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INSTALLATION & OPERATING INSTRUCTION MANUAL owners COUNTERFLOW DIRECT VENT manual GAS WALL FURNACES MODEL NOS . READ THIS OWNERS MANUAL 4007332 4007732 CAREFULLY BEFORE YOU INSTALL 5507332 YOUR NEW WILLIAMS WALL FURNACE 6257732 WARNING : If the information in this manual is not followed exactly , a fire or ex - FOR USE WITH plosion may result causing property NATURAL GAS ONLY damage , personal injury or loss of life . - - Do not store or use gasoline or other flammable 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 MODEL NOS . not use any phone in your building . • Extinguish any open flame . 4007331 • Immediately call your gas supplier 4007731 from a neighbor's phone . Follow the 5507331 gas supplier's instructions . 6257731 • If you cannot reach your gas supplier , call the fire department . FOR USE WITH Installation and service must be per - LIQUEFIED formed by a qualified installer , service PETROLEUM ( L . P . ) agency or the gas supplier . GAS ONLY WARNING : Improper installation , adjust - Save This Manual For ment , alteration , service or maintenance Future Reference . can cause injury or property damage . Refer to this manual . For assistance or additional information consult a qualified installer , service agency or the gas supplier . WARNING : This direct vent furnace is approved for aftermarket mobile home installations ( once the mobile home is sold , installed and stationary ) unless prohibited by local codes . Not for mobile home manufacturer ( factory ) installation . Do not install any of these furnaces ( natural or L . P . Gas ) in trailers or recreational vehicles . Williams Furnace Co . , 225 Acacia St . , Colton , CA 92324 , USA PRINTED IN U . S . A . 12 / 98 P321004
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Contents Your Williams Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 2 Vent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mounting Your Furnace . . . . . . . . . . . . . . . . . . . . . 14 - 15 Basic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gas Supply and Piping . . . . . . . . . . . . . . . . . . . . . . 15 - 16 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Helpful Installation Information . . . . . . . . . . . . . . . . . . . 3 Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating Your Furnace . . . . . . . . . . . . . . . . . . . . . 19 - 24 Unpack Your Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . 5 How To Care For Your Furnace . . . . . . . . . . . . . . . 25 - 26 Basic Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Furnace Technical Information . . . . . . . . . . . . . . . . . . 26 Basic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 28 TROUBLESHOOTING CHART . . . . . . . . . . . . . . . 29 - 34 Installing Your Wall Furnace . . . . . . . . . . . . . . . . . . . . . 6 Locating Wall Furnace and Thermostat . . . . . . . . . . 6 - 7 Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 - 44 Recessed Mount Installation . . . . . . . . . . . . . . . . . 7 - 9 SERVICE HINTS . . . . . . . . . . . . . . . . . . . . . . Back Cover Surface Mount installation . . . . . . . . . . . . . . . . . . 9 - 10 How To Order Repair Parts . . . . . . . . . . . . . Back Cover Thermostat Installation . . . . . . . . . . . . . . . . . . . . . 11 - 12 Your Warranty The Manufacturer , Wilflams Furnace Co , warrants this wa _ l furnace or heater to the 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 liability is assumed by the Manufacturer for remova _ or installation labor costs , nor for freight or delivery charges . LIMITED EXTENDED WARRANTY 1 . In addition to the above limited one * year warranty on the complete unit . any heat exchanger which burns out or rusts under normal installation , 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 FITNESS 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 THEREOE 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 implied warranty lasts , and some states do not allow the exclusion or fimitation 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 installation 4 This warranty does not cover claims which do not involve defective workmanship or materials DUTIES OF THE CONSUMER 1 The heating equipment must be installed by a qualified installer and operated in accordance with the installation and homeowner's instructions furnished with the equipment 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 . If , within a reasonable time after contacting your dealer , satisfactory service has not 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 Model No . Serial 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 i
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A Word From The Manufacturer Dear Customer , To set up our furnace assembly procedures , severe / hundred quality assurance , safety audit and design performance tests have been conducted according to the standards provided by the American Nationa / Standards / nstitute , the Department of Energy and our certification agency - - the American Gas Association Laboratories . This was done to assure you of receiving the best value and most re / iab / e appliance of its type available today We are confident that your Wi / / iarns furnace can provide you years of low cost , efficient , heating comfort . Thank you for purchasing a Williams furnace . Sincerely , Employees of Williams Furnace Company 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 in found within this instruction manual . Basic Description The direct vent wall furnace is shipped ready to install The sealed combustion system draws combustion air against an exterior wall not exceeding 12 " in thickness . directly from outdoors into the combustion chamber and Furnace may also be recessed up to 10 " in a wall with combustion gases are discharged directly to the outdoors studs spaced 16 " center - to - center . through tubes mounted to the rear of the furnace . Always consult your local heating or plumbing inspector , The furnace heat exchanger is built of heavy gauge steel building department or gas utility company regarding treated for corrosion resistance . The fan at the top forces regulations , codes or ordinaces which apply to the installa - air down along the front , back and sides of the heat ex - tion of a direct vent furnace . changer where it is discharged into the room . The furnace cabinet is also constructed of heavy gauge steel and has Air is drawn in at the top by the fan and discharged through a enamel paint finish . a grille near the floor . A two - speed fan is used with Models 5507332 , 6257732 , 5507331 , and 6257731 . A single speed The furnace controls are located behind an access door fan is used on all other models . The furnace contains a on the lower front of the furnace . All models are equipped multi - slot burner ( two on Models 5507332 , 6257732 , with American Gas Association listed gas valves and pilots . 5507331 , and 6257731 ) and burns either natural or L . R ( li - Models 4007332 , 4007331 , 5507332 , and 5507331 are quefied petroleum ) gas , depending on the model you have equipped with an electric ignition automatic pilot relight purchased . system . Optional Accessories Side Outlet Grille Kit 6701 Side Grille Kit 6702 Lets you route some heated air to a second room . Mounts Lets you route some heated air to side of furnace in the on side wall of second room and must be within 10 inches same room . See pages 7 & 10 . of wall furnace . See pages 7 & 10 . Trim Strip Kit 4701 Diffuser Grille Kit 6703 or 6704 Provides finished edge at side of wall furnace . Neutral Lets you route some heated air in a two - way direction . Kit beige enamel steel . 6704 for one - way direction . Replacement Vent Cap Assembly 9801 Should for any reason your vent cap becomes damaged NOTE and its operation impaired , replace it immediately . Kits are identified on the carton by manufacturing number 6701 , 6702 , 6703 and 6704 are also listed on the furnace rating plate . Helpful Installation Information The following booklets will help you in making the installation : ANSI / NFPA 70 - 1990 or current edition " National Electrical Code . " In Canada : CSA C22 . 1 Canadian Electrical Code . American National Standard NFPA54 / ANSI Z223 . 1 1988 or current edition " National Fuel Gas Code . " Obtain from - - American National Standards Institute , Inc . , 1430 Broadway , New York , N . Y . 10018 . In Canada : CAN / CGA B149 Installation Code . - - 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 , us - INSTALLATION MUST CONFORM TO LOCAL CODES . IN ing the vent assembly supplied with the furnace , so THE ABSENCE OF LOCAL CODES , INSTALLATION that harmful gases will not collect inside the building . MUST CONFORM WITH THE NATIONAL FUEL GAS 9 . PROVIDE FOR ADEQUATE COMBUSTION AIR around CODE , ANSI Z223 . 1 . THE APPLIANCE , WHEN IN - vent cap on outside , see Fig . 2 , pg . 6 and adequate STALLED , MUST BE ELECTRICALLY CONNECTED AND air circulation around cabinet inside the open room . GROUNDED IN ACCORDANCE WITH LOCAL CODES OR , IN THE ABSENCE OF LOCAL CODES , WITH THE 10 . NEVER vent flue gases into another room , a fireplace CURRENT NATIONAL ELECTRICAL CODE ANSI / NFPA or any space inside a building . This could cause pro - NO . 70 . perty damage , bodily injury or death . 11 . NEVER test for gas leaks with an open flame . Use IN CANADA soap suds to check all gas connections . This will avoid 1 . INSTALLATION MUST CONFORM TO LOCAL the possibility of fire or explosion . CODES OR , IN THE ABSENCE OF LOCAL 12 . CODES , THE CURRENT CAN / CGA B149 IN - ALLOW furnace to cool before servicing . Always shut STALLATION CODE . off electricity and gas to furnace when working on it . 2 . THE APPLIANCE , WHEN INSTALLED , MUST BE This will prevent any electrical shocks or burns . ELECTRICALLY CONNECTED AND GROUND - 13 . DUE TO HIGH TEMPERATURES , locate the furnace ED IN ACCORDANCE WITH LOCAL CODES OR , out of traffic and away from furniture and draperies . IN THE ABSENCE OF LOCAL CODES , WITH THE CURRENT CSA C22 . 1 CANADIAN ELEC - 14 . ALERT children and adults to the hazards of high sur - TRICAL CODE . face temperature and to keep away to avoid burns or 3 . REFERENCE IS MADE IN THIS MANUAL clothing ignition . REGARDING GAS TYPE AS LP . BE ADVISED 15 . CAREFULLY supervise young children when they are THAT L . R IS NOT AVAILABLE IN CANADA , in the same room with the furnace . REFER TO PROPANEIL . P . GAS . 16 . DO NOT place clothing or other flammable material on or near furnace . 1 . USE ONLY MANUFACTURER'S REPLACEMENT 17 . INSTALLATION and REPAIR must be done by a PARTS . USE OF ANY OTHER PARTS COULD CAUSE qualified service person . The appliance should be in - INJURY OR DEATH . spected before use and at least annually by a profes - 2 . DO NOT install this furnace in an alcove . sional service person . More frequent cleaning may be required due to excessive lint from carpeting , bedding 3 . DO NOT install these furnaces in a travel trailer , recreational vehicle or mobile home . material , etc . It is imperative that control compart - ments , burners and circulating air passages be kept 4 . MAINTAIN all clearances specified in section clean . " Locating Wall Furnace and Thermostat " and " Vent 18 . Installation . " BEFORE INSTALLING : To avoid electrical shock , turn off electrical circuits that pass through the wall where 5 , BE SURE furnace is for type of gas to be used . Check you are going to install the furnace . the rating plate by the gas valve in the lower cabinet . 19 . Do not change it to use other gases . Unsafe opera - BE AWARE of good safety practices by wearing per - tion could result and could cause bodily injury and sonal protective equipment such as gloves and safe - death . ty glasses to avoid being injured by sharp metal edges in or around furnace and while cutting or drilling holes 6 . For Natural gas , the minimum inlet gas supply in wood and or sheet metal . pressure 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 For L . R gas , the minimum inlet gas supply pressure and dangerous operation . Verify proper operation after for the purpose of input adjustment is 11 " water col - servicing . 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 The furnace is shipped in two cartons , one containing the furnace and the other containing the vent cap with inlet and vent tubes . 1 . Lay carton horizontally . Open carton and remove top trim cover from its packing . Remove thumb screw at top of furnace , raise top front panel 1 / 2 inch and remove panel from cabinet . 2 . Place these and other parts , as they are removed from furnace , where they cannot be lost or damaged before you need them . 3 . Bottom front panel can be removed by grasping just below handle and pulling it outward and then upward . See Fig . 1 . NOTE Check the burner rating plate , located in burner com - partment , to make sure your furnace is equipped to operate on the type of gas available ( either Natural or L . P . Gas ) . DO NOT convert unit from natural gas to L . P gas or from L . P gas to natural . 4 . Remove all literature and package containing ther - mostat , wire and metal anchors used for free standing installation . BoTmU FROHT PAHEL - 5 . Check the fan blade to be sure it spins freely . 6 . Take out four screws holding fan shroud to side flanges of cabinet and remove shroud . See Fig . 1 . 8 . Loosen 1 / 8 " " allen head " set screw holding fan blade NOTE to motor shaft and remove the fan . Place fan blade The fan blade must be removed in order to remove and fan shroud where they will not be damaged . cardboard shipping brace located under motor . I 9 . Remove cardboard shipping brace located under motor mounting brackets . 10 . Future electrical connections will be made in this 7 . Before removing the fan blade , remember its position upper cabinet area , inside electrical junction box , by examining the blade nut and the amount of shafto behind transformer . visible . Scribe or mark the motor shaft in order t 11 . Properly dispose of shipping materials . reinstall the fan blade to its original place on the shaft . Basic Tools Needed Stud Locator or small finish nails Hand drill or properly grounded electric drill . Expansion bit 1 / 2 " to 1 - 5 / 8 " or 1 / 2 " and 11 / 2 ' ' Blade bits Tin Snips 1 / 8 " and 3 / 16 " drill bit ( metal ) 8 " adjustable wrench 6 ft . folding rule or tape measure 12 " adjustable wrench Screwdriver ( reed . blade ) and ( Phillips head ) Key hole saw or Sabre saw Hack saw Pliers ( wire cutting ) Hammer 2 - 10 " or 12 " pipe wrenches 1 / 8 " Allen wrench Gloves and safety glasses Basic Materials Pipe and fittings to make connections to furnace . ( Page Electrical wiring supplies as needed ( See Page 17 ) . 16 ) . Minimum wire size is # 14 gauge copper . Caulking Compound - Silicone Rubber with a temperature 3 / 4 " Quarter Round or other wood trim molding approx . rating of 500OF . 16 ' long or Trim accessory 4701 . DO NOT USE types advertised as paintable or for bath 2 " x 4 " x ( length as required ) Spacer Block ( See Page 8 ) . tub use as most contain fillers and will not withstand high 1 x 1 wood strips if Optional Side Outlet Grille Kit 6701 is temperatures . used . Pipe Joint Compound resistant to L . P . gases . m5 - -
