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Back To Williams Wall Furnace       Model: 1403621.05 or 140362105 Williams Gravity Direct Vent Wall Furnace
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INSTALLATION & OPERATING INSTRUCTION MANUAL DIRECT VENT FU RNACE FoMRANUFAOTOREO / MOB , , EI owner's manual HOME APPLICATIONS MODEL NOS : 1403621.05 3003621.05 READ THIS OWNERS • Unpacking MANUAL CAREFULLY • Installation BEFORE YOU INSTALL • Operation YOUR NEW WILLIAMS • Repair Parts WALL FURNACE WARNING : If the information in this manual is not followed exactly , a fire or ex - plosion may result causing property damage , personal injury or loss of life . Do not store or use gasoline or other flam - mable vapors and liquids in the vicinity of this or any other appliance . WHAT TO DO IF YOU SMELL GAS • Open all windows . • Do not try to light any appliance . • Do not touch any electrical switch ; do WARNING : Improper installation , adjust - not use any phone in your building . ment , alteration , service or maintenance • Extinguish any open flame . can cause injury or property damage . • Immediately call your gas supplier from Refer to this manual . For assistance or a neighbor's phone . Follow the gas additional information consult a qualified supplier's instruction . installer , service agency or the gas • If you cannot reach your gas supplier , supplier . call the fire department . Installation and service must be per - formed by a qualified installer , survice agency or the gas supplier . WILLIAMS Furnace Co . , 225 Acacia St . , Colton , CA 92324 PRINTED IN USA 7 / _ 8 P322874
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Contents Thermostst Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 Your Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Thermostat Connection at Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . 12 Introductioin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Furnace Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Basic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cabinet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 14 Optional Accesories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Helpful Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating Your Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Unpack Your Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety , Operating and Shutdown Instructions . . . . . . . . . . . . 16 Basic Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gas Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 How To Care For Your Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Basic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installing Your Wall Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 - 20 Locating Wall Furnace and Thermostat . . . . . . . . . . . . . . . . . . . . . 6 - 7 Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 - 24er Service Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cov Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 How To Order Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover Optional Blower Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gas Supply and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11 Your Warranty The Manufacturer , Williams Furnace CO , warrants this wall furnace or healer to Ihe original purchaser under the following conditions : LIMITED ONE - YEAR WARRANTY 1 Any part thereof which proves to be defective in material or workmanship within one year from date of original purchase for use will be repaired or replaced at the Manufacturer's option , FOB its factory 2 NO fiability is assumed by the Manufacturer for removal or installation labor costs , nor for freight or delivery charges LIMITED EXTENDED WARRANTY 1 . _ n addition to the above limited one - year warranty on the complete unit , any heat exchanger which burns out or rusts under normal instaflafion , use and service conditions during a period of nine years following expiration of the one - year warranty period will be exchanged for a like or functionally similar part , FOB Manufac - turer's factory . 2 . No liability is assumed by the Manufacturer for removal or installation labor costs , nor for freight or delivery charges . LIMITATIONS 1 . THIS LIMITED WARRANTY IS THE ONLY WARRANTY MADE BY THE MANUFACTURER IMPLIED WARRANTIES OF MERCHANTABILITY OR F _ TNESS FOR ANY PARTICULAR PURPOSE ARE LIMITED TO THE SAME ONE YEAR TERM AS THIS EXPRESS WARRANTY . UNDER NO CIRCUMSTANCES SHALL THE MANUFACTURER BE LIABLE FOR INCIDENTAL , CONSEQUENTIAL , SPECIAL OR CONTINGENT DAMAGES OR EXPENSES ARISING DIRECTLY OR INDIRECT - LY FROM ANY DEFECT IN THE PRODUCT OR ANY COMPONENT OR FROM THE USE THEREO ! : THE REMEDIES SET FORTH HEREIN ARE THE EXCLUSIVE REMEDIES AVAILABLE TO THE USER AND ARE IN LIEU OF ALL OTHER REMEDIES Some states do not allow limitations on how long an impfled warranty _ asts , and some states do not allow the exclusion or limitation of incidental or consequential damages , so the above limitations or exclusions may not apply to you 2 This warranty does not include any charge for labor or installation . 3 . This warranty does not extend to painted surfaces nor to damage or defects resulting from accident , alteration , misuse or abuse , or improper ststaflation . 4 . This warranty does not cover claims which do not involve defective workmanship or malerials DUTIES OF THE CONSUMER 1 The heating equipment must be instalted by a qualified installer and operated in accordance with the installation and homeowner * s instrucbons furnished with the equtpment 2 Any travel , diagnostic costs , service labor , and labor to repair the defective unit will be the responsibility of the owner . 3 . A bill of sale , cancelled check , payment record or permit should be kept to verify purchase date to establish the warranty period 4 Have the installer enter the requested information in the space below . GENERAL 1 . The Manufacturer neither assumes nor authorizes any person to assume for it any other obligation or liability in connection with said equipment . 2 . Service under this warranty should be obtained by contacting your dealer Provide the dealer with the model number , serial number and purchase date verification 3 . g , within a reasonable time after contacting your dealer , satisfactory service has nol been received , contact : Customer Service Department , 225 Acacia St . , Colton , CA 92324 , for assistance . 4 . THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS , AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE . INSTALLATION INFORMATION Serial No . Model No . Orig . Purchaser . Address City and State _ Zip Dealer Address City and State _ Zip Installation date Signed by . ( Dealer or authorized representative who certifies that this appliance has been installed in accordance with Manufacturer's instructions and local codes . ) - - 2 - -
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Introduction Please read our instructions before you install and use your furnace . This will help you obtain the full value from this furnace . It could help you avoid needless service costs , if the answer to the problem is found within this instruction manual . Basic Description The sealed combustion system draws combustion air Your direct vent wall furnace is shipped ready to install directly from outdoors into the combustion chamber and against an exterior wall up to 9 inches thick . For walls combustion gases are discharged directly to the outdoors greater than 9 inches , and up to 24 inches thick , use an through tubes mounted to the rear of the furnace . optional VENT EXTENSION KIT listed under OPTIONAL ACCESSORIES . The furnace heat exchanger is built of heavy gauge steel treated for corrosion resistance . The furnace may burn either Natural or LP . Gas , depend - ing on the model you have purchased . The furnace cabinet is also constructed of heavy gauge steel and has an enamel paint finish . No electric power is required unless furnace is equipped The furnace controls are located behind an access door with an optional blower accessory . on the lower front of the furnace . All models are equippedas with American Gas Association and Canadian G Association listed gas valves and pilots . Always consult your local heating or plumbing inspector , building department or gas utility company regarding MODELS 1403611 , 1403612 , 2203611 , 2203612 , 3003611 regulations , codes or ordinances which apply to the in - and 3003612 are equipped with a built - in thermostat . stallation of a direct vent furnace . MODELS 1403621 , 1403622 , 2203621 , 2203622 , 3003621 and 3003622 are equipped with a wall thermostat . Optional Accessories ALL MODELS MODEL : 3003621,05 For walls less than 41 / 2 inches thick , a thin Wall Collar Kit 9307 may be used to increase wall thickness if wood strips To increase circulation of warmed air within the heated are undesirable . space , you may use Blower Accessory Kit 2302 , which is equipped with a two - speed fan and automatic fan switch . ALL MODELS : NOTE For additional vent cap protection , Vent Cap Guard 9308 may be used . This mounts to the outside of the exterior Accessories are identified on the carton by their manufac - wall over the vent cap . turing number . ( For example : 9301 ; 9302 ; 9303 . ) These manufacturing numbers are also listed on the furnace rating plate so you can be sure you have the accessory MODEL : 1403621.05 that fits your furnace . For walls greater than 9 inches thick and up to 24 inches thick , use one of the following Vent Extension Kits : KIT NUMBER WALL THICKNESS 9304 9 inches to 15 inches 9303 15 inches to 24 inches MODEL : 3003621.05 For walls greater than 9 inches thick and up to 24 inches thick , use one of the following Vent Extension Kits : KIT NUMBER WALL THICKNESS 9301 9 inches to 15 inches 9303 15 inches to 24 inches ( 140 ( or ) 300 model series ) - - 3 - -
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Safety Rules WARNING umn . The maximum inlet gas supply pressure is 13 " water column . READ THESE RULES AND THE INSTRUCTIONS CAREFULLY . FAILURE TO FOLLOW THESE 7 . ANY SAFETY SCREEN , GUARD OR PARTS RE - RULES AND INSTRUCTIONS COULD CAUSE A MOVED FOR SERVICING AN APPLIANCE MUST BE MALFUNCTION OF THE FURNACE . THIS COULD REPLACED PRIOR TO OPERATING THE AP - RESULT IN DEATH , SERIOUS BODILY INJURY , PLIANCE TO AVOID PROPERTY DAMAGE , BODILY AND / OR PROPERTY DAMAGE . INJURY OR DEATH . 8 , INSTALL the furnace vent directly to the outdoors , so INSTALLATION MUST CONFORM TO LOCAL CODES . IN that harmful gasses will not collect inside the building . THE ABSENCE OF LOCAL CODES , INSTALLATION MUST Follow the venting instructions for your type installa - CONFORM WITH THE NATIONAL FUEL GAS CODE , ANSI tion exactly . Use only the type and size of vent pipe Z223 . 1 . THE APPLIANCE , WHEN INSTALLED , MUST BE and fittings specified . ELECTRICALLY CONNECTED AND GROUNDED IN 9 , BE SURE to provide for adequate combustion and ACCORDANCE WITH LOCAL CODES OR , IN THE ventilation air . See page 7 . The flow of this air to the ABSENCE OF LOCAL CODES , WITH THE CURRENT furnace must not be blocked . NATIONAL ELECTRICAL CODE ANSI / NFPA NO . 70 . 10 . NEVER vent flue gases into another room , a fireplace IN CANADA or any space inside a building . This could cause pro - petty damage , bodily injury or death . 1 . INSTALLATION MUST CONFORM TO LOCAL 11 . NEVER test for gas leaks with an open flame . Use CODES OR , IN THE ABSENCE OF LOCAL soap suds to check all gas connections . This will avoid CODES , THE CURRENT CANICGA B149 IN - the possibility of fire or explosion . STALLATION CODE . 2 . THE APPLIANCE , WHEN INSTALLED , MUST BE 12 . ALLOW furnace to cool before servicing . Always shut ELECTRICALLY CONNECTED AND GROUND - off electricity and gas to furnace when working on it . ED IN ACCORDANCE WITH LOCAL CODES OR , This will prevent any electrical shocks or burns . IN THE ABSENCE OF LOCAL CODES , WITH 13 . DUE TO HIGH TEMPERATURES , locate the furnace THE CURRENT CSA C22 . 1 CANADIAN ELEC - out of traffic and away from furniture and draperies . TRICAL CODE . 3 . REFERENCE IS MADE IN THIS MANUAL 14 . ALERT children and adults to the hazards of high sur - REGARDING GAS TYPE AS L . PG . BE ADVISED face temperature and to keep away to avoid burns or THAT LP . G . IS NOT AVAILABLE IN CANADA , clothing ignition . REFER TO PROPANE / L . I _ GAS . 15 . CAREFULLY supervise young children when they are in the same room with the furnace . 16 . DO NOT place clothing or other flammable material 1 . USE ONLY MANUFACTURER'S REPLACEMENT on or near furnace . PARTS . USE OF ANY OTHER PARTS COULD CAUSE INJURY OR DEATH . 17 . INSTALLATION and REPAIR must be done by a quali - 2 . DO NOT install this furnace in an alcove . fied service person . The appliance should be inspected 3 . DO NOT install these furnaces in a travel trailer or before use and at least annually by a professional serv - ice person . More frequent cleaning may be required recreational vehicle . due to excessive lint from carpeting , bedding material , 4 . MAINTAIN all clearances specified in section " Lo - etc . It is imperative that control compartments , burners cating Wall Furnace and Thermostat " and " Vent In - and circulating air passages be kept clean . stallation " . 18 . BEFORE INSTALLING : To avoid electrical shock , turn 5 . Furnace must be equipped for proper type of gas off electrical circuits that pass through the wall where being used . ( L . P . Gas or NAT . Gas ) . This furnace you are going to install the furnace . is factory equipped for LP . Gas . If conversion is re - 19 . BE AWARE of good safety practices by wearing per - quired , this must be done by a qualified service per - sonal protective equipment such as gloves and safe - son . Follow closely conversion instructions outlined ty glasses to avoid being injured by sharp metal edges in this manual and on rating plate . in or around furnace and while cutting or drilling holes 6 . For Natural gas , the minimum inlet gas supply pres - in wood and or sheet metal . sure for the purpose of input adjustment is 5 " col - 20 . umn . The maximum inlet gas supply pressure is 7 " CAUTION : Label all wires prior to disconnection when water column . servicing controls . Wiring errors can cause improper and dangerous operation . Verify proper operation after For L . P . gas , the minimum inlet gas supply pressure servicing . for the purpose of input adjustment is11 ° water col - WARNING DO NOT USE THIS HEATER IF ANY PART HAS BEEN UNDER WATER . IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE HEATER AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER . , , _ 4 _ _
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Unpack Your Furnace lost or damaged before you need them . This direct - vent furnace is packaged complete including the vent cap , vent tube and air inlet tube ready for instal - NOTE : lation on an exterior wall with a total thickness of from 5 inches minimum to a maximum of 9 inches . Check the burner rating plate located in burner compart - ment , to make sure your furnace is equipped to operate Open the carton and remove all parts . on the gas available ( either NATURAL or L . P . GAS ) . Convert for your field requirement . Furnace must match Examine all packing material carefully , Look for loose parts gas usage exactly . before discarding . Store all parts where they cannot be Basic Tools Needed Tin snips Hand drill or properly grounded electric drill 8 " adjustable wrench Expansion bit 1 / 2 " to 1 - 5 / 8 " or 1 / 2 " or 1 - 1 / 2 " blade bits 12 " adjustable wrench 1 / 8 " and 3 / 16 " drill bit ( metal ) Key hole saw or Sabre saw 6 ft . folding rule or tape measure Hack saw Screwdriver ( Phillips head ) 2 - 10 " or 12 " pipe wrenches Pliers ( wire cutting ) Gloves and safety glasses Hammer Stud tocator or small finish nails Basic Materials Pipe joint compound resistant to EFt Gases . Pipe and fittings to make connections to furnace ( see page 10 ) . Electrical wiring supplies as needed for optional blower if equipped ( see page 9 ) . Caulking compound - silicone rubber with a temperature rating of 500 ° E Minimum wire size is # 14 gauge copper . Do not use types advertised as paintable or for bath tub use as most contain fillers and will not withstand high temperatures . Installing Your Wall Furnace IMPORTANT The following steps are needed for proper installation and safe operation of your furnace . If you have any doubts as For satisfactory and trouble - free operation be sure to : to any requirements , check with local authorities for local 1 . Properly locate the furnace within the space to be and state codes affecting the installation . heated . Obtain professional help where needed . 2 . Provide for adequate combustion air around vent cap DO NOT install these furnaces in a travel trailer , recrea - on outside , see Fig . 1 , page 6 and adequate air circula - tional vehicle . tion around cabinet inside the open room , see Fig . 2 , page 6 . 3 . Maintain all minimum clearances on pages 6 and 7 which apply to your furnace model . Helpful Installation Information American National Standard Z223 . 1 current edition " Na - The following booklets will help you in making the installa - tional Fuel Gas Code . " tion . Check at the library or they may be purchased from the source listed below . In Canada : CAN / CGA - B149 . 1 ( . 2 ) Canadian Standard . Obtain from - American National Standards Institute , Inc . , ANSI / NFPA 70 current edition " National Electrical Code . " In Canada : C22 . 1 Canadian Electrical Code . 1430 Broadway , New York , NY 10018 . - - 5 m
