furnace families include 140,000 BTUH input models.

5. Ventsizing for Canadianinstallationover 4500ft.(1370 m) abovesea levelare subject toacceptance bylocal authoritieshaving jurisdiction.

6. Size both the combustion air and vent pipe independently, then use the larger size for both pipes.

7. Assume two 45° degree elbows equal one 90° degree elbow. Wide radius elbows are desirable and may be required insome cases.

8. Elbow and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.

9. The minimum pipe length is 5 (1.5) linear feet (meters) for all applications.

10. Use 3--in (76 mm) diameter vent termination kit for installations requiring a 4--in (102 mm) diameter pipe.

140

60 50 110

18 16 33

ELBOW CONFIGURATIONS

Long

Medium

440 01 7104 02 47

VENT TERMINAL CONFIGURATIONS

Concentric

Mitered

Standard 2-in., 3-in., or optional 4-in. termination.

A13110

Specifications subject to change without notice.

Page 48

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Venting System Length Calculations

The Total Equivalent Vent Length for EACH combustion air or vent pipe equals the length of the venting system, plus the equivalent length of elbows used in the venting system from Table 15. Standard vent terminations or factory accessory concentric vent terminations count for zero deduction. See vent system manufacturer’s data for equivalent lengths of flexible vent pipe or other termination systems. DO NOT ASSUME that one foot of flexible vent pipe equals one foot of straight PVC/ABS DWV vent pipe. Compare the Total Equivalent Vent Length to the Maximum Equivalent Vent Lengths in Tables 14.

Example 1

A direct-vent 60,000 BTUH furnace installed at 2100 ft. (640M). Venting system includes FOR EACH PIPE 100 feet (30 M) of vent pipe, 95 feet (28 M) of combustion air inlet pipe, (3) 90º long-radius elbows, (2) 45º long-radius elbows, and a factory accessory concentric vent kit.

Can this application use 2-in. (50 mm ND) PVC/ABS DWV vent piping?

Measure the required linear length of air inlet and vent pipe; insert the longest of the two here

Add equiv length of (3) 90º long-radius elbows (use the highest number of elbows for either the vent or inlet pipe)

Add equiv length of (2) 45º long-radius elbows (use the highest number of elbows for either the vent or inlet pipe)

Add equiv length of factory concentric vent term 0 ft. From Table 15

Add correction for flexible vent pipe, if any 0 ft.

Total Equivalent Vent Length (TEVL)

3 x

2 x

3ft

(0.9 M)

1.5 ft

(0.5 M)

100 ft.

(30 M)

9 ft.

(2.7 M)

3ft

(0.9 M)

112 ft.

(34 M)

Use length of the longer of the vent or air inlet piping system

From Table 15

From Vent Manufacturer’s instructions; zero for PVC/ABS DWV

Add all of the above lines

Maximum Equivalent Vent Length (MEVL)

Is TEVL less than MEVL? YES Therefore, 2” pipe MAY be used

127 ft.

(38.7 M)

For2”pipefromTable14

Example 2

A direct-vent 60,000 BTUH furnace installed at 2100 ft. (640M). Venting system includes FOR EACH PIPE 100 feet (30 M) of vent pipe, 95 feet (28 M) of combustion air inlet pipe, (3) 90º long-radius elbows, and a polypropylene concentric vent kit. Also includes 20 feet (6.1 M) of flexible polypropylene vent pipe, included within the 100 feet (30 M) of vent pipe.

Assume that one meter of flexible 60mm or 80mm polypropylene pipe equals 1.8 meters of PVC/ABS pipe. VERIFY FROM VENT MANUFACTURER’S INSTRUCTIONS.

Can this application use 60mm (o.d.) polypropylene vent piping? If not, what size piping can be used?

Measure the required linear length of air inlet and vent pipe; insert the longest of the two here

Add equiv length of (3) 90º long-radius elbows (use the highest number of elbows for either the vent or inlet pipe)

Add equiv length of (2) 45º long-radius elbows (use the highest number of elbows for either the vent or inlet pipe)

Add equiv length of factory concentric vent term 9M x 3.3 ft/M =

Add correction for flexible vent pipe, if any 1.8 x

Total Equivalent Vent Length (TEVL)

3 x

0 x =

3ft

(0.9 M)

20 ft

(6.1 M)

100 ft.

(30 M)

9 ft.

(2.7 M)

0 ft.

(0 M)

30 ft. (9 M)

36 ft.

(11 M) 175 ft.

