Whirlpool WFAU, WFLU, WFAR, WFLR, WFAT Installation Instructions Manual

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80% GAS FURNACE INSTALLATION INSTRUCTIONS

Table of Contents

GAS FURNACE SAFETY................................................................1

INSTALLATION REQUIREMENTS................................................3

Tools and Parts ............................................................................3

Location Requirements................................................................3

Installation Configurations ...........................................................4

Duct Work Requirements.............................................................6

Electrical Requirements ...............................................................6

Gas Supply Requirements...........................................................6

Venting Requirements..................................................................6

INSTALLATION INSTRUCTIONS..................................................8

Inspect Shipment......................................................................... 8

Plan Vent System.........................................................................8

Connect Venting.........................................................................11

Install Duct Work ........................................................................11

Filter Specifications....................................................................11

Make Electrical Connections .....................................................12

Make Gas Connections..............................................................13

Check the Furnace Input Rate ...................................................13

Adjust the Furnace Input Rate ...................................................14

Complete Installation..................................................................15

Sequence of Operation ..............................................................16

Controls ......................................................................................16

TROUBLESHOOTING ..................................................................17

ASSISTANCE OR SERVICE.........................................................20

Accessories ................................................................................20

GAS FURNACE SAFETY

Your safety and the safety of others are very important.

We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages.

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word “DANGER” or

“WARNING.” These words mean:

You can be killed or seriously injured if you don't immediately follow instructions.

can be killed or seriously injured if you don't

You follow instructions.

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can

Models WFAU, WFAR, WFAT

46924D003

happen if the instructions are not followed.

WFLU, WFLR, WFLT

Whirlpool® Home Cooling and Heating

7901 S.W. 6th Court

Plantation, Florida 33324

IMPORTANT SAFETY INSTRUCTIONS

■ Use only with type of gas approved for this furnace.

Refer to the furnace rating plate.

■ Install this furnace only in a location and position as

specified in the Location Requirements section of these instructions.

■ Provide adequate combustion and ventilation air to the

furnace space as specified in the “Venting Requirements” section of these instructions.

■ Combustion products must be discharged outdoors.

Connect this furnace to an approved vent system only, as specified in the “Venting Requirements” section of these instructions.

■ Never test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Make Gas Connections” section of these instructions.

■ Always install furnace to operate within the furnace’s

intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Complete Installation” section of these instructions. See furnace rating plate.

SAVE THESE INSTRUCTIONS

■ When a furnace is installed so that supply ducts carry

air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

■ A gas-fired furnace for installation in a residential

garage must be installed as specified in the “Location Requirements” section of these instructions.

■ The furnace is not to be used for temporary heating of

buildings or structures under construction.

■ The furnace shall be installed so the electrical

components are protected from water.

■ Furnaces for indoor installation on combustible

flooring shall not be installed directly on carpeting, tile or other combustible material other than wood flooring.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm.

This appliance can cause low-level exposure to some of the substances listed, including benzene, formaldehyde, carbon monoxide, toluene, and soot.

ADDITIONAL SAFETY INFORMATION

In the State of Massachusetts, the following installation instructions apply:

■

Installations and repairs must be performed by a qualified or licensed contractor, plumber, or gasfitter qualified or

licensed by the State of Massachusetts.

■

If using a ball valve, it shall be a T-handle type.

■

A flexible gas connector, when used, must not exceed 3 feet.

INSTALLATION

REQUIREMENTS

These instructions are intended as a general guide only for use by qualified persons and do not supersede any national or local codes in any way. Compliance with all local, state, or national codes pertaining to this type of equipment should be determined prior to installation.

Read this entire instruction manual, as well as the instructions supplied in separate equipment, before starting the installation.

The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of the National Fire Protection Association; the National Fuel Gas Code, ANSI Z223.1/NFPA No. 54 (latest edition) and the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States, and any state laws, local ordinances (including plumbing or wastewater codes), or local gas utility requirements. Local authorities having jurisdiction should be consulted before installation is made. Such applicable regulations or requirements take precedence over the general instructions in this manual.

This furnace is design certified by CSA International as a Category I furnace using air from inside the structure for combustion. The combustion system is fan-assisted, which means it is equipped with an integral mechanical means to draw products of combustion through the heat exchanger.

Location Requirements

Explosion Hazard

Keep flammable materials and vapors, such as gasoline, away from furnace.

Place furnace so that burners are at least 18 inches (46 cm) above the floor for a garage installation.

Failure to follow these instructions can result in death, explosion, or fire.

Tools and Parts

Assemble the required tools before starting installation. Read and follow the instructions provided with any tools listed here.

Tools Needed:

■ Pipe wrench

■ Screwdriver

■ Tape measure

■ Thread sealant

Parts Needed:

Check local codes and with gas supplier. Check existing gas supply, electrical supply, and venting, and read “Duct Work Requirements,” “Electrical Requirements,” “Gas Supply Requirements” and “Venting Requirements” before purchasing parts.