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Locating Wall Furnace Consider the following points before attempting to install MINIMUM DIMENSIONS FROM VENT the furnace : ALL MODELS 1 . This is a direct vent wall furnace . It must be installed on an OUTSIDE WALL for proper venting of flue gases ( Fig . 1 ) . 2 . Wall furnace can be surface mounted on an outside wall up to 24 inches thick when using an optional VENT EXTENSION KIT . 3 . Check the clearances needed from the furnace and vent ( Figs . 1 and 2 ) . You must place the furnace where you will have no less than the clearances shown . 4 . The outside vent must be at least 18 inches away from any window or other building opening . 5 . The furnace will not work if anything stops free entry of fresh air into the vent , or free flow of flue gases from it . Be sure the center of the vent cap is at least 12 inches above ground level or shrubs as shown in Fig . 1 . Make sure shrubs are kept trimmed . It must also be at least 18 inches from any wall or other blockage and 30 inches below any overhang . 6 . Try to place the furnace near the center of the space to be heated for good air circulation . Do not put it behind a door or draperies . Do not put in a closet , alcove , hallway or other confined space . 7 . Be sure that gas piping and electrical wiring ( optional INTERIOR CLEARANCES blower only ) can be brought to the furnace . See sec - tions on gas piping for your type of mounting . J 8 . To provide adequate clearance and service access , the front of the furnace must face the open room . INTERIOR CLEARANCES ( Refer to Fig . 2 ) ( 1 ) 18 " MIN . MODEL : 1403621.05 ( 2 ) 24 " MIN . 1 . There must be at least 1 - 3 / 16 inches of space between the floor ( top of floor covering ) and the bottom of cabinet . \ 2 . The top of the furnace must be at least 18 inches from the ceiling or other projecting overhang . 3 . The side of the furnace must not be closer than 2 in - ches to an adjacent wail . MODEL : 3003621.05 1 . There must be at least 5 - 1 / 2 inches of space between the floor ( top of floor covering ) and the bottom of cabinet . 2 . The top of the furnace must be at least 24 inches from ( 1 ) 1 - 3 / 16 - the ceiling or other projecting overhang . 3 . The side of the furnace must not be closer than 2 ( 2 ) 5 - 11 _ " / inches to an adjacent wall , ( 1 ) MODEL : 1403621.05 ( 2 ) MODEL : 3003621.05 FIG . - - 6 - -
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Locating Wall Furnace ( cont . ) HOT SPOTS : COLD SPOTS : Concealed pipes or ducts Concealed pipes or ducts Stairwells - drafts ALL MODELS Fireplaces Doors - drafts Registers TV sets Unheated rooms on Choose a location for the thermostat about 5 feet above Radios other side of wall DEAD SPOTS : the floor on an inside wall . The thermostat wire supplied Lamps Behind doors with your furnace is 20 feet long , which should be enough Direct sunlight Kitchen Corners and alcoves to run up through the attic so the thermostat can be a max - imum of 16 feet from furnace measured in a straight line , After picking a location that meets the requirements , in - or approximately 12 feet from the furnace if the wire is run spect the wall , floor and outside areas . Make sure there under the floor . The thermostat should be sensing average are no pipes , wiring , or anything else that would interfere room temperature , avoid the following : with furnace or vent or thermostat installation . If required , move them or pick a new location . Installation BEFORE YOU BEGIN : To avoid electrical shock turn off Make sure the inside and outside wall openings are aligned so tubes and vent will fit properly . electrical circuits that pass through the wall where you are going to install the furnace . IN NEW CONSTRUCTION frame in 9 - 1 / 4 inch x 9 - 1 / 4 inch opening centered between studs spaced 16 inches on This furnace must be installed using only the vent tube , center , and center point located as noted per Fig . 3 . air inlet tube and vent cap assembly supplied by the manufacturer . Before the furnace is installed an opening must be cut through the wall for the vent cap . NO'W . : g - - 1 / 4 x 9 - - 1 , / 40P _ IING MAY BE ROUND OR SQUARE CUT , FIND THE STUDS E _ lSllN P - CONSlRUC110N Find the studs where the furnace is to be placed . Use a stud Iocator or small finishing nails . Repeatedly drive and remove a nail into the wall in the area of the stud until vyoue find it . Then find one side . Leave the nail there . Dri another nail just on the other side of the same stud . The inside edge of the other stud should be about 14 - 1 / 2 inches from the one found . Drive a finishing nail on the inside edge of this stud , then another nail on the outside edge . Using a level , draw vertical lines that will represent the two stud center lines . CUT VENT OPENING After locating studs , use the cardboard template ( Fig . 4 , page 8 ) . Line up the CENTER OF STUD lines on the template with the center lines you have drawn on the wall . Use the template to draw the 9 - 1 / 4 inch diameter circle on the wall . Then mark the location of the gas supply line . Using a window , door or wall corner for reference , measure to find where vent will be on outside wall . Check to be sure of proper clearances ( Figs . 1 and 2 , page 6 ) . tf necessary , relocate for proper clearances . Drill a 1 / 4 inch hole in the wall at the vent opening center mark all the way through to the outside . Cut the 9 - 1 / 4 inch diameter hole through inside wall . Using the 1 / 4 inch hole ( 1 ) MODEL : 1403621.05 as center , cut a matching hole in outside wall . It may be ( 2 ) MODEL : 3003621.05 better to work from the outside when breaking through brick , stone or tile . RB . $ - - 7 - -
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Installation ( cont . ) IMPORTANT GAS AND ELECTRICAL SUPPLY OPENINGS Holes must be drilled for the gas line ( and electrical For walls more than 9 inches thick , read note below . supply if you use an optional Blower Kit ) . Drill a 1 - 1 / 2 NOTE inch hole in wall for gas line where indicated on cardboard template or refer to Fig . 3 , page 7 . You will ( Refer to Fig . 5 . ) The vent tube " C " and air inlet tube " D " have to determine whether the gas line will enter the are factory installed for walls up to 9 inches thick only . For home through the outside wall or wall floor plate . These wall thicknesses up to 24 inches , follow the instructions instructions can only guide you in where the gas line packed with the appropriate factory built VENT EXTEN - will enter the furnace . SION KIT . See OPTIONAL ACCESSORIES on page 3 . TEMPLATE FURNACE MOUNTING Set the furnace body against the wall , legs on the floor , with the vent tubes ( " C " and " D " Fig . 5 ) extending TEMPLATE through the spacer plate . Fasten the furnace to the wall through holes at the top and bottom of the support legs using four ( 4 ) # 8 roundhead ( long ) screws ( " F " Fig . 5 ) provided . Push the air inlet shield " J " on from the exterior side of wall . Rotate the air inlet shield until notches on the end \ / L _ . / j of the tube are straddling the standoff tabs on the mount - ing spacer plate " A ' _ . Trim the air inlet shield " J " flush with the exterior of the wall . The gas line can be run at this time or done after the furnace is mount - ed . See section GAS SUPPLY and FASTEN LEG TO WALL \ PIPING , page 10 . © No electric power is required unless / - AIR IN T HI D / furnace is equipped with an optional blower kit . / L / i _ EMBOSSED _ TOP " CAP Do not connect 115V service line to the gas valve or wall thermostat . MODEL 3003621.05 WITH OPTIONAL BLOWER KIT 2302 ONLY Installan electrical junction box at the location shown in Fig . 7 , page 9 . Route the 115V electrical supply wir - ing to the junction box making sure to leave enough excess wire to make connections later . INSTALL SPACER PLATE Installthe mounting spacer plate ( " A " Fig . 5 ) with spacers entering and centered within the 9 - 1 / 4 inch vent opening in wall . Level top of spacer FASTEN ON FINISHED FLOOR plate ( embossed top ) and fasten to in - TO WALL terior wall using six ( 6 ) # 8 roundhead ® RG . ( long ) screws ( " B " Fig . 5 ) provided . - - 8 - -
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Installation ( cont . ) INSTALL VENT CAP POSITION OF VENT CAP Outside , place a single strip of mastic ( provided ) around EXTERIOR WALL the back flange of the vent cap ( " G " Fig . 5 , page 8 ) . In - WITH VENT CAP stall the vent cap by inserting it into the air inlet tube and over the vent tube . ' TOP " IMPORTANT The top of the vent cap is embossed " TOP " . Install it in I the correct position to prevent water from entering the wall . Level the vent cap and attach it to the outside wall with four ( 4 ) # 8 roundhead ( long ) screws ( Fig . 6 ) . If the wall surface is not flat ( shiplapped siding , etc . ) or less than 5 inches thickness use Thin Wall Collar Kit ( 9307 ) i or , build up a flat surface with wood strips . Do not tilt or bend cap to fit uneven surfaces . The vent cap flange must be tight against the wall to prevent rain or wind penetra - tion . Use standard caulking compound if required ( not provided ) . For brick , masonry or plaster walls , it may be necessary \ to use lag screws or expanding anchor bolts which are not furnished with the furnace . Optional Blower Installation and Operating Instructions The automatic fan switch " E " turns on the blower after 1 . Remove knock - out plates " A " and " B " from right side of furnace inner casing . the heater has been operating a few minutes and turns off the blower after the heater is shut off . 2 . Remove junction box cover , place blower and junction box assembly in position shown and fasten to inner cas - NOTE ing through pre - punched holes with screws " C " and Blower will not operate unless fan switch is pulled to " On " " D " provided . position , either " High " or " Low . " To check " On " position , 3 . Remove knock - out " G " from bottom of junction box turn automatic fan switch " E " to 70 , then pull chain on and install 115V line in accordance with local electrical switch to obtain High , Low or Off position . Set the fan code , connecting as shown on the wiring diagram switch dial at 110 and readjust higher or lower as below . necessary to obtain blower operation within 4 to 5 minutes 4 . Replace junction box cover . after the main burner is in operation . 5 . After blower and junction box are installed , rotate The unit must be electrically grounded in accordance with ANSI / NFPA 70 current edition of the " National Electrical bushing " H " if needed to prevent motor wire binding Code . " In Canada : Follow C22 . 1 Canadian Electrical Code . against blower case . IMPORTANT : Oil yearly with SAE 20 high temp oil . BLOWER ACCESSORY KIT 2302 I illch V _ I p , _ ) I I I I U _ = , - - , / I . b " s % c . l 16 - - 1 / 2 " E . - I fiNISHrn FLOORj " - - 9 - -
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Gas Supply & Piping 2 . Do not thread pipe too far . Valve distortion or malfunc - Gas control valve , within the furnace , is shipped with a seal over gas inlet tapping . Do not remove this seal until tion may result from excess pipe within control . ready to connect piping . Apply moderate amount of good quality dope to pipe only , leaving 2 end threads bare . If L . IR Gas installa - WARNING tion , use compound resistant to action of liquefied DANGER OF PROPERTY DAMAGE , petroleum gases . BODILY INJURY OR DEATH . , MAKE SURE THE FURNACE IS EQUIPPED TO Use ground joint unions . OPERATE ON THE TYPE OF GAS AVAILABLE . 4 . Install a drip leg to trap dirt and moisture before it can FURNACE DESIGNATED FOR USE WITH enter the gas valve . Drip leg must be a minimum of 3 LIQUIFIED PETROLEUM ( L . P . ) GAS RHAVEE inches long . ORFICES SIZED FOR COMMERCIALLY PU 5 . Install a manual shut - off valve . PROPANE GAS . THEY CANNOT BE USED WITH BUTANE OR A MIXTURE OF BUTANE AND PROPANE . FIELD CONVERTED MODELES DESIGNATED AS NATURAL GAS ARE TO BE GAS SUPPLY PIPING USED WITH NATURAL GAS ONLY . GAS SUPPLY For Natural Gas , the minimum inlet gas supply pressure for the purpose of input adjustment is 5 " column . The max - imum inlet gas supply pressure is 7 " water column . For L . IR Gas , the minimum inlet gas supply pressure for the purpose of input adjustment is 11 " water column . The maximum inlet gas supply pressure is 13 " water column . Gas pressures and input to the burners must not exceed the rated input and pressure shown on the rating plate . On Natural Gas the manifold pressure should be 4 inches water column . The manifold pressure should be 10.5 inches water column for LP . Gas . See page 13 for operation above 2000 feet altitude . Office change may be required to suit gas supplied . Check with your local gas supplier . ORIFICE SIZES Furnace Technical Information , page 13 , shows the cor - rect orifice sizes for the different input ratings when using Natural or L . P . Gas . GAS PIPING The gas supply line must be of adequate size to handle the BTU / HR requirements and length of the run for the unit being installed . _ ' _ = ALL BLr4OS tN M [ IAt i IL IUllrt _ G SIIL ) UL [ I t _ I 5ML ) OT _ 4 Determine the minimum pipe size from Fig . 10 , page 11 , _ " , AUIION S _ tJT OH rt _ MAIN _ A % % UPPLY IJEFOr _ E 14EMOVIt _ G Li _ { J CAP It } , u _ [ V [ NI GAS r _ i ) M _ qLLIr _ G TH £ WORK A [ I [ A I [ ' * T FO _ GAS LEAr , basing the length of the run from the gas meter or source A ( ; E Wll [ r _ INSTAl _ A ! bON IS COMPLETE to the unit . All piping must comply with local codes and ordinances or with the National Fuel Gas Code ( ANSI Z223 . 1 NFPA No . 54 ) , whichever applies . IN Canada : Follow CAN / CGA - B149 . 1 ( . 2 ) Canadian Standard . PROPER PIPING PRACTICE Refer to Fig . 8 for the general layout at the unit . It shows 2 IMP ( ` RFECT CONTRO L USE MODERAT _ AMOUNT OF DOPE THREAOS the basic fittings needed . The following rules apply : 1 . Use new , properly reamed pipe free from chips such THREAD piP ( . RIGHT LENGTH LEAVE 2 ENO THR ( ` ADS BARE as steel or black iron pipe and fittings or other approved by local codes . - - lO - -
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Gas Supply & Piping ( cont . ) Tighten all joints securely . GAS PIPE SIZES CHECKING THE GAS PIPING NATURAL GAS PIPE CAPACITY - BTU PER HOUR Test all piping for leaks . When checking gas piping to the ( INCLUDES FITTINGS ) furnace with gas pressure at less than 1 / 2 PSI , shut off PIPE SIZE manual gas valve for the furnace . If gas piping is to be LENGTH OF checked with the pressure at or above 1 / 2 PSI , the furnace PIPE - FEET 1 / 2 inch 3 / 4 inch 1 inch and manual shut off valve must be disconnected during 20 92,000 190,000 350,000 testing . ( SEE WARNING BELOW . ) Apply soap suds ( or 40 63,000 130.000 245,000 a liquid detergent ) to each joint . Bubbles forming indicates 60 50,000 105,000 195,000 a leak . Correct even the slightest leak at once . L . P . GAS PIPE CAPACITY - BTU PER HOUR WARNING ( INCLUDES FITTINGS ) LENGTH OF PIPE - FEET 112 inch 3 / 4 inch 1 inch DANGER OF PROPERTY DAMAGE , BODILY INJURY OR DEATH . 20 189,000 393,000 732,000 NEVER USE A MATCH OR OPEN FLAME TO TEST 40 129,000 267,000 504,000 FOR LEAKS . NEVER EXCEED SPECIFIED 60 103,000 217,009 409,000 PRESSURES FOR TESTING . HIGH PRESSURES MAY DAMAGE THE GAS VALVE AND CAUSE GAS CONNECTION OVER - FIRING WHICH MAY RESULT IN HEAT EX - CHANGER FAILURE . LIQUID PETROLEUM ( L . P . ) If installation is for L . P . Gas have L . P . installer use two - GAS IS HEAVIER THAN AIR AND IT WILL SETTLE stage regulation and make all connections from storage IN ANY LOW AREA , INCLUDING OPEN DEPRES - tank to furnace . SION AND IT WILL REMAIN THERE UNLESS Use two pipe wrenches when making the connection to AREA IS VENTILATED . the vaive to prevent turning or damage to gas valve . NEVER ATTEMPT START - UP OF UNIT BEFORE Connection between shut off valve and burner control THOROUGHLY VENTILATING AREA . assembly can be made with an A . G . A . / C . G . A . design cer - tified flexible connector if allowed by local codes . Thermostat Installation ROUTE THERMOSTAT CABLE ALL MODELS 1 . If an old thermostat is being replaced and is in a satisfactory location and the wiring appears to be in good condition , use existing wiring . If in doubt , use new wire . 2 . If a new location is chosen or if this is a new installa - tion , thermostat cable must first be run to the location selected . All wiring must agree with local codes and ordinances . These instructions cover bringing the wire down from the attic but it can be run from a basement or crawl space using similar methods . 3 . Before drilling hole in wall at selected location , drive a small finishing nail through the ceiling in the corner of the wall and ceiling above the thermostat location . Pull the nail out and push a small stiff wire through the hole so it can be found in the attic . Drill a 1 / 2 inch hole through the ceiling wall plate . 4 . Probe for obstructions in the partition . Then drill a 1 / 2 inch hole through wall at selected location for thermostat . 5 . From the attic , feed the thermostat cable or a stiff wire through the wall until even with thermostat location . - - 11 - -