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Installing Your Wall Furnace 1 . Properly locate the furnace within the space to be The following steps are needed for proper installation and heated . safe operation of your furnace . If you have any doubts as to any requirements , check with local authorities for local 2 . Provide for adequate combustion air around vent cap and state codes affecting the installation on outside , see Fig . 2 and adequate air circulation around cabinet inside the open room . Obtain professional help where needed . 3 . Maintain minimum clearance : Floor 0 " or ceiling 4 " , DO NOT install these furnaces in a travel trailer , recrea - side wall 4 " . For exception to minimum side wall tional vehicle or mobile home . clearance , see Figs . 4 , 5 & 6 , pg . 7 . IMPORTANT For satisfactory and trouble - free operation , be sure to : Locating Wall Furnace & Thermostat Studs must be spaced on 16 inch centers or stud space Consider the following points before attempting to install the furnace : will have to be framed in . See pg . 7 , Recessed Mounting . 1 . This is a direct vent wall furnace . It must be installed 2 . The top of the furnace must be at least 4 inches from on an OUTSIDE WALL for proper venting of flue gases the ceiling . ( Fig . 2 ) . 3 . Check the clearances needed from the furnace and a . Wall furnace can be surface mounted on an outside vent ( Fig . 2 and Fig . 4 , pg . 7 ) . You must place the fur - wall . ( Surface Mount ) nace where you will have no less than the clearances b . Ideally , the wall should be the least windy side of the shown . See Fig . 5 & 6 , Page 7 . dwelling , as strong gusts may extinguish the pilot . c . Furnace may be installed flush against a wall or 4 . When using optional kits 6703 or 6704 , maintain the recessed up to 10 " maximum . Wall thickness from clearances as shown in Figs . 5 & 6 , pg . 7 . back surface of furnace to outside of wall can be 3 / 4 " minimum to 12 " maximum . See Fig . 3 , pg . 7 . 5 . When using optional kit 6701 , maintain clearance as shown in Fig . 4 , pg . 7 . Use only optional outlet and With standard furnace discharge outlet , do not install grille kits available from manufacturer . closer than 4 " to intersecting wall . See Fig . 4 , pg . 7 . 6 . The outside vent cap must be at least 18 inches away MINIMUM DIMENSIONS FROM VENT from any window or other building opening ( Fig . 2 ) . 7 . 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 18 inches above ground level or shrubs are as shown in Fig . 2 , pg . 6 . Make sure shrubs are kept trimmed . It must also be at least 18 inches from any overhang , wall , or other blockage . 8 . 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 . 9 . Be sure that gas piping and electrical wiring can be brought to the furnace . See sections on gas piping and electrical wiring for your type of furnace mounting . 10 . The bottom of the furnace must rest directly on a wood or concrete floor . If floor is other than wood or con - d . If wall has a brick , block or other facing at least crete , such as carpet or sheet vinylflooring , there must 3 / 4 - inch thick , the furnace can be mounted so it is be a piece of wood or sheet metal under the tfurnacehe that is at least the same size as the bottom of recessed into the waft between standard 2 x 4 wall furnace . studs . WARNING IF VINYL SIDING IS USED ON EXTERIOR WALL SURFACE , HEAT FROM VENT CAP COULD CAUSE DISTOR - TION / DISCOLORATION . SHIELD TO PROTECT SIDING . CHECK WITH MANUFACTURER FOR ADDITIONAL OPTIONS . m6 - -
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Locating Wall Furnace & Thermostat ( ton't ) 10 . Be sure to provide adequate clearance and service access . The front of the furnace must face the open room . 11 . Choose a location for the thermostat about 5 feet r - - - - - - _ VENT CAP above the floor on an inside wall . The thermostat wire supplied with your furnace is 20 feet long , which 12 M Ii _ b should be enough to run up through the attic of a single - story home , so the thermostat can be a max - imum of 16 feet from the furnace measure in a straight _ i / I [ _ " OUTLET line , or about 8 feet from the furnace if the wire is run ° U : L oT 6 , Ol - - under the floon If more length is required , see note on page 11 . The thermostat should be sensing average room temperature ; avoid the following ; HOT SPOTS : COLD SPOTS : Concealed pipes Concealed pipes or ducts or ducts Stairwells - drafts Fireplaces Doors - drafts sRegisters TV set Unheated rooms on ¢ _ . - , , _ VENT CAP Radios other side of wall DEAD SPOTS : Lamps 12 MAX I = I Behind doors Direct sunlight Kitchen Corners , and alcoves 12 . After picking a location that meets the requirements , inspect the wall , floor and outside areas . Make sure there are no pipes , wiring , or anything else that would interfere with furnace or vent or thermostat installa - 7 / % \ tion . If required , move them or pick a new location . 12 " MIN WHEN OPTIONAL 6703 TWO - WAY FRONT DIFFUSING GRILLE IS USED t ' - - - - - _ VENT CAP J1 I ' _ 3 / 4 " MIN ' , i ' : 1 I _ VENT CAP _ 10 " MAX OPTIONAL OUTLET [ _ - A I : x _ RECESSEDINSTALLATION CLEARANCE NOTE " - ' - - 1 6702 6702 rflon of the furnace that is recessed into a wall up to { I 10 ' maximum recess may have ( 0 ) zero inch clearance to I _ 18 MIN - _ I combustibles . ( See Fig . 3 ) . All other clearances for the I [ unrecessed portion must be observed . J Recessed Mount Installation FIND THE STUDS CUT WALL OPENING Use a stud Iocatoror small finishing nails . Repeatedly ndrivetil 1 . Lay out the required opening to be cut in inside wall and remove a nail into the wall in the area of the stud u ( Fig . 7 , pg . 8 ) . Mark center of the vent hole on wall . you find it . Then find one side . Leave the nail there . Drive Using a window , door or wall corner for reference , another nail just on the other side of the same stud . measure to find where vent will be on outside wall . Inside edge of the other stud should be about 141 / 2inches Check to be sure clearances ( Fig . 2 , Fig . 4 , Fig . 5 and Fig . 6 ) will be right . from the one found . Drive finishing nail on inside edge of this stud . 2 . Drill a 1 / 4inch hole through vent hole center to the out - side wall to mark vent location . NOTE 3 . Make the required cutout in inside wall . ( Fig . 7 , pg . 8 ) IF STUDS ARE NOT ON 16 INCH CENTERS , SEE ICLOSE OFF STUD SPACE , PAGE 8 . - - 7 - -
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Recessed Mount Installation ( Con't ) 4 . Using the hole drilled through to the outside wall as the center , cut a 91 / 4 inch diameter hole for the vent . It may be better to work from outside , especially when CEJUNC - - F } breaking through brick , stone or tile . ( See Fig . 7 ) . PLATE 1 5 . In new stud wall construction , install blocks as shown I / in Figure 7 and install plaster grounds around inside 2 × ' _ BAC _ KING J _ l of wall opening . / IF _ O _ E ] HAN 18 " Bg - _ t _ EH 6 . The vertical height of the opening shown is 3 inches TOP OF CUTOUT greater than height of furnace to allow space for AND C _ 3UNG PLJ _ TE connection of wiring after furnace is installed . I I NOTE 9 - 1 / 4 " DIA . VERTICAL MEASUREMENTS ARE FROM HOLE CUTOUT I FINISHED FLOOR . ( Fig . 7 ) EC _ qS ] ] NG STUD _ II i , ELECTRICAL 1 CONDUIT 91 / 4 , DIA HOLE FLOOR pLATE THROUGH EXTERIOR WALL \ ELECTRIC CONNECTION IN TOP 90 ( 1 ) 80 _ . 4 ( , 2 " ) BLOCKS 1 " x3 " - - I - - GASINLE ' ' NOOTTO 68vz ° ( 1 ) 59 " ( 2i VENT & AIR FLOOR - - _ 787 " ( 1 ) r , . . . . _ q BACK WALL OPENING FOR RECESSED INSTALLATION - 3V2 " ( 1 ) MODELS 7z / e " ( 2 ) 5507332 . 5507331 , 6257732 , AND 6257731 ; 81 / 2 " ( 1 ) ( 2 ) MODELS s9 " ( 2 ) 4007332 , 4007331 , 4007732 . AND 4007731 GAS INLET SIDE CLOSE OFF STUD SPACE ( If Required ) 1 J _ _ If studs are not on 16 inch centers , cut the hole for the 2 " furnace next to an existingstudand frame in the other side using a 2 x 4 and spacer blocks as required . Fig . 8 . _ - - FINISH _ . - _ 141 / a " FLOOR If the distance from the top of the cutout to the ceiling wall ( 1 ) MODELS plate is more than 18 inches , it is recommended that it be 5507332 , 5507331 , 6257732 , AND 6257731 closed off . ( 2 ) MODELS Nail a 2 x 4 long enough to go between the studs at the 4007332 , 4 ( 307331 , 4007732 , AND 4007731 top of the opening to close off the stud space . - - 8 - -
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Recessed Mount Installation ( Con't ) GAS AND ELECTRICAL SUPPLY OPENINGS run wires up through adjoining stud space from crawl space or basement . Holes must be drilled for the gas line and electrical sup - ply . Holes must be located from each side of furnace as Run the electrical supply with ground wire and thermostat shown in Fig . 9 , pg , 8 . cable to the openings . Leave enough length to connect in the junction box after the furnace is installed . See Decide whether the gas line will come through the floor section " Electrical Wiring , " page 17 . or wall . Drill a 11 / 2 - inch hole in wall or floor as needed . Gas lines can be run at this time or done after furnace CAUTION is mounted , see section : Gas Supply and Piping , pg . 15 . Do not run wire in any location where it might be The electrical supply opening should be at the upper left damaged . Avoid splicing thermostat wire unless of the furnace , to match openings shown in Fig . 9 , pg . 8 . the spliced wires are properly cleaned , soldered , Mark ceiling wail plate and drill holes . If not practical to and taped . run wiring from the attic , drill holes through wall stud and Offset Wall Installation To mount the wall furnace on an offset wall , the area Use sheet rock or paneling etc . to finish area . behind the furnace must be made flush or flat . Follow procedures under Surface Mount Installation . Use lumber ( 2 x 4 ' s , 2 x 6 ' s etc . ) to furr the offset area to make the surface flush with other portion of wall . Surface Mount Installation FIND THE STUDS Gas line can be run at this time or done after furnace is mounted , see section : Gas Supply and Piping , pg . 15 . 1 . Find two studs at spot where furnace is to be placed . Mark ceiling or wall to match wall furnace openings and Use a stud Iocator or small finishing nails . Repeatedlyhe drive and remove a nail into the wall in the area of t drill a 1 - inch hole for the power supply and a 1 / 2 - inch hole for the thermostat cable . Run the electrical supply and stud until you find it . Then find one side . Leave the nail ground wires to the opening . Leave enough length to there . Drive another nail just on the other side of the connect in the junction box after the furnace is installed . same stud . See section " Electrical Wiring , " pg . 17 . 2 . Inside edge of the other stud should be about 141 / 2 inches from the one found , Drive finishing nail on in - WALL OPENING ( SURFACE MOUNT ) side edge of this stud . CUT VENT OPENINGS 1 . Lay out and mark the center of the hole to be cut through the wall for the vent ( Fig . 7 , pg . 8 ) . Using a window , door , or wall corner for reference , measure to find where vent will be on outside wall . Check to be sure clearances are correct . ( Fig . 2 , 4 , 5 & 6 , pgs . 6 & 7 ) _ OF9t / _ DIA HOLE & FURNACE 2 . Drill a 1 / , - inch hole through vent hole center to the out - 68 _ ( 1 ) side . Cut the 91 / , - inch diameter hole through inside 59 ( 2 ) wall . Using the 1 / 4 - inch hole as the center , cut a match - ing hole in outside wall . It may be better to work from 1 / _ the outside , especially when breaking through brick , stone or tile . ( 1 ) MODELS GAS AND ELECTRICAL SUPPLY OPENINGS 5507332 , 5507331 , 6257732 , AND 6257731 Holes must be drilled for the gas line and electrical ( 2 ) MODELS supply . Holes must be located from each side of furnace 4007332 . 4007331 , 4007732 , AND 4 ( X ) 7731 as shown in Fig . 9 , pg . 8 . Drill a 11 / 2 - inchhole in floor or wall for gas line . - - 9 - -