■ Non-corrosive leak check solution

■ Test g a uge wi t h ¹⁄₈ in. NPT

connection (for measuring gas supply pressure)

Explosion Hazard Do not install this furnace in a mobile home. Doing so can result in death, explosion, fire, or

carbon monoxide poisoning.

IMPORTANT: Do not use the furnace as a heater in a building under construction. The furnace can be severely damaged due to the abnormal environment caused by construction. Chlorides from sources such as paint, stain, or varnish; tile and counter cements; adhesives; and foam insulation are abundant in a structure under construction and can be highly corrosive. Low return air temperature can cause condensation in the furnace and other damage that can shorten the life of the furnace.

■ The furnace is suitable for installation in buildings

constructed on site. The furnace should be centralized in respect to the heat distribution system as much as practicable.

■ All models are suitable for closet or utility room installation.

Utility room installation requires: A door opening large enough for the widest part of the

furnace. A door opening large enough to remove/replace any other

appliance located in the utility room, such as a water heater. Any other appliances arranged so that each appliance can be

removed/replaced without disturbing the furnace.

■ In a residential garage, a gas-fired furnace must be installed

so the burner(s) and the ignition source are located not less than 18 in. above the floor. The furnace is to be located or protected to avoid physical damage by vehicles.

■ WFAR, WFLR, WFAT, and WFLT models may be installed as

suspended units in the horizontal position. These furnaces are not designed for direct attachment of suspension rods to the furnace casing. See the “Installation Configurations” section.

■ If the furnace is to be installed in an attic or other insulated

space, it must be kept free and clear of insulating materials.

Installation Clearances

■ A 2 in. minimum clearance is required in front for air openings

into the combustion chamber.

■ All servicing and cleaning of the furnace can be performed

from the front. If installed in a closet or utility room, provide 24 in. clearance in front for service if the door to the room is not in line with the front of the furnace. Where servicing clearances are greater than clearances to combustibles, servicing clearances take precedence.

Minimum Clearance to Combustibles Chart

(all measurements in inches)

Upflow and Counterflow Installations

Cabinet

Width

14.5 4

17.5 4

21.0 4

24.5 4

Front Back Top Vent

01 623

01 622

01 6200

Horizontal Installations

(Models WFAT and WFLT only)

Cabinet Width Front Back Vent

14.5 4

17.5 4

21.0 4

24.5 4

0623

0622

0621010

Airflow

R to L L to R

Top Bottom Top Bottom

013

012

Sides

Left Right

Horizontal Installations

(Models WFAR and WFLR only)

Airflow

Cabinet Width Front Back Vent

R to L L to R

Top Bottom Top Bottom

14.5 4

17.5 4

21.0 4

24.5 4

May be 2" when Type B-1 vent pipe is used.

May be 1" when Type B-1 vent pipe is used.

Where values greater than 0 are shown, may be 0" when Type

0621313

0621222

0621010

B-1 vent pipe is used.

High Altitude Installations

■ This furnace is approved for operation at altitudes from 0 to

4,500 feet above sea level without any required modifications.

■ From 4,500 to 7,500 ft, the gas manifold pressure needs to be

adjusted according to the information shown in the Manifold Pressure vs. Altitude charts.

IMPORTANT:

For installations above 7,500 ft, the furnace input rate is to be reduced per the requirements of the National Fuel Gas Code (ANSI Z223.1/NFPA 54, latest edition), at the rate of 4 percent for each 1,000 feet above sea level.

The furnace is not recommended for installation above 10,000 ft.

Installation Configurations

Models WFAU and WFLU must be installed only as an upflow furnace. Models WFAT and WFLT may be installed as an upflow or horizontal furnace. Models WFAR and WFLR may be installed as either a counterflow or a horizontal furnace.

Models WFAR, WFLR, WFAT and WFLT furnaces can be horizontally installed for airflow right to left or left to right.

Upflow Installations

WFAU, WFLU, WFAT and WFLT model furnaces can be installed with either a side or bottom air return. For bottom air return the bottom air return knockout plate must be removed. For units that do not include a side or bottom return filter rack, kit no. AFILT524-1 (side return) or kit no. AFILT529-1 (bottom return) can be used.

To provide sufficient filter area for installations requiring more than 1600 CFM nominal air delivery, return air will have to be brought through both sides of the furnace, or through one side and the bottom, or an optional filter rack WAFILTHA7 may be used.

Horizontal Installations

WFAR, WFLR, WFAT and WFLT model furnaces can be horizontally installed for airflow right to left or left to right. To ensure access to parts for servicing, install upflow and counterflow furnaces so that the burner and blower access panels are readily accessible.

NOTE: When installed horizontally, the installer must install a sheet metal screw to retain the upper door as shown following, in either Position 1 or 2, depending on installation configuration.