(53 M)

Use length of the longer of the vent or air inlet piping system

From Vent Manufacturer’s instructions

Add all of the above lines

Maximum Equivalent Vent Length (MEVL)

Is TEVL less than MEVL? NO

Maximum Equivalent Vent Length (MEVL)

Is TEVL less than MEVL? YES Therefore, 80mm pipe MAY be used

48 440 01 7104 02

127 ft.

(38.7 M)

250 ft.

(76.2 M)

Specifications subject to change without notice.

For2”pipefromTable14

Therefore, 60mm pipe may NOT be used; try 80mm

For3”pipefromTable14

Page 49

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Attach gaskets to vent pipe and combustion air adapters.

Figure 42 -- Vent Coupling and Adapter with Gaskets

PSC INDUCER ASSEMBLY

INDUCER OUTLET

Vent Coupling and Adapter

VENT ELBOW CLAMP TORQUE 15 LB-IN.

VENT PIPE CLAMP TORQUE 15 LB-IN.

VENT ELBOW

INDUCER OUTLET CHOKE 40,000 BTUH MODELS WITH 10 FT. (3.1 M) OF VENT OR LESS

A13074

Figure 43 -- Inducer Vent Elbow

EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS.

Figure 44 -- Sample Inlet Air Pipe Connection for Polypropylene Venting Systems

A14277

A12220

440 01 7104 02 49

Specifications subject to change without notice.

Page 50

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Any other unused knockout may be used for combustion air connection.

Rotate vent elbow to

required position.

UPFLOW LEFT CONFIGURATION

DOWNFLOW LEFT CONFIGURATION

A11309A

Rotate vent elbow to required position.

A11311A

ny other unused knockout may be used for combustion air connection.

Rotate vent elbow to required position.

ny other unused knockout may be used for combustion air connection.

UPFLOW RIGHT CONFIGURATION

ny other unused knockout may be used for combustion air connection.

DOWNFLOW RIGHT CONFIGURATION

A11308A

A11312A

UPFLOW VERTICAL VENT

Figure 45 -- Upflow Configurations (Appearance may vary)

See “Notes for Venting Options”

50 440 01 7104 02

A11310A

Figure 46 -- Downflow Configurations (Appearance may

Specifications subject to change without notice.

Requires Accessory Internal Vent Kit.

See Product Data for current kit number.

DOWNFLOW VERTICAL

vary) See “Notes for Venting Options”

A11313A

Page 51

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

ALTERNATE COMBUSTION AIR CONNECTIONS

HORIZONTAL LEFT--VERTICAL VENT CONFIGURATION

HORIZONTAL RIGHT--VERTICAL VENT CONFIGURATION

Vent Pipe

Alternate combustion air connection.

HORIZONAL LEFT--LEFT VENT CONFIGURATION

A11327A

Rotate vent elbow to required position.

A11328A

A11337

Requires Internal Vent Kit

See Product Data for Current Kit Number

HORIZONTAL RIGHT--LEFT VENT CONFIGURATION

A11336

ALTERNATE COMBUSTION AIR CONNECTIONS

Requires Accessory Vent Kit

See Product Data for

Current Kit Number

HORIZONTAL LEFT--RIGHT VENT CONFIGURATION

Figure 47 -- Horizontal Left (Appearance may vary)

See “Notes for Venting Options”

440 01 7104 02 51

HORIZONTAL RIGHT--RIGHT VENT CONFIGURATION

A11329A

Figure 48 -- Horizontal Right (Appearance may vary)

Specifications subject to change without notice.

A11335

See “Notes for Venting Options”

Page 52

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

NOTES FOR VENTING OPTIONS

1. Attach vent pipe adapter with gasket to furnace casing.

2. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.

3. Slide vent pipe through adapter and coupling into vent elbow.

4. Insert vent pipe into vent elbow.

5. Torque all clamps 15 lb.--in.

6. Attach combustion air pipe adapter with gasket to furnace.

7. Attach combustion air pipe to adapter with silicone. Pilot drill a1/8--in. hole in adapter and secure with a #7 x 1/2--in. sheet metal screw.

VENT PIPE ADAPTER WITH GASKET INSTALLED ON FURNACE. VENT PIPE IS CUT FLUSH WITH TOP OF ADAPTER. PRIME AND CEMENT VENT PIPE TO ADAPTER. ALLOW TO DRY BEFORE INSTALLING VENT COUPLING.

VENT PIPE FLUSH WITH ADAPTER

Figure 49 -- Vent Pipe Flush with Adaptor

ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND-OFF ON ADAPTER. TORQUE LOWER CLAMP 15 LB-IN. WHEN REMAINING VENT PIPE IS INSTALLED, TORQUE UPPER CLAMP TO 15 LB-IN.