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Surface Mount Installation ( Con't ) ROUGH - IN OPTIONAL SIDE OUTLET NO . 6701 5 . Fasten metal filler strips to side of furnace casing with front surface exactly opposite front of wood backup Install plasterground as shown in Figs . 11 & 12 . Flanges strip . of plasterground extend the thickness of normal piaster . 6 . After furnace is placed in position , pass outer boot If " dry - wall " or other thin material , flanges must be trimmed off flush with wall surface . through plasterground tight against furnace casing . Then mark and cut off outer end flush with wall surface . Follow measurements given carefully , and note that when Press inner boot against liner , mark and cut off flush a side outlet is used , the furnace casing must be exactly with wall surface . Installouter boot first , then inner boot , 4 inches from surface of adjacent wall except minimum fastening through all holes with screws provided . clearance may be 3 / 4 - inch when optional 1 - way Diffusing Grille Kit 6704 is used . VENT CAP F . . . . . . R ' STR ! ' ' , I , KIT 6701 METAL FILLER . - J _ . - 1H 8 OPTIONAL 2 - WAY DIFFUSING GRILLE KIT NO . 6703 SIDE PLASTER GROUND CENTERS EXACTLY 6 FROM RACK OF THE HEATER Refer to Fig . 14 . CAUTION For use only in conjuction with a front outlet when i _ e ] ll ilP , ; i the furnace is spaced at least 12 inches from an intersecting wall ( see Fig . 5 , pg . 7 ) . , I t " PLASTER Metal clips on backside of optional grille snap into side louvers of front warm air outlet . Adjust clips with pliers if necessary . Grille may also be attached with sheet metal • , , _ GROUND screws . 1 - WAY FRONT DIFFUSING GRILLE KIT NO . 6704 15 ] _ FINISH Followinstructions for 2 - WAYFRONT DIFFUSING GRILLE FLOOR 6703 ABOVE , except furnace clearance to an adjacent wall may be 3 / 4 - inch minimum . CAUTION MOUNTING OPTIONAL SIDE OUTLET GRILLE KIT NO . Use only optional kits available from the 6701 manufacturer . Refer to Fig . 13 . 1 . Before setting furnace into position , cut 5 x 7 rec - tangular opening in furnace outer casing where marked . See Fig . 9 , pg . 8 . LOWER DOOR CASING 2 . Place outer boot against casing with inner flanges exactly on edges of cut hole , mark screw location , remove boot and drill # 33 holes for sheet metal screws . 3 . Remove knockout plate and knockoutsfor screws from inner liner . OPTIONAL TWO - WAY DIFFUSING GRILLE 6703 4 . Secure 1 x 1 wood strip ( not included with this kit ) to wall next to side outlet as a backup for metal filler strips . - - 10 - -
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Thermostat Installation 1 . If an old thermostat is being replaced and is in a MOUNTING THE THERMOSTAT satisfactory location and the wiring appears to be 1 . To remove thermostat cover , squeeze cover and pull in good condition , use existing wiring . If in doubt , use straight outward ( see Fig . 27 , page 18 ) . Carefully new wire . remove and discard the packing tab protecting the 2 . If a new location is chosen or if this is a new installa - switch contacts . tion , thermostat cable must first be run to the location 2 . Connect thermostat wires to the terminal screws on the selected . All wiring must agree with local codes and thermostat base . Make sure wiring does not interfere ordinances . These instructions cover bringing the wirent with thermostat operation . down from the attic but it can be run from a baseme 3 . Push any excess wire back through hole in wall and or crawl space using similar methods . plug hole with insulation to prevent drafts from affect - 3 . Before drilling hole in wall at selected location , drive ing thermostat operation . a small finishing nail through the ceiling in the corner 4 . Being sure to level thermostat for best appearance , of the wall and ceiling above the thermostat location . fasten thermostat base to wall through mounting holes Pull the nail out and push a small stiff wire through the with screws provided . hole so it can be found in the attic . Drill a 1 / 2 - inchhole 5 . Replace the thermostat cover . through the ceiling wall plate . 4 . Probe for obstructions in the partition . Then drill a THERMOSTAT HEAT ANTICIPATOR 1 / 2 - inch hole through wall at selected location for thermostat . SET THE THERMOSTAT HEAT ANTICIPATOR 5 . From the attic , feed the thermostat cable or a stiff wire A simple method of setting . the heat anticipator in a 24 - volt through wall until even with thermostat location . thermostat ( without an A . C . ammeter ) is to first read the 6 . Snag thermostat cable through hole and pull cable label on the gas control valve and match its rating . through hole in wall so that 6 inches of cable protrudes . Example : If the ampere draw for the valve is . 5 amps , 7 . Route cable to wall furnace . set thermostat heat anticipator at the same setting ( . 5 ) . ADJUST THERMOSTAT ANTICIPATOR ROUTE THERMOSTAT CABLE Refer to Fig . 16 , Page 12 . Many factors affect this setting - - room size , lengthof ther - mostat wire , thermostat location , etc . Additional small adjustment to increase or decrease heatingcycles ( 4 - 6 per hour typical ) may be required . If an A . C . ammeter is available , see instructions supplied with thermostat . NOTE For longer " ON " times move the nanticipator - clockwise . For shorter " ON " times move the a I ticipator counter clockwise . SMAtL NOTE FINISH NAIL 10 Use heavier wire size if more than 20 ft . of wire is tOCAT { H [ AD [ _ required . NOTE Refer to installation instructions packed in the ther - mostat carton if you have any doubt about the above I procedures . - - 11 - -
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Thermostat Installation ( Con't ) When all is adjusted properly , the furnace burner should shut off slightly before the desired room temperature is reached . The stored heat in the appliance is enough to bring room temperature up to desired level . The heat anticipator thus makes it possible to maintain very close temperature control . Vent Installation WARNING DANGER OF PROPERY DAMAGE , WALL THICKNESS BODILY INJURY OR DEATH . f PROPER VENT INSTALLATION IS CRITICAL TO . - - , , - - . - - d THE SAFE OPERATION OF THE FURNACE . U , i I U , WALL THEREFORE , CAREFULLY READ AND FOLLOW WIIH LJ SIOtNG ALL THE INSTRUCTIONS GIVEN IN THIS SURFA ( _ SECTION . MOUNI / " , - - - - ' - - - - I i \ / The following instructions are for either surface or recess \ \ , l mounted wall furnace . X - X USE ONLY THE VENT ASSEMBLY SUPPLIED . IMPORTANT ALL JOINTS IN THE INLET AND VENT TUBES AND ALL GASKETS MUST BE TIGHT . INSTALLATION IN ANY OTHER MANNER VOIDS THE A . G . A . DESIGN CERTIFICATION AND WILL AFFECT THE WARRANTY . Refer to Fig . 18 , pg . 13 for the name and location of the vent parts . HELPFUL CUTTING HINT DETERMINE PROPER LENGTHS To make a straight cut , measure from the end and mark IMPORTANT tube in several places . Align a piece of tape with the marks and wrap around the tube . Use the edge of the tape as To prevent harmful flue gases from entering the a guide to help keep the cut straight . house , make sure NOT to trim air or vent tubes shorter than specified below . ATTACHING TUBE TO FURNACE The smaller diameter vent tube ( Fig . 18 - - " B " , pg . 13 ) must Air inlet air tube W and vent tube ' B ' are supplied in be installed first . lengths to handle wall thickness up to 12 inches . The easiest way to install the vent tubes and get the To find the correct vent and air tube length , measure gaskets positioned properly is to have the furnace lying exact distance ' X ' between surface on which back of front down on a flat surface . cabinet will rest ( inside of recessed cavity or face of wall when freestanding ) and the outside wall surface . See Figs . IMPORTANT 17 & 18 - pg . 13 . Be sure not to use longer screws than specified , as Inlet air tube W - - Add 7 / 8 inch to dimension ' X ' . Mark this could keep the furnace from functioning properly . I on tube starting from end with collar and holes . Cut off evenly . File off any burrs resulting . Vent tube ' B ' - - Add 2 - 118inches to dimension ' X ' . Mark 1 . Attach vent tube ( Fig . 18 - - " B " , pg . 13 ) and gasket to on tube starting from end with collar and holes . Cut off the back of the furnace heat exchanger with ( 8 ) # 8 x 3 / 8 evenly . File off any burrs resulting . inch sheet metal screws provided . CUT ONLY THE PLAIN END ( WITHOUT FLANGE ) 2 . Attach air tube ( Fig . 18 - - " A " , pg . 13 ) and gasket to the OF THE TUBES . MAKE A SQUARE CUT TO EXACT back of the furnace casting with ( 8 ) # 8 x 3 / 8 inch sheet LENGTH . metal screws provided . - - 12 - -
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Vent and Inlet Tube Installation ( Con't ) MOUNT FURNACE THROUGH WALL NOTE Mount the furnace through the wall using surface or Each tube must overlap the collars of the vent cap a minimum of 1 1 / 4 inch , which is obtained when recessed mounting instructions . See pgs . 7 - 10 . tubes are cut correctly as previously described . Refer to Fig . 18 for the following steps . 1 . Check to see that the air tube protrudes through wall VENT INSTALLATION 7 / 8 inch min . to 1 inch max . for proper seal in vent cap . 2 . Check to see that the vent tube protrudes past the air CONDUIT tube 1 / 8 inch rain . to 1 / 4 inch max . for proper seal in vent cap . MASTIC 3 . Apply a single strip of mastic " E " provided in vent cap MOUNTING PLATEP " carton , continuously around the outer edge of the vent EMSOSSED " TO cap mounting plate . 4 . Holding the vent cap in an upright position ( embossed " top " on mounting plate towards top of furnace ) , push into place until stops are contacted . If stops prevent mounting plate from reaching wall , refer back to " DETERMINE PROPER LENGTHS " pg . 12 . NOTE SCREWS The smaller tube in vent cap must slide over vent _ B _ . VENT , TUBE 5 . Fasten the vent cap mounting plate to wall with ( 4 ) ( 1 ) 68 - 112 ' I : 1 I , , . TUBE 11 / 2 - inch wood screws " D " provided . ( 2 ) 59 " 6 . On masonry construction , drill into wall and use plugs SEE or anchors . Additional sealant ( silicone ) may be INSTRUCTIONS required if the mounting surface is uneven . NOTE : BACK OF FURNACE _ , PLATE OF VENT 3AP EQUIPPED WITH STUD SPACERS TO PRE - FINISHED VENT INSTALLA - FLOOR TION THRU OPENING OF LESS \ THAN 91 / 4 " DL _ . M FURNACEITEM ( 1 ) MODELS 5507332 ( 2 ) MODELS 4007332 6257732 4007732 55O7331 4007331 J 6257731 4007731 Top trim cover provided Trim TRiM MOULDING To conceal the space between the furnace and wall , use ( OPTIONAL } 4701 Trip Strip Package ( not furnished with furnace ) , 3 / 4 quarter round or other wood trim . TRIM COVER . c : : _ Place trim cover on top of furnace . See Fig . 19 . Drill through top casing flange and fasten through each side with a sheet metal screw . This plate covers the space be - tween the top of the furnace and wall opening after elec - trical connections are made . - - 13 - -
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Mounting Your Furnace FASTEN FURNACE BOTTOM To obtain adequate clearance for fastening furnace or to install gas supply fittings , it may be necessary to remove ( Surface and Recessed Mount ) the burner and control assembly as follows : NOTE Fasteners are not furnished because of different CAUTION requirements of various types of wall construction . Be careful not to damage burner pan gasket when removing burner and control assembly . Fasten furnace to floor through holes provided in furnace bottom . If you have concrete flooring , use an alternate 1 . Lay the furnace on its back for the following steps . fastening method . See Fig . 20 . If furnace burner and control assembly were removed , Remove burner compartment door by pulling door top replace by reversing steps la through ld . out and up . IMPORTANT MODELS 4007332 , 6257332 , When replacing burner and control assembly , be 4007331 , 5507331 . sure that pins " B " all enter slots in upper heating element support . To prevent damage to wire , a . Remove screws holdhlg ignition control unit and be careful not to pinch them between furnace com - cover to casing . ponents and route them away from burner pan surface . b . Remove ( 3 ) screws ' A ' holding burner pan to upper heating element support ( Fig . 21 , pg . 15 ) . Rotate FASTEN FURNACE TOP burner pan toward front until ( 3 ) pins ' B ' disengage ( Surface Mounting ) from upper heating element support . Fasten furnace top to wall using ( 2 ) metal anchors ( pack - c . Remove necessary wire to free control module from ed in plastic bag with thermostat ) by placing them over its mounting location . Mark or tag each wire re - the back flange of furnace top and screwing to wall . See moved for its exact reconnection ( Fig . 22 , pg . 15 ) . Fig . 20 . d . Remove burner and control assembly from furnace . FURNACE MOUNTING MODELS 4007732 , 6257732 , 4007731 , 6257731 . RECESSEDMOUNT a . Remove manual spark ignitor and bracket by re - moving ( 2 ) screws and disconnecting wire at back _ REA _ MOUNTG of ignitor . TOP FASTENIN b . Disconnect two ( 2 ) slip - on connectors ( 24 voltwires ) I from the gas valve . I c . Remove ( 3 ) screws ' A ' holding burner pan to upper II heating element support ( Fig . 21 , pg . 15 ) . Rotate NOT _ - I0 _ 1 FOR burner toward front until ( 3 ) pins ' B ' disengage from upper heating element support slots . d . Remove burner and control assembly from furnace . NOTE Attach vent tubes BEFORE mounting furnace . See pgs . 12 & 13 . 2 . If furnace is recessed in wall , clear recess of all debris . 3 . Be sure that gas is shut off at meter . 4 . Before placing furnace in position , remove gas piping stub if necessary to locate furnace . 5 . After installing vent tubes , carefully move furnace into position being sure not to bend the vent tubes . BOI " rOMFAS'T1E ] _ NG WDOOFLDOR NO'W . : DO NOT USE DOTrOM DOOR HOLES FOR MOLJNllNG - - 14 - -
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Mounting Your Furnace ( ton't ) FASTEN FURNACE TOP ( Recessed Mounting ) Fasten furnace top by drilling ( 2 ) holes through side flange Be careful not to damage furnace components or furnace top and securing with ( 2 ) screws or nails to wall wiring when drilling holes . CAUTION I studs . See Fig . 20 , pg . 14 . o Io 5 , L Io WlLUAMS IGNITION CONTROL PART NUMBER P3219t0 Gas Supply and Piping Gas control valve , within the furnace , is shipped with a Orifice change may be required to suit gas supplied . seal cover gas inlet tapping . Do not remove seal until ready Check with your local gas supplier . to connect piping . ORIFICE SIZES WARNING Furnace Technical Information , Page 26 , shows the DANGER OF PROPERTY DAMAGE , correct orifice sizes for the different input ratings when BODILY INJURY OR DEATH . using Natural or L . R Gas . MAKE SURE THE FURNACE IS EQUIPPED TO GAS PIPING OPERATE ON THE TYPE OF GAS AVAILABLE . The gas supply line must be of an adequate size to MODELS DESIGNATED AS NATURAL GAS ARE TO handle the BTU / HR requirements and length of the run BE USED WITH NATURAL GAS ONLY . FURNACE for the unit being installed . DESIGNATED FOR USE WITH LIQUEFIED Determine the minimum pipe size from Fig . 25 , pg . 16 , bas - PETROLEUM ( L . R ) GAS HAVE ORIFICES SIZED ing the length of the run from the gas meter or source FOR COMMERCIALLY PURE PROPANE GAS . to the unit . THEY CAN NOT BE USED WITH BUTANE OR A MIXTURE OF BUTANE AND PROPANE . All piping must comply with local codes and ordinances or with the National Fuel Gas Code ( ANSI Z22 & l - 1988 ) , whichever applies . In Canada : Follow CAN / CGA B149 In - stallation Code . GAS SUPPLY Refer to Fig . 23 , pg . 16 for the general layout at the unit . For Natural gas , the minimum inlet gas supply pressure It shows the basic fittings needed . for the purpose of input adjustment is 5 " water column . The following rules apply : The Maximum inlet gas supply pressure is 7 " water column . 1 . Use new , properly reamed pipe free from chips such as steel or black iron pipe and fittings or other For L . IR gas , the minimum inlet gas supply pressure for approved by local codes . the purpose of input adjustment is 11 " water column . The 2 . Do not thread pipe too far . Valve distortion or mal - maximum inlet gas supply pressure is 13 " water column . function may result from excess pipe within control . Gas pressures and input to the burners must not exceed Apply moderate amount of good quality dope to pipe the rated input and pressure shown on the rating plate . only , leaving 2 end threads bare . If LP gas installation , On Natural Gas , the manifold pressure should be 4 inch - use compound resistant to action of liquefied petroleum es water column . The manifold pressure should be 10.5 gases . inches water column for LP . Gas See pg . 18 for opera - 3 . Use ground joint unions . tion above 2000 feet altitude . - - 15 - -
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Gas Supply and Piping ( Con't ) Connection between shutoff valve and burner control 4 . Install a drip leg to trap dirt and moisture before it can enter the gas valve . Drip leg must be a minimum of 3 assembly can be made with an A . G . A . / C . G . A . design cer - inches long . tified flexible connector if allowed by local codes . 5 . Install a manual shut - off valve . Tighten all joints securely . 6 . Provide a 1 / 8 NPT test gauge connection immediately CHECKING THE GAS PIPING before the gas supply connection to the furnace . Test all piping for leaks . When checking gas piping to the furnace with gas pressure less than 1 / 2 PSI , shut off manual gas valve for the furnace . If gas piping is to be checked with the pressure at or above 1 / 2PSI , the furnace DROp and manual shut off valve must be disconnected during I PIpIE D GROUNO JOINT testing . ( SEE WARNING BELOW . ) Apply soapsuds ( or a liquid detergent ) to each joint . Bubbles forming indicates a leak . Correct even the slightest leak at once . GAS PIPE SIZES 3 , [ 62mml GAS NATURAL GAS _ tt _ rMUM _ ANUAL SHUT OFF SUPPLY PIPE CAPACITY - BTU PER HOUR ( INCLUDES FITTINGS ) PIPE SIZE . LENGTH OF PIPE - FT . I / 2 " 3 / 4 " I " HOnlZON'r AL TUBING _ It _ IMUM 20 92,000 190.000 350,000 ; oF : 40 63.000 130,000 245.000 60 S0 , 000 105,000 195,000 L . P , GAS PIPE CAPACITY - BTU PER HOUR LENGTH ( INCLUDES FITTINGS ) OF _ 31n 1762mml PIPE - FT . 1 / 2 " 3 / 4 " 1 " M _ NIMUM 20 189,000 393,000 732,000 _ ALL BENDS IN METALLIC TUBING SHOULO 9E SMOOTH 40 129.000 267,000 504,000 _ CAUTION : SHOT OF € THE MA _ N CA $ SUPPLY BE , _ ORE REMOVING ENO CAP 60 103,000 217.000 409,000 TO PREVI _ NT GAS FROM F ( LLINC THE WORK AAEA TE _ T FOR GAS LEAK . AGE WHEN INSTALLATION I _ COMPLETE WARNING DANGER OF PROPERTY DAMAGE , PROP [ R PtPtMG PRACTI ¢ _ BODILY INJURY OR DEATH . 2 IMPERFECT CONTRO L USE MODERATE AMOUNT OF DOPE THR £ AD5 NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS . NEVER EXCEED SPECIFIED PRESSURES FOR TESTING . HIGHER PRESSURES MAY DAMAGE THE GAS VALVE AND \ THREAD PIPE RIGHT L _ NGTH LEAVE 2 END THREADS 8ARE " _ CAUSE OVERFIRING WHICH MAY RESULT IN HEAT EXCHANGER FAILURE . LIQUID PETROLEUM ( L . R ) IS HEAVIER THAN AIR AND IT GAS CONNECTION WILL SETTLE IN ANY LOW AREA , INCLUDING OPEN DEPRESSIONS AND IT WILL REMAIN If installation isfor L . R Gas , have L . R installer use two - THERE UNLESS AREA IS VENTILATED . stage regulation and make all connections from storage tank to furnace . NEVER ATTEMPT STARTUP OF UNIT BEFORE Use two pipe wrenches when making the connection to THOROUGHLY VENTILATING AREA . the valve to prevent turning or damage to gas valve . - - 16 - -
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Electrical Wiring ELECTRICAL POWER SUPPLY WARNING DANGER OF PROPERTY DAMAGE , A branch circuit including this furnace must not exceed BODILY INJURY OR DEATH . 15 amperes or run a separate 115V . , 60 Hz . , 15 Ampere TURN OFF ELECTRIC POWER AT FUSE BOX circuit from a separate circuit breaker or fuse in your serv - OR SERVICE PANEL BEFORE MAKING ANY ice panel to the furnace junction box . Do not run supply ELECTRICAL CONNECTIONS . wires inside the furnace cabinet , except from the top of cabinet down to junction box . Connect as shown in Fig . 26 . INSULATE WHERE NECESSARY . ALL LINE VOLTAGE AND GROUND CONNEC - TIONS MUST BE COMPLETED BEFORE CONNECTING SUPPLY WIRING ELECTRICAL POWER IS RESTORED . All electrical work must conform to your local codes and MAKE CONDUIT WIRES MARKED LINE CONNECTION HERE ordinances or in their absence , with National Electrical PUSH BACK INSIDE JUNC lION BOX Code , ANSI / NFPA 70 . If you are not familiar with wiring _ , , _ _ lO THERMOSTA " codes , in general , have a competent electrician do this job . _ ! ! ) AO , NE In Canada : Follow C22 . 1 , Canadian Electrical Code . CAUTION Label all wires prior to disconnection when servicing controls . Wiring errors can cause improper and dangerous operation . Verify proper operation after servicing . JUNCTION BOX MAKE WIRE CONNECTIONS Power supply connections are made inside the junction box in the upper left corner of the cabinet . See Fig . 26 . TO APPROVED GROUND Do not connect 115V service line to the gas control CAUTION I _ ( FIELD WIRED ) valve or wall thermostat . " J " BOX COVER PLATE _ HOWN REMOVED ) MOTOR GROUNI ELECTRICAL CONNECTION FACTORY WIRED Connect 115V . conduit to top of furnace as shown in Fig . ON TRANSFORMER TO GAS VALVE 18 , pg . 13 . Remove screws holding junction box cover and transformer for access to junction box . Remove the cover plate with transformer attached . Pull supply wires through conduit and into junction box . LOW VOLTAGE CONNECTIONS Attach your 115V.supply wire to " LINE " factory wires . Use wire nuts provided . CAUTION Replace junction box cover and make final ground The Heat Anticipator WILL BURNOUT if 24 volts are connections with screws for plate cover . applied directly to thermostat by shorting out the gas Refer to paragraph covering GAS AND ELECTRICAL valve or primary control during testing or by incorrect SUPPLY OPENINGS , pg . 9 . Follow Wiring Diagrams , pgs . wiring . 27 and 28 . If you have any doubt regarding electrical hookup , or com - WALL THEMOSTAT WIRING pliance with code or ordinace , consult your electrical inspector or a licensed electrician . Run thermostat wire to the furnace . HELPFUL HINT Connect thermostat to two wires marked " Thermostat " extending from top of furnace , using two wire nuts pro - After wire nuts are screwed to wires , a small strip of elec - vided . See Wiring Diagrams , pgs . 27 and 28 . Refer to Fig . trical tape can be applied over wire nut at its base and 15 , pg . 11 , also , onto wires to make a very solid connection . Replace fan to original position on motor shaft , tighten - GROUNDING ing securely . Replace fan shroud , making sure it is A ground lug is installed for the ground connection . Use centered vertically on the fan . a copper conductor ( # AWG ) from the unit to a grounded Tighten screws securely . connection in the electric service panel or a propedy driven Replace top front panel and secure with thumbscrew . and electrically grounded ground rod . COMPLETE WIRING DIAGRAMS ON PAGES 27 AND 28 . - - 17 - -
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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 . Pages 19 thru 24 . WARNING WARNING NATURAL GAS HEATING VALUE ( BTU PER CUBIC FOOT ) CAN VARY SIGNIFICANTLY , THEREFORE , DANGER OF PROPERTY DAMAGE , IT IS THE INSTALLER'S RESPONSIBILITY TO SEE BODILY INJURY OR DEATH . THAT BTU INPUT TO THE FURNACE IS ADJUSTED LIQUIFIED PETROLEUM L . IR GAS IS HEAVIER PROPERLY . FAILURE TO DO SO COULD CAUSE THAN AIR AND IT WILL SETTLE IN ANY LOW HEAT EXCHANGER FAILURE , ASPHYXIATION , AREA , INCLUDING OPEN DEPRESSIONS ANDIS FIRE OR EXPLOSION , RESULTING IN DAMAGE , IT WILL REMAIN THERE UNLESS AREA BODILY INJURY OR DEATH . REFER TO THE VENTILATED . NATURAL FUEL GAS CODE ( NFPA - 54 ) TO BEE NEVER ATTEMPT STARTUP OF UNIT BEFORE SURE THE FURNACE IS BURNING FUEL AT TH THOROUGHLY VENTILATING AREA . PROPER RATE . Check the furnace operation as outlined in the following Underfiring could cause inadequate heat , excessive con - instructions . If any sparking , odors or unusual noises are densation or ignition problems . Overfiring could cause encountered , shut off electric power immediately . Recheck sooting flame impingement or overheating of heat for wiring errors , or obstructions in or near fan motor . exchanger . CHECK GAS INPUT AND PRESSURES Before starting natural gas input check , obtain heating value of gas ( BTU per cubic foot ) at standard conditions For furnace located at elevations between sea level and from your local supplier . This factor is used in " Check the 2000 feet , the measured input must not be greater than Gas Input " section and procedure . the input shown on the rating plate of the furnace . For elevations above 2000 feet , the measured input must not To measure the input using the gas meter , proceed as follows : exceed the input of the rating plate reduced by 4 percent . for each 1000 feet that the furnace is above sea level 1 . Turn off gas supply to all other appliances except Gas supply pressure and manifold pressure with the burn - the furnace . ers operating must also be as specified on the rating plate . 2 . With the furnace operating , time the smallest dial on the meter for one complete revolution . If this is a 2 Type of Gas Manifold Pressure , In . W . C . | cubic foot dial , divide the seconds by 2 ; if it is a 1is Natural 4 cubic foot dial , use the time in seconds as is . Th ] L . P . 10.5 gives the seconds per cubic foot of gas being delivered to the furnace . Rated input will be obtained on 2500 Btu propane at 10.5 inch manifold pressure with factory - sized orifices . If LP gas 3 . Assuming natural gas with a heating value of 1000 BTU having a different heating value is supplied , orifices must per cubic foot and 34 seconds per cubic foot as be changed by a qualified service technician before the determined by step ( 2 ) , then : furnace is operated . Input = 1,000 x 3,600 + 34 = 106,000 BTU Per Hour This measured input must not be greater than the CHECK THERMOSTAT input indicated on the rating plate of the furnace . Check thermostat operation . When set above temperature 4 . Relight all other appliances turned off in step 1 above . shown on the thermostat , the main burner should light . Be sure all pilot burners are operating . Make certain the thermostat turns off the furnace when room temperature reaches the selected setting and starts the furnace when room temperature falls a few degrees . THERMOSTAT ( TYPICAL ) SURE TH _ ANTICIPATORIS SET PROPERLY ADJUST PILOT BURNER NOTE STANDING PILOT MODELS ONLY Pilot flame should surround 5 / 8 to 1 / 2 inch of the thermocouple tip . Toadjust , remove cap from pilotad - SQUEEZE FIRMLY justing screw on gas valve . Turn screw counterclock - BOTH SIDES wise to increase flame , clockwiseto decrease . Replace AND LIFT TO cap . See Figs , 31 , Page 25 and Fig . 32 , Page 26 . REMOVE COVER CHECK THE MANIFOLD GAS PRESSURE A tapped opening is provided in the gas valve to facilitate WARNING measuring the manifold gas pressure . A " U Tube " DANGER OF IGNITION FLASH manometer having a scale range from 0 to 12 inches ofd AND EYE INJURY OR BLINDNESS water should be used for this measurement . The manifol PROTECT YOUR EYES . NEVER ATTEMPT TO pressure must be measured with the burner and pilot LIGHT PILOT WITH GAS CONTROL VALVE KNOB operating , Any major changes in flow must be made by IN " ON " POSITION . FLASH BACK COULD changing the size of the burner orifice , Check with your OCCUR . local gas supplier for proper orifice sizing . - - 18 - -
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Operating Your Furnace STANDING PILOT MODELS " WARNING 4007732 , 6257732 , DANGER OF BODILY INJURY OR DEATH . 4007731 , 6257731 . DO NOT OPERATE THE FURNACE WITH A BROKEN OR MISSING PILOT OBSERVATION NOTE : DOOR . For models equipped with WILLIAMS gas valve P322041Y or P322042 refer to this sheet and sheet 20 for " SAFET & LIGHTING INSTRUCTION " and " TURN GAS OFF TO For models equipped with WILLIAMS gas valve APPLIANCE . " P321704 or P321705 . For models equipped with WILLIAMS gas valve P321704 Models are equipped with a two - rate control valve . The rate or P321705 refer to this sheet and sheet 21 for " SAFETY knob on the gas valve is marked " LO " and " HI . " Turn the & LIGHTING INSTRUCTIONS " and " TURN GAS OFF TO rate knob to the " LO " position and the room thermostat APPLIANCE . " will operate the main burner at about 70 % of maximum ( All other models refer to sheet 22 , 23 & 24 . ) capacity . Turn the rate knob to the " HI " position only when a fast heat - up is desired during extremely cold weather . These furnaces are equipped with a manually operated High operation develops maximum capacity of the furnace Piezo spark igniter device to ignite the pilot gas . Follow the steps under " Lighting Instructions " ( see Page 20 or Page 21 ) and use the manual spark ignitor to light the pilot in Step 10 . Press spark ignitor button repeatedly . A two - speed fan is used with Models 6257732 , and On new installations , the gas lines will be filled with air 6257731 . and it may take several minutes to establish the pilot flame . Blower will operate at low speed then shift to high speed Keep all access doors and panels in place except for in - as the furnace heats up . spection and maintenance . WARNING WARNING THE SURFACE OF THE FURNACE IS HOT DUR - DANGER OF PROPERTY DAMAGE ING OPERATION . KEEP CHILDREN , CLOTHING , BODILY INJURY OR DEATH . FRNITURE , AND FLAMMABLE MATERIAL AWAY IF THE FURNACE OVERHEATS OR FAILS TO FROM IT . SHUT OFF , CLOSE MANUAL GAS VALVE FOR THE FURNACE BEFORE TURNING OFF ELECTRIC DO NOT STORE OR USE GASOLINE OR OTHER POWER . FLAMMABLE LIQUIDS OR VAPORS NEAR THE FURNACE . SAFETY LIMIT CONTROL These furnaces are protected against unsafe operation by four automatic safety controls : ( 1 ) A safety pilot acts to shut OFF the gas valve in case of pilot failure ; ( 2 ) A redundant gas valve ; ( 3 ) A limit switch shuts down the main burner to prevent overheating the furnace cabinet ; this limit switch will reset when furnace cools ; and ( 4 ) A thermal overload protects the motor against burnout caused by current surges or if anything should block the flow of air tthroughor the furnace . This switch will reset itself when the mo cools down and it cannot be adjusted . - - 19 - -
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FOR YOUR SAFETY , READ BEFORE LIGHTING I 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 hand , When lighting the pilot , follow these instructions department . 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 serv - 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 • Do not try to light any appliance or strike a match . D . 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 phone . Follow the gas supplier's instructions . under water . LIGHTING INSTRUCTIONS 1 . STOP ! Read the safety information above . 8 . Find pilot - - follow metal tube from gas control , The pilot 2 . Set the thermostat to lowest setting . is mounted on side of burner . 9 . Turn knob on gas control counterclockwise J _ 3 . Turn off all electric power to the appliance . to " PILOT , " 4 . Remove control access panel . 10 . Push in red reset button THERMO - _ 1 , [ _ , = 5 . Turn gas control knob clockwise _ to " OFF " . all the way and hold in . COUPLE Immediately light the pilot . Continue to hold RESET BUTTON the red reset button in for about PILOT GAS ( 1 ) minute after the pilot is lit , Release BURNER CONTROL button and it will pop back up . Pilot should KNOB remain lit . If it goes out , repeat steps 5 through 10 . • If button 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 the gas control knob to " OFF " and call your service technician or gas supplier . 11 . Close pilot observation door , tighten wingnut ( if equipped ) , 12 . Turn gas control knob counterclockwise _ to " ON " , 6 . Wait five ( 5 ) minutes to clear out any gas then smell for Knob can be turned to " ON " only if red reset button is gas , including near the floor . If you then smell gas , stop ! up . Follow " B " in the safety information above . If you don't 13 . Replace control access panel . smell gas , go to next step . 14 . Turn on all electric power to the appliance . 7 . Loosen wingnut and open pilot observation door ( if 15 . Set thermostat to desired setting . equipped ) . TO TURN OFF GAS TO APPLIANCE 1 . Set the thermostat to lowest setting . 2 . Turn off all electric power to the appliance if service is to be performed . 3 . Remove control access panel . 4 . Push in gas control knob slightly and turn clockwise _ to " OFF " . Do not Force . 5 . Replace 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 . - - 20 - -
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FOR YOUR SAFETY , READ BEFORE LIGHTING WARNING : If you do not follow these instructions exactly , a fire or explosion may result causing property damage , personal injury or loss of life , • If you cannot reach your gas supplier , call the fire A . This appliance has a pilot which must be lighted by department . hand . When lighting the pilot , follow these instructions exactly . C . Use only your hand to push in or move the selector arm . Never use tools . If the arm will not push in or B . BEFORE LIGHTING smell around the appliance area move by hand , don't try to repair it , call a qualified for gas . Be sure to smell next to the floor because some service technician . Force or attempted repair may result gas is heavier than air and will settle on the floor . in a fire or explosion . WHAT TO DO IF YOU SMELL GAS O . Do not use this appliance if any part has been under • Do not try to light any appliance or strike a match . water . Immediately call a qualified service technician to • Oo not touch any electric switch ; do not use any inspect the appliance and to replace any part of the phone in your building . control system and any gas control which has been • immediately call your gas supplier from a neighbor's under water . phone , Follow the gas supplier'a Instructions . LIGHTING INSTRUCTIONS 8 . Find pilot - - follow metal tube from gas control . The pilot is mounted on side of burner . 1 . STOP ! Read the safety information above . 9 . Hold lighted match at pilot 2 . Set the thermostat to lowest setting , burner . 3 . Turn off all electric power to the appliance . f0 . Move selector arm to 4 . Remove control access panel . " SET " postlon and light 5 . From " ON " position , depress and move selector pilot , Hold in " SET " position arm on gas control to " OFF " position , Do not force . for 1 / 2 minute after pilot is lit . NOTE : Sufficient time must be allowed PILOT GAS CONTROL for pilot flame to heat thermocouple BURNER SELECTOR ARM SHOWN and hold safety magnet in locked - up position , IN = OFF " also , time must be allowed for air to be purged POSITION from gas lines during first starting operation . 11 . Release selector arm , and if pilot remains lit , move selector arm to " ON " position , • If the pilot will not stay lit after several tries , move the selector arm to " OFF " and call your service technician or gas supplier . 12 . Close pilot observation door and tighten wingnut ( if equipped ) . 6 . Wait five minutes to clear out any gas then smell for gas , 13 . Replace control access panel . including near the floor . If you then smell gas , stop ! Follow 14 . Turn on all electric power to the appliance . " B ' " In the safety information above . If you don't smell 15 . Set thermostat to desired setting . gas , go to next step . : 7 . Loosen wingnut and open pilot observation door ( if equipped ) . TO TURN OFF GAS TO APPLIANCE 1 . Set the thermostat to lowest setting . 2 . Turn off all electric power to the appliance if service is to be performed . 13 . Remove control access panel . 4 . From " ON " position , depress and move selector arm on gas control to " OFF " position . Do not force . 5 . Replace 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 . - - 21 - -
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Operating Your Furnace ELECTRONIC IGNITION MODELS * WARNING 4007332 , 5507332 , DANGER OF BODILY INJURY OR DEATH . 4007331 , 5507331 . DO NOT OPERATE THE FURNACE WITH A BROKEN OR MISSING PILOT OBSERVATION NOTE : DOOR . For models equipped with WILLIAMS gas valve P322043 or P322044 refer to this sheet and sheet 23 for " SAFETY & LIGHTING INSTRUCTION " and " TURN GAS OFF TO For models equipped with WILLIAMS gas valve APPLIANCE . " P321897 or P321898 . For models equipped with WILLIAMS gas valve P321897 Models are equipped with a two - rate control valve . The rate or P321898 refer to this sheet and sheet 24 for " SAFETY knob on the gas valve is marked " LO " and " HI . " Turn the & LIGHTING INSTRUCTIONS " and " TURN GAS OFF TO rate knob to the " LO " position and the room thermostat APPLIANCE . " will operate the main burner at about 70 % of maximum ( All other models refer to sheet 19 , 20 & 21 . ) capacity . Turn the rate knob to the " HI " position only when a fast heat - up is desired during extremely cold weather . High operation develops maximum capacity of the furnace . THE FURNACE WORKS LIKE THIS : 1 . Thermostat turns on the control module . 2 . Automatic relight system ( in module ) opens gas valve A two * speed fan is used with Models 5507332 , and and electronically ignites pilot . After pilot flame has 5507331 . been established and proven by the control module , main gas valve circuit opens and pilot lights main Blower will operate at low speed then shift to high speed burners . as the furnace heats up . 3 . Heat builds up in the furnace and starts the fan . The heated air comes out the front bottom Iouvered panel WARNING at floor level . 4 . When the thermostat setting is reached , it shuts off the DANGER OF PROPERTY DAMAGE main burner . BODILY INJURY OR DEATH . 5 . The fan runs until the heat is removed from furnace , IF THE FURNACE OVERHEATS OR FAILS TO then it turns off . SHUT OFF , CLOSE MANUAL GAS VALVE FOR THE FURNACE BEFORE TURNING OFF ELECTRIC POWER . SAFETY LIMIT CONTROL These furnaces are protected against unsafe operation by three automatic safety controls : ( 1 ) The electronic ignition system ; ( 2 ) A limit switch shuts down the main burner to prevent overheating the furnace cabinet ; this limit switch will reset when furnace cools ; ( 3 ) A thermal overload pro - tects the motor against burnout caused by current surges or if anything should block the flow of air through the fur - nace , the switch will turn the main burner off . When motor cools down , this switch will reset itself . This switch can - not be adjusted . WARNING THE SURFACE OF THE FURNACE IS HOT DUR - ING OPERATION . KEEP CHILDREN , CLOTHING , FURNITURE , AND FLAMMABLE MATERIAL AWAY FROM IT . DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS NEAR THE FURNACE . - - 22 - -