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Thermostat Installation ( cont . ) 6 . Snag thermostat cable through wall so that 6 inches 3 . Push any excess wire back through hole in wall and of cable protrudes . plug hole with insulation to prevent drafts from affect - ing thermostat operation . 7 . Route cable to wall furnace leaving enough excess cable to make the connections at the gas valve . 4 . Being sure to level thermostat for best appearance , fasten thermostat base to wall through mounting holes MOUNTING THE THERMOSTAT with screws provided . 1 . To remove the thermostat cover , grasp cover and pull 5 . Replace the thermostat cover . straight outward . Carefully remove and discard the NOTE packing tab protecting the switch contacts . 2 . Connect thermostat wires to the terminal screws on the Refer to installation instructions packed in the thermostat back of thermostat base . carton if you have any doubt about the above procedures . Thermostat Connection at Gas Valve down from the attic but it can be run from a basement or crawl space using similar methods . ALL MODELS 3 . Before drilling hole in wall at selected location , drive a small finishing nail through the ceiling in the corner 1 . If an old thermostat is being replaced and is in a of the wall and ceiling above the thermostat location . satisfactory location and the wiring appears to be in Pull the nail out and push a small stiff wire through the good condition , use existing wiring . If in doubt , use new wire . hole so it can be found in the attic . Drill a 1 / 2 inch hole through the ceiling wall plate . 2 . If a new location is chosen or if this is a new installa - tion , thermostat cable must first be run to the location 4 . Probe for obstructions in the partition . Then drill a 1 / 2 selected . All wiring must agree with local codes and inch hole through wall at selected location for thermostat . ordinances . These instructions cover bringing the wire I ; 1 [ _ dl ilP _ INNER CASING7 - - " COMSUSTION CHAMBER - ELEMENT SHIELD PILOT OBEERVATION DOOR , " GENERATOR ( PEEP WIRES HOLE COVEF DOOR ; ANUAL SPARK - - IGNITOR PRESS REPBATEOLY TUBE GROUND / JOINT UNION FITTING - CONTROL KNOB DRiP LE ( _ MANUAL SHUT - OFF VALVE - - 12 - -
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Furnace Technical Information HTG . CAP . MODEL TYPEI INPUT * MAIN BURNER OFIFICE RATING RATING NUMBER GAS IBTU / HR BTU / HR DRILL DEC . QTY . | 10,059 1405621.05 i L . P . 114,000 # 58 . 0420 1 10,059 1405622.051 NAT . I 14,000 # 51 . 0670 1 21,849 5005621.05 L . P . 150,000 # 55 . 0595 1 21,849 # 42 . 0955 1 5005622.05 NAT . 150,000 * For elevations above 2000 feet reduce ratings 4 % for each 1000 feet above sea level . Btuh = British Thermal Units per hour . The efficiency ratging of these appliances is a product thermal efficiency rating system determined under con - tinuous operating conditions and was determined independently of any installed system . Cabinet Installation MODEL : 1403621.05 MODEL : 3003621.05 Set cabinet over furnace body , dropping rear top flange between support legs and wall . Open cabinet door and Set cabinet over furnace body , dropping rear top flange attach cabinet to inner casing with two ( 2 ) sheet metal into slot in top of Spacer Plate and into slots between sup - ( short ) screws ( Fig . 14 ) . port legs and wall . When correctly positioned side to side , a dimple on the rear top flange will slide against the in - side of each support leg . Attach two ( 2 ) tension springs through bottom flange of heat exchanger and bottom of cabinet ( Fig . 15 ) . Fasten trim strip to bottom of support legs I _ _ _ REAR using two ( 2 ) sheet metal ( short ) screws ( Fig . 15 ) . CABINET _ TOP FLANGE fll CABINET _ J BINET ( CASING ) TRIM STRIP _ - - 13 - -
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Start - Up Procedure Start the furnace using the procedures in section CHECK THE GAS INPUT ( NATURAL GAS ONLY ) Operating Your Furnace on pages 15 through 19 . WARNING WARNING NATURAL GAS HEATING VALUE ( BTU PER CUBIC DANGER OF BODILY iNJURY OR DEATH FOOT ) CAN VARY SIGNIFICANTLY , THEREFORE , IT IS THE INSTALLER'S RESPONSIBILITY TO SEE LIQUEFIED PETROLEUM ( L . R ) GAS IS HEAVIERW THAT BTU INPUT TO THE FURNACE IS ADJUSTED THAN AIR AND IT WILL SETTLE IN ANY LO " PROPERLY . FAILURE TO DO SO COULD CAUSE AREA , INCLUDING OPEN DEPRESSIONS AND IT HEAT EXCHANGER FAILURE , ASPHYXIATION , FIRE WILL REMAIN THERE UNLESS AREA IS OR EXPLOSION , RESULTING IN DAMAGE , BODILY VENTILATED . INJURY OR DEATH . REFER TO THE NATURAL NEVER ATTEMPT START - UP OF UNIT BEFORE FUEL GAS CODE ( NFPA - 54 ) TO BE SURE THE FUR - NACE IS BURNING FUEL AT THE PROPER RATE . THOROUGHLY VENTILATING AREA . Underfidng could cause inadequate heat , excessive conden - sation or ignition problems . Overfiring could cause soot - Check the furnace operation as outlined in the following ing flame impingement or overheating of heat exchanger . instructions . If any sparking , odors or unusual noises are encountered , shut off electrical power immediately . Before starting natural gas input check , obtain heating Recheck for wiring errors , or obstructions in or near op - value of gas ( BTU per cubic foot ) at standard conditions tional blower motor . from your local supplier . This factor is used in " Check the Gas Input " section and procedure . NOTICE : To measure the input using the gas meter , proceed as follows : During the initial firing of this unit some smoke and odor may occur . We recommend ventilating the area during this Step 1 : Turn off gas supply to all other appliances except initial " break in period . " the furnace . Step 2 : With the furnace operating , time the smallest dial CHECK GASINPUT AND PRESSURES on the meter for one complete revolution . If this For furnace located at altitudes between sea level and is a 2 cubic foot dial , divide the seconds by 2 ; if 2000 feet , the measured input must not be greater than it is a 1 cubic foot dial , use the time in seconds the input shown on the rating plate of the furnace . For as is . ( 3,600 = Sec . Per Hr . ) This gives the elevations above 2000 feet , the measured input must not seconds per cubic foot of gas being delivered to exceed the input of the rating plate reduced by 4 percent ' the furnace . for each 1000 feet that the furnace is above sea level . Step 3 : Assuming natural gas witha heating value of 1000 Gas supply pressure and manifold pressure with the Btu per cubic foot and 34 seconds per cubic foot burners operating must also be as specified on the rating as determined by step ( 2 ) , then : plate . Input : 1,000 X 3,600 ÷ 34 = 106000 Btu Per Hour This measured input must not be greater than the input indicated on the rating plate of the furnace . TYPE OF GAS MANIFOLD PRESSURE , IN . W . C . Step 4 : Relight all other appliances turned off in step 1 Natural 4 above . Be sure all pilot burners are operating . L . P . 10.5 ADJUST PILOT BURNER ( SEE FIG . 12 , PAGE 12 ) NOTE : Pilot gas may need adjustment depending on Rated input will be obtained on 2500 BTU propane at inlet pressure , increase or decrease to obtain 10.5 inches manifold pressure with factory - sized offices . proper setting . If LP . Gas having a different heating value is supplied , orfices must be changed by a qualified installer before Pilot flame should surround 3 / 8 inch to 1 / 2 inch of the ther - the furnace is operated . mocouple tip . Toadjust , if needed , remove pilotadjustment cap ( do not lose gasket ) . CHECK THE MANIFOLD GAS PRESSURE 1 . Remove screw cover over pilot adjusting screw . A tapped opening is provided in the gas valve to facilitate 2 . Insert small screwdriver . Adjust flame as needed . Turn measuring the manifold gas pressure . A " U Tube " screw counterclockwise ( 1 € ' _ ) to increase flame , manometer having a scale range from 0 to 12 inches of clockwise ( _ ) to decrease . water should be used for this measurement . The manifold 3 . Turnthermostat to highestsetting . Main burners should ( pressure must be measured with the burner and pilot light quickly and smoothly . Turn thermostat to lowest operating . Any major changes in the flow must be made setting . Main burners should go out . Pilot should re - by changing the size of the burner orifice . Check with local main lighted . gas company for proper orifice size . 4 . Replace screw cover over pilot adjusting screw . m14 . - -
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Operating Your Furnace Refer to this sheet and sheet 16 for " Safety , Operating IF GAS CONVERSION IS REQUIRED , IT MUST BE Instructions " and " Turn Gas Off To Appliance . " These DONE BY A QUALIFIED TECHNICIAN . Input and output furnaces are equipped with a manually operated piezo shown on the rating plate , located in burner compartment spark ignition device to ignite the pilot gas . Follow the must not be exceeded . steps under " Operating Instructions " and use the manual spark ignitor ( shown in Fig . 13 ) to light the pilot in place of a match . Press spark ignitor button repeatedly . WARNING WARNING I DO NOT STORE OR USE GASOLINE OR OTHER I THE SURFACE OF THE FURNACE IS HOT DUR - FLAMMABLE LIQUIDS OR VAPORS NEAR THE ING OPERATION . KEEP CHILDREN , CLOTHING , FURNACE . FURNITURE , AND FLAMMABLE MATERIAL AWAY I FROM IT . On new installations the gas lines will be filled with air and it may take several tries to establish the pilot flame . LIGHTING THE FURNACE WITH A MATCH Check the manual shut - off valve in the gas line . It must If the spark ignitor fails to provide spark to light the pilot , be in the open position ( handle parallel to gas line ) before loosen the wing nut holding the peep hole cover . This will you can light your furnace . open the peep hole into the heat exchanger and the pilot can be ignited with a match . Your furnace is equipped with a 100 % safety pilot which will shut off the gas valve in case the pilot is not burning 1 . Follow the instructions under " LIGHTING AND or functioning properly . Make sure the pilot is adjusted pro - OPERATING INSTRUCTIONS " and use a match to perly and that the thermocouple or generator connection light the pilot as instructed . at the control valve is tight . If furnace will not stay lit , call your local gas utility company . WARNING Your furnace is equipped with a built - in pressure regulator . DANGER OF IGNITION FLASH L . R Gas models also have a regulator at the supply tank . AND EYE INJURY OR BLINDNESS If you have a question regarding the amount of fuel consumed , call your local gas utility or gas supplier . DO PROTECT YOUR EYES . NEVER ATTEMPT TO NOT TAMPER WITH THE REGULATORS OR BURNER LIGHT PILOT WITH GAS CONTROL VALVE ORIFICES , AS PROBLEMS RESULTING THEREFROM KNOB IN " ON " POSITION . FLASHBACK COULD MAY CAUSE PRODUCT FAILURE NOT COVERED BY OCCUR . WARRANTY . Input and Output shown on the Rating Plate , located in burner compartment , must not be exceeded . 2 . After lighting the pilot , carefully replace the pilot IMPORTANT observation door ( peep hole cover ) and tighten wing KEEP BURNER AND CONTROL COMPARTMENT nut down . CLEAN . WARNING THERMOSTAT ( TYPICAL ) DANGER OF BODILY INJURY OR DEATH DO NOT OPERATE THE FURNACE WITH A BROKEN OR MISSING PILOT OBSERVATION DOOR . SQUEEZE FIRMLY BOTH SIDES AND UFT TO REMOVE COVER - - 15 - -
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FOR YOUR SAFETY , READ BEFORE LIGHTING WARNING : If you do not follow these instructions exactly , a fire or explosion I may result causing property damage , personal injury or loss of life . I A . This appliance has a pilot which must be lighted by • If you cannot reach your gas supplier , call the fire department . hand . When lighting the pilot , follow these instructions exactly . C . Use only your hand to push in or turn the gas control B . BEFORE LIGHTING smell around the appliance area knob . Never use tools . If the knob will not push in or for gas . Be sure to smell next to the floor because some turn by hand , don't try to repair it , call a qualified sew - gas is heavier than air and will settle on the floor . ice technician . Force or attempted repair may result in a fire or explosion . WHAT TO DO IF YOU SMELL GAS D . • Do not try to light any appliance . Do not use this appliance if any part has been under • Do not touch any electric switch ; do not use any water . Immediately call a qualified service technician to phone in your building , inspect the appliance and to replace any part of the • Immediately call your gas supplier from a neighbor's control system and any gas control which has been under water . phone . Follow the gas supplier's instructions . OPERATING INSTRUCTIONS 8 . 1 . STOP ! Read the safety information above . Find pilot - - follow metal tube 2 , Set the thermostat to lowest setting . from gas control , The pilot is mounted on side of burner . 3 . Turn off all electric power to the appliance . ( If applicable ) . 9 _ 4 . Remove control access panel . Turn knob on gas control 5 . Push in gas control knob slightly and turn counterclockwise _ to " PILOT , " clockwise / _ to " OFF . ' GENERATOR PILOT BURNER 10 . Push in control knob all the way and hold in . Immedi - ately light the pilot . Continue to hold the control knob in for about one ( 1 ) IN " OFF " minute after the pilot is lit , Release knob and it will pop POSITION back up . Pilot should remain lit , If it goes out , repeat oow steps 5 through 10 , • If knob does not pop up when released , stop and immediately call your service technician or gas supplier . • If the pilot will not stay lit after several tries , turn NOTE : Knob cannot be turned from " PILOT " to " OFF " the gas control knob to " OFF " and call your service unless knob is pushed in slightly . Do not force . technician or gas supplier , 6 . Wait five ( 5 ) minutes to clear out any gas , then smell for 11 . Close pilot observation door , tighten wingnut gas , including near the floor . If you then smell gas , STOP ! ( if equipped ) , Follow " B " in the safety information above . If you don't 12 . Turn gas control knob counterclockwise _ to " ON " , smell gas _ go to the next step . 13 . Close control access panel . 7 . Loosen wlngnut and open the pilot observation door ( if 14 . Turn on all electric power to the appliance equipped ) . ( if applicable ) . 15 . Set thermostat to desired setting . TO TURN OFF GAS TO APPLIANCE 1 . Set the thermostat to lowest setting . 2 . Turn off all electric power to the appliance if serv - 4 , Push in gas control knob slightly and turn ice is to be performed ( if applicable ) . clockwise _ to " OFF . " Do not force . 3 . Open control access panel , 5 , Close control access panel . WARNING : DUE TO HIGH SURFACE TEMPERATURES - - KEEP CHILDREN , CLOTHING , FURNITURE OR ANY COMBUSTIBLE MATERIAL AWAY FROM FURNACE . IMPORTANT : KEEP BURNER AND CONTROL COMPARTMENT CLEAN , SEE INSTALLATION AND OPERATING INSTRUCTIONS ACCOMPANYING APPLIANCE . - - 16 - -
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Gas Conversion WARNING CONVERSION MUST BE DONE BYA NOTE : ALL MODELS ARE FACTORY SET FOR L . P . QUALIFIED SERVICE TECHNICIAN . GAS USAGE . IF CONVERSION IS REQUIRED TO FAILURE TO COMPLY WITH INSTRUCTIONS NATURAL GAS FOLLOW INSTRUCTIONS BELOW COULD RESULT IN PERSONAL INJURY , PROPER - EXACTLY . TY DAMAGE AND / OR DEATH . Conversion Instructions CONVERSION PARTS ARE IN A CLOTH BAG ATrACHED TO THE GAS CONTROLS . FROM L . P . GAS TO NATURAL GAS FROM NATURAL GAS TO L . P . GAS 1 . BE SURE GAS TO APPLIANCE IS OFE 1 . BE SURE GAS TO APPLIANCE IS OFE 2 . THE CONTROL VALVE IS FACTORY SET FOR 2 . THE CONTROL VALVE IS FACTORY SET FOR L . P . GAS . L . P . GAS . 3 . TO CHANGE TO LP . GAS REMOVE THE 3 . TO CHANGE TO NAT . GAS REMOVE THE BLACK PLASTIC THREAD PROTECTOR . BLACK PLASTIC THREAD PROTECTOR . UNSCREW THE PROTECTOR CAM . FLIP IT UNSCREW THE PROTECTOR CAM . FLIP IT OVER AND REINSTALL INTO VALVE . THE RED OVER AND REINSTALL INTO VALVE . THE RED STRIPE SHOULD NOW BE CLOSER TO THE STRIPE SHOULD NOW BE FURTHER AWAY VALVE . REINSTALLTHE BLACK PLASTIC FROM THE VALVE . REINSTALL THE BLACK THREAD PROTECTOR . PLASTICTHREAD PROTECTOR . 4 . REMOVE SIX ( 6 ) SCREWS SECURING BURNER 4 . REMOVE SIX ( 6 ) SCREWS SECURING BURNER MOUNTING PLATE ( CONTROL DOOR ) TO THE MOUNTING PLATE ( CONTROL DOOR ) TO THE COMBUSTION CHAMBER . CAUTION : BE CARE - COMBUSTION CHAMBER . CAUTION : BE CARE - FUL NOT TO DAMAGE GASKET , FUL NOT TO DAMAGE GASKET . 5 . REMOVE TWO ( 2 ) SCREWS HOLDING MAiN 5 . REMOVE TWO ( 2 ) SCREWS HOLDING MAIN BURNER . BURNER . 6 . REMOVE MAIN BURNER NAT . GAS ORIFICE 6 . REMOVE MAIN BURNER LP . GAS ORIFICE STAMPED # 42 OR # 51 AND REPLACE WITH STAMPED # 53 OR # 58 AND REPLACE WITH L . P . GAS ORIFICE STAMPED # 53 OR # 58 NAT . GAS ORIFICE STAMPED # 42 OR # 51 ( DEPENDING ON MODEL ) LOCATED IN CLOTH ( DEPENDING ON MODEL ) LOCATED IN CLOTH BAG ATTACHED TO PILOT TUBE . BAG ATTACHED TO PILOT TUBE . 7 . DISCONNECT PILOT TUBE FROM PILOT 7 . DISCONNECT PILOT TUBE FROM PILOT ASSEMBLY , REMOVE NAT . GAS PILOT ORIFICE ASSEMBLY . REMOVE L . P . GAS PILOT ORIFICE MARKED " IV . 013 , REPLACE IT WITH L . P , MARKED TV . 010 . REPLACE IT WITH NAT . GAS ORIFICE MARKED " iV . 010 . RECONNECT GAS ORIFICE MARKED TV . 013 . RECONNECT PILOT TUBE TO PILOT ASSEMBLY . BE SURE PILOT TUBE TO PILOT ASSEMBLY . BE SURE ALL CONNECTIONS ARE TIGHT . ALL CONNECTIONS ARE TIGHT . 8 . REINSTALL MAIN BURNER TO BURNER 8 . REINSTALL MAIN BURNER TO BURNER MOUNTING PLATE ( CONTROL DOOR ) BY IN - MOUNTING PLATE ( CONTROL DOOR ) BY IN - STALLING TWO ( 2 ) SCREWS . STALLING TWO ( 2 ) SCREWS . 9 . REINSTALL BURNER MOUNTING PLATE 9 . REINSTALL BURNER MOUNTING PLATE ( CONTROL DOOR ) TO COMBUSTION CHAM - ( CONTROL DOOR ) TO COMBUSTION CHAM - BER BY REINSTALLING THE SIX ( 6 ) SCREWS BER BY REINSTALLING THE SIX ( 6 ) SCREWS PREVIOUSLY REMOVED . CHECK GASKET TO PREVIOUSLY REMOVED . CHECK GASKET TO BE SURE THERE NO HOLES OR GAPS . RE - BE SURE THERE NO HOLES OR GAPS . RE - PLACE IF NECESSARY . PLACE IF NECESSARY . 10 , TURN ON GASAND CHECK FOR LEAKS USING 10 . TURN ON GAS AND CHECK FOR LEAKS USING SOAP / WATER SOLUTION , CORRECT EVEN SOAP / WATER SOLUTION . CORRECT EVEN THE SLIGHTEST LEAK AT ONCE . THE SLIGHTEST LEAK AT ONCE . 11 . STORE REPLACED ORIFICES IN CLOTH BAG 11 . STORE REPLACED ORIFICES IN CLOTH BAG A'I - I'ACHED TO PILOT TUBE . ATFACHED TO PILOT TUBE . 12 . TURN PILOTADJUSTING SCREW TO RE - 12 . TURN PILOTADJUSTING SCREW TO RE - ADJUST PILOT FLAME ( IF NECESSARY ) . ADJUST PILOT FLAME ( IF NECESSARY ) . - 17 -
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How To Care For Your Furnace MAINTENANCE BURNER FLAME It is recommended that a competent serviceman perform Start the furnace and let it operate about 10 minutes then these checks at the beginning of each heating season : look at the burner flame . Flames should be soft and blue , see Fig . 27 . If flames appear abnormal , contact your gas a . Burner and Control Compartments company . Keep clean at all times . Clean all foreign materials from top of burner . For access to burner : ( 1 ) Remove cabinet . ( Reverse procedure outlined in MAiN BURNER FLAME PATTERN " Cabinet Installation " . ) ( 2 ) Shut off gas supply to furnace . IIIItt / llllllllllIIlttlll ( 3 ) Remove six ( 6 ) # 10 - 24 screws securing control door assembly to heating element . ( 4 ) Carefully remove control door and burner assembly from heating element . Be careful not to damage the control door gasket . TOO MUCH / ' JR . CONES NBRIGHTTS . BLUE AND REAL SHARP POI ( 5 ) After cleaning , replace control door and burner SOMETIMES UFTING FROM PORTS assembly by reversing above procedure . Replace the control door gasket if its condition is in doubt . CORRECT b . Motor and Blower For maximum motor life of optional blower , the manufacturer recommends the motor be inspected yearly , dust blown out of the ventilating holes . Oil yearly with SAE 20 high temp oil . INSUFFICIENT mR , LONG OPEN INNE _ R CONES UGHlr BLUE POINTED TOP ) c . Vent System OUTER MANTLE UGHT BLUE . END CONES . YELLOW IN COLOR PROPER FLAME 1 / 2 " TO 3 / 4 " HIGH Check vent cap and tube to be sure birds or children have not blocked inlet air or flue openings . The flowbe of combustion and ventilation air must not obstructed . Clean or replace before using furnace . d . Pilot Flame See paragraph " ADJUST PILOT BURNER " under Start - Up Procedure , page 14 , and Fig . 28 . TOP VIEW e . Appliance Area For better circulation and more effective heating , do PILOT - SIDE VIEW not place obstructive furniture closer than 4 feet to thet . BLUE FLAME front of the cabinet or 2 feet to the side of the cabine PILO _ The appliance area must be kept clear and free from combustible material , gasoline and other flammable vapor and liquids . ORANGE TIP y LIGHT NAT , GAS WARNING BL E ° NE BLUE CONE DANGER OF BODILY INJURY OR DEATH . AT . GAS TURN OFF ELECTRIC POWER SUPPLY AT P . GAS DISCONNECT SWITCH , FUSE BOX OR SERVICE END VIEW END VIEW PANEL BEFORE REMOVING ANY DOORS OR AC - CAST IRON BURNER C _ . ST IRON BURNER LP , G . GAS NAT . GAS CESS OR SERVICE PANELS FROM UNIT , IF EQUIPPED WITH ACCESSORY BLOWER . f . Cabinet Finish Clean cabinet with damp rag . Never use abrasive cleaners . Cabinets are finished in heat resistant bak - ed enamel - DO NOT refinish with wall paint . - 18 -
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Troubleshooting Gravity Direct Vent Wail Furnace SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION A . 1 . Pilot will not stay lit after Thermocouple or gen - Check pilot flame - must impinge on thermocou - erator producing insuffi - carefully following pie or generator . Be sure thermocouple or generator cient millivoltage . lighting instructions . is fully inserted in bracket . Make sure pilot lighting door is tightly closed . B . Loose or dirty thermocou - Clean and / or tighten thermocouple or generator pie or generator connec - connections at valve . tions at gas valve . C . Thermocouple or gen - Check thermocouple with millivolt meter . Should erator defective . generate approximately 30 millivolts when not con - nected to load . When connected to load , should generate approximately 14 millivolts ; if below 7 millivolts , replace . Check generator with millivolt meter . Take reading at generator terminals of valve with pilot burning and thermostat contacts closed , Should be 140 millivolts or more . O . Grounded thermostat Remove thermostat lead wires from valve terminals . lead wire ( Wall ther - If pilot now stays lit , trace thermostat wiring circuit mostat model ) . for a ground . May be grounded to furnace or gas supply . E . Thermomagnet pilot Replace gas valve after above is checked out . safety defective . A . Manual valve not turned 2 . Pilot burning - no gas Turn gas valve knob to " On " position . to main burner . to " On " position after lighting pilot . B . Temperature dial or ther - Set temperature dial or thermostat to a position call - mostat not turned to a ing for heat . position calling for heat . C . Plugged burner orifice . Check - clean or replace . D Temperature dial out of See valve manufacturer's instructions . calibration . ( Bulb control model . ) E . Mis - wired or broken ther - Check connections at valve terminals . Jumper mostat wires . Defective across thermostat terminals on valve - if valve thermostat . ( Wall thermo - operates check thermostat wires . star model . F Pilot generator may not See 1A above . be generating sufficient millivoltage to open valve . G , Defective valve . Replace . 3 . Burner comes " On " but A . Check vent tube and air inlet tube . Follow installa - Tubes not properly installed . goes " Off " after operating tion instructions . Be sure joints are tight and both for no apparent reason . tubes are in place . Use only tubes furnished . Do not extend tubes beyond original length . g . Furnace may be Check for high pressure at valve - see rating plate overrated . for specified minimax supply pressure . Check burner orifice . ( continued next page ) - 19 -
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Troubleshooting . . . ( cont . ) SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION A . 4 . Furnace oper _ es but Sensing bulb not located Check location of sensing bulb - should be attach - turns " Off " before room ed to back of control valve . properly . ( Bulb control temperature is attained , model . ) B . Temperature dial out of See valve manufacturer's instructions . calibration . ( Bulb control model . ) C . Thermostat location . Check thermostat location - should not be in the ( Wall thermostat model . ) path of warm air discharge from furnace , near a lamp , or above a T _ / . or stereo set . O . Defective thermostat . Check thermostat calibration or replace . ( Wall thermostat model . ) A . Check heat loss calculations . 5 . Furnace not producing Furnace may be too small sufficient heat . for space being heated . B . Furnace not burning at Check for low gas pressure ( see 3B page 19 ) . Check burner office . full rate . A . 6 . Furnace operates but will Sensing bulb not located Check location of sensing bulb - should be attach - not shut " Off " when room ed to back of control valve . properly . ( Bulb control temperature is attained . model . ) B . Temperature dial out of See valve manufacturer's instruction . calibration . ( Bulb control model . ) C . Bulb or capillary broken . Replace valve . ( Bulb control model . ) D . Thermostat wiring defec - Thermostat lead wires may be shorted together tive . ( Wall thermostat caused by a nail or staple - check by removing ther - model . ) mostat leads from valve terminals . E . Thermostat location . Check thermostat location - if on an outside wall ( Wall thermostat model . ) or a hole in wall behind thermostat is causing cold air to contact thermostat - relocate . E Defective thermostat . Check thermostat calibration or replace . ( Wall thermostat model . ) G . Dirt under valve seat or Replace valve . valve stuck open . A . Adjust pilot flame . Check vent tube and air inlet tube 7 . Pilot outage problem . Pilot flame may be low ( see 3A page 19 ) . Be sure pilotlightingdoor is clos - or blowing ( high ) caus - ed . Pilot orfice or aerating hole may be plugged ing safety to drop out . ( check for spiders , webs or other organic material ) . A . 8 . Abnormal operation . Delayed ignition - pilot Adjust pilot flame . flame may be too low . B , Expansion noise ticking . Check installation - casing may be distorted by be - ing fastened to an uneven wall . Vent tube and air inlet tube may be in a bind with vent cap assembly - be sure hole through wall is correct and parts fit without binding . - 20 -
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Williams Direct Vent Gas - Fired Wall Furnace REPLACEMENT PARTS FOR OPTIONAL BLOWER ACCESSORY 2302 MODEL : 3003621.05 USE ONLY I _ ANUFACTURE'S AUTHORIZED PARTS REF . PART NO . DESCRIPTION NO . 6A24 SWITCH BRACKET 1 6B3,3 SWITCH BOX 2 3 P , 321017 SWITCH - PULL CHAIN 4 P129700 SWITCH - AUTOMATIC 5 6A23 SWITCH BOX COVER MOTOR 6 P130600 MOTOR SUPPORT 7 6A93 VIBRATION ISOLATOR 2 REQ'D 8 P128400 9 P130700 BLOWER WHEEL 10 6B64 BLOWER FRAME NOTE : SCREWS AND BOLTS ARE STANDARD HARDWARE ITEI _ S , AVAILABLE LOCALLY . - 21 -
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Williams Direct Vent Gas - Fired Wall Furnace REPLACEMENT PARTS FOR MODEL : 1403621 05 REF . PART NO . DESCRIPTION NO . 1 8C28 CASING WRAPPER 2 8A72 ELEMENT SHIELD , _ 3 8B61 COMBUSTION CHAMBER 4 P147001 FLUE TUBE GASKET 5 8B62 INNER CASING 6 P147001 FLUE TUBE GASKET 7 P147000 AIR PAN GASKET 8 6C54 - 1 AIR INLET SHIELD ( MAX . 9 " THICK WALL ) 9 9506 VENT CAP 10 6C51 AIR INLET COLLAR ( MAX . 9 " THICK WALL ) 11 8A85 FLUE EXTENSION ( MAX . 9 " THICK WALL ) 12 BB64 MOUNTING SPACER PLATE 15 P121800 AIR INLET GASKET VENT _ FLUE EXTENSION - 15 INCH WITH ( 1 ) P147001 GASKET _ t EXTENSION KIT _ AIR INLET COLLAR - 15 INCH WITH ( 1 ) P147000 GASKET 1 _ 9504 _ AIR INLET SHIELD - - 15 INCH VENT _ FLUE EXTENSION - 24 INCH WITH ( 1 ) P147001 GASKET , _ . EXTENSION KIT " k AIR INLET COLLAR - 24 - INCH WITH ( 1 ) P147000 GASKET 9503 _ AIR INLET SHIELD - 24 INCH ! _ NOT SHOWN _ ' NOT AVAILABLE SEPARATELY ( KIT FORM ONLY ) FOR PARTS ILLUSTRATION SEE PAGE 23 US _ ONLY MANUFAC'RJRE'S AUTHORIZED : PARTS . NOTE : SCREWS AND BOLTS ARE STANDARD HARDWARE ITEMS , AVAILABLE LOCALLY . - 22 -
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Williams Direct Vent Gas - Fired Wall Furnace REPLACEMENT PARTS FOR MODEL : 1405621.05 FOR PARTS LISTING SEE PAGE 22 . USE ONLY MANUFACTURER'S AUTHORIZED PARTS . - 23 -
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Williams Direct Vent Gas - Fired Wall Furnace REPLACEMENT PARTS FOR MODELS : 3003621.05 REF . PART NO . DESCRIPTION NO . 1 6C62 CASING WRAPPER 2 6B149 ELEMENT SHIELD 5 P147001 FLUE TUBE CASKET 4 6A190 FLUE EXTENSION ( MAX . 9 " THICK WALL ) 5 P147000 AIR PAN GASKET 6 6C51 AIR INLET COLLAR ( MAX . 9 " THICK WALL ) 7 6C66 MOUNTINC SPACER PLATE 8 6C54 - 1 AIR INLET SHIELD ( MAX . 9 " THICK WALL ) 9 9506 VENT CAP 10 4517 INNER CASING AND TOP LOUVER KIT 11 P147001 FLUE TUBE GASKET 12 P121800 AIR INLET GASKET 15 6C57 COMBUSTION CHAMBER 14 6B25 LEG COVER PLATE VENT _ FLUE EXTENSION - 15 INCH WITH ( 1 ) P147001 GASKET g _ , EXTENSION _ AIR INLET COLLAR - 15 INCH WITH ( 1 ) P147000 GASKET KIT ' € _ 9501 _ AIR INLET SHIELD - 15 INCH VENT " k FLUE EXTENSION - 24 INCH WITH ( 1 ) P147001 GASKET ' € _ EXTENSION _ AIR INLET COLLAR - 24 INCH WITH ( 1 ) P147000 GASKET KIT 9505 _ AIR INLET SHIELD - 24 INCH g _ " NOT SHOWN ' _ NOT AVAILABLE SEPARATELY ( KIT FORM ONLY ) SEE PAGE 25 FOR PARTS ILLUSTRATION USE ONLY MANUFACTURE'S AUTHORIZED PARTS . NOTE : SCREWS AND BOLTS ARE STANDARD HARDWARE ITEMS , AVAILABLE LOCALLY . - 24 -
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Williams Direct Vent Gas - Fired Wall Furnace REPLACEMENT PARTS FOR MODEL : 5005621.05 FOR PARTS LISTING SEE PAGE 24 . USE ONLY MANUFACTURER'S AUTHORIZED PARTS . - 25 -
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Williams Direct Vent Gas - Fired Wall Furnace REPLACEMENT PARTS FOR MODEL : 1405621o05 REF . NO . PART NO . DESCRIPTION I P168400 CAST IRON BURNER 2 8AI05 CONTROL DOOR WITH P147100 GASKET 3 P304800 GAS VALVE ( CONVERTIBLE - PRESET FOR LP . GAS ) 4 7675 CONVERSION KIT ( NAT . GAS ) 5 8A57 MANIFOLD WITH P147200 GASKET 6 P090500 ORIFICE - SPECIFY GAS TYPE AND INPUT 7 P522400 MANUAL SPARK IGNITOR 8 P . 322399 PILOT , L . P . G . ( PG9 ) 9 12B40 OBSERVATION DOOR WITH PIOOIO0 GASKET REPLACEMENT PARTS FOR MODEL : 5005621.05 REF . NO . PART NO . DESCRIPTION 1 P147400 CAST IRON BURNER 2 8A103 CONTROL DOOR WITH P147100 GASKET 5 P504800 GAS VALVE ( CONVERTIBLE - PRESET FOR L . P . GAS ) 4 7674 CONVERSION KIT ( NAT . GAS ) 5 6B76 MANIFOLD WITH P147200 GASKET 6 P090500 ORIFICE - SPECIFY GAS TYPE AND INPUT 7 P522400 MANUAL SPARK IGNITOR 8 P522399 PILOT , L . P . G . ( PG9 ) 9 12B40 OBSERVATION DOOR WITH PIO010O GASKET FOR PARTS ILLUSTRATION SEE PAGE 27 USE ONLY MANUFACTURE'S AUTHORIZED PARTS . NOTE : SCREWS AND BOLTS ARE STANDARD HARDWARE ITEMS , AVAILABLE LOCALLY . - 26 -
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Williams Direct Vent Gas - Fired Wall Furnace CONTROL ASSEMBLY FOR MODEL I 1403621.05 P322016 FOR PARTS LISTING SEE PAGE 26 . USE ONLY MANUFACTURE'S AUTHORIZED PARTS . CONTROL ASSEMBLY FOR MODEL 3003621.05 - 27 -
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Service Hints If your furnace fails to work right , you may avoid inconvenience and the Cost of a service call by checking the following points before you call for service . FOR YOUR SAFETY FOR YOUR SAFETY Do not store or use gasoline If you smell gas : owner's or other flammable vapors and 1 . Open windows . manual liquids in the vicinity of this or any 2 . Don't touch electrical . other appliance 3 . Extinguish any open flame . 4 . immediately call your gas supplier . POSSIBLE CAUSE WHAT TO DO SERVICE If your furnace is not heating or not giving enough heat - - Thermostat is not set correctly . Reset thermostat to desired setting . Pilot is out . Check pilot . Relight if necessary follow - MODEL NOS . ing instructions for " Operating Your Furnace " . 1403621.05 Pilot is on but burner won't come If gas valve is set at other than " On " on . 3003621.05 furnace will not operate . Shut furnacefor down and following instructions relighting in " Operating Your Furnace " section . Burner is not operating properly . Check flame . If it is yellow , the burner is not getting enough air . Or if flame is blue and noisy and seems to lift off the burner , the burner is getting too " much air . See " Checks and Adjustments , page 14 . Air flow restricted Check that doors , drapes or furniture are not blocking louvers . Pilot goes out time after time - - Furnace flue blocked . Locate vent outlet blockage and clean . Pilot and burner access door not Check the door . See section on closed properly . " Operating Your Furnace " beginning on page 15 . If burner is noisy - - Gas input amount is incorrect . Contact Williams Service Department . Too much primary air . Contact Williams Service Department . If blower does not run - - Fuse is blown . Replace fuse . Blower not connected to electric Connect to electric power . power . If blower motor is noisy - - Housing rattling . Tighten screws . Clean blower wheel . Blower dirty . Blower wheel bent . Straighten or replace . See troubleshooting section for more detailed information . How to Order Repair Parts When ordering repair parts , always give the following All parts listed herein may be ordered from your equip - information : ment supplier . 1 . MODELNUMBER The Model Number of your Williams wall furnace will be 2 , MFG , DATE CODE 3 . PARTNUMBER found on the rating plate near gas valve , inside control 4 , PART DESCRIPTION compartment . WILLIAMS FURNACE COMPANY MANUFACTURED 225 Acacia Street IN THE U . S . A . Colton , CA 92324 USA Established 1916 ( 909 ) 825 - 0993 FAX : ( 909 ) 824 - 8009 _ 1998 The Williams Furnace Company Rev . 7 / 98 Printed in U . S . A . P322874
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