VENT PIPE FLUSH SHOWING COUPLING

A13076

(NON-DIRECT VENT FOR ALL MODELS EXCEPT MODULATING UNLESS

52 440 01 7104 02

12" (256mm) minimum to 60”(1524 mm) or 1 additional elbow maximum

CASING SIDE OR TOP ATTACHMENT

COMBUSTION AIR PIPE

INSTALLED IN ATTIC OR CRAWL SPACE)

Figure 50 -- Combustion Air Pipe Attachment

Specifications subject to change without notice.

A13406

Page 53

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

NOTE: The following is based upon National codes for gas appliances, and is provided as a reference. Refer to Local codes which may supersede these standards and/or recommendations.

Item Clearance Description

Clearance above grade, veranda, porch, deck, balcony or

B Clearance to a window or door that may be opened

C Clearance to a permanently closed window

Vertical clearance to a ventilated soffit located above the

terminal within a horizontal distance of 2 feet (61 cm) from

E Clearance to an unventilated soffit F Clearance to an outside corner G Clearance to an inside corner

Clearance to each side of the centerline extended above

K Clearance to a mechanical air supply inlet 6 ft. (1.8 M) 3ft. (.9 M)

L Clearance under a veranda, porch, deck, or balcony

0 Clearance from a plumbing vent stack 3ft.(.9M) 3 ft. (.9 M)

> greater than, ≥ greater than or equal to, < less than, ≤ less than or equal to

electrical meter or gas service regulator assembly

I Clearance to service regulator vent outlet 3ft. (.9 M) SeeNote4.

Clearance to non—mechanical air supply inlet to building or

the combustion air inlet to any other appliance

Clearance to each side of the centerline extended above or

below vent terminal of the furnace to a dryer or water heater

vent, or other appliance’s vent intake or exhaust

Furnace combustion air intake clearance to a water heater

vent, dryer vent or other types of appliance exhausts

Clearance above paved sidewalk or paved driveway located

anticipated snow level

the centerline of the terminal

on public property

Notes:

1. In accordance with the current CAN/CSA B149.1, Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

3. NOTE: This table is based upon National codes for gas appliances, and are provided as a reference.

Refer to Local codes which may supersede these standards and/or recommendations.

4. For clearances not specified in ANSI Z223.1/NFPA 54 or CAN/CSA B 149.1, clearances shall be in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.

5. When locating vent terminations, consideration must be givento prevailing winds, location, andother conditions which may cause recirculation ofthe combustion products of adjacent vents. Recirculation can cause poor combustion, inlet condensate problems, vent termination icing and/or accelerated corrosion of the heat exchangers.

6. Design and position vent outlets to avoid ice build-up on and moisture damage to surrounding surfaces.

7. The vent for this appliance shall not terminate:

a. Near soffit vents of crawl space vents or other areas where condensate or vapor could create a nuisance or hazard or property damage; or b. Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

8. Avoid venting under a deck or large overhang. Recirculation could occur and cause performance or system problems. Ice build-up may occur.

440 01 7104 02 53

Canadian Installations

(per CAN/CSA B149.1)

12 in. (305 mm)

18 in. (457 mm) above roof surface.

12 in. (305 mm) for appliances >10,000 Btuh (3 kW)

and </=100,000 Btuh ( 30 kW),

36 in. (914 mm) for appliances >100,000 Btuh (30 kW)

For clearances not specified in ANSI Z223.1/NFPA 54 or CAN/CSA B149.1, clearances shall be in accordance with local

installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.

3 ft. (.9 M) within 15 ft. (4.6 M)

above the meter/regulator assembly.

12 in. (305 mm) for appliances >10,000 Btuh(3 kW)

and </= 100,000 Btuh ( 30 kW),

36 in. (914 mm) for appliances >100,000 Btuh (30 kW)

12 in. (305 mm).

Permitted only if veranda, porch, deck, or balcony is fully open on a

minimum of two sides beneath the floor.

12 in. (305 mm) 12 in. (305 mm)

3ft.(.9M) 3 ft. (.9 M)

7 ft. (2.1 M).

Vent shall not terminate above a sidewalk or paved driveway that is

located between two single family dwellings and serves both

dwellings.

(1 )

Manufacturer’s Recommendation: See Notes 3-8.

Figure 51 -- Direct Vent Termination Clearance

Specifications subject to change without notice.

U.S. Installations

(per ANSI Z223.1/NFPA 54)

12 in. (305 mm)

9 in. (229 mm) for appliances >10,000 Btuh (3 kW)

and </= 50,000 Btuh ( 15 kW),

12 in. (305 mm) for appliances >50,000 Btuh (15kW)

3 ft. (.9 M) within 15 ft. (4.6 M)

above the meter/regulator assembly.