Horizontal Installation (WFAR and WFLR models)

Return

Supply

Installation for Counterflow (Downflow) Models

WARNING

Fire Hazard

Before installing counterflow (downflow) furnace on combustible surface, such as wood, install one of the following kits:

WABASE 511 (14.5" cabinets) WABASE 512 (17.5" cabinets) WABASE 568 (21" cabinets) WABASE 569 (24.5" cabinets)

1. Screw placement for Left to Right airflow

2. Screw placement for Right to Left airflow

Horizontal Installation (WFAT and WFLT models)

Supply

Return

1. Screw placement for Right to Left airflow

2. Screw placement for Left to Right airflow

Horizontal Installation - Suspended

WFAR, WFLR, WFAT and WFLT model furnaces may be installed as suspended units in the horizontal position. These furnaces are not designed for direct attachment of suspension rods to the furnace casing.

■ The suspending means must be field fabricated, and should

consist of two “cradles” made by attaching two rods to a length of angle iron or suitable gauge steel.

■ Locate the cradles so that they are as close as possible to the

ends of the furnace (this will provide access for removal of major components such as the blower assembly).

■ Provide enough clearance between the suspension rods and

the furnace to allow removal of access panels.

Contact your local dealer. Failure to do so can result in death or fire.

IMPORTANT:

■ The furnace may be installed directly on the supply plenum or

coil cabinet if the furnace is installed on a non-combustible floor.

■ For installations on combustible flooring, a special base must

be ordered and used. See the “Accessories” section.

1. Cut, size and frame opening in floor to fit the Combustible

floor base and provide a minimum 1in. clearance between the Supply Duct and combustible materials. The 4 legs on the base assembly should recess into the floor, and the base should rest on all 4 outside flanges.

2. Construct duct connections with 1in. to 1³⁄₄ in. right angle

flanges, and long enough to extend below the floor joists.

3. Drop the duct connections through the top of the base

assembly with the right angle flanges in good contact with the glass tape on top of the base assembly.

4. Carefully position the furnace over the right angle duct

flanges.

Combustible Floor Installation (Counterflow Models only)

1 2

3 4

■ In all instances, other than wiring for the thermostat, the

wiring to be done and any replacement of wire shall conform with the temperature limitation for Type T wire – 63°F (35°C) rise.

■ The line voltage supply should be routed through a readily

accessible disconnect located within sight of the furnace. A junction box on the furnace side panel is provided for line voltage connections. See the furnace wiring diagram for specific connection information.

■ Proper polarity of the supply connections (“HOT” and

“NEUTRAL”) must be observed to ensure that safety controls provide the protection intended.

Gas Supply Requirements

This furnace is equipped for use with natural gas. A conversion kit is required for use with propane. To order the correct conversion kit, see “Accessories.”

■ Gas supply piping should be installed in accordance with

local codes and the regulations of the utility. Piping must be of adequate size to prevent undue pressure drop. Consult the local utility or gas supplier for complete details on special requirements for sizing gas piping.

■ If local codes allow the use of a flexible gas appliance

connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance.

1. Furnace

2. Woven glass tape (between flanges of outlet duct and base assembly)

3. Base assembly

4. Combustible flooring

5. Leg

6. Supply plenum or coil cabinet (not provided - accessory)

Duct Work Requirements

Install the conditioned air plenum, ducts and air filters (if not provided on the furnace) in accordance with NFPA 90B Standard for the Installation of Warm Air Heating and Air-Conditioning Systems (latest edition).

The furnace is provided with flanges for the connection of the plenum and ducts.

All air filters must be listed as Class 2 furnace air filters.

Electrical Requirements

WARNING

Venting Requirements

Adequate provisions for combustion air and ventilation of furnace must be made. Refer to Section 5.3, “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA54 (latest edition), or applicable provisions of the local building codes. For Category 1 furnaces, vent installations shall be in accordance with parts 7 and 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, the local building codes, and the furnace and vent manufacturer’s instructions.

Unconfined Space

An unconfined space is defined as “a space whose volume is more than 50 cu ft per 1000 BTU per hour of the combined input rating of all appliances installed in that space.”

When a furnace is installed in an unconfined space in a building, it can be assumed that the infiltration will be sufficient to supply the required air.

If the furnace is installed in a ventilated attic or crawl space, it is assumed that the air infiltration is sufficient to supply the required combustion air. However, in a building of unusually tight construction, additional outdoor air should be provided.

Confined Space

A confined space is defined as “a space whose volume is less than 50 cu ft per 1000 BTU per hour of the combined input rating of all appliances installed in that space.”

Confined Space Installation/Air from Inside Structure

Electrical Shock Hazard Electrically ground furnace. Connect ground wire to green ground screw.

Failure to do so can result in death or electrical shock.

■ The furnace must be grounded and wired in accordance with

local codes or, in the absence of local codes, with the National Electrical Code ANSI/NFPA No. 70 (latest edition).

If the furnace is installed in a confined space within the building and combustion air is taken from a heated space, the combustion air and ventilating air must enter and leave the space through two permanent openings of equal area. One opening shall be located within 12 in. of the ceiling and the other within 12 in. of the floor.

NOTE: Each opening must have a free area of at least 1 square inch per 1000 BTU/HR of total input rating of all equipment in the enclosure, and not less than 100 square inches each.

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