Grandaire WFAR, WFAR080B048 Installation Instructions Manual

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

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.

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

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

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

9.

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.

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.

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.

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

60

/ 16˚C

L12F010

A10490

440 01 7104 02 7

Specifications subject to change without notice.

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.

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

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.

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

2

/kW) for combined input of all gas appliances in

mm

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.

2

/kW) for combined input of all gas

2

/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.

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:

3

I

other

1000 Btu/hr

3

I

1000 Btu/hr

fan

2

/1,000 Btuh

A04002

A04003

2

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

2

/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.

2

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

mm

2

/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.

2

/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

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

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

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

4

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

5

relief port on condensate
trap.

A11587

14 440 01 7104 02

Specifications subject to change without notice.

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.

INSTALLATION INSTRUCTIONS Gas Furnace: WFAR

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

If alternate vent position

5

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

6

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

9

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

7

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

Route pressure switch tube
underneath relief tube and

8

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.

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

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.

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.