9 in. (9 mm) for appliances >10,000 Btuh (3 kW)

and </= 50,000 Btuh (15 kW),

12 in.(305 mm) for appliances >50,000 Btuh (15kW)

SeeNote4.

Manufacturer’s Recommendation: See Notes 3-8.

SeeNote4.

Manufacturer’s Recommendation: See Notes 3-8.

(2 )

2 5 -- 2 4 -- 6 5 -- 2

Page 54

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

NOTE: The following is based upon National codes for gas appliances, and is provided as a reference. Refer to Local codes which may supersede these standards and/or recommendations.

Item

Clearance above grade, veranda, porch, deck, balcony or

B Clearance to a window or door that may be opened

C Clearance to a permanently closed window

Vertical clearance to a ventilated soffit located above the

terminal within a horizontal distance of 2 feet (61 cm) from

E Clearance to an unventilated soffit F Clearance to an outside corner

G Clearance to an inside corner

Clearance to each side of the centerline extended above

I Clearance to service regulator vent outlet 3ft. (.9 M) SeeNote4.

K Clearance to a mechanical air supply inlet 6ft.(1.8M) 3ft. (.9 M)

L Clearance under a veranda, porch, deck, or balcony

> greater than, ≥ greater than or equal to, < less than, ≤ less than or equal to

electrical meter or gas service regulator assembly

Clearance to non—mechanical air supply inlet to building or

the combustion air inlet to any other appliance

Clearance to each side of the centerline extended above or

below vent terminal of the furnace to a dryer or water heater

vent, or other appliance’s direct vent intake or exhaust

Clearance above paved sidewalk or paved driveway located

Clearance Description

anticipated snow level

the centerline of the terminal

Clearance to a moisture exhaust duct

(dryer vent, spa exhaust, etc.)

on public property

Notes:

1. In accordance with the current CAN/CSA B149.1, Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

3. NOTE: This table is based upon National codes for gas appliances, and are provided as a reference.

Refer to Local codes which may supersede these standards and/or recommendations.

5. When locating vent terminations, consideration must be givento prevailing winds, location, andother conditions which may cause recirculation ofthe combustion products of adjacent vents. Recirculation can cause poor combustion, inlet condensation problems, vent termination icing, and/or accelerated corrosion of the heat exchangers.

6. Design and position vent outlets to avoid ice build-up on and moisture damage to surrounding surfaces.

7. The vent for this appliance shall not terminate:

8. These National standards apply to all non-direct-vent gas appliances. Contact Local code officials for additional requirements and/or exclusions.

Figure 52 -- Ventilated Combustion Air and Non--Direct Vent Termination Clearance

54 440 01 7104 02

2 5 -- 2 4 -- 6 5 -- 2

Canadian Installations

(per CAN/CSA B149.1)

12 in. (305 mm)

18 in. (457 mm) above roof surface.

12 in. (305 mm) for appliances >10,000 Btuh (3 kW)

and </=100,000 Btuh ( 30 kW),

36 in. (914 mm) for appliances >100,000 Btuh (30 kW)

For clearances not specified in ANSI Z223.1/NFPA 54 or CAN/CSA B149.1, clearances shall be in accordance with local

installation codes and the requirements of the gas supplier and the manufacturer’s installation instructions.

3ft.(.9M)within15ft.(4.6M)

above the meter/regulator assembly.

12 in. (305 mm) for appliances >10,000 Btuh(3 kW)

and </= 100,000 Btuh ( 30 kW),

36 in. (914 mm) for appliances >100,000 Btuh (30 kW)

12 in. (305 mm).

Permitted only if veranda, porch, deck, or balcony is fully open

on a minimum of two sides beneath the floor.

12 in. (305 mm) 12 in. (305 mm)

12 in. (305 mm) See Note 4. 12 in. (305 mm) See Note 4.

7 ft. (2.1 M).

Vent shall not terminate above a sidewalk or paved driveway

that is located between two single-family dwellings and serves

both dwellings.

Specifications subject to change without notice.

(1 )

(per ANSI Z223.1/NFPA 54)

4ft. (1.2M) below or to the side of the opening,

1 ft (.3M) above the opening.

Manufacturer’s Recommendation: See Note 8.

Manufacturer’s Recommendation: See Notes 3-8.

3 ft. (.9 M) within 15 ft. (4.6 M)

above the meter/regulator assembly.

4ft. (1.2M) below or to the side of the opening,

1 ft (.3M) above the opening.

Manufacturer’s Recommendation: See Note 8

Manufacturer’s Recommendation: See Notes 3-8.

U.S. Installations

12 in. (305 mm)

SeeNote4.

7ft. (2.1M)

(2 )

Page 55

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Vertical separation between combustion air and vent

8 ¾ in. (22 2mm) for 3 in.( 76mm) 6 ¾ i n. (172mm) for 2in. (51mm)

Maintain 12 in. (305mm) min. Clearance above highest anticipated snow level maximum of 24 in. (614mm) above roof

18 in. Maximum

(457mm)

At least 36 in.

(914mm)

At least 36 in. (914mm)

RoofTermination (Preferred)

Note:

“A” denotes 0 To 2 in. (51mm)

Between the first 2 vents Third vent (and fourth v ent, if used) must be 36 in. Away (914mm)

Abandoned masonry used as raceway (per code)

Concentric Vent and Combustion Air Side Termination

12 in. Min from overhang or roof (Typ.)

12 in. (305mm) separation between bottom of com-bustion air and bottom of vent (Typ.)

Maintain 12 in. (305mm)min. Clearance above highest an -ticipated snow level or grade whichever is greater (Typ.)

At least 36 in.

(914mm)

Concentric Vent and Combustion Air

Roof Termination (preferred)

At least 36 in. (914mm)

Note:

“A” denotes 0 To 2 in. (51mm) Between the first 2 vents Third vent (and fourth vent, if used) must be 36 in. Away (914mm)

Note:

36--in. separation between pairs of inlets only required for direct--vent systems

Mai ntai n 12 in. (3 05mm) min. Clearance above highest anticipated snow level maximum of 24in. (614mm) above roof

1 in. (25mm) maximum (Typ.) from wall to inlet

12 in. From Overhang or roof (Typ.)

Maintain 12 in. (305mm) min. Clear-At least 36 in. (914mm)

Side wall termination of less than 12 in. (305mm) above highest snow level

ance above highest anticipated snow

level or grade whichever is greater

(Typ.)

L12F044

Figure 53 -- Combustion Air and Vent Pipe Termination for Direct Vent (2--Pipe) System

Roof Termination (Preferred)

Ven t

(305mm)

Maintain 12 in .

minimum clearance

above highest anticipated

snow level maximum of

24 in. (610mm) above roof.

Abandoned masonry used as raceway (per code)

12 in. min. (305 mm)from

overhang or roof

Sidewall Termination

with Straight Pipe (preferred)

Maintain 12 in. (305mm) minimum clearance above highest anticipated snow level or grade whichever is greater

90°

Side wall termination with 2 elbows (preferred)

12 in. (305 mm) min. from

overhang or roof

Maintain 12 in. (305mm) minimum clearance above highest anticipated snow level or grade whichever is greater.

6 in. (152mm) minimum clearance

between wall and end of vent pipe.

10 in. (254mm) maximum pipe length

Figure 54 -- Vent Pipe Termination for Non--Direct Vent and Ventilated Combustion Air System

440 01 7104 02 55

A05091

Specifications subject to change without notice.

Page 56

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

OPTIONAL TERMINATION BRACKET FOR 2-PIPE TERMINATIONS

12 IN. (305 MM) MIN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT.

12-IN. (305 MM)

ABOVE ANTICIPATED

SNOW LEVEL

EXHAUST

OPTIONAL BRACKET COUPLI NG

COMBUSTION-AIR

(ELBOW PARALLEL TO WALL)

OVERHANG

CLEARANCE TO OVERHANG PER CODE

12 IN. (305 MM) MIN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT.

MAINTAIN 12 IN. (305 MM) CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.

Figure 55 -- Alberta and Saskatchewan Vent Termination

56 440 01 7104 02

12 IN.

(305 MM) MIN. GROUND

LEVEL OR ANTICIPATED SNOW LEVEL

Specifications subject to change without notice.

A13078

Page 57

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

Ventilated Combustion Air intake pipe

Pipe hangar

3” (76 mm)

Ventilated Combustion Air intake termination in crawl space

12” (305 mm)

CRAWL SPACE

highest level of insulation

Figure 56 -- Vent Terminations for Ventilated Combustion Air

440 01 7104 02 57

ATTIC

A10497

Specifications subject to change without notice.

Page 58

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

TO CODE--APPROVED DRAIN OR CONDENSATE PUMP

Representative drawing only, some models may vary in appearance

Figure 57 -- Recommended Combustion Air Inlet Moisture Trap

L12F028

58 440 01 7104 02

Specifications subject to change without notice.

Lewisburg, TN 37091 USA