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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
START−UP, ADJUSTMENT, AND SAFETY CHECK
GENERAL
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PRIME CONDENSATE TRAP WITH WATER
PURGE GAS LINES
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ADJUSTMENTS
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CHECK INLET GAS PRESSURE
ADJUST MANIFOLD PRESSURE
ADJUST TEMPERATURE RISE
ADJUST BLOWER OFF DELAY (HEAT MODE)
BLOWER OFF DELAY JUMPER POSITIONS
ADJUST COOLING AIRFLOW
ADJUST THERMOSTAT HEAT ANTICIPATOR
CHECK SAFETY CONTROLS
CHECKLIST
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ALTITUDE DERATE MULTIPLIER.
GAS RATE (CU FT./HR)
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ORIFICE SIZE AND MANIFOLD PRESSURE
AIR DELIVERY − CFM
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SERVICE AND MAINTENANCE PROCEDURES
PRESSURE SWITCHES
. . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING HEAT EXCHANGERS
SEQUENCE OF OPERATION
PARTS REPLACEMENT INFORMATION GUIDE
Printed in U.S.A.
MANUAL
Single Stage, PSC Blower Motor
Save this manual for future reference.
Safety Labeling and Signal Words
DANGER,
WARNING,
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WFAR
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.
3
3
3
3
3
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5
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7
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7
7
7
7
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11
13
14
14
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24
28
MODELS
WFAR040A030
WFAR060B048
WFAR080B048
WFAR080C060
WFAR100C048
WFAR100C060
WFAR120D060
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 04
10/15/2018
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Related Manuals for International comfort products WFAR040A030
Summary of Contents for International comfort products WFAR040A030
- Page 1 TABLE OF CONTENTS MODELS WFAR040A030 START−UP, ADJUSTMENT, AND SAFETY CHECK ..GENERAL ........
- Page 2 SAFETY CONSIDERATIONS WARNING Improper ins t allation, adjus t ment, alteration, serv ic e, 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 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 instructions to match the required orifice to the manifold CAUTION pressure to the heat content and specific gravity of the gas. To do this: 1. Obtain average yearly gas heat value (at installed FURNACE DAMAGE HAZARD altitude) from local gas supplier. Failure to follow this caution may result in reduced 2.
- Page 5 10. Turn furnace gas valve electric switch to OFF Main burner flame should be clear blue, almost position. transparent (See Fig. 12.) 11. Turn gas supply manual shutoff valve to OFF i. Remove jumper R to W. position. 2. Verify natural gas input rate by clocking meter. 12.
- Page 6 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 4. Set heat anticipator on thermostat per thermostat WARNING instructions and install on sub-base or wall. 5. Install blower access door. ELECTRICAL OPERATION HAZARD Electronic thermostat: Set cycle rate for 3 cycles per hr. Check Safety Controls Failure to follow this warning could result in personal injury or death.
- Page 8 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 0.93 R Y W G 4001–5000...
- Page 9 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 04 Specifications subject to change without notice.
- Page 11 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 Manifold...
- Page 13 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 040A030 SIDE/BOTTOM Yellow Black 1600 1545 1505 1475 1505 1445...
- Page 14 SERVICE AND MAINTENANCE point of the switch is 0.10 inches of water above the maximum break point of the switch PROCEDURES Example: Nominal break point on pressure switch is 0.68−in. W.C. The minimum break point of the switch is Untrained personnel can perform basic maintenance func- 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 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 04...
- Page 24 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−...
- Page 25 A12421 Fig. 15 − Troubleshooting Guide Specifications subject to change without notice. 440 04 7113 04...
- Page 26 A11440 Troubleshooting Guide (Cont) 440 04 7113 04 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 04...
- Page 28 TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the “Heating Equipment“ or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name, or contact: International Comfort Products Consumer Relations Department P.O. Box 128 Lewisburg, TN 37091, USA 931−270−4100...
- Page 29 SALES DIGIT EXTRA DIGIT Have available the product/model number and the serial number located on the unit rating plate to ensure correct replacement parts. Copyright 2018 International Comfort Products Lewisburg, TN 37091 USA Specifications subject to change without notice. 440 04 7113 04...
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