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Grandaire WFAR Series Service And Technical Support Manual

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SERVICE AND TECHNICAL SUPPORT
35" Tall, High Efficiency Condensing Gas Furnace
DANGER, WARNING, CAUTION, and NOTE
The
signal
words
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an 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.

TABLE OF CONTENTS

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Printed in U.S.A.
MANUAL
Single Stage, PSC Blower Motor
WFAR080B048 (B Series Only)
WFAR (All C Series)
Save this manual for future reference.
Safety Labeling and Signal Words
DANGER,
WARNING,
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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.
WFAR040A030C
3
3
WFAR060B048C
3
WFAR080B048B
3
WFAR080B048C
3
WFAR080C060C
4
WFAR100C048C
5
WFAR100C060C
6
7
WFAR120D060C
7
7
7
7
7
8
9
11
13
14
14
20
24
28
MODELS
Use of the AHRI Certified TM Mark indicates a
manufacturer's participation in the program.
For verification of certification for individual
products, go to www.ahridirectory.org .
440 04 7113 02
12/5/2014

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  • Page 1: Table Of Contents

    SERVICE AND TECHNICAL SUPPORT MANUAL Single Stage, PSC Blower Motor 35” Tall, High Efficiency Condensing Gas Furnace WFAR080B048 (B Series Only) WFAR (All C Series) Save this manual for future reference. Safety Labeling and Signal Words DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals signal words...
  • Page 2 SAFETY CONSIDERATIONS WARNING Impr oper i ns tal lat ion , adj us tmen t, alt era ti on, s er vi ce , PERSONAL INJURY, AND/OR PROPERTY DAMAGE maintenance, or use can cause explosion, fire, electrical shock, HAZARD or other conditions which may cause death, personal injury, or Failure to carefully read and follow this warning could property damage.

  • Page 3: Start--Up, Adjustment, And Safety Check

    START- - UP, ADJUSTMENT, AND SAFETY Prime Condensate Trap with Water CHECK WARNING NOTICE CARBON MONOXIDE POISONING HAZARD Failure to follow these warnings could result in personal IMPORTANT INSTALLATION START- -UP injury or death. PROCEDURES Failure to use a properly configured trap or NOT Failure to follow this procedure may result in a nuisance water-priming trap before operating furnace may allow smoke or odor complaint.

  • Page 4: Check Inlet Gas Pressure

    Tables have been provided in the furnace installation CAUTION instructions to match the required orifice to the manifold pressure to the heat content and specific gravity of the gas. To do this: FURNACE DAMAGE HAZARD 1. Obtain average yearly gas heat value (at installed Failure to follow this caution may result in reduced altitude) from local gas supplier.

  • Page 5: Adjust Manifold Pressure

    11. Turn gas supply manual shutoff valve to OFF i. Remove jumper R to W. position. j. Reinstall manifold pressure tap plug from gas valve. 12. Turn off furnace power supply. 2. Verify natural gas input rate by clocking meter. 13.

  • Page 6: Adjust Temperature Rise

    TWINNING AND/OR COMPONENT TEST BLOWER OFF-DELAY TERMINAL J2 JUMPER BLOWER OFF-DELAY HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) 24-V THERMOSTAT TERMINALS TRANSFORMER 24-VAC CONNECTIONS TEST/TWIN 0.5 AMP@24VAC 3-AMP FUSE FUSE 3-AMP SEC-2 SEC-1 LED OPERATION & EAC-2 DIAGNOSTIC LIGHT PL1-LOW VOLTAGE MAIN HARNESS CONNECTOR 115-VAC(L2)NEUTRAL CONNECTIONS...

  • Page 7: Adjust Blower Off Delay (Heat Mode)

    Check Safety Controls (Read following caution before changing taps). CAUTION The flame sensor, gas valve, and pressure switch were all checked in the Start--up procedure section as part of normal operation. UNIT DAMAGE HAZARD 1. Check Main Limit Switch To avoid operating outside the rise range and avoid This control shuts off combustion system and component damage: energizes air--circulating blower motor, if furnace...

  • Page 8: Altitude Derate Multiplier

    Table 2 – Altitude Derate Multiplier for U.S.A. THERMOSTAT SUBBASE TERMINALS WITH ALTITUDE PERCENT DERATE THERMOSTAT REMOVED MULTIPLIER (ANITICIPATOR, CLOCK, ETC., DERATE FACTOR* MUST BE OUT OF CIRCUIT.) 0–2000 0- -610 1.00 HOOK-AROUND AMMETER 2001–3000 610- -914 4- -6 0.95 3001–4000 914- -1219 6- -8...

  • Page 9: Gas Rate (Cu Ft./Hr)

    Table 3 – Gas Rate (CU ft./hr) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 REVOLUTION FOR 1 REVOLUTION 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1800 1636 1500...
  • Page 10 338309-201 Rev. E A11602 Fig. 5 - - Service Label Information 440 04 7113 02 Specifications subject to change without notice.

  • Page 11: Orifice Size And Manifold Pressure

    Table 4 – Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice Manifold Orifice...
  • Page 12 Table 4 - - Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate (Cont.) SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice...

  • Page 13: Air Delivery -- Cfm

    Table 5 – Air Delivery - - CFM (With Filter) WIRE TEST AIRFLOW DELIVERY @ VARIOUS EXTERNAL STATIC PRESSURES RETURN AIR SIZE LEAD COOLING CONNECTION COLOR TONS /TON Black 1145 1100 1060 1015 Blue 040A030C SIDE/BOTTOM Yellow Black 1600 1545 1505 1475 1505...

  • Page 14: Service And Maintenance Procedures

    SERVICE AND MAINTENANCE Example: Nominal break point on pressure switch is 0.68--in. W.C. The minimum break point of the switch is PROCEDURES 0.63--in. W.C. The maximum break point of the switch is Untrained personnel can perform basic maintenance func- 0.73--in. W.C. The maximum make point of the switch is tions such as cleaning and replacing air filters.
  • Page 15 THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE OF THE BURNER SECTION,...
  • Page 16 4. For approximately 2 sec, short (jumper) the COM-24v For continuing high performance and to minimize possible terminal on control to the TEST/TWIN 3/16—in. (5 furnace failure, periodic maintenance must be performed on mm) quick-connect terminal on control until the LED this furnace.
  • Page 17 “Filter Arrangement” under the “Installation” section of this a. Loosen the clamps on the vent couplings and manual. combustion air pipe external to the furnace. b. Separate the pipes from the couplings and move WARNING them aside. c. Loosen the clamps on the vent couplings and combustion air pipe located on the blower shelf.
  • Page 18 NOTE: Be sure to attach ground wire and reconnect blower 3. Remove control door and set aside. harness plugs to blower motor. 4. Turn electric switch on gas valve to OFF. 5. Disconnect the gas pipe from gas valve and remove WARNING pipe from the furnace casing.
  • Page 19 Flushing Collector Box and Drainage System WARNING WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal ELECTRICAL SHOCK AND FIRE HAZARD injury, death, and/or property damage. Failure to follow this warning could result in personal Never purge a gas line into a combustion chamber.

  • Page 20: Cleaning Heat Exchangers

    11. Flush condensate drain lines with warm water. WARNING Remember to check and clean the relief port on the collector box. ELECTRICAL SHOCK, FIRE OR EXPLOSION 12. Shake trap dry. HAZARD 13. Clean port on collector box with a small wire. Failure to follow this warning could result in personal To re-install Condensate Drain and Trap: injury or death, or property damage.
  • Page 21 Secondary Heat Exchangers The condensing side (inside) of the secondary heat exchanger CANNOT be serviced or inspected without complete removal of the heat exchanger assembly. Detailed information on heat exchanger removal can be obtained from your Distributor. WINTERIZATION CAUTION 1-1/4-in. (31.8) 2-1/2-in.
  • Page 22 Burner Flame Burner Manifold A11461 Fig. 12 - - Burner Flame GROMMET MOTOR SHAFT FLAT MOTOR ARM SCREW SET SCREW MOTOR WHEEL HUB SEE DETAIL SCREW LOCATION BLO HSG ASSY BRACKET BRACKET ENGAGEMENT DETAIL CUTOFF, BLOWER WHEEL, BLOWER BLOWER HSG ASSY BRACKET CAPACITOR OR POWER CHOKE...
  • Page 23 IGNITER BURNER SUPT. ASSY BRACKET, IGNITER BURNER ASSY FLAME ROLLOUT SWITCH FLAME SENSOR (BELOW BURNER) A11403 Fig. 14 - - Burner Assembly Specifications subject to change without notice. 440 04 7113 02...

  • Page 24: Sequence Of Operation

    SEQUENCE OF OPERATION EAC--1 is energized and remains energized as long as the blower motor BLWM is energized. NOTE: Furnace control must be grounded for proper f. Blower- -Off Delay-- When the thermostat is operation or control will lock out. Control is grounded satisfied, the R--to--W circuit is opened, de-- through green/yellow wire routed to gas valve and manifold energizing the gas valve GV, stopping gas flow to the...
  • Page 25 A12421 Fig. 15 - - Troubleshooting Guide Specifications subject to change without notice. 440 04 7113 02...
  • Page 26 A11440 Troubleshooting Guide (Cont) 440 04 7113 02 Specifications subject to change without notice.
  • Page 27 339236- -2 Rev A Fig. 16 - - Wiring Diagram Specifications subject to change without notice. 440 04 7113 02...

  • Page 28: Parts Replacement Information Guide

    PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Blower door Burner Bottom plate Flame sensor Control door Gas valve Door knob assembly Hot surface igniter Top filler plate Manifold Electrical Group Orifice Heat Exchanger Group 3--Amp fuse Circuit board Containment plate Control box Coupling box...

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