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FOR YOUR SAFETY , READ BEFORE LIGHTING WARNING : If you do not follow these instructions exactly , a fire or explosion may result causing property damage , personal injury or loss of life . • if you cannot reach your gas supplier , call the fire A . This appliance is equipped with an ignition device which department . automatically lights the pilot . Do not try to light the pilot by hand . C . Use only your hand to push in or turn the gas control knob . Never use tools . If the knob will not push in or B . BEFORE LIGHTING smell around the appliance area turn by hand , don't try to repair it , call a qualified serv - for gas . Be sure to smell next to the floor because some ice technician . Force or attempted repair may result in a gas is heavier than air and will settle on the floor . fire or explosion . WHAT TO DO IF YOU SMELL GAS O . Do not use this appliance if any part has been under • Do not try to light any appliance or strike a match . water . Immediately call a qualified service technician to • Do not touch any electric switch ; do not use any inspect the appliance and to replace any part of the phone In your building . control system and any gas control which has been • Immediately call your gas supplier from a neighbor's under water . phone . Follow the gas suppller's Instructions . LIGHTING INSTRUCTIONS S . Turn the gas control knob counterclockwise 1 . STOP ! Read the safety information above . to " ON " . 2 . Set the thermostat to lowest setting . 3 . Turn off all electric power to the appliance , 9 . Replace control access panel . 4 . This appliance is equipped with an ignition device which 10 . Turn on all electric power to the appliance . automatically lights the pilot . Do not try to light the pilot 11 . Turn thermostat to on ( HEAT ) position . Set thermostat by hand . higher than room temperature . Pilot will automatically 5 . Remove control access panel . light and main burner ( s ) will light in approximately 45 6 . Turn gas control knob clockwise ( _ to " OFF " . seconds . NOTE : On initial start - up or after prolonged shut down , GAS CONTROL - - ' _ . several ignition cycles may be required to purge gas KNOB SHOWN . , lines . To accomplish the recycle - repeat steps 5 IN " OFF " r - r through 11 until pilot is established . 12 . Set thermostat to desired setting . IN 13 . After the room thermostat turns the system off , a delay of approximately one minute is required before the system can be turned on again . POSITION _ 14 . If the appliance will not operate , follow the instructions " To Turn Off Gas To Appliance " and call your service / technician or gas supplier . Wait five ( 5 ) minutes to clear out any gas then smell for gas , including near the floor . If you then smell gas , stop ! Follow " B " in the safety information above . If you don't smell gas , go to next step . TO TURN OFF GAS TO APPLIANCE 1 . Set the thermostat to lowest setting . 2 . Turn off all electric power to the appliance if service is to be performed . 3 . Remove control access panel . 4 . Push in gas control knob slightly and turn clockwise _ to " OFF " . Do not Force . 5 . Replace control access panel . WARNING : DUE TO HIGH SURFACE TEMPERATURES - - KEEP CHILDREN , CLOTHING , I FURNITURE OR ANY COMBUSTIBLE MATERIAL AWAY FROM FURNACE . I IMPORTANT : KEEP BURNER AND CONTROL COMPARTMENT CLEAN . I - - 23 - -
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FOR YOUR SAFETY , READ BEFORE LIGHTING WARNING : If you do not follow these instructions exactly , a fire or explosion may result causing property damage , personal injury or loss of life . A . This appliance is equipped with an ignition device which • If you cannot reach your gas supplier , call the fire department . automatically lights the pilot . Do not try to light the pilot by hand . C . Use only your hand to push in or move the selector B . BEFORE LIGHTING smell around the appliance area arm . Never use tools . If the arm will not push in or for gas . Be sure to smell next to the floor because some move by hand , don't try to repair it , call a qualified gas is heavier than air and will settle on the floor . service technician . Force or attempted repair may result in a fire or explosion . WHAT TO DO iF YOU SMELL GAS O . • DO not try to light any appliance or strike a match . Do not use this appliance if any part has been under water . Immediately call a qualified service technician to • Do not touch any electric switch ; do not use any phone in your building . inspect the appliance and to replace any part of the control system and any gas control which has been • Immediately call your gas supplier from a neighbor's under water . phone . Follow the gas supplier's instructions . LIGHTING INSTRUCTIONS 1 . STOP ! Read the safety information above . 8 . Move selector arm to " ON " position . 2 . Set the thermostat to lowest setting . 9 . Replace control access panel . 3 . Turn off all electric power to the appliance . 10 . Turn on all electric power to the appliance . 4 . This appliance is equipped with an ignition device which 11 . Turn thermostat to on ( HEAT ) position . Set thermostat automatically lights the pilot . Do not try to light the pilot higher than room temperature . Set thermostat higher by hand . than room temperature . Pilot will automatically light 5 . Remove control access panel . and main burner ( s ) will light in approximately 45 6 . From " ON " position , depress and move selector arm on seconds . gas control to " OFF " position . Do not force . NOTE : On initial start - up or after prolonged shut down , several ignition cycles may be required to purge gas GAS CON'I _ OL SELECTOR lines . To accomplish the recycle - repeat steps 6 ARM SHOWN through 11 until pilot is established . IN " OFF " 12 . Set thermostat to desired setting . POSITION 13 . After the room thermostat turns the system off , a delay of approximately one minute is required before the system can be turned on again . 14 . If the appliance will not operate , follow the instructions " To Turn Off Gas To Appliance " and call your service technician or gas supplier . 7 . Wait five ( 5 ) minutes to clear out any gas then smell for gas , including near the floor . If you then smell gas , atop ! Follow " B " in the safety information above . If you don't smell gas , go to next step . TO TURN OFF GAS TO APPLIANCE 1 . Set the thermostat to lowest setting . 2 . Turn off all electric power to the appliance if service is to be performed . 3 . Remove control access panel . 4 . From " ON " position , depress and move selector arm on gas control to " OFF " position . Do not force . 5 . Replace 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 . - - 24 - -
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How To Care For Your Furnace WARNING PILOT BURNER DANGER OF BODILY INJURY OR DEATH Light pilot using instructions in OPERATING YOUR FURNACE ( on Pages 19 thru 24 , depending on your TURN OFF ELECTRIC POWER SUPPLY AT model ) . DISCONNECT SWITCH , FUSE BOX OR SERVICE PANEL BEFORE REMOVING ANY DOORS OR Pilot flame should surround 5 / 8 to 1 / 2 inch of the thermo - ACCESS OR SERVICE PANELS FROM UNIT . couple tip . Refer to Fig . 32 , Page 26 . If flame needs adjusting , do it as follows : ADJUST PILOT BURNER CABINET FINISH See Fig . 31 and 32 . ( Page 26 ) Clean cabinet with damp rag . Never use abrasive cleaners . 1 . Remove screw cover over pilot adjusting screw . Cabinets are finished in heat resistant baked enamel - DO 2 . Insert small screwdriver , Adjust flame as needed . Turn NOT refinish with wail paint . screw counterclockwise ( _ ) to increase flame , clockwise ( _ ) to decrease . 3 . Turnthermostat to highest setting . Main burners should COMBUSTION AND VENTILATION AIR light quickly and smoothly . Turn thermostat to lowest The combustion and ventilation air supply must not be setting . Main burners should go out . Pilot should re - blocked . main lit except for electronic ignition models . 4 . Replace screw cover over pilot adjusting screw . Do not put anything in or on the furnace cabinet . BURNER FLAME For better circulation and more effective heating , do not Start the furnace and let it operate about 10 minutes then place obstructive furniture closer than four feet to the front look at the burner flame . Flames should be soft and blue , of the cabinet or two feet to the side of the cabinet . see Fig . 31 . If flames appear abnormal , contact the gas company or a qualified service technician immediately . FURNACE AREA Keep the area near the furnace clear and free from com - VENTING SYSTEM bustible materials , gasoline , and other flammable liquids Make sure that no parts of the vent air system are block - and vapors . ed , rusted or damaged ( including joint gaskets ) . Clean or replace before using furnace . See Page 12 and 13 for ANNUAL UPKEEP NEEDED proper assembly and reseating of vent - air system . It is recommended that a qualified service technician per - form these checks at the beginning of each heating season . CLEANING AND OILING Shut off electricity , then remove cabinet door and front panel . Clean any lint or dirt from fan blades , fan motor , and exposed air passages . Use a brush . Put 5 drops of SAE 20 oil in each of the two cups or oil tubes on the fan motor , See Fig . 30 , below . MOTOR OIL HOLES Oft Ius { S OR Oft CUPS ON EACH END OF MOIOR FAN MOIOR - - 25 - -
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How To Care For Your Furnace ( ton't ) BURNER CLEANING Check burner . If cleaning is required , contact a qualified service technician to clean and service burner . WARNING DANGER OF BODILY INJURY OR DEATH MAKE SURE ELECTRIC POWER AND GAS SUPPLY ARE OFF BEFORE REMOVING PANELS OR DOORS , ETC . SENSOR SLtGHT ORANGE TIP Disconnect Gas line inside cabinet . NATURAL GAS ELECTnODE TYPICAL Remove three screws from the front of the combustion - TYPICAL BLUE CONE , _ A / BLUE CONE [ L P GAS _ , _ ( _ l _ NATURAL chamber bottom panel and drop assembly down . Clean inside the combustion chamber and the burner with a shop type vacuum cleaner . To remove burners remove screw from end of burner and slide burner out of bracket ( may be necessary to slightly BURNER CASTING spring bracket ) . Inspect the Burner Box gasket . Replace if damaged . Replace burner assembly and control assembly by re - versing the above procedures . Furnace Technical Information * * RATING MODEL TYPE IN BTUH MAIN BURNER ORIFICE NUMBER GAS INPUT HTG . CAPAC . DRILL DEC . QTY . 4007332 NAT 40,000 32,000 # 34 . 1110 1 4007331 L . P . 40,000 32,000 # 50 . 0700 1 4007732 NAT 40,000 32,000 # 34 , 1110 1 4007731 L . P . 40,000 32,000 # 50 . 0700 1 5507332 NAT 55,000 44,000 # 42 . 0935 2 5507331 L . P . 55,000 44,000 # 54 . 0550 2 6257732 NAT 62,500 5O , 0OO # 39 . 0995 2 6257731 L . P . 62,500 50,000 # 53 . 0595 2 * * For elevations above 2000 feet reduce ratings 4 % for each 1000 feet above sea level . * * * Btuh = British Thermal Units per hour The efficiency rating of these appliances is a product thermal efficiency rating determined under continuous operating conditions and was determined independently of any installed system . - - 26 - -
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WIRING DIAGRAMS FOR MODELS 4007732 and 4007731 6257732 and 6257731 FOR 62.5M B . T . U . FOR 40M B . T . U . FAN TYPE DIRECT VENT WALL FURNACE FAN TYPE DIRECT VENT WALL FURNACE WITH CONTINUOUS PILOT CONTROL SYSTEM WITH CONTINUOUS PILOT CONTROL SYSTEM L1 _ _ 115v 60HZ , L2 HOT | Hf NEUT I UMIT SWITCH ' ( _ " I1RAN S . TOTHERMOSTAT _ [ _ GAS VALVE + _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ Gj - A - HSV _ W I L _ _ _ THERMOCOUPLE THERMOCOUPLE J _ ( ; IE3 _ D NOTE : LEGEND NOTE : m FACTC _ Y _ lINE _ OLTAGE , 1 Ifanyoftheoriginalwireassupplied m FACTORy _ UNE VOLTAGE . 1 . Ifanyoftheoriginalwiteassupplied - - FACTORY _ LOW VOLTAGF . . with the appliance has to be replac - - - FAI _ [ IO _ y _ LOW " YOLTAG _ * with the appliance has to be replac - 11 / _ 4 _ CONNECT " i _ MINAL ed , use only 18 Ga . , 4 / 64 insulation , 1 / 4 . QUICKCONNECT _ TMZNAL ed , use only 18Ga . , 4 / 64 insulation , FACI ' ( _ T " _ RING * 105 ° C . AWM copper wire or its f ' ( _ FAt _ O _ " _ R ] NG . 105 ° C AWM copper wire or ils _ tllRE CO _ CTOI _ F01t FAC _ I101 _ Y equivalent 115V - 60Hz - lessthan • f _ R £ CONNECTOR FOR FACTORY equivalent 115v - 60Hz - less than 3 amps WIRING LINE VOLTAGE . 3 ampsR _ NG LINE VOLTAGE . 2 MOTOR IS THERMALLY OVER - MOTO IS THERMALLY OVER - _ _ LOW V0LTAilI _ LOAD PROTECTED _ _ INAL LOW VOLTAGE . 2 . LOAD PROTECTED 115 % L60Hz - LESS THAN 3 AMPS 115V . 60Hz - LESS THAN 3 AMPS . 115V 60H7 . THERMOSTAT HIOT ] NEUT " THERMOSTAT f B _ CK A BLiU _ r BI . gE _ K'O _ F ( _ _ UMIT • 1 _ s _ Ta _ _ THERMC ¢ - . , ' _ N . IPLE L THERMOCOUPLE GAS VALVE G _ V _ - - 27 - -
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WIRING DIAGRAMS FOR MODELS 4007332 and 4007331 5507332 and 5507331 FOR 40M B . T . U . FOR 55M BT . U . FAN TYPE DIRECT VENT WALL FURNACE FAN TYPE DIRECT VENT WALL FURNACE WITH INTERMtTFENT IGNITION CONTROL SYSTEM WITH INTERMITI - ENT IGNITION CONTROL SYSTEM 1.1 | . 115V8ONZ . | L2 ul lu HOTi _ 115VS0HZ - I N _ . UT HOT ! S _ f ) R _ | NEUT L _ r _ 115V I I T . _ _ _ _ . _ _ T . - _ eJ . . . . , o ru _ LIMIT SWITCH . _ m , _ , a , SE _ ISOR GND _ O - - - / TR _ PV ( P ) TL s _ so _ ? - ioFv / _ ( vc ) " - - / SF _ NOS - PV , , 1W ( cV ) , - - PV Ol - - - . - ' r - lOIMV ( _ ) / PV O , Mv ( u ) THOl _ IF " cAs MV ( Z ) - _ - ' J I VALV _ ION _ _ _ - - IN'W _ RMII " TF _ NTIGN . INTERMII " R _ T IGN . CONTROLMODULE CONTROL MODULE NOTE : NOTE : LEGI0 _ ID _ L _ E _ FACTORY _ lINE VOLTA _ E , 1 . If any of the original wire as supplied 1 . If any of the original wire as supplied with the opp _ lence has to b _ replec * _ FACTORy _ RED LINE VOLTAQF - - - YA _ _ LOW VOLTAGE . with the appliance has to be replec - ed , use only 18 Ga . , 4 / 64 insulation , - - FACTQ _ qY _ LOWVOLTAGE . 1 / 4 QUICKCONNECT ed , use only 18 Ga . 4 / 64 insulation , 105 ° C . AWM copper w = re ot its FORF _ Y I - - 3 1 / 4 QUICKCON _ C'r TERM1NAL 105 = C AWM copper wire or ils equivalent 115V - 60Hz . - less than FOR FACTORYI _ NG . _ CONNECqORFOR FACTORY equivalent 115V - 60Hz - less Ihan 3 amps . tiRiNg MNE VOLTA _ . . WIRECONNECTORFOR FACTORY 3 amps 2 . MOTOR IS THERMALLY OVER - _ li _ lP - LINE V ( _ . TAaE , 2 , MOTOR IS THERMALLY OVER = ( d _ _ _ LOWVOLTAGE . LOAD PROTECTED . LOAD PROTECTED , _ _ INAL LOW VOLTAGE . 115M 60Hz - LESS THAN 3 AMPS 115V , 60Hz - LESS THAN 3 AMPS 115V 60HZ 31 " IERMOSTAT 115V 60HZ 1HERMOSTAT HOT I NEUT . HOT NEUT . _ . - c _ FAN - - 28 - -
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Troubleshooting Chart for Models 4007732 , 6257732 , 4007731 and 6257731 SYMPTOM CORRECTIVEACTION POSSIBLECAUSE ( S ) 1 . Pilotwill not staylit afterfollow - a . a . Thermocoupleproducinginsuffi - Checkpilot flame - - mustimpingeon thermocouple . ing lighting instructions . cientmillivoltage . Pilotflamemaybe lowor blowing ( high ) causingsafe - tytodropout . Pilotorificeoraeratingholemaybeplugg - ed ( checkforspiders , websorotherorganicmaterial ) . Besurethe thermocoupleis fullyinsertedinbracket . b . Loose or dirty thermocouple b . Cleanand / ortightenthermocouplefittingatconnection to valve connectionat gas valve . C , c . Thermocoupldeefective . Check thermocouplewith millivolt meter - - should generateapproximately30 millivoltswhen not con - nected to load . When connectedto load , should generateapproximatel1y4millivoltsi , f below7 millivolts , replace . d . Thermomagnept ilotsafety e . Replacegasvalveafteraboveis checkedout . defective . 2 . MainburnerwillnotcomeON - - a . Gas valveturnedOFE a . Turngasvalveknobto " ON " position - - if nomaingas pilotburningandthermostast et flow , proceedto Step . " b " . for heat . - Continued Next Page - - - 29 - -
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Troubleshooting Chart for Models 4007732 , 6257732 , 4007731 and 6257731 ( Continued ) CORRECTIVEACTION SYMPTOM POSSIBLECAUSE ( S ) 2 Mainburnerwill notcomeon - - b Electric powerto furnaceturned b . Checkfor linevoltageatfurnace - - if okayandnomain OFE gas flow , proceedto Step " c " . pilotburningandthermostatset for heat ( continued ) C . c . Low voltagetransformeror limit Checkfor 24volts at the lowvoltageterminalsof the switchdefective transformerI . f no voltage , turn OFFelectricpowerto furnace . Removeonewirefromlimitswitchandcheck for continuityacrossbothterminals . No continuity - - replacelimitswitch . Witha goodlimitswitchbackin the circuit andthe electric powerturnedON - - if no voltage , replacetransformerN . OTE : Beforereplacing thetransformeorrlimitswitch , checkwiringforlosecon - nectionsorbrokenwiresandrepairasneededI . fvoltage is presentat transformerp , roceedto Step " d " . d . Wallthermostatdefective . d . Withthermostatsetfor heat ( contactsclosed ) , check for voltageat terminalson gasvalve . If no voltageis present , replacedefectivethermostat . NOTE : Before replacingthermostatb , esureto checkwiringfromfur - nacetothermostaftorlooseconnectionosrbrokenwires andreplaceas needed . Ifvoltageis presentat terminalsongasvalveandstill no gas flowto mainburners , proceedto Step " e " . e . Burnerorificeplugged . e . Cleanor replaceorifice - - if okayandstillnogasflow to mainburners , proceedto Step " f " . f . Gas valvedefective . f . Replacedefectivegas valve . 3 . BurnercomesON , butgoesOFF a . Defectivewiring . a . Turnoff electricpowerto furnace . Removetop front beforeblowerturns ON . " panel , fan shroudand blowerwheel . Referto wiring diagram and check all wiring inside junction box . Removecenterfrontpanelandcheckall wiringinside switchbox containingfan , limitandselectorswitches . Correctif necessaryI . f correct , proceedto Step " b " . NOTES : electorswitchusedonlyonModels - - 5507331 , 55073326 , 2577316 , 257732 . b . Defectiveswitch . a . IfburnergoesOFFinlessthanfiveminutesfromroom temperaturestart , checklimitcontrolswitch . If defec - tive - - replace . NOTE : Blowershouldturn ON within 3 minutesafterburneris ONfromaroomtemperature start . If not , proceedto Step " c " . C . c . Defectivemotor ( 2 - speed ) Jumperacrossfanswitcht , urnelectricpowerON , motor shouldrotate . A2 - speedmotoris used - - jumperfrom " brown " terminalonfanswitchto # 2 ( red ) terminalon selectorswitch , motorshouldrotateon " LOW " speed . Jumperfromsame " brown " terminalon fanswitchto # 3 ( black ) terminalon selectorswitch , motorshould rotateon " HIGH " speed . Replacemotorif defective . d . Defectivemotor ( t - speed ) . d . Jumperacrossfanswitcht , urnelectripcowerON , motor shouldrotate . Replacemotorif defective . * Alsoapplicableto Models40073325 , 507332,4007331and5507331 . - Continued Next Page - - - 30 - -
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Troubleshooting Chart for Models 4007732 , 6257732 , 4007731 and 6257731 ( Continued ) CORRECTIVEACTION SYMPTOM POSSIBLECAUSE ( S ) e . Detectivfean switch . 3 . Burner comes ON , but goes e . If , after checking above possibilities , problem still OFF before blower turns ON exists , replacefan switch ( continued ) . 4 . BurnercomesON , blowercomes Furnacenotoperatingat full rate . Checkfor lowgas pressureat gasvalve - - shouldbe ON , but cycles ON and OFF 4 " W £ . fornaturagl as , 11 " W . Cf . orL . RG . Checkburner while burner remains ON . * orifice . 5 . BurnecromesON , blowercomes a . Furnaceoperatingover - rate . a . Checkfor highgas pressureat gasvalve - - correctif ON , but burnercyclesOFFand necessary . Seecorrectpressureabove . ON with blowerON . * b . Linevoltagetoo low . b . Checklinevoltageto motor ; if below115volts , motor will runtoo slow . c . Recirculation . I c . Heatedair dischargingagainstan objectcausingre - circulation , suchas a hallinstallationora largepiece of furniturewithin4 ' of discharge . a . Thermostatlocation . a . ChecklocatioonfthermostatI . tshouldnotbeinthepath 6 . FurnaceoperatesbutturnsOFF before room temperature is of warmairdischargefrom furnace , neara lamp , or attained . * abovea TV set orstereo . b . Defectivethermostat . b . Checkthermostactalibratioonr replace . 7 . Furnaceoperatesbut will not a , Thermostatwiringdefective . a Check thermostatwiringfrom furnaceto thermostat shut OFF whenroom temper - ( maybe shortedtogetherby a nail , or staple ) . atureis attained . * b . Thermostaltocation . b . Checkthermostalotcation - - if anoutsidewallorahole in wallbehindthermostatcausingcold airto contact thermostat - - relocate . c . Improper thermostat anticipator setting . c . SetanticipatoprerTHERMOSTAINTSTALLATIOpNa , ge 11 . a . Blowernoise . a . Check motormounts - - they maybe loose . Blower 8 . Abnormal noises * during operation . wheelcouldbeoutof balance . Setscrewmaybeloose on motorshaft . Blowermayberubbingonfanshroud . Motormayneedoiling . Correctas needed , b , Checkinstallation - - casingmaybetwistedornotlevel b . Expansionnoiseticking . wheninstalled . Expansionslip joint maybe binding ; checkbyremovingventcapassemblyfromoutsidewall . c . Selectosr witchdefective , C , Duringnormalfurnaceoperationm , otorwill be on " LOW " speedwhenoperatingon minimum input ( 2 - speedmotor ) capacitayndon " HIGH " speedwhenoperatingonmax - imuminput capacityI , f there is no changein motor speed , replaceselectosrwitch , 9 . Burnecr omesONbutgoesOFF Vent tube and air inlet tube in - Checkventtube andair inlet tube . Followinstallation afteroperatingfor no apparent properlyinstalled , instructions - - besurejointsaretightandbothtubes reason . * areinplace . Useonly tubesfurnished . Do notextend tubes beyondoriginallength . * Alsoapplicableto Models4 ( Y ) 73325 , 50T3324 , 007331and5,507331 . - Continued Next Page - - 31 - -
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Troubleshooting Chart for Models 4007332 , 5507332 , 4007331 and 5507331 NOTE : Before troubleshooting the intermittent pilot system , be sure thermostat is turned to highest setting , gas shut - off valve and gas valve knob are in the ON position , and electric power is turned ON the furnace . Follow all steps in sequence . A volt - ohm meter will be needed to satisfactorily determine if any components are malfunctioning . CORRECTIVEACTION SYMPTOM POSSIBLECAUSE ( S ) a . Nomainpower . a . - e . Perform normal system checks of main power , 1 . Nospark - - no pilot gas . transformer , thermostat , limit switch , and replace faulty component . b . Faultytransformer , WithpowerON , turnthermostattothelowestsetting , wait 10secondsandreturnto HIGHsetting . With powerONandthermostast etat itshighestposition , c . Faultythermostat . set voltmeterto 24V scale and attach probesto terminals " TR " and " TH " ontheignitioncontroul nit . Ifyouread24Vandthereisstillnosparkorpilotgas , d . Faultylimit switch . the ignitioncontroilsdefectiveandmustbereplaced . e . Faultyignitioncontrol . f . Faultywiring . f . Testwiring . Repairor replace . a . See1 . e . 2 . Spark - - but no pilot gas . a . Faultyignition . b . No gas suppliedto pilot valve . b . Checkfor availabilityof gas atgascontrol . Makesure the manualvalveupstreamof thegas controlandthe manualvalve ( gascock ) on the gascontrolarein the full ON position . No pilot gas couldbecausedby a pluggedpilottub - ing . Alsocheckthepilotadjustmenta , tthegascontrol . c . See2 . b . c . Manualvalvesin OFFpositions . d . See2b . d . Faultypilot valve . e . See t . f . e . Faultywiring . ' f . See2 . b . f . Restrictedpilotlineorcloggepdilot orifice . - - 32 - - - Continued Next Page -
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Troubleshooting Chart for Models 4007332 , 5507332 , 4007331 and 5507331 ( Continued ) CORRECTIVEACTION SYMPTOM POSSIBLECAUSE ( S ) a , a . Faultyignitioncontrol WithpowerON , turnthermostatto the lowestsetting , 3 . Pilot gas - - but no spark . wait10secondsandreturnto highsetting . Withpower ON and thermostatset at its highestposition , set voltmeterto 24Vscaleandattachprobesto terminals " TR " and " TH " ontheignitioncontrolunit . Ifyouread 24Vandthereis stillnosparkor pilotgas , the ignition controlis defectiveand mustbe replaced . Withthermostatturnedto its highestsetting , settest meterto 24V scale . Touchprobesto " C " and " P " terminalsonGasValveI . fyoudo notgeta 24Vreading , checkwiring , Ifwiringtestsokayc , heckignitioncontrol . b . Broken or shorted electrode b . Removewireat " COM " terminaal t the ignitioncon - assembly . trol , beingcarefulnotto touchanymetalparts ; discon - nectthe electrodewireattheignitioncontrol . Connect oneendofthejumperwireto termina " lGND " , ( DONOT REMOVEEXISTINGWIRE . A ) ttachtheotherendofthe jumperwireto the metalbladeof a smallscrewdriver . Positionendof metalbladeapprox , 1 / 8 " from " HIGH VOLTAGE ( " IGN ) terminalR . econnec " tCOM " terminal . Sparkingshouldocccurbetweenecrev , _ lrivbelradeand " HIGH VOLTAGEt " erminal . If no sparkingoccurs , the ignition controlmust be replaced . Checkthepilotandelectrodeassemblyforprobeer leo trode gap ( 3 / 32 " to 1 / 8 " ) or any possibleshortingof electrodetosurroundingmetasl urfacesM . akesurethe sparkignitorandelectrodeconnectionsto the ignition controlaretight . The ignitioncontrolandpilot burner mustbothbechassisground . If thereis stillno spark , the pilot and electrodeassemblymust be replaced . a . See3 . a . 4 . Pilotlit - - but mainburnerwon't a . Faultyignitioncontrol . comeon . b . See 1 . f , b . Faultywiring . C . NOTE : Waitatleast90secondasfterpilotlightsbefore c . Lowpilot flame . doingthecheckoutproceduresforproblemnumbe4r . WiththermostaOt N , be surethatthepilotandsensor areproperlyalignedso thatthe pilot flameimpinges thetop 5 / 8inchof thesensorB . esurethatthe sensor ispushedallthewayintopilotbracketA . djusptilotflame with pilot adjustment , if necessaryA . lsocheckinlet supply pressureand pilotorifice , If pilot hood or sensorisbent , thedefectiveunitshouldbereplaced . Ifmainburnerstillwon'ct omeON , makesurethemain burner orifices are clear . If orificesare clear , set voltmetetor 24Vscaleandtouchprobestotheterminals of the maingas operatoron the gasvalve ; Attachto terminal " M " , " C " onGasValve . If youread24 ' , / and theburnerwon'tturnON , replacetheentiregasvalve . - Continued Next Page - - - 33 - -
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Troubleshooting Chart for Models 4007332 , 5507332 , 4007331 and 5507331 SYMPTOM CORRECTIVEACTION POSSIBLE CAUSE ( S ) 4 . Pilotlit - - but mainburnerwon't d . WhenmainburnercomesON , ensurethatpilotflame d , Improperalignment of sensor in pilot flame . is strongs , ensorisproperlyaligneda , ndthatpilotflame comeON ( continued ) . impingesthetop5 / 8inchofthesensor ( Seeprocedures forcheckingforproperpilotflameandalignmenitnpro - blem4 . c . ) Checkthe pilotandelectrodeassemblyfor properelectrodegap ( 3 / 32 " to 1 / 8 " ) or any possible shortingof electrodeto surroundingmetalsurfaces . Makesurethe sparkignitorandelectrodeconnections tothe ignitioncontrolaretight . Theignitioncontroal nd pilot burnermustbothbe chassisground . If thereis still no spark , the pilotand electrodeassemblymust be replaced . e , e . Faultyflamesensor . BE SUREPOWERIS OFF , BEFOREPERFORMING THISTEST _ ! Settestmeterto " ohm " scaleorusecontinuictyheeke _ Touchoneendofprobestotipofflamesensort , heother to " SENS " terminalontheignitioncontrol . Ohmmeter shouldread " 0 " , continuityshouldbe evident . If you don'tobtainareading , removewiringfromsensorand testbothindividuallyI . fcontinuiitsynotevidentr , eplace wiringand / orsensor . Thereshouldbe NO continuitybetweensensorand " GND " terminalonthe ignitioncontrolT . estingwiringn andsensorindividuallyd , eterminewhichis shortedo ground . Replaceor repair . TurnON Power . 5 . PilotcyclesOFFandONbyitself , a . See2 . b . a . Faultypilotvalve . b . See l . f . b . Faultywiring . 6 . Mainburnershutsdownbefore a . See4 . C . a . Lowpilot flame . thermostatis satisfied . b . See4 . d . b . Improperalignmentof sensorin pilotflame . c . WhenmainburnercomesON , ensurethatthe pilot c . Pilotflamebeingdrownawayfrom sensor . flameisstrongandthe sensoirs properlyalignedand that the pilot flameimpingesthe top 5 / 8 inchof ltheot sensor . ( Seeproceduresfor checkingfor properpi flameandalignmenint problem4 . d . ) Ifthepilotflame is drawnawayfromthe sensorwhenthe omainburnert comesON , the causecouldbethemanualvalveis n in the full ON position . NOTE : Lowinletgas pressureto the gas controlcan be causedbyseverapl roblemsandis notwithinthe scopeoftheprocedureosutlinedinthisserviceguide . Consultyourlocalutilityor gassupplier . d . see 6 . c . d . Improperheatanticipatosretting . Checkthe settingof the heatanticipatoirn the wall thermostaSt , etitto settingspecifiedonthegasvalve , e . Faultylimit . e . Thesystemmaybecyclingona faultylimit . Usinga testmeters , ettothe110voltscalec , heckfor avoltagets readingacrossthe limitwhenthemainburnershu OFF . If yougeta 24 voltor110voltreadingonshut - down , replacedefectivelimit . - - 34 - - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE REPAIR PARTS FOR MODELS - - 4007332 , 4007331 , 4007732 and 4007731 CABINET and BODY ASSEMBLY % USE ONLY MANUFACTURER'S AUTHORIZED PARTS FOR PARTS LIST SEE PAGE 37 - - 35 - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE FOR CONTROL ASSEMBLY MODELS - 4007732 & 4007731 FOR PARTS LIST SEE PAGE 38 I USE ONLY MANUFACTURER'S AUTHORIZED PARTS I • ! WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE FOR CONTROL ASSEMBLY MODELS - 4007332 & 4007331 - - 36 - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE REPLACEMENT PARTS LIST FOR MODELS - - 4007332 , 4007732 , 4007331 and 4007731 PART NO . FOR MODEL : REF . 4007731 4007332 4007732 4007331 DESCRIPTION NO . 11C42 - 2 11 C42 - 2 11C42 - 2 11C42 - 2 1 Outer Casing with Air Pan 11C67 11C67 11C67 11C67 2 Heating Element 11C37 11C37 11C37 11C37 Element Tube 3 11B46 11B46 11B46 11B46 4 Inner Liner 11C63 11C63 11C63 11C63 Deflector Baffle Handle 5 11B86 11B86 11B86 11B86 6 Fan Shroud 11A40 11A40 11A40 11A40 7 Top Trim Cover 11B102 11B102 11B102 11B102 8 Top Front Panel 11C62 11C62 11C62 11C62 9 Center Front Panel 11B103 11B103 11B103 11B103 10 Bottom Front Panel 1tA103 11A103 11A103 11A103 Element Face Cover 11 P200300 P200300 P200300 P200300 12 Limit Switch P200200 P200200 P200200 P200200 13 Fan Switch F151101 P151101 P151101 P151101 14 Motor 7B46 7B46 7B46 7B46 15 Motor Support ( 2 Req . ) P024200 P024200 P024200 P024200 16 Transformer 17 Internal Wires ( Except Ignition Control Wires For Models 11A152 11A152 11A152 11A152 4007332 & 4007331 ) P022800 P022800 P022800 18 P022800 Vibration Mounts ( 4 Req . ) P200600 P200600 P200600 19 Fan Blade P200600 11B05 11B05 11B05 20 Switch Box 11B05 11C68 11C68 11C68 21 11C68 Switch Box Cover 12B40 12B40 11A18 23 11A18 Peep Hole Cover P200900 P200900 P200900 24 Element Face Gasket P200900 P151900 P151900 P151900 25 P151900 Air Pan Tunnel Gasket P103100 P103100 P103100 26 P103100 Seal Gasket tlC09 11C09 11C09 27 11C09 Vent Cap 11A97 11A97 11A97 28 11A07 Flue Extension - - 9801 Kit 11B49 11B49 11B49 29 Air Inlet Extension 11B49 4701 4701 4701 , _ 4701 , it 4701 Trim Strip Kit 3O * Inner Boot 6701 6701 6701 * Outer Boot - - 6701 Side Outlet Kit 10 " Boots 31 6701 32 * Plaster Ground 6702 6702 33 6702 6702 6702 Side Casing Grille Kit 6703 6703 34 6703 6703 * 6703 Diffusing Grille Kit - Two - Way 6704 6704 6704 6704 * 6704 Diffusing Grille Kit - One - Way P321020 P321020 34A Gasket , Burner Pan ( 2 Req . ) P321020 P321020 P321004 P321004 . _ P321004 P321004 Owner's Manual For paM illu _ ration see page 35 , * Not available separately , in kit form only NOTE : Screws and bolts are standard hardware items , available locally . Not shown . Continued - - 37 - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE REPLACEMENT PARTS LIST FOR MODELS ( Con't ) - - 4007332 , 4007732 , 4007331 and 4007731 PART NO . FOR MODEL : REF . NO . DESCRIPTION 4007332 4007732 4007331 4007731 35 Manifold 11S58 11B58 11B58 11B58 36 Manifold Gasket P151700 P151700 P151700 P151700 37 P090500 Orifice Fitting , Specify Model & Gas P090500 P090500 P090500 38 Burner , Cast Iron , Nat . or L . P . G . P025600 P025600 P025600 P025600 39 Locknut ( 2 Req . ) P026200 P026200 P026200 P026200 40 Burner Pan 11C64 - 2 11C64 - 2 11C04 - 2 11C64 - 2 41 m _ Valve , Williams Nat . P322041 Valve , Williams L . P . G , - - P322042 Valve , Williams Nat . P322043 Valve , Williams L . P . G . - - P322044 Pilot , Cast Iron Burner , L . P , G . 42 - - - - P229200 P229200 Pilot , Cast Iron Burner , Nat . P229100 P229100 43 Thermocouple - - P254000 P254000 Flame Sensor P271100 - - P271100 Pilot Tube Gasket 44 P151800 P151800 P151000 P151800 Pilot Tube Seal 45 11A41 11A41 11A41 11A41 Gasket 44 inch 46 P101600 P101600 P101600 P101600 Burner Spacer , Cast Iron Burner 47 P018100 P018100 P018100 P018100 Thermostat 48 P322017 P322017 P322017 P322017 49 Ignition Control Unit , Williams P321910 - - - - P321910 50 Piezo Gas Lighter ( Manual Spark Lighter ) - - P285500 P285500 Manifold Adapter 53 P321887 P321888 P321887 P321808 54 Ignition Shield 7C79 - - - - 7C79 Ignition Control Wires 31B036 - - - - 31 B036 Not available separately , in kit form only For pa _ illustration see page 36 . NOTE : Screws and bolts are standard hardware items , available locally . Not shown . - - 38 - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE FURNACE ASSEMBLY FOR MODELS - - 5507332 and 5507331 CABINET and BODY ASSEMBLY I FOR PARTS LIST SEE PAGE 41 USE ONLY MANUFACTURER'S AUTHORIZED PARTS - - 39 - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE FOR CONTROL ASSEMBLY MODELS - 6257732 & 6257731 FOR PARTS LIST SEE PAGE 42 USE ONLY MANUFACTURER'S " _ AUTHORIZED PARTS WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE FOR CONTROL ASSEMBLY MODELS - 5507332 & 5507331 s I . . . . J LAI07 - - _ 40 - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE REPLACEMENT PANTS LIST FOR MODELS - - 5507332 and 5507331 PART NO . FOR MODEL : REF . NO . DESCRIPTION 5507332 5507331 11C42 - 1 1 Outer Casing with Air Pan 11C42 - 1 2 Heating Element 11C66 11C66 3 Element Tube 11C37 11C37 Inner Liner 4 7B79 7B79 6 Deflector Baffle Handle 11C63 11C63 7 Fan Shroud 11B86 11B86 8 11A40 Top Trim Cover 11A40 9 11B102 11Bt02 Top Front Panel 10 Center Front Panel 11C59 11C59 11 Bottom Front Panel ttB103 11B103 12 Element Face Cover 11A103 11A103 13 Limit Switch P296001 P296001 14 Selector Switch P200400 P2OO400 15 Fan Switch P200200 P200200 16 Motor P062101 P062101 17 7B46 7B46 Motor Support ( 2 Req . ) 18 Transformer P024200 P024200 19 7A194 7A194 Internal Wires ( Except ignition control wires ) 20 P022800 P022800 Vibration Mounts ( 4 Req , ) 21 Fan Blade P200600 P200600 22 Switch Box 11B05 11B05 23 Switch Box Cover 11C68 11C68 25 Peep Hole Cover 12B40 12B40 26 Element Face Gasket P200900 P2O090O 27 Air Pan Tunnel Gasket P151900 P151900 28 Seal Gasket P103106 P103100 29 Vent Cap 11C09 11C09 30 Flue Extension - - 9801 Kit 11A97 11A97 31 Air Inlet Extension 11B49 11B49 4701 4701 * 4701 Trim Strip Kit 32 _ r Inner Boot 33 * Outer Boot - - 6701 Side Outlet Kit 6701 6701 34 * Plaster Ground 35 6702 6702 6702 Side Casing Grille Kit 36 6703 6703 6703 Diffusing Grille Kit - Two - Way 36 6704 6704 6704 Diffusing Grille Kit - One - Way 36A P321020 P321020 Gasket , Burner Pan ( 2 Req . ) Owner's Manual P321004 P321004 * Not available separately , in kit form only For part illustration see page 39 . NOTE : Screws and bolts are standard hardware items , available locally . _ r Not shown . Continued - - 41 - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE REPLACEMENT PARTS LIST FOR MODELS ( Con't ) - - 5507332 , 6257732 , 5507331 and 6257731 PART NO . FOR MODEL : RER NO , DESCRIPTION 5507332 6257732 5507331 6257731 11B57 37 Manifold 11B57 11B57 t1B57 P151700 P151700 P151700 38 Manifold Gasket P151700 P090500 P090500 P090500 39 P090500 Orifice Fitting , Specify Model & Gas P025600 P025600 P025600 P025600 40 Burner , Cast Iron , Nat . or L . P . G , ( 2 req . ) P026200 P026200 P026200 P026200 41 Locknut ( 2 Req ) 11C64 - 1 11C64 - 1 11C64 - 1 11C64 - 1 42 Burner Pan P322041 43 Valve , Williams Nat . - - P322042 Valve , Williams L . P . G . 43 P322043 Valve , Williams Nat . P322044 Valve , Williams L . P . G P229200 P229200 44 Pilot , Cast Iron Burner , L . P . G . P229100 P229100 Pilot , Cast Iron Burner , Nat 45 P254000 Thermocouple - - P254000 Flame Sensor P271100 P271100 46 Pilot Tube Gasket P151800 P151800 P151800 P151800 47 Pilot Tube Seal 11A41 11A41 11A41 11A41 48 Gasket 44 inch P101600 P101600 P101600 P101600 49 P018100 P018100 P018100 P018100 Burner Spacer , Cast Iron Burner 50 Thermostat P322017 P322017 P322017 P322017 51 P321910 P321910 Ignition Control Unit , Williams 53 P285500 - - P285500 Piezo Gas Lighter ( Manual Spark Lighter ) 56 P321887 P321688 P321887 P321866 Manifold Adapter 57 7C79 7C79 Ignition Shield 31B036 31B036 Ignition Control Wires , * Not available separately , in kit form only For pad illustr _ ion see page 40 . NOTE : Screws and bolts are standard hardware items , available locally . _ r Not shown . - - 42 - -
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WILLIAMS DIRECT VENT GAS - FIRED WALL FURNACE FURNACE ASSEMBLY FOR MODELS - - 6257732 and 6257731 CABINET and BODY ASSEMBLY FOR PARTS LIST SEE PAGE 44 USE ONLY MANUFACTURER'S AUTHORIZED PARTS - - 43 - -
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WILLIAMS DIRECT VENT WALL FURNACE REPLACEMENT PARTS LIST FOR MODELS - 6257732 and 6257731 REF . PART NO . FOR MODEL : NO . DESCRIPTION 6257732 6257731 1 11C42 - 1 OUTER CASING W / . AIR PAN 11C42 - 1 2 AIR PAN TUNNEL GASKET P151900 P151900 3 INNER LINER 11B120 11B120 4 HEATING ELEMENT 11C66 11C66 5 PEEPHOLE COVER 12B40 12B40 6 P521020 BURNER PAN GASKET ( 2 RE ( ; } . ) P321020 7 BOTTOM FRONT PANEL 11B103 11B105 8 CENTER FRONT PANEL 11C59 11C59 9 BOTTOM AIR DEFLECTOR 11B125 11B125 10 CENTER AIR DEFLECTOR 11Bl19 11Bl19 11 SELECTOR SWITCH P20O40O P200400 12 FAN SWITCH P200200 P200200 13 SWITCH BOX COVER 11C68 11C68 14 SWITCH BOX 11B05 11B05 15 SEAL GASKET P105100 P103100 16 ELEMENT BAFFLE 11Bl16 11Bl16 17 LIMIT SWITCH P521942 P521942 18 TOP AIR DEFLECTOR 11Bl19 11Bl19 19 TOP FRONT PANEL 11B102 11B102 20 FAN SHROUD 11B86 11B86 21 ELEMENT FACE GASKET P304000 P504000 22 FAN BLADE P200600 P200600 23 MOTOR P321601 P321601 24 MOTOR SUPPORT ( 2 REQ . ) 7B46 7B46 25 P022800 VIBRATION MOUNTS ( 4 REQ . ) P022800 26 TRANSFORMER P024200 P024200 27 INTERNAL WIRES 6257752 6257751 28 ELEMENT TUBE 11C57 11C37 TOP TRIM COVER 29 11A40 11A40 3O VENT CAP 11C09 11C09 31 FLUE EXTENSION - 9801 KIT 11A97 11A97 32 AIR INLET EXTENSION 11B49 11B49 53 _ " INNER BOOT _ ' OUTER BOOT 6701 SIDE 34 6701 6701 PLASTERGROUND OUTLET KIT 35 56 " _ 6702 SIDE CASING GRILLE KIT 6702 6702 37 _ ' 6705 DIFFUSING GRILLE KIT - 2 WAY 6705 6703 37A _ ' 6704 DIFFUSING GRILLE KIT - 1 WAY 6704 6704 _ ' 4701 TRIM STRIP KIT ( NOT SHOWN ) 4701 4701 see page 45 _ " Not available separately , in kit form only . For parts Illustration NOTE : Screws and bolts are standard hardware Items , available locally . - - 44 - -
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Service Record DATE MAINTENANCE PERFORMED COMPONENTS REQUIRED . - - 45 m
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- - Notes - - - - 46 - -
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- - Notes - -
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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 owners Do not store or use gasoline If you smell gas : manual or other flammable vapors and 1 . Open windows . 2 . Don't touch electrical . liquids in the vicinity of this or any 3 . Extinguish any open flame . other appliance . 4 . Immediately call your gas supplier . SERVICE POSSIBLE CAUSE WHAT TO DO If fan motor is noisy - - MODEL NOS . Housing rattling . Tighten screws . 4007332 Clean fan blade . Fan dirty . Fan blade bent . Replace fan blade . 4007732 Oil motor . Motor bearings need oiling . 5507332 If fan does not run - 6257732 Replace fuse or reset breaker . Fuse blown or tripped circuit 4007331 breaker . Oil motor . Motor bearings need oiling . 4007731 5507331 If burner is noisy - - Pilot observation door loose or Tighten wingnut or replace 6257731 door . missing . ( peep hole cover ) If your furnace is not heating or not giving enough heat - - Fuse blown or tripped circuit Replace fuse or reset breaker , breaker . Reset thermostat to desired Thermostat is not set correctly . setting . Air flow restricted . Check that doors , drapes or furniture are not blocking furnace louvers . If your furnace short cycles - - Set anticipator ( See Page 11 ) . Thermostat anticipator not set correctly . If your furnace pops and cracks - - Heat exchanger expansion and Normal condition , especially contraction , with newer furnaces . See troubleshooting section for more detailed information . Illustrations are representative only . Specifications are subject to change without notice . 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 . DATECODE found on the rating plate near gas valve , inside control 3 . PART NUMBER 4 . PART DESCRIPTION compartment . WILLIAMS FURNACE COMPANY MANUFACTURED IN THE U . S . A . 225 Acacia Street Established 1916 Colton , CA 92324 USA FAX : ( 909 ) 824 - 8009 ( 909 ) 825 - 0993 © 1998 The Williams Furnace Company Printed in U . S . A . Rev . 12 / 98 P321004