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Whirlpool WFAU Installation Instructions Manual

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80% GAS FURNACE INSTALLATION INSTRUCTIONS
GAS FURNACE SAFETY................................................................1
INSTALLATION REQUIREMENTS ................................................3
Tools and Parts ............................................................................3
Location Requirements................................................................4
Installation Configurations ...........................................................5
Ductwork Requirements ..............................................................7
Electrical Requirements ...............................................................7
Gas Supply Requirements ...........................................................7
Venting Requirements..................................................................7
INSTALLATION INSTRUCTIONS ..................................................9
Inspect Shipment .........................................................................9
Plan Vent System .........................................................................9
Determine Vent Pipe Direction...................................................12
Connect Venting.........................................................................14
Install Duct Work ........................................................................14
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:
WARNING
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can
happen if the instructions are not followed.
®
Whirlpool
Models
WFAU, WFAR, WFAT,
WFLU, WFLR, WFLT
46924B008

GAS FURNACE SAFETY

Your safety and the safety of others are very important.
DANGER

Table of Contents

Filter Specifications ....................................................................14
Make Electrical Connections .....................................................15
Make Gas Connections..............................................................16
Check the Furnace Input Rate (if required) ................................17
Adjust the Furnace Input Rate (if required) ................................17
Complete Installation..................................................................18
Shut Down..................................................................................19
SEQUENCE OF OPERATION ......................................................19
Heating .......................................................................................19
Fan On ........................................................................................19
Cooling .......................................................................................20
CONTROLS ...................................................................................20
TROUBLESHOOTING ..................................................................21
ASSISTANCE OR SERVICE .........................................................24
Accessories ................................................................................24
You can be killed or seriously injured if you don't immediately
follow instructions.
You can be killed or seriously injured if you don't follow
instructions.
Whirlpool
®
Home Cooling and Heating
14610 Breakers Drive
Jacksonville, FL 32258

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Table of Contents
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  • Page 1: Table Of Contents

    All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed. ® Whirlpool Models Whirlpool ® Home Cooling and Heating WFAU, WFAR, WFAT, 14610 Breakers Drive WFLU, WFLR, WFLT Jacksonville, FL 32258 46924B008...
  • Page 2: Save These Instructions

    IMPORTANT SAFETY INSTRUCTIONS Use only with type of gas approved for this furnace. When a furnace is installed so that supply ducts Refer to the furnace rating plate. carry air circulated by the furnace to areas outside the space containing the furnace, the return air Install this furnace only in a location and position shall also be handled by duct(s) sealed to the as specified in the “Location Requirements”...
  • Page 3: Installation Requirements

    WARNING: Gas leaks cannot always be detected by smell. Gas suppliers recommend that you use a gas detector approved by UL or CSA. For more information, contact your gas supplier. If a gas leak is detected, follow the “What to do if you smell gas” instructions. The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.
  • Page 4: Location Requirements

    Location Requirements structure under construction and can be highly corrosive. Low WARNING 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.
  • Page 5: Installation Configurations

    Manifold Pressure vs. Altitude charts. Installation Configurations Models WFAU and WFLU must be installed only as an upflow Installation for Counterflow (Downflow) Models 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.
  • Page 6 For installations on combustible flooring, a special base must Horizontal Installations be ordered and used. See “Accessories.” 1. Cut, size and frame opening in floor to fit the Combustible WFAR, WFLR, WFAT and WFLT model furnaces can be floor base and provide a minimum 1" (2.5 cm) clearance horizontally installed for airflow right to left or left to right.
  • Page 7: Ductwork Requirements

    Ductwork Requirements Install all conditioned air plenums, ducts and air filters (if not All air filters must be listed as Class 2 furnace air filters. provided on the furnace) in accordance with NFPA 90B All ductwork must be made of materials and insulated to Standard for the Installation of Warm Air Heating and Air- meet local, state and national codes.
  • Page 8 Confined Space WARNING: A confined space is defined as “a space whose volume is less CARBON MONOXIDE POISONING HAZARD than 50 cu. ft (1.4 m ) per 1,000 Btu/h of the combined input rating of all appliances installed in that space.” Failure to follow the steps outlined below for each appliance connected to the venting system being Contaminated Combustion Air...
  • Page 9: Installation Instructions

    INSTALLATION INSTRUCTIONS WARNING Plan Vent System Confined Space Installation—Nondirect Venting Air from Inside 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 Explosion Hazard through two permanent openings of equal area.
  • Page 10 Equipment in Confined Space—All Air from Outside NOTE: Another option is to use horizontal combustion ducts. If (Inlet air from crawl space and outlet air to ventilated attic) horizontal combustion ducts are run, 1 sq. in. (6.4 cm ) per 2,000 Btu/h of the total input rating of all equipment in the enclosure is required.
  • Page 11 Vent Option—Vent Through Ceiling Sidewall Venter Limitations Chart Vent pipe diameter 4" (10.1 cm) Minimum vent pipe length 48" (121.9 cm) Maximum vent pipe length 25 ft* (7.6 m) Maximum number of 90° elbows *When fewer than 4 elbows are used, maximum vent pipe length can be increased by 5 ft (1.5 m) per unused elbow.
  • Page 12: Determine Vent Pipe Direction

    Factory-Built Chimney Venting Extend the vent connector into the chimney so that it is flush with the inside of the flue liner. Seal the joint between the pipe and the liner. Masonry chimneys serving fireplaces cannot be used for venting purposes unless the fireplace opening is permanently sealed.
  • Page 13 Sidewall Vent Terminal Clearances—Nondirect Vented Furnaces (Horizontal Venting) Vent Terminal Air Supply Intake Inside Corner Detail Area Where Terminal Is Not Permitted Operable Fixed Closed Fixed Closed Operable U.S. Installations Clearance above grade, veranda, porch, deck, or balcony 12" (30.5 cm) Clearance to window or door that may be opened 48"...
  • Page 14: Connect Venting

    Connect Venting 1. Using a ¹⁄₄" (6.4 mm) sheet metal screw, secure the vent pipe 3. Check that the venting is open, and that it is the correct size. to the inducer blower outlet. 4. Check that the vent pipe terminates outside the building. 2.
  • Page 15: Make Electrical Connections

    Minimum Filter Requirements Chart Disposable Filters Cleanable Filters Airflow Minimum Area— Minimum Area— Descriptor sq. in. (cm Size—in. (cm) Quantity sq. in. (cm Size—in. (cm) Quantity 480 (3,096.8) 20 x 25 (50.8 x 63.5) 240 (1,548.4) 16 x 20 (40.6 x 50.8) 480 (3,096.8) 20 x 25 (50.8 x 63.5) 240 (1,548.4)
  • Page 16: Make Gas Connections

    WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 17: Check The Furnace Input Rate (If Required)

    Check the Furnace Input Rate (if required) IMPORTANT: For natural gas, check the furnace rate by observing the gas meter, making sure all other gas appliances are turned off. The furnace input rate must not exceed the input rating on The test hand on the meter should be timed for at least one the furnace rating plate.
  • Page 18: Complete Installation

    Manifold Pressure vs. Altitude Chart— Manifold Pressure vs. Altitude Chart— Models WFAR, WFAT, WFLU, WFLR, WFLT Only Model WFAU 150 only Natural Gas Natural Gas Manifold Manifold Heating Value Pressure— Input Heating Value Pressure— Input Altitude—ft (m) (Btu/ft W.C. Factor Altitude—ft (m)
  • Page 19: Shut Down

    Adjust Blower Speed 1. Disconnect power. WARNING 2. For heating speed, check the temperature rise and make the necessary adjustments to the blower speed tap. See the wiring diagrams in the “Troubleshooting” section. 3. Reconnect power. 4. Recheck the temperature rise. Repeat the procedure as necessary to achieve optimum temperature rise.
  • Page 20: Cooling

    Cooling During a call for cooling, the thermostat energizes the R - Y As cooling demand is met, the thermostat de-energizes the R - Y circuit of the control board. After a 1-second cooling “on” delay, circuit of the control board. After a 60-second cooling “off” delay, the control energizes the cooling fan speed.
  • Page 21: Troubleshooting

    TROUBLESHOOTING Furnace Fails to Operate Properly Failure Codes Review “Sequence of Operation” and visually inspect the The system has a built-in, self-diagnostic capability. The control following before troubleshooting: continuously monitors its own operation and the operation of the system. If a system problem occurs, a failure code is indicated by the LED on the ignition control.
  • Page 22 Wiring Connection Diagram—Honeywell ® VR 8205 System Line Voltage - Factory Line Voltage - Field Hot Surface Igniter Low Voltage - Factory Low Voltage - Field Interlock Switch Circulation Blower W (NEUT) R (LO) OR (MED/LO) BU (MED) Y (MED/HI) BK (HIGH) Induced Not on all models...
  • Page 23 Wiring Schematic—Honeywell ® HR 8205 System 120/1/60 Interlock Switch Neutrals Hot Surface Igniter Neutrals Humidifier Neutrals Induced Draft Blower Neutrals Air Cleaner Heat Neutrals Blower Motor Cool 120 VAC Neutrals Transformer 24 VAC Pin 3 Pin 6 If Used Flame Sensor Pin 2 Pin 5 Rollout Switch...
  • Page 24: Assistance Or Service

    WABASE569 Combustible Floor Base (24¹⁄₂" [62.3 cm] cabinets) Honeywell is a trademark of Honeywell International, Inc. 46924B008 ®Registered Trademark/TM Trademark of Whirlpool, U.S.A., 3/08 © 2008. All rights reserved. Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida...

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