WILLIAMS Furnace/Heater, Gas Manual L0408178

User Manual: WILLIAMS WILLIAMS Furnace/Heater, Gas Manual WILLIAMS Furnace/Heater, Gas Owner's Manual, WILLIAMS Furnace/Heater, Gas installation guides

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INSTALLATION & OPERATING

INSTRUCTION MANUAL

owners

manual

MODEL NOS.

4007332

4007732

5507332

6257732

FOR USE WITH

NATURAL GAS ONLY

MODEL NOS.

4007331

4007731

5507331

6257731

FOR USE WITH

LIQUEFIED

PETROLEUM (L.P.)

GAS ONLY

Save This Manual For

Future Reference.

COUNTERFLOW DIRECT VENT

GAS WALL FURNACES

READ THIS OWNERS MANUAL

CAREFULLY BEFORE YOU INSTALL

YOUR NEW WILLIAMS WALL FURNACE

WARNING: If the information in this

manual is not followed exactly, a fire or ex-

plosion may result causing property

damage, personal injury or loss of life.

-- Do not store or use gasoline or other

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

not use any phone in your building.

• Extinguish any open flame.

• Immediately call your gas supplier

from a neighbor's phone. Follow the

gas supplier's instructions.

• If you cannot reach your gas supplier,

call the fire department.

Installation and service must be per-

formed by a qualified installer, service

agency or the gas supplier.

WARNING: Improper installation, adjust-

ment, alteration, service or maintenance

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

Contents

Your Williams Warranty ......................... 2

Introduction .................................. 3

Basic Description .............................. 3

Optional Accessories ........................... 3

Helpful Installation Information ................... 3

Safety Rules ................................. 4

Unpack Your Furnace .......................... 5

Basic Tools Needed ............................ 5

Basic Materials ............................... 5

Installing Your Wall Furnace ..................... 6

Locating Wall Furnace and Thermostat .......... 6-7

Recessed Mount Installation ................. 7-9

Surface Mount installation .................. 9-10

Thermostat Installation ..................... 11-12

Vent Installation .......................... 12-13

Mounting Your Furnace ..................... 14-15

Gas Supply and Piping ...................... 15-16

Electrical Wiring ............................. 17

Start Up Procedure ........................... 18

Operating Your Furnace ..................... 19-24

How To Care For Your Furnace ............... 25-26

Furnace Technical Information .................. 26

Wiring Diagrams ........................... 27-28

TROUBLESHOOTING CHART ............... 29-34

Repair Parts .............................. 35-44

SERVICE HINTS ...................... Back Cover

How To Order Repair Parts ............. Back Cover

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

1Any 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 alike 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 aqualified 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.

Orig. Purchaser_

Address

Serial No.

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

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

against an exterior wall not exceeding 12" in thickness.

Furnace may also be recessed up to 10" in a wall with

studs spaced 16" center-to-center.

Always consult your local heating or plumbing inspector,

building department or gas utility company regarding

regulations, codes or ordinaces which apply to the installa-

tion of a direct vent furnace.

Air is drawn in at the top by the fan and discharged through

a grille near the floor. A two-speed fan is used with Models

5507332, 6257732, 5507331, and 6257731. A single speed

fan is used on all other models. The furnace contains a

multi-slot burner (two on Models 5507332, 6257732,

5507331, and 6257731) and burns either natural or L.R (li-

quefied petroleum) gas, depending on the model you have

purchased.

The sealed combustion system draws combustion air

directly from outdoors into the combustion chamber and

combustion gases are discharged directly to the outdoors

through tubes mounted to the rear of the furnace.

The furnace heat exchanger is built of heavy gauge steel

treated for corrosion resistance. The fan at the top forces

air down along the front, back and sides of the heat ex-

changer where it is discharged into the room. The furnace

cabinet is also constructed of heavy gauge steel and has

a enamel paint finish.

The furnace controls are located behind an access door

on the lower front of the furnace. All models are equipped

with American Gas Association listed gas valves and pilots.

Models 4007332, 4007331, 5507332, and 5507331 are

equipped with an electric ignition automatic pilot relight

system.

Optional Accessories

Side Outlet Grille Kit 6701

Lets you route some heated air to a second room. Mounts

on side wall of second room and must be within 10 inches

of wall furnace. See pages 7 & 10.

Diffuser Grille Kit 6703 or 6704

Lets you route some heated air in a two-way direction. Kit

6704 for one-way direction.

NOTE

Kits are identified on the carton by manufacturing

number 6701, 6702, 6703 and 6704 are also listed on

the furnace rating plate.

Side Grille Kit 6702

Lets you route some heated air to side of furnace in the

same room. See pages 7 & 10.

Trim Strip Kit 4701

Provides finished edge at side of wall furnace. Neutral

beige enamel steel.

Replacement Vent Cap Assembly 9801

Should for any reason your vent cap becomes damaged

and its operation impaired, replace it immediately.

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--

Safety Rules

WARNING

READ THESE RULES AND THE INSTRUCTIONS

CAREFULLY. FAILURE TO FOLLOW THESE

RULES AND INSTRUCTIONS COULD CAUSE A

MALFUNCTION OF THE FURNACE. THIS COULD

RESULT IN DEATH, SERIOUS BODILY INJURY,

AND/OR PROPERTY DAMAGE.

umn. The maximum inlet gas supply pressure is 13"

water column.

ANY SAFETY SCREEN, GUARD OR PARTS RE-

MOVED FOR SERVICING AN APPLIANCE MUST BE

REPLACED PRIOR TO OPERATING THE AP-

PLIANCE TO AVOID PROPERTY DAMAGE, BODILY

INJURY OR DEATH.

INSTALLATION MUST CONFORM TO LOCAL CODES. IN

THE ABSENCE OF LOCAL CODES, INSTALLATION

MUST CONFORM WITH THE NATIONAL FUEL GAS

CODE, ANSI Z223.1. THE APPLIANCE, WHEN IN-

STALLED, MUST BE ELECTRICALLY CONNECTED AND

GROUNDED IN ACCORDANCE WITH LOCAL CODES

OR, IN THE ABSENCE OF LOCAL CODES, WITH THE

CURRENT NATIONAL ELECTRICAL CODE ANSI/NFPA

NO. 70.

IN CANADA

1. INSTALLATION MUST CONFORM TO LOCAL

CODES OR, IN THE ABSENCE OF LOCAL

CODES, THE CURRENT CAN/CGA B149 IN-

STALLATION CODE.

2. THE APPLIANCE, WHEN INSTALLED, MUST BE

ELECTRICALLY CONNECTED AND GROUND-

ED IN ACCORDANCE WITH LOCAL CODES OR,

IN THE ABSENCE OF LOCAL CODES, WITH

THE CURRENT CSA C22.1 CANADIAN ELEC-

TRICAL CODE.

3. REFERENCE IS MADE IN THIS MANUAL

REGARDING GAS TYPE AS LP. BE ADVISED

THAT L.R IS NOT AVAILABLE IN CANADA,

REFER TO PROPANEIL.P. GAS.

1. USE ONLY MANUFACTURER'S REPLACEMENT

PARTS. USE OF ANY OTHER PARTS COULD CAUSE

INJURY OR DEATH.

2. DO NOT install this furnace in an alcove.

3. DO NOT install these furnaces in a travel trailer,

recreational vehicle or mobile home.

4. MAINTAIN all clearances specified in section

"Locating Wall Furnace and Thermostat" and "Vent

Installation."

5, BE SURE furnace is for type of gas to be used. Check

the rating plate by the gas valve in the lower cabinet.

Do not change it to use other gases. Unsafe opera-

tion could result and could cause bodily injury and

death.

6. For Natural gas, the minimum inlet gas supply

pressure for the purpose of input adjustment is 5" col-

umn. The maximum inlet gas supply pressure is 7"

water column.

For L.R gas, the minimum inlet gas supply pressure

for the purpose of input adjustment is 11" water col-

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

INSTALL the furnace vent directly to the outdoors, us-

ing the vent assembly supplied with the furnace, so

that harmful gases will not collect inside the building.

PROVIDE FOR ADEQUATE COMBUSTION AIR around

vent cap on outside, see Fig. 2, pg. 6 and adequate

air circulation around cabinet inside the open room.

NEVER vent flue gases into another room, a fireplace

or any space inside a building. This could cause pro-

perty damage, bodily injury or death.

NEVER test for gas leaks with an open flame. Use

soap suds to check all gas connections. This will avoid

the possibility of fire or explosion.

ALLOW furnace to cool before servicing. Always shut

off electricity and gas to furnace when working on it.

This will prevent any electrical shocks or burns.

DUE TO HIGH TEMPERATURES, locate the furnace

out of traffic and away from furniture and draperies.

ALERT children and adults to the hazards of high sur-

face temperature and to keep away to avoid burns or

clothing ignition.

CAREFULLY supervise young children when they are

in the same room with the furnace.

DO NOT place clothing or other flammable material

on or near furnace.

INSTALLATION and REPAIR must be done by a

qualified service person. The appliance should be in-

spected before use and at least annually by a profes-

sional service person. More frequent cleaning may be

required due to excessive lint from carpeting, bedding

material, etc. It is imperative that control compart-

ments, burners and circulating air passages be kept

clean.

BEFORE INSTALLING: To avoid electrical shock, turn

off electrical circuits that pass through the wall where

you are going to install the furnace.

BE AWARE of good safety practices by wearing per-

sonal protective equipment such as gloves and safe-

ty glasses to avoid being injured by sharp metal edges

in or around furnace and while cutting or drilling holes

in wood and or sheet metal.

CAUTION: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper

and dangerous operation. Verify proper operation after

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---

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.

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.

NOTE

The fan blade must be removed in order to remove

cardboard shipping brace located under motor.

7. Before removing the fan blade, remember its position

by examining the blade nut and the amount of shaft

visible. Scribe or mark the motor shaft in order to

reinstall the fan blade to its original place on the shaft.

BoTmU FROHT PAHEL-

8. Loosen 1/8" "allen head" set screw holding fan blade

to motor shaft and remove the fan. Place fan blade

and fan shroud where they will not be damaged.

9. Remove cardboard shipping brace located under

motor mounting brackets.

10. Future electrical connections will be made in this

upper cabinet area, inside electrical junction box,

behind transformer.

11. Properly dispose of shipping materials.

Basic Tools Needed

Hand drill or properly grounded electric drill.

Expansion bit 1/2" to 1-5/8" or 1/2" and 11/2'' Blade bits

1/8" and 3/16" drill bit (metal)

6 ft. folding rule or tape measure

Screwdriver (reed. blade) and (Phillips head)

Pliers (wire cutting)

Hammer

1/8" Allen wrench

Stud Locator or small finish nails

Tin Snips

8" adjustable wrench

12" adjustable wrench

Key hole saw or Sabre saw

Hack saw

2 - 10" or 12" pipe wrenches

Gloves and safety glasses

Basic Materials

Pipe and fittings to make connections to furnace. (Page

16).

Caulking Compound -Silicone Rubber with a temperature

rating of 500OF.

DO NOT USE types advertised as paintable or for bath

tub use as most contain fillers and will not withstand high

temperatures.

Electrical wiring supplies as needed (See Page 17).

Minimum wire size is #14 gauge copper.

3/4" Quarter Round or other wood trim molding approx.

16' long or Trim accessory 4701.

2" x 4" x (length as required) Spacer Block (See Page 8).

1 x 1 wood strips if Optional Side Outlet Grille Kit 6701 is

used.

Pipe Joint Compound resistant to L.P. gases.

m5--

Installing Your Wall Furnace

The following steps are needed for proper installation and

safe operation of your furnace. If you have any doubts as

to any requirements, check with local authorities for local

and state codes affecting the installation

Obtain professional help where needed.

DO NOT install these furnaces in a travel trailer, recrea-

tional vehicle or mobile home.

IMPORTANT

For satisfactory and trouble-free operation, be sure to:

1. Properly locate the furnace within the space to be

heated.

2. Provide for adequate combustion air around vent cap

on outside, see Fig. 2 and adequate air circulation

around cabinet inside the open room.

3. Maintain minimum clearance: Floor 0" or ceiling 4",

side wall 4". For exception to minimum side wall

clearance, see Figs. 4, 5 & 6, pg. 7.

Locating Wall Furnace & Thermostat

Consider the following points before attempting to install

the furnace:

1. This is a direct vent wall furnace. It must be installed

on an OUTSIDE WALL for proper venting of flue gases

(Fig. 2).

a. Wall furnace can be surface mounted on an outside

wall. (Surface Mount)

b. Ideally, the wall should be the least windy side of the

dwelling, as strong gusts may extinguish the pilot.

c. Furnace may be installed flush against a wall or

recessed up to 10" maximum. Wall thickness from

back surface of furnace to outside of wall can be 3/4"

minimum to 12" maximum. See Fig. 3, pg. 7.

With standard furnace discharge outlet, do not install

closer than 4" to intersecting wall. See Fig. 4, pg. 7.

MINIMUM DIMENSIONS FROM VENT

d. If wall has a brick, block or other facing at least

3/4-inch thick, the furnace can be mounted so it is

recessed into the waft between standard 2 x 4 wall

studs.

Studs must be spaced on 16 inch centers or stud space

will have to be framed in. See pg. 7, Recessed Mounting.

2. The top of the furnace must be at least 4 inches from

the ceiling.

3. Check the clearances needed from the furnace and

vent (Fig. 2 and Fig. 4, pg. 7). You must place the fur-

nace where you will have no less than the clearances

shown. See Fig. 5 & 6, Page 7.

4. When using optional kits 6703 or 6704, maintain the

clearances as shown in Figs. 5 & 6, pg. 7.

5. When using optional kit 6701, maintain clearance as

shown in Fig. 4, pg. 7. Use only optional outlet and

grille kits available from manufacturer.

6. The outside vent cap must be at least 18 inches away

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 awood

or concrete floor. If floor is other than wood or con-

crete, such as carpet or sheet vinylflooring, there must

be a piece of wood or sheet metal under the furnace

that is at least the same size as the bottom of the

furnace.

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--

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

above the floor on an inside wall. The thermostat wire

supplied with your furnace is 20 feet long, which

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

line, or about 8 feet from the furnace if the wire is run

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:

Concealed pipes

or ducts

Fireplaces

Registers

TV sets

Radios

Lamps

Direct sunlight

Kitchen

COLD SPOTS:

Concealed pipes

or ducts

Stairwells-drafts

Doors-drafts

Unheated rooms on

other side of wall

DEAD SPOTS:

Behind doors

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-

tion. If required, move them or pick a new location.

r-- -- -- _ VENT CAP

12 M Ii _b

_i /I[_" OUTLET

°U:L oT 6,Ol--

¢_.-,,_ VENT CAP

12 MAX I = I

7/%\

12" MIN WHEN OPTIONAL 6703

TWO-WAY FRONT DIFFUSING GRILLE IS USED

t'- -- -- _ VENT CAP

J1 I

'_ 3/4" MIN ',i ':1 I

_10" MAX

[_-A I:x_RECESSEDINSTALLATION CLEARANCE NOTE "-'--1

rflon of the furnace that is recessed into a wall up to {

I 10' maximum recess may have (0) zero inch clearance to I

Icombustibles. (See Fig. 3). All other clearances for the I

[ unrecessed portion must be observed. J

6702

_18 MIN -_

_VENT CAP

OPTIONAL

OUTLET

6702

Recessed Mount Installation

FIND THE STUDS

Use a stud Iocatoror small finishing nails. Repeatedly drive

and remove a nail into the wall in the area of the stud until

you find it. Then find one side. Leave the nail there. Drive

another nail just on the other side of the same stud.

Inside edge of the other stud should be about 141/2inches

from the one found. Drive finishing nail on inside edge of

this stud.

INOTE

IF STUDS ARE NOT ON 16 INCH CENTERS, SEE

CLOSE OFF STUD SPACE, PAGE 8.

CUT WALL OPENING

1. Lay out the required opening to be cut in inside wall

(Fig. 7, pg. 8). Mark center of the vent hole on wall.

Using a window, door or wall corner for reference,

measure to find where vent will be on outside wall.

Check to be sure clearances (Fig. 2, Fig. 4, Fig. 5 and

Fig. 6) will be right.

2. Drill a1/4inch hole through vent hole center to the out-

side wall to mark vent location.

3. Make the required cutout in inside wall. (Fig. 7, pg. 8)

--7--

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

breaking through brick, stone or tile. (See Fig. 7).

5. In new stud wall construction, install blocks as shown

in Figure 7 and install plaster grounds around inside

of wall opening.

6. The vertical height of the opening shown is 3 inches

greater than height of furnace to allow space for

connection of wiring after furnace is installed.

NOTE

VERTICAL MEASUREMENTS ARE FROM

FINISHED FLOOR. (Fig. 7)

ELECTRICAL

CONDUIT

91/4, DIA HOLE

THROUGH EXTERIOR

WALL \

68vz°(1)

59"(2i

90 (1)

80_.4,"(2)

BLOCKS

1"x3"

FLOOR

r, .... _ q

WALL OPENING FOR RECESSED INSTALLATION

(1) MODELS

5507332. 5507331, 6257732, AND 6257731

(2) MODELS

4007332, 4007331, 4007732. AND 4007731

CLOSE OFF STUD SPACE (If Required)

If studs are not on 16 inch centers, cut the hole for the

furnace next to an existingstudand frame in the other side

using a2 x 4 and spacer blocks as required. Fig. 8.

If the distance from the top of the cutout to the ceiling wall

plate is more than 18 inches, it is recommended that it be

closed off.

Nail a 2 x 4 long enough to go between the studs at the

top of the opening to close off the stud space.

CEJUNC --F}

PLATE 1

2×'_ BAC_KING J_l

IF _O_E ]HAN /

18" Bg-_t_EH

TOP OF CUTOUT

AND C_3UNG PLJ_TE

9-1/4" DIA.

HOLE CUTOUT I

EC_qS]]NG STUD _

FLOOR pLATE

ELECTRIC CONNECTION IN TOP

--I --GASINLE''NOOTTO

(1) MODELS

VENT & AIR

BACK

-3V2"

GAS

INLET

SIDE

J__

_.-_ 141/a"

5507332, 5507331, 6257732, AND 6257731

(2) MODELS

4007332, 4(307331, 4007732, AND 4007731

--_787" (1)

7z/e" (2)

;81/2" (1)

s9"(2)

_-- FINISH

FLOOR

--8--

Recessed Mount Installation (Con't)

GAS AND ELECTRICAL SUPPLY OPENINGS

Holes must be drilled for the gas line and electrical sup-

ply. Holes must be located from each side of furnace as

shown in Fig. 9, pg, 8.

Decide whether the gas line will come through the floor

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

is mounted, see section: Gas Supply and Piping, pg. 15.

The electrical supply opening should be at the upper left

of the furnace, to match openings shown in Fig. 9, pg. 8.

Mark ceiling wail plate and drill holes. If not practical to

run wiring from the attic, drill holes through wall stud and

run wires up through adjoining stud space from crawl

space or basement.

Run the electrical supply with ground wire and thermostat

cable to the openings. Leave enough length to connect

in the junction box after the furnace is installed. See

section "Electrical Wiring," page 17.

CAUTION

Do not run wire in any location where it might be

damaged. Avoid splicing thermostat wire unless

the spliced wires are properly cleaned, soldered,

and taped.

Offset Wall Installation

To mount the wall furnace on an offset wall, the area

behind the furnace must be made flush or flat.

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.

Use sheet rock or paneling etc. to finish area.

Follow procedures under Surface Mount Installation.

Surface Mount Installation

FIND THE STUDS

1. Find two studs at spot where furnace is to be placed.

Use a stud Iocator or small finishing nails. Repeatedly

drive and remove a nail into the wall in the area of the

stud until you find it. Then find one side. Leave the nail

there. Drive another nail just on the other side of the

same stud.

2. Inside edge of the other stud should be about 141/2

inches from the one found, Drive finishing nail on in-

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)

2. Drill a 1/,-inch hole through vent hole center to the out-

side. Cut the 91/,-inch diameter hole through inside

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

the outside, especially when breaking through brick,

stone or tile.

GAS AND ELECTRICAL SUPPLY OPENINGS

Holes must be drilled for the gas line and electrical

supply. Holes must be located from each side of furnace

as shown in Fig. 9, pg. 8.

Drill a 11/2-inchhole in floor or wall for gas line.

Gas line can be run at this time or done after furnace is

mounted, see section: Gas Supply and Piping, pg. 15.

Mark ceiling or wall to match wall furnace openings and

drill a 1-inch hole for the power supply and a 1/2-inch hole

for the thermostat cable. Run the electrical supply and

ground wires to the opening. Leave enough length to

connect in the junction box after the furnace is installed.

See section "Electrical Wiring," pg. 17.

WALL OPENING (SURFACE MOUNT)

_OF9t/_ DIA HOLE

& FURNACE

68_ (1)

59 (2)

1/_

(1) MODELS

5507332, 5507331, 6257732, AND 6257731

(2) MODELS

4007332. 4007331, 4007732, AND 4(X)7731

--9--

Surface Mount Installation (Con't)

ROUGH-IN OPTIONAL SIDE OUTLET NO. 6701

Install plasterground as shown in Figs. 11 & 12. Flanges

of plasterground extend the thickness of normal piaster.

If "dry-wall" or other thin material, flanges must be

trimmed off flush with wall surface.

Follow measurements given carefully, and note that when

a side outlet is used, the furnace casing must be exactly

4 inches from surface of adjacent wall except minimum

clearance may be 3/4-inch when optional 1-way Diffusing

Grille Kit 6704 is used.

5. Fasten metal filler strips to side of furnace casing with

front surface exactly opposite front of wood backup

strip.

6. After furnace is placed in position, pass outer boot

through plasterground tight against furnace casing.

Then mark and cut off outer end flush with wall surface.

Press inner boot against liner, mark and cut off flush

with wall surface. Installouter boot first, then inner boot,

fastening through all holes with screws provided.

_.-1H 8

SIDE PLASTER GROUND CENTERS EXACTLY

6 FROM RACK OF THE HEATER

i_e]ll ilP,;i

,It" PLASTER

•,, _ GROUND

15]_

FINISH

FLOOR

MOUNTING OPTIONAL SIDE OUTLET GRILLE KIT NO.

6701

Refer to Fig. 13.

1. Before setting furnace into position, cut 5 x 7rec-

tangular opening in furnace outer casing where

marked. See Fig. 9, pg. 8.

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.

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.

VENT CAP

F ......

R' STR''I,!,

KIT 6701 METAL FILLER .-J

OPTIONAL 2-WAY DIFFUSING GRILLE KIT NO. 6703

Refer to Fig. 14.

CAUTION

For use only in conjuction with a front outlet when

the furnace is spaced at least 12 inches from an

intersecting wall (see Fig. 5, pg. 7).

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

screws.

1-WAY FRONT DIFFUSING GRILLE KIT NO. 6704

Followinstructions for 2-WAYFRONT DIFFUSING GRILLE

6703 ABOVE, except furnace clearance to an adjacent wall

may be 3/4-inch minimum.

CAUTION

Use only optional kits available from the

manufacturer.

LOWER DOOR CASING

OPTIONAL TWO-WAY DIFFUSING GRILLE 6703

--10--

Thermostat Installation

1. If an old thermostat is being replaced and is in a

satisfactory location and the wiring appears to be

in good condition, use existing wiring. If in doubt, use

new wire.

2. If a new location is chosen or if this is a new installa-

tion, thermostat cable must first be run to the location

selected. All wiring must agree with local codes and

ordinances. These instructions cover bringing the wire

down from the attic but it can be run from a basement

or crawl space using similar methods.

3. Before drilling hole in wall at selected location, drive

a small finishing nail through the ceiling in the corner

of the wall and ceiling above the thermostat location.

Pull the nail out and push a small stiff wire through the

hole so it can be found in the attic. Drill a 1/2-inchhole

through the ceiling wall plate.

4. Probe for obstructions in the partition. Then drill a

1/2-inch hole through wall at selected location for

thermostat.

5. From the attic, feed the thermostat cable or a stiff wire

through wall until even with thermostat location.

6. Snag thermostat cable through hole and pull cable

through hole in wall so that 6 inches of cable protrudes.

7. Route cable to wall furnace.

ROUTE THERMOSTAT CABLE

SMAtL

FINISH

NAIL 10

tOCAT{

H[AD[_

MOUNTING THE THERMOSTAT

1. To remove thermostat cover, squeeze cover and pull

straight outward (see Fig. 27, page 18). Carefully

remove and discard the packing tab protecting the

switch contacts.

2. Connect thermostat wires to the terminal screws on the

thermostat base. Make sure wiring does not interfere

with thermostat operation.

3. Push any excess wire back through hole in wall and

plug hole with insulation to prevent drafts from affect-

ing thermostat operation.

4. Being sure to level thermostat for best appearance,

fasten thermostat base to wall through mounting holes

with screws provided.

5. Replace the thermostat cover.

THERMOSTAT HEAT ANTICIPATOR

SET THE THERMOSTAT HEAT ANTICIPATOR

A simple method of setting.the heat anticipator in a 24-volt

thermostat (without an A.C. ammeter) is to first read the

label on the gas control valve and match its rating.

Example: If the ampere draw for the valve is .5 amps,

set thermostat heat anticipator at the same

setting (.5).

ADJUST THERMOSTAT ANTICIPATOR

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 anticipator

clockwise. For shorter "ON" times move the an-

ticipator counter clockwise.

NOTE

Use heavier wire size if more than 20 ft. of wire is

required.

NOTE

Refer to installation instructions packed in the ther-

mostat carton if you have any doubt about the above

procedures.

--11--

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,

BODILY INJURY OR DEATH.

PROPER VENT INSTALLATION IS CRITICAL TO

THE SAFE OPERATION OF THE FURNACE.

THEREFORE, CAREFULLY READ AND FOLLOW

ALL THE INSTRUCTIONS GIVEN IN THIS

SECTION.

The following instructions are for either surface or recess

mounted wall furnace.

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.

DETERMINE PROPER LENGTHS

IMPORTANT

To prevent harmful flue gases from entering the

house, make sure NOT to trim air or vent tubes

shorter than specified below.

Air inlet air tube W and vent tube 'B' are supplied in

lengths to handle wall thickness up to 12 inches.

To find the correct vent and air tube length, measure

exact distance 'X' between surface on which back of

cabinet will rest (inside of recessed cavity or face of wall

when freestanding) and the outside wall surface. See Figs.

17 & 18- pg. 13.

Inlet air tube W -- Add 7/8 inch to dimension 'X'. Mark

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

on tube starting from end with collar and holes. Cut off

evenly. File off any burrs resulting.

CUT ONLY THE PLAIN END (WITHOUT FLANGE)

OF THE TUBES. MAKE A SQUARE CUT TO EXACT

LENGTH.

IU,

\\,l

WALL THICKNESS

.--,,--.--d

",----'----I

SURFA(_

MOUNI

U,i

i\ /

-X

WALL

WIIH

SIOtNG

HELPFUL CUTTING HINT

To make a straight cut, measure from the end and mark

tube in several places. Align a piece of tape with the marks

and wrap around the tube. Use the edge of the tape as

a guide to help keep the cut straight.

ATTACHING TUBE TO FURNACE

The smaller diameter vent tube (Fig. 18--"B", pg. 13)must

be installed first.

The easiest way to install the vent tubes and get the

gaskets positioned properly is to have the furnace lying

front down on a flat surface.

IMPORTANT

Be sure not to use longer screws than specified, as

this could keep the furnace from functioning properly. I

1. Attach vent tube (Fig. 18--"B", pg. 13) and gasket to

the back of the furnace heat exchanger with (8) #8 x 3/8

inch sheet metal screws provided.

2. Attach air tube (Fig. 18--"A", pg. 13)and gasket to the

back of the furnace casting with (8) #8 x 3/8 inch sheet

metal screws provided.

--12--

Vent and Inlet Tube Installation (Con't)

NOTE

Each tube must overlap the collars of the vent cap

a minimum of 1 1/4 inch, which is obtained when

tubes are cut correctly as previously described.

VENT INSTALLATION

CONDUIT

(1) 68-112'

(2) 59"

FINISHED

FLOOR \

(1) MODELS 5507332

6257732

55O7331

6257731

MASTIC

MOUNTING PLATE

EMSOSSED "TOP"

SCREWS

VENT

,TUBE

I:1 I,,. TUBE

SEE

INSTRUCTIONS

NOTE:

BACK OF FURNACE

_, PLATE OF VENT

3AP EQUIPPED

WITH STUD

SPACERS TO PRE-

VENT INSTALLA-

TION THRU

OPENING OF LESS

THAN 91/4"DL_.M

(2) MODELS 4007332

4007732

4007331

4007731

Trim

To conceal the space between the furnace and wall, use

4701 Trip Strip Package (not furnished with furnace), 3/4

quarter round or other wood trim.

TRIM COVER

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.

MOUNT FURNACE THROUGH WALL

Mount the furnace through the wall using surface or

recessed mounting instructions. See pgs. 7-10.

Refer to Fig. 18 for the following steps.

1. Check to see that the air tube protrudes through wall

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

tube 1/8 inch rain. to 1/4 inch max. for proper seal in

vent cap.

3. Apply a single strip of mastic "E" provided in vent cap

carton, continuously around the outer edge of the vent

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

The smaller tube in vent cap must slide over vent

_B _.

5. Fasten the vent cap mounting plate to wall with (4)

11/2-inch wood screws "D" provided.

6. On masonry construction, drill into wall and use plugs

or anchors. Additional sealant (silicone) may be

required if the mounting surface is uneven.

FURNACEITEM

Top trim cover

provided

.c::_

TRiM

MOULDING

(OPTIONAL}

--13--

Mounting Your Furnace

To obtain adequate clearance for fastening furnace or to

install gas supply fittings, it may be necessary to remove

the burner and control assembly as follows:

CAUTION

Be careful not to damage burner pan gasket when

removing burner and control assembly.

1. Lay the furnace on its back for the following steps.

Remove burner compartment door by pulling door top

out and up.

MODELS 4007332, 6257332,

4007331, 5507331.

a. Remove screws holdhlg ignition control unit and

cover to casing.

b. Remove (3) screws 'A' holding burner pan to upper

heating element support (Fig. 21, pg. 15). Rotate

burner pan toward front until (3) pins 'B' disengage

from upper heating element support.

c. Remove necessary wire to free control module from

its mounting location. Mark or tag each wire re-

moved for its exact reconnection (Fig. 22, pg. 15).

d. Remove burner and control assembly from furnace.

FASTEN FURNACE BOTTOM

(Surface and Recessed Mount)

NOTE

Fasteners are not furnished because of different

requirements of various types of wall construction.

Fasten furnace to floor through holes provided in furnace

bottom. If you have concrete flooring, use an alternate

fastening method. See Fig. 20.

If furnace burner and control assembly were removed,

replace by reversing steps la through ld.

IMPORTANT

When replacing burner and control assembly, be

sure that pins "B" all enter slots in upper heating

element support. To prevent damage to wire,

be careful not to pinch them between furnace com-

ponents and route them away from burner pan

surface.

FASTEN FURNACE TOP

(Surface Mounting)

Fasten furnace top to wall using (2) metal anchors (pack-

ed in plastic bag with thermostat) by placing them over

the back flange of furnace top and screwing to wall. See

Fig. 20.

MODELS 4007732, 6257732,

4007731, 6257731.

a. Remove manual spark ignitor and bracket by re-

moving (2) screws and disconnecting wire at back

of ignitor.

b. Disconnect two (2) slip-on connectors (24 voltwires)

from the gas valve.

c. Remove (3) screws 'A' holding burner pan to upper

heating element support (Fig. 21, pg. 15). Rotate

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.

FURNACE MOUNTING

RECESSEDMOUNT

_REA_ MOUNT

TOP FASTENING

NOT _-I0_1 FOR

BOI"rOMFAS'T1E]_NG

WDOOFLDOR

NO'W.: DO NOT USE DOTrOM DOOR HOLES FOR MOLJNllNG

--14--

Mounting Your Furnace (ton't)

FASTEN FURNACE TOP

(Recessed Mounting)

Fasten furnace top by drilling (2) holes through side flange

furnace top and securing with (2) screws or nails to wall

studs. See Fig. 20, pg. 14. CAUTION I

Be careful not to damage furnace components or

wiring when drilling holes.

5 ,

oIo

WlLUAMS IGNITION CONTROL

PART NUMBER P3219t0

Gas Supply and Piping

Gas control valve, within the furnace, is shipped with a

seal cover gas inlet tapping. Do not remove seal until ready

to connect piping.

WARNING

DANGER OF PROPERTY DAMAGE,

BODILY INJURY OR DEATH.

MAKE SURE THE FURNACE IS EQUIPPED TO

OPERATE ON THE TYPE OF GAS AVAILABLE.

MODELS DESIGNATED AS NATURAL GAS ARE TO

BE USED WITH NATURAL GAS ONLY. FURNACE

DESIGNATED FOR USE WITH LIQUEFIED

PETROLEUM (L.R) GAS HAVE ORIFICES SIZED

FOR COMMERCIALLY PURE PROPANE GAS.

THEY CAN NOT BE USED WITH BUTANE OR A

MIXTURE OF BUTANE AND PROPANE.

GAS SUPPLY

For Natural gas, the minimum inlet gas supply pressure

for the purpose of input adjustment is 5" water column.

The Maximum inlet gas supply pressure is 7" water

column.

For L.IR gas, the minimum inlet gas supply pressure for

the purpose of input adjustment is 11" water column. The

maximum inlet gas supply pressure is 13" water column.

Gas pressures and input to the burners must not exceed

the rated input and pressure shown on the rating plate.

On Natural Gas, the manifold pressure should be 4 inch-

es water column. The manifold pressure should be 10.5

inches water column for LP. Gas See pg. 18 for opera-

tion above 2000 feet altitude. --15--

Orifice change may be required to suit gas supplied.

Check with your local gas supplier.

ORIFICE SIZES

Furnace Technical Information, Page 26, shows the

correct orifice sizes for the different input ratings when

using Natural or L.R Gas.

GAS PIPING

The gas supply line must be of an adequate size to

handle the BTU/HR requirements and length of the run

for the unit being installed.

Determine the minimum pipe size from Fig. 25, pg. 16, bas-

ing the length of the run from the gas meter or source

to the unit.

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.

Refer to Fig. 23, pg. 16 for the general layout at the unit.

It shows the basic fittings needed.

The following rules apply:

1. Use new, properly reamed pipe free from chips such

as steel or black iron pipe and fittings or other

approved by local codes.

2. Do not thread pipe too far. Valve distortion or mal-

function may result from excess pipe within control.

Apply moderate amount of good quality dope to pipe

only, leaving 2 end threads bare. If LP gas installation,

use compound resistant to action of liquefied petroleum

gases.

3. Use ground joint unions.

Gas Supply and Piping (Con't)

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

inches long.

5. Install a manual shut-off valve.

6. Provide a 1/8 NPT test gauge connection immediately

before the gas supply connection to the furnace.

DROp

IPIpIE D GROUNO JOINT

3, [ 62mml GAS

_tt_rMUM _ANUAL SHUT OFF SUPPLY

HOnlZON'r AL TUBING _It_IMUM

;oF:

_ 31n 1762mml

M_NIMUM

_ALL BENDS IN METALLIC TUBING SHOULO 9E SMOOTH

_ CAUTION: SHOT OF€ THE MA_N CA$ SUPPLY BE,_ORE REMOVING ENO CAP

TO PREVI_NT GAS FROM F(LLINC THE WORK AAEA TE_T FOR GAS LEAK.

AGE WHEN INSTALLATION I_ COMPLETE

Connection between shutoff valve and burner control

assembly can be made with an A.G.A./C.G.A. design cer-

tified flexible connector if allowed by local codes.

Tighten all joints securely.

CHECKING THE GAS PIPING

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

and manual shut off valve must be disconnected during

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

NATURAL GAS

PIPE CAPACITY - BTU PER HOUR

(INCLUDES FITTINGS)

PIPE SIZE.

LENGTH

PIPE-FT. I/2" 3/4" I"

20 92,000 190.000 350,000

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)

PIPE-FT. 1/2" 3/4" 1"

20 189,000 393,000 732,000

40 129.000 267,000 504,000

60 103,000 217.000 409,000

WARNING

PROP[R PtPtMG PRACTI¢_

2 IMPERFECT CONTRO L USE MODERATE AMOUNT OF DOPE

THR£AD5

THREAD PIPE RIGHT L_NGTH LEAVE 2 END THREADS 8ARE "_

GAS CONNECTION

If installation isfor L.R Gas, have L.R installer use two-

stage regulation and make all connections from storage

tank to furnace.

Use two pipe wrenches when making the connection to

the valve to prevent turning or damage to gas valve.

DANGER OF PROPERTY DAMAGE,

BODILY INJURY OR DEATH.

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

CAUSE OVERFIRING WHICH MAY RESULT IN

HEAT EXCHANGER FAILURE. LIQUID

PETROLEUM (L.R) IS HEAVIER THAN AIR AND IT

WILL SETTLE IN ANY LOW AREA, INCLUDING

OPEN DEPRESSIONS AND IT WILL REMAIN

THERE UNLESS AREA IS VENTILATED.

NEVER ATTEMPT STARTUP OF UNIT BEFORE

THOROUGHLY VENTILATING AREA.

--16--

Electrical Wiring

WARNING

DANGER OF PROPERTY DAMAGE,

BODILY INJURY OR DEATH.

TURN OFF ELECTRIC POWER AT FUSE BOX

OR SERVICE PANEL BEFORE MAKING ANY

ELECTRICAL CONNECTIONS.

INSULATE WHERE NECESSARY.

ALL LINE VOLTAGE AND GROUND CONNEC-

TIONS MUST BE COMPLETED BEFORE

ELECTRICAL POWER IS RESTORED.

All electrical work must conform to your local codes and

ordinances or in their absence, with National Electrical

Code, ANSI/NFPA 70. If you are not familiar with wiring

codes, in general, have a competent electrician do this job.

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

Power supply connections are made inside the junction

box in the upper left corner of the cabinet. See Fig.26.

CAUTION I

Do not connect 115V service line to the gas control

valve or wall thermostat.

ELECTRICAL CONNECTION

Connect 115V. conduit to top of furnace as shown in Fig.

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.

Attach your 115V.supply wire to "LINE" factory wires. Use

wire nuts provided.

Replace junction box cover and make final ground

connections with screws for plate cover.

Refer to paragraph covering GAS AND ELECTRICAL

SUPPLY OPENINGS, pg. 9. Follow Wiring Diagrams, pgs.

27 and 28.

If you have any doubt regarding electrical hookup, or com-

pliance with code or ordinace, consult your electrical

inspector or a licensed electrician.

HELPFUL HINT

After wire nuts are screwed to wires, a small strip of elec-

trical tape can be applied over wire nut at its base and

onto wires to make a very solid connection.

GROUNDING

A ground lug is installed for the ground connection. Use

a copper conductor (#AWG) from the unit to a grounded

connection in the electric service panel or a propedy driven

and electrically grounded ground rod.

ELECTRICAL POWER SUPPLY

A branch circuit including this furnace must not exceed

15 amperes or run a separate 115V., 60 Hz., 15 Ampere

circuit from a separate circuit breaker or fuse in your serv-

ice panel to the furnace junction box. Do not run supply

wires inside the furnace cabinet, except from the top of

cabinet down to junction box. Connect as shown in Fig. 26.

CONNECTING SUPPLY WIRING

WIRES MARKED LINE

PUSH BACK INSIDE

JUNC lION BOX

MAKE CONDUIT

CONNECTION HERE

_ ,,__ lO THERMOSTA"

_ !!) AO,NE

MAKE WIRE CONNECTIONS

"J" BOX COVER PLATE

_HOWN REMOVED)

TO APPROVED

GROUND

_(FIELD WIRED)

MOTOR GROUNI

FACTORY WIRED

ON TRANSFORMER TO GAS VALVE

LOW VOLTAGE CONNECTIONS

CAUTION

The Heat Anticipator WILL BURNOUT if 24 volts are

applied directly to thermostat by shorting out the gas

valve or primary control during testing or by incorrect

wiring.

WALL THEMOSTAT WIRING

Run thermostat wire to the furnace.

Connect thermostat to two wires marked "Thermostat"

extending from top of furnace, using two wire nuts pro-

vided. See Wiring Diagrams, pgs. 27 and 28. Refer to Fig.

15, pg. 11, also,

Replace fan to original position on motor shaft, tighten-

ing securely. Replace fan shroud, making sure it is

centered vertically on the fan.

Tighten screws securely.

Replace top front panel and secure with thumbscrew.

COMPLETE WIRING DIAGRAMS ON PAGES 27 AND 28.

--17--

Start-Up Procedure

Start the furnace using the procedures in section

OPERATING YOUR FURNACE. Pages 19 thru 24.

WARNING

DANGER OF PROPERTY DAMAGE,

BODILY INJURY OR DEATH.

LIQUIFIED PETROLEUM L.IR GAS IS HEAVIER

THAN AIR AND IT WILL SETTLE IN ANY LOW

AREA, INCLUDING OPEN DEPRESSIONS AND

IT WILL REMAIN THERE UNLESS AREA IS

VENTILATED.

NEVER ATTEMPT STARTUP OF UNIT BEFORE

THOROUGHLY VENTILATING AREA.

CHECK THE GAS INPUT (NATURAL GAS ONLY)

WARNING

NATURAL GAS HEATING VALUE (BTU PER CUBIC

FOOT) CAN VARY SIGNIFICANTLY, THEREFORE,

IT IS THE INSTALLER'S RESPONSIBILITY TO SEE

THAT BTU INPUT TO THE FURNACE IS ADJUSTED

PROPERLY. FAILURE TO DO SO COULD CAUSE

HEAT EXCHANGER FAILURE, ASPHYXIATION,

FIRE OR EXPLOSION, RESULTING IN DAMAGE,

BODILY INJURY OR DEATH. REFER TO THE

NATURAL FUEL GAS CODE (NFPA-54) TO BE

SURE THE FURNACE IS BURNING FUEL AT THE

PROPER RATE.

Check the furnace operation as outlined in the following

instructions. If any sparking, odors or unusual noises are

encountered, shut off electric power immediately. Recheck

for wiring errors, or obstructions in or near fan motor.

CHECK GAS INPUT AND PRESSURES

For furnace located at elevations between sea level and

2000 feet, the measured input must not be greater than

the input shown on the rating plate of the furnace. For

elevations above 2000 feet, the measured input must not

exceed the input of the rating plate reduced by 4 percent

for each 1000 feet that the furnace is above sea level.

Gas supply pressure and manifold pressure with the burn-

ers operating must also be as specified on the rating plate.

Type of Gas Manifold Pressure, In. W.C. |

Natural 4 ]

L.P. 10.5

Rated input will be obtained on 2500 Btu propane at 10.5

inch manifold pressure with factory-sized orifices. If LP gas

having a different heating value is supplied, orifices must

be changed by a qualified service technician before the

furnace is operated.

CHECK THERMOSTAT

Check thermostat operation. When set above temperature

shown on the thermostat, the main burner should light.

Make certain the thermostat turns off the furnace when

room temperature reaches the selected setting and starts

the furnace when room temperature falls afew degrees.

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-

justing screw on gas valve. Turn screw counterclock-

wise to increase flame, clockwiseto decrease. Replace

cap. See Figs, 31, Page 25 and Fig. 32, Page 26.

CHECK THE MANIFOLD GAS PRESSURE

A tapped opening is provided in the gas valve to facilitate

measuring the manifold gas pressure. A "U Tube"

manometer having a scale range from 0 to 12 inches of

water should be used for this measurement. The manifold

pressure must be measured with the burner and pilot

operating, Any major changes in flow must be made by

changing the size of the burner orifice, Check with your

local gas supplier for proper orifice sizing.

Underfiring could cause inadequate heat, excessive con-

densation or ignition problems. Overfiring could cause

sooting flame impingement or overheating of heat

exchanger.

Before starting natural gas input check, obtain heating

value of gas (BTU per cubic foot) at standard conditions

from your local supplier. This factor is used in "Check the

Gas Input" section and procedure.

To measure the input using the gas meter, proceed as

follows:

1. Turn off gas supply to all other appliances except

the furnace.

2. With the furnace operating, time the smallest dial on

the meter for one complete revolution. If this is a 2

cubic foot dial, divide the seconds by 2; if it is a 1

cubic foot dial, use the time in seconds as is. This

gives the seconds per cubic foot of gas being delivered

to the furnace.

3. Assuming natural gas with a heating value of 1000 BTU

per cubic foot and 34 seconds per cubic foot as

determined by step (2), then:

Input = 1,000 x 3,600 + 34 =106,000 BTU Per Hour

This measured input must not be greater than the

input indicated on the rating plate of the furnace.

4. Relight all other appliances turned off in step 1 above.

Be sure all pilot burners are operating.

THERMOSTAT (TYPICAL)

SQUEEZE FIRMLY

BOTH SIDES

AND LIFT TO

REMOVE COVER

WARNING

DANGER OF IGNITION FLASH

AND EYE INJURY OR BLINDNESS

PROTECT YOUR EYES. NEVER ATTEMPT TO

LIGHT PILOT WITH GAS CONTROL VALVE KNOB

IN "ON" POSITION. FLASH BACK COULD

OCCUR.

--18--

Operating Your Furnace

STANDING PILOT MODELS"

4007732, 6257732,

4007731, 6257731.

NOTE:

For models equipped with WILLIAMS gas valve P322041

or P322042 refer to this sheet and sheet 20 for "SAFETY

& LIGHTING INSTRUCTION" and "TURN GAS OFF TO

APPLIANCE."

For models equipped with WILLIAMS gas valve P321704

or P321705 refer to this sheet and sheet 21 for "SAFETY

& LIGHTING INSTRUCTIONS" and "TURN GAS OFF TO

APPLIANCE."

(All other models refer to sheet 22, 23 &24.)

These furnaces are equipped with a manually operated

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.

On new installations, the gas lines will be filled with air

and it may take several minutes to establish the pilot flame.

Keep all access doors and panels in place except for in-

spection and maintenance.

WARNING

DANGER OF BODILY INJURY OR DEATH.

DO NOT OPERATE THE FURNACE WITH A

BROKEN OR MISSING PILOT OBSERVATION

DOOR.

For models equipped with WILLIAMS gas valve

P321704 or P321705.

Models are equipped with a two-rate control valve. The rate

knob on the gas valve is marked "LO" and "HI." Turn the

rate knob to the "LO" position and the room thermostat

will operate the main burner at about 70% of maximum

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

A two-speed fan is used with Models 6257732, and

6257731.

Blower will operate at low speed then shift to high speed

as the furnace heats up.

WARNING

THE SURFACE OF THE FURNACE IS HOT DUR-

ING OPERATION. KEEP CHILDREN, CLOTHING,

FRNITURE, AND FLAMMABLE MATERIAL AWAY

FROM IT.

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE LIQUIDS OR VAPORS NEAR THE

FURNACE.

WARNING

DANGER OF PROPERTY DAMAGE

BODILY INJURY OR DEATH.

IF THE FURNACE OVERHEATS OR FAILS TO

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

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 through

the furnace. This switch will reset itself when the motor

cools down and it cannot be adjusted.

--19--

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

hand, When lighting the pilot, follow these instructions

exactly.

B. BEFORE LIGHTING smell around the appliance area

for gas. Be sure to smell next to the floor because some

gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance or strike a match.

•Do not touch any electric switch; do not use any

phone in your building.

•Immediately call your gas supplier from a neighbor's

phone. Follow the gas supplier's instructions.

•If you cannot reach your gas supplier, call the fire

department.

Use only your hand to push in or turn the gas control

knob. Never use tools. If the knob will not push in or

turn by hand, don't try to repair it, call a qualified serv-

ice technician, Force or attempted repair may result in a

fire or explosion,

Do not use this appliance if any part has been under

water. Immediately call a qualified service technician to

inspect the appliance and to replace any part of the

control system and any gas control which has been

under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. Remove control access panel.

5. Turn gas control knob clockwise _to "OFF".

GAS

CONTROL

KNOB

RESET

BUTTON

6. 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.

7. Loosen wingnut and open pilot observation door (if

equipped).

8. Find pilot--follow metal tube from gas control, The pilot

is mounted on side of burner.

9. Turn knob on gas control counterclockwise J_

to "PILOT,"

10. Push in red reset button THERMO-_1 ,[_,=

all the way and hold in. COUPLE

Immediately light the

pilot. Continue to hold

the red reset button in for about PILOT

(1) minute after the pilot is lit, Release BURNER

button and it will pop back up. Pilot should

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",

Knob can be turned to "ON" only if red reset button is

up.

13. Replace control access panel.

14. Turn on all electric power to the appliance.

15. Set thermostat to desired setting.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if 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--

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 has a pilot which must be lighted by

hand. When lighting the pilot, follow these instructions

exactly.

B. BEFORE LIGHTING smell around the appliance area

for gas. Be sure to smell next to the floor because some

gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance or strike a match.

•Oo not touch any electric switch; do not use any

phone in your building.

• immediately call your gas supplier from a neighbor's

phone, Follow the gas supplier'a Instructions.

• If you cannot reach your gas supplier, call the fire

department.

Use only your hand to push in or move the selector

arm. Never use tools. If the arm will not push in or

move by hand, don't try to repair it, call a qualified

service technician. Force or attempted repair may result

in a fire or explosion.

Do not use this appliance if any part has been under

water. Immediately call a qualified service technician to

inspect the appliance and to replace any part of the

control system and any gas control which has been

under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting,

3. Turn off all electric power to the appliance.

4. Remove control access panel.

5. From "ON" position, depress and move selector

arm on gas control to "OFF" position, Do not force.

GAS CONTROL

SELECTOR

ARM SHOWN

IN =OFF"

POSITION

6. Wait five 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.

:7. Loosen wingnut and open pilot observation door (if

equipped).

f0.

Find pilot--follow metal tube from gas control. The pilot

is mounted on side of burner.

Hold lighted match at pilot

burner.

Move selector arm to

"SET" postlon and light

pilot, Hold in "SET" position

for 1/2 minute after pilot is lit.

NOTE: Sufficient time must be allowed PILOT

for pilot flame to heat thermocouple BURNER

and hold safety magnet in locked-up position,

also, time must be allowed for air to be purged

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).

13. Replace control access panel.

14. Turn on all electric power to the appliance.

15. Set thermostat to desired setting.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if 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--

Operating Your Furnace

ELECTRONIC IGNITION MODELS*

4007332, 5507332,

4007331, 5507331.

NOTE:

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

APPLIANCE."

For models equipped with WILLIAMS gas valve P321897

or P321898 refer to this sheet and sheet 24 for "SAFETY

& LIGHTING INSTRUCTIONS" and "TURN GAS OFF TO

APPLIANCE."

(All other models refer to sheet 19, 20 & 21.)

THE FURNACE WORKS LIKE THIS:

1. Thermostat turns on the control module.

2. Automatic relight system (in module) opens gas valve

and electronically ignites pilot. After pilot flame has

been established and proven by the control module,

main gas valve circuit opens and pilot lights main

burners.

3. Heat builds up in the furnace and starts the fan. The

heated air comes out the front bottom Iouvered panel

at floor level.

4. When the thermostat setting is reached, it shuts off the

main burner.

5. The fan runs until the heat is removed from furnace,

then it turns off.

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

DANGER OF BODILY INJURY OR DEATH.

DO NOT OPERATE THE FURNACE WITH A

BROKEN OR MISSING PILOT OBSERVATION

DOOR.

For models equipped with WILLIAMS gas valve

P321897 or P321898.

Models are equipped with a two-rate control valve. The rate

knob on the gas valve is marked "LO" and "HI." Turn the

rate knob to the "LO" position and the room thermostat

will operate the main burner at about 70% of maximum

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.

A two*speed fan is used with Models 5507332, and

5507331.

Blower will operate at low speed then shift to high speed

as the furnace heats up.

WARNING

DANGER OF PROPERTY DAMAGE

BODILY INJURY OR DEATH.

IF THE FURNACE OVERHEATS OR FAILS TO

SHUT OFF, CLOSE MANUAL GAS VALVE FOR THE

FURNACE BEFORE TURNING OFF ELECTRIC

POWER.

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--

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.

This appliance is equipped with an ignition device which

automatically lights the pilot. Do not try to light the pilot

by hand.

BEFORE LIGHTING smell around the appliance area

for gas. Be sure to smell next to the floor because some

gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance or strike a match.

•Do not touch any electric switch; do not use any

phone In your building.

•Immediately call your gas supplier from a neighbor's

phone. Follow the gas suppller's Instructions.

•if you cannot reach your gas supplier, call the fire

department.

Use only your hand to push in or turn the gas control

knob. Never use tools. If the knob will not push in or

turn by hand, don't try to repair it, call a qualified serv-

ice technician. Force or attempted repair may result in a

fire or explosion.

Do not use this appliance if any part has been under

water. Immediately call a qualified service technician to

inspect the appliance and to replace any part of the

control system and any gas control which has been

under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance,

4. This appliance is equipped with an ignition device which

automatically lights the pilot. Do not try to light the pilot

by hand.

5. Remove control access panel.

6. Turn gas control knob clockwise (_ to "OFF".

GAS CONTROL --'_.

KNOB SHOWN .,

IN "OFF" r-r

POSITION _

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.

S. Turn the gas control knob counterclockwise

to "ON".

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Turn thermostat to on (HEAT) position. Set thermostat

higher than room temperature. Pilot will automatically

light and main burner(s) will light in approximately 45

seconds.

NOTE: On initial start-up or after prolonged shut down,

several ignition cycles may be required to purge gas

lines. To accomplish the recycle - repeat steps 5

through 11 until pilot is established.

12. Set thermostat to desired setting.

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.

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. I

--23--

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

automatically lights the pilot. Do not try to light the pilot

by hand.

B. BEFORE LIGHTING smell around the appliance area

for gas. Be sure to smell next to the floor because some

gas is heavier than air and will settle on the floor.

WHAT TO DO iF YOU SMELL GAS

•DO not try to light any appliance or strike a match.

•Do not touch any electric switch; do not use any

phone in your building.

•Immediately call your gas supplier from a neighbor's

phone. Follow the gas supplier's instructions.

•If you cannot reach your gas supplier, call the fire

department.

Use only your hand to push in or move the selector

arm. Never use tools. If the arm will not push in or

move by hand, don't try to repair it, call a qualified

service technician. Force or attempted repair may result

in a fire or explosion.

Do not use this appliance if any part has been under

water. Immediately call a qualified service technician to

inspect the appliance and to replace any part of the

control system and any gas control which has been

under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which

automatically lights the pilot. Do not try to light the pilot

by hand.

5. Remove control access panel.

6. From "ON" position, depress and move selector arm on

gas control to "OFF" position. Do not force.

GAS CON'I_OL

SELECTOR

ARM SHOWN

IN "OFF"

POSITION

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.

8. Move selector arm to "ON" position.

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Turn thermostat to on (HEAT) position. Set thermostat

higher than room temperature. Set thermostat higher

than room temperature. Pilot will automatically light

and main burner(s) will light in approximately 45

seconds.

12.

13.

14.

NOTE: On initial start-up or after prolonged shut down,

several ignition cycles may be required to purge gas

lines. To accomplish the recycle - repeat steps 6

through 11 until pilot is established.

Set thermostat to desired setting.

After the room thermostat turns the system off, a delay

of approximately one minute is required before the

system can be turned on again.

If the appliance will not operate, follow the instructions

"To Turn Off Gas To Appliance" and call your service

technician or gas supplier.

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--

How To Care For Your Furnace

WARNING

DANGER OF BODILY INJURY OR DEATH

TURN OFF ELECTRIC POWER SUPPLY AT

DISCONNECT SWITCH, FUSE BOX OR SERVICE

PANEL BEFORE REMOVING ANY DOORS OR

ACCESS OR SERVICE PANELS FROM UNIT.

CABINET FINISH

Clean cabinet with damp rag. Never use abrasive cleaners.

Cabinets are finished in heat resistant baked enamel - DO

NOT refinish with wail paint.

COMBUSTION AND VENTILATION AIR

The combustion and ventilation air supply must not be

blocked.

Do not put anything in or on the furnace cabinet.

For better circulation and more effective heating, do not

place obstructive furniture closer than four feet to the front

of the cabinet or two feet to the side of the cabinet.

FURNACE AREA

Keep the area near the furnace clear and free from com-

bustible materials, gasoline, and other flammable liquids

and vapors.

ANNUAL UPKEEP NEEDED

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

FAN

MOIOR

Oft Ius{S

Oft CUPS

ON EACH

END OF

MOIOR

PILOT BURNER

Light pilot using instructions in OPERATING YOUR

FURNACE (on Pages 19 thru 24, depending on your

model).

Pilot flame should surround 5/8 to 1/2 inch of the thermo-

couple tip. Refer to Fig. 32, Page 26. If flame needs

adjusting, do it as follows:

ADJUST PILOT BURNER

See Fig. 31 and 32. (Page 26)

1. Remove screw cover over pilot adjusting screw.

2. Insert small screwdriver, Adjust flame as needed. Turn

screw counterclockwise ( _) to increase flame,

clockwise ( _ ) to decrease.

3. Turnthermostat to highest setting. Main burners should

light quickly and smoothly. Turn thermostat to lowest

setting. Main burners should go out. Pilot should re-

main lit except for electronic ignition models.

4. Replace screw cover over pilot adjusting screw.

BURNER FLAME

Start the furnace and let it operate about 10 minutes then

look at the burner flame. Flames should be soft and blue,

see Fig. 31. If flames appear abnormal, contact the gas

company or a qualified service technician immediately.

VENTING SYSTEM

Make sure that no parts of the vent air system are block-

ed, rusted or damaged (including joint gaskets). Clean or

replace before using furnace. See Page 12 and 13 for

proper assembly and reseating of vent-air system.

--25--

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.

Disconnect Gas line inside cabinet.

Remove three screws from the front of the combustion

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

spring bracket).

Inspect the Burner Box gasket. Replace if damaged.

Replace burner assembly and control assembly by re-

versing the above procedures.

SENSOR

SLtGHT

ORANGE TIP

NATURAL GAS

ELECTnODE TYPICAL

-TYPICAL BLUE CONE ,_A /BLUE CONE

[L P GAS _,_(_l_ NATURAL

BURNER

CASTING

Furnace Technical Information

MODEL

NUMBER

4007332

4007331

4007732

4007731

5507332

5507331

6257732

6257731

TYPE

GAS

NAT

L.P.

NAT

L.P.

NAT

L.P.

NAT

L.P.

**RATING

IN BTUH

INPUT HTG.CAPAC.

32,000

44,000

5O,0OO

50,000

DRILL DEC.

#34 .1110

#50 .0700

#34 ,1110

#50 .0700

#42 .0935

#54 .0550

#39 .0995

#53 .0595

40,000

55,000

62,500

MAIN BURNER ORIFICE

QTY.

**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 aproduct thermal efficiency rating determined under continuous operating

conditions and was determined independently of any installed system.

--26--

WIRING DIAGRAMS FOR MODELS

4007732 and 4007731 6257732 and 6257731

FOR 40M B.T.U.

FAN TYPE DIRECT VENT WALL FURNACE

WITH CONTINUOUS PILOT CONTROL SYSTEM

UMIT SWITCH' (_"I1RAN S.

_____________.___________j--HGASV_W I

THERMOCOUPLE

J_(;IE3_D NOTE:

m FACTC_Y _lINE _OLTAGE, 1 Ifanyoftheoriginalwireassupplied

-- FACTORY _LOW VOLTAGF.. with the appliance has to be replac-

11/_4 _CONNECT "i_MINAL ed, use only 18 Ga., 4/64 insulation,

FACI'(_T" _RING* 105 °C. AWM copper wire or its

_tllRE CO_CTOI_ F01t FAC_I101_Y equivalent 115V- 60Hz -lessthan

3 amps

_NG LINE VOLTAGE. 2 MOTOR IS THERMALLY OVER-

_ _ LOW V0LTAilI_ LOAD PROTECTED

115%L60Hz - LESS THAN 3 AMPS

THERMOSTAT

•1

GAS VALVE

115V 60H7.

HOTI ]NEUT"

_ THERMC¢-.,'_N.IPLE

FOR 62.5M B.T.U.

FAN TYPE DIRECT VENT WALL FURNACE

WITH CONTINUOUS PILOT CONTROL SYSTEM

L1 __ 115v 60HZ ,L2

HOT| Hf NEUT

TOTHERMOSTAT _ [_ GAS VALVE +

L___

THERMOCOUPLE

LEGEND NOTE:

m FACTORy _UNE VOLTAGE. 1. Ifanyoftheoriginalwiteassupplied

-- FAI_[IO_y _LOW "YOLTAG_* with the appliance has to be replac-

1/4. QUICKCONNECTT_MZNAL ed, use only 18Ga., 4/64 insulation,

f'(_ FAt_O_ " _R]NG. 105° CAWM copper wire or ils

•f_R£ CONNECTOR FOR FACTORY equivalent 115v -60Hz - less than

WIRING LINE VOLTAGE. 3 amps

MOTOR IS THERMALLY OVER-

_ _INAL LOW VOLTAGE. 2. LOAD PROTECTED

115V.60Hz -LESS THAN 3 AMPS.

B_CK

BLiU_

BI.gE_K'O_ F(__

UMIT

_ s_Ta_

THERMOSTAT

THERMOCOUPLE

G_ V_

--27--

WIRING DIAGRAMS FOR MODELS

4007332 and 4007331 5507332 and 5507331

FOR 40M B.T.U.

FAN TYPE DIRECT VENT WALL FURNACE

WITH INTERMtTFENT IGNITION CONTROL SYSTEM

ul lu

HOTi_ 115VS0HZ -I N_.UT

_ O- --

/ TR _PV(P) TL

/SF_NSO- PV,,1WV(c) ,--

/ PV O, Mv(u)

INTERMII"R_T IGN.

CONTROL MODULE

LEGI0_ID

_FACTORy _RED LINEVOLTAQF-

-- FACTQ_qY_LOWVOLTAGE.

I--3 1/4 QUICKCON_C'r TERM1NAL

FOR FACTORYI_NG.

WIRECONNECTORFOR FACTORY

_li_lP- LINEV(_.TAaE,

_ _INAL LOW VOLTAGE.

NOTE:

1. If any of the original wire as supplied

with the appliance has to be replec-

ed, use only 18 Ga. 4/64 insulation,

105= C AWM copper wire or ils

equivalent 115V - 60Hz - less Ihan

3 amps

2, MOTOR IS THERMALLY OVER=

LOAD PROTECTED,

115V, 60Hz -LESS THAN 3 AMPS

1HERMOSTAT 115V 60HZ

HOT NEUT.

FAN

FOR 55M BT.U.

FAN TYPE DIRECT VENT WALL FURNACE

WITH INTERMITI-ENT IGNITION CONTROL SYSTEM

1.1 |. 115V8ONZ .| L2

HOT ! S_f)R _|NEUT

L_r_115V II

T.____.__T. -_eJ....,o ru_

LIMIT SWITCH ._ m,_,a, SE_ISOR

GND

s_so_ ?-ioFv/_v(c) "--

PV Ol--- .-'r-lOIMV (_)

THOl_ IF" cAs

MV (Z)-_ -'J I VALV_

ION___ --

IN'W_RMII"TF_NTIGN.

CONTROLMODULE

_L_E_FACTORY_ lINE VOLTA_E,

-- YA_ _ LOWVOLTAGE.

1/4 QUICKCONNECT

FORF_Y

_CONNECqORFOR FACTORY

tiRiNg MNE VOLTA_..

(d_ _ _ LOWVOLTAGE.

NOTE:

1. If any of the original wire as supplied

with the opp_lence has to b_ replec*

ed, use only 18 Ga., 4/64 insulation,

105° C. AWM copper w=re ot its

equivalent 115V - 60Hz. - less than

3 amps.

2. MOTOR IS THERMALLY OVER-

LOAD PROTECTED.

115M 60Hz - LESS THAN 3 AMPS

31"IERMOSTAT 115V 60HZ

HOT I NEUT.

_.-c_

--28--

Troubleshooting Chart for Models

4007732, 6257732, 4007731 and 6257731

SYMPTOM

1. Pilotwill not staylit afterfollow-

ing lighting instructions.

2. MainburnerwillnotcomeON--

pilotburningandthermostatset

for heat.

POSSIBLECAUSE(S)

a. Thermocoupleproducinginsuffi-

cientmillivoltage.

b. Loose or dirty thermocouple

connectionat gas valve.

c. Thermocoupledefective.

d. Thermomagnetpilotsafety

defective.

a. Gas valveturnedOFE

CORRECTIVEACTION

a. Checkpilot flame-- mustimpingeon thermocouple.

Pilotflamemaybe lowor blowing(high)causingsafe-

tytodropout.Pilotorificeoraeratingholemaybeplugg-

ed(checkforspiders,websorotherorganicmaterial).

Besurethe thermocoupleis fullyinsertedinbracket.

b. Cleanand/ortightenthermocouplefittingatconnection

to valve

C, Check thermocouplewith millivolt meter--should

generateapproximately30 millivoltswhen not con-

nected to load. When connectedto load, should

generateapproximately14millivolts,if below7 millivolts,

replace.

e. Replacegasvalveafteraboveis checkedout.

a. Turngasvalveknobto "ON" position-- if nomaingas

flow,proceedto Step."b".

-Continued Next Page -

--29--

Troubleshooting Chart for Models

4007732, 6257732, 4007731 and 6257731 (Continued)

SYMPTOM

2 Mainburnerwill notcomeon --

pilotburningandthermostatset

for heat (continued)

3. BurnercomesON,butgoesOFF

beforeblowerturns ON."

POSSIBLECAUSE(S)

b Electric powerto furnaceturned

OFE

c. Low voltagetransformeror limit

switchdefective

d. Wallthermostatdefective.

e. Burnerorificeplugged.

f. Gas valvedefective.

a. Defectivewiring.

b. Defectiveswitch.

c. Defectivemotor(2-speed)

d. Defectivemotor(t-speed).

CORRECTIVEACTION

b. Checkfor linevoltageatfurnace-- if okayandnomain

gas flow,proceedto Step"c".

C. Checkfor 24volts at the lowvoltageterminalsof the

transformer.If no voltage,turn OFFelectricpowerto

furnace.Removeonewirefromlimitswitchandcheck

for continuityacrossbothterminals.No continuity--

replacelimitswitch.Witha goodlimitswitchbackin

the circuit andthe electric powerturnedON-- if no

voltage,replacetransformer.NOTE:Beforereplacing

thetransformerorlimitswitch,checkwiringforlosecon-

nectionsorbrokenwiresandrepairasneeded.Ifvoltage

is presentat transformer,proceedto Step "d".

d. Withthermostatsetfor heat(contactsclosed),check

for voltageat terminalson gasvalve.If no voltageis

present,replacedefectivethermostat.NOTE:Before

replacingthermostat,besureto checkwiringfromfur-

nacetothermostatforlooseconnectionsorbrokenwires

andreplaceas needed.

Ifvoltageis presentat terminalsongasvalveandstill

no gas flowto mainburners,proceedto Step"e".

e. Cleanor replaceorifice-- if okayandstillnogasflow

to mainburners,proceedto Step "f".

f. Replacedefectivegas valve.

a. Turnoff electricpowerto furnace.Removetop front

panel,fan shroudand blowerwheel.Referto wiring

diagram and check all wiring inside junction box.

Removecenterfrontpanelandcheckall wiringinside

switchbox containingfan, limitandselectorswitches.

Correctif necessary.If correct,proceedto Step"b".

NOTE:SelectorswitchusedonlyonModels-- 5507331,

5507332,6257731,6257732.

a. IfburnergoesOFFinlessthanfiveminutesfromroom

temperaturestart,checklimitcontrolswitch.If defec-

tive-- replace.NOTE:Blowershouldturn ON within

3 minutesafterburneris ONfromaroomtemperature

start.If not,proceedto Step"c".

C. Jumperacrossfanswitch,turnelectricpowerON,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. Jumperacrossfanswitch,turnelectricpowerON,motor

shouldrotate.Replacemotorif defective.

*Alsoapplicableto Models4007332,5507332,4007331and5507331. -Continued Next Page -

--30--

Troubleshooting Chart for Models

4007732, 6257732, 4007731 and 6257731 (Continued)

SYMPTOM

3. Burner comes ON, but goes

OFF before blower turns ON

(continued).

4. BurnercomesON,blowercomes

ON, but cycles ON and OFF

while burner remains ON.*

5. BurnercomesON,blowercomes

ON,but burnercyclesOFFand

ON with blowerON.*

6. FurnaceoperatesbutturnsOFF

before room temperature is

attained.*

7. Furnaceoperatesbut will not

shut OFF whenroom temper-

atureis attained.*

8. Abnormal noises* during

operation.

POSSIBLECAUSE(S)

e. Detectivefan switch.

Furnacenotoperatingat full rate.

a. Furnaceoperatingover-rate.

b. Linevoltagetoo low.

c. Recirculation.

a. Thermostatlocation.

b. Defectivethermostat.

a, Thermostatwiringdefective.

b. Thermostatlocation.

c. Improper thermostat anticipator

setting.

a. Blowernoise.

b. Expansionnoiseticking.

c. Selectorswitchdefective,

(2-speedmotor)

CORRECTIVEACTION

e. If, after checking above possibilities,problem still

exists,replacefan switch

Checkfor lowgas pressureat gasvalve-- shouldbe

4" W£. fornaturalgas,11"W.C.forL.RG.Checkburner

orifice.

a. Checkfor highgas pressureat gasvalve-- correctif

necessary.Seecorrectpressureabove.

b. Checklinevoltageto motor;if below115volts,motor

will runtoo slow.

I c. Heatedair dischargingagainstan objectcausingre-

circulation,suchasa hallinstallationora largepiece

of furniturewithin4' of discharge.

a. Checklocationofthermostat.Itshouldnotbeinthepath

of warmairdischargefrom furnace,neara lamp,or

abovea TV set orstereo.

b. Checkthermostatcalibrationor replace.

a Check thermostatwiringfrom furnaceto thermostat

(maybe shortedtogetherby a nail,or staple).

b. Checkthermostatlocation-- if anoutsidewallorahole

in wallbehindthermostatcausingcold airto contact

thermostat-- relocate.

c. SetanticipatorperTHERMOSTATINSTALLATION,page

11.

a. Check motormounts-- they maybe loose.Blower

wheelcouldbeoutof balance.Setscrewmaybeloose

on motorshaft.Blowermayberubbingonfanshroud.

Motormayneedoiling.Correctas needed,

b, Checkinstallation-- casingmaybetwistedornotlevel

wheninstalled.Expansionslip joint maybe binding;

checkbyremovingventcapassemblyfromoutsidewall.

C, Duringnormalfurnaceoperation,motorwill be on

"LOW" speedwhenoperatingon minimum input

capacityandon"HIGH"speedwhenoperatingonmax-

imuminput capacity,If there is no changein motor

speed,replaceselectorswitch,

9. BurnercomesONbutgoesOFF 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)7332,550T332,4007331and5,507331. - Continued Next Page

--31 --

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.

SYMPTOM

1. Nospark-- no pilot gas.

2. Spark-- but no pilot gas.

POSSIBLECAUSE(S)

a. Nomainpower.

b. Faultytransformer,

c. Faultythermostat.

d. Faultylimit switch.

e. Faultyignitioncontrol.

f. Faultywiring.

a. Faultyignition.

b. No gas suppliedto pilot valve.

c. Manualvalvesin OFFpositions.

d. Faultypilot valve.

CORRECTIVEACTION

a.-e.Perform normal system checks of main power,

transformer,thermostat,limit switch,and replace

faulty component.

WithpowerON,turnthermostattothelowestsetting,

wait 10secondsandreturnto HIGHsetting.With

powerONandthermostatsetat itshighestposition,

set voltmeterto 24V scale and attach probesto

terminals"TR" and"TH" ontheignitioncontrolunit.

Ifyouread24Vandthereisstillnosparkorpilotgas,

the ignitioncontrolisdefectiveandmustbereplaced.

f. Testwiring. Repairor replace.

a. See1.e.

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.Alsocheckthepilotadjustment,atthegascontrol.

c. See2.b.

d. See2b.

e. Faultywiring.

f. Restrictedpilotlineorcloggedpilot

orifice.

e. See t.f.

' f. See2.b.

--32-- - Continued Next Page -

Troubleshooting Chart for Models

4007332, 5507332, 4007331 and 5507331

(Continued)

SYMPTOM

3. Pilot gas-- but no spark.

4. Pilotlit-- but mainburnerwon't

comeon.

POSSIBLECAUSE(S)

a. Faultyignitioncontrol

b. Broken or shorted electrode

assembly.

a. Faultyignitioncontrol.

b. Faultywiring.

c. Lowpilot flame.

CORRECTIVEACTION

a, WithpowerON,turnthermostatto the lowestsetting,

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"

terminalsonGasValve.Ifyoudo notgeta 24Vreading,

checkwiring,Ifwiringtestsokay,checkignitioncontrol.

b. Removewireat "COM" terminalat the ignitioncon-

trol,beingcarefulnotto touchanymetalparts;discon-

nectthe electrodewireattheignitioncontrol.Connect

oneendofthejumperwireto terminal"GND",(DONOT

REMOVEEXISTINGWIRE.)Attachtheotherendofthe

jumperwireto the metalbladeof a smallscrewdriver.

Positionendof metalbladeapprox,1/8"from"HIGH

VOLTAGE"(IGN)terminal.Reconnect"COM"terminal.

Sparkingshouldocccurbetweenecrev,_lriverbladeand

"HIGH VOLTAGE"terminal.

If no sparkingoccurs,the ignition controlmust be

replaced.

Checkthepilotandelectrodeassemblyforprobereleo

trode gap (3/32" to 1/8") or any possibleshortingof

electrodetosurroundingmetalsurfaces.Makesurethe

sparkignitorandelectrodeconnectionsto the ignition

controlaretight. The ignitioncontrolandpilot burner

mustbothbechassisground.If thereis stillno spark,

the pilot and electrodeassemblymust be replaced.

a. See3.a.

b. See 1.f,

C. NOTE:Waitatleast90secondsafterpilotlightsbefore

doingthecheckoutproceduresforproblemnumber4.

WiththermostatON,be surethatthepilotandsensor

areproperlyalignedso thatthe pilot flameimpinges

thetop 5/8inchof thesensor.Besurethatthe sensor

ispushedallthewayintopilotbracket.Adjustpilotflame

with pilot adjustment,if necessary.Alsocheckinlet

supply pressureand pilotorifice, If pilot hood or

sensorisbent,thedefectiveunitshouldbereplaced.

Ifmainburnerstillwon'tcomeON,makesurethemain

burner orifices are clear. If orificesare clear, set

voltmeterto24Vscaleandtouchprobestotheterminals

of the maingas operatoron the gasvalve;Attachto

terminal"M", "C" onGasValve.If youread24',/and

theburnerwon'tturnON,replacetheentiregasvalve.

- Continued Next Page -

--33--

Troubleshooting Chart for Models

4007332, 5507332, 4007331 and 5507331

SYMPTOM

4. Pilotlit -- but mainburnerwon't

comeON(continued).

POSSIBLE CAUSE(S)

d, Improperalignment of sensor in

pilot flame.

e. Faultyflamesensor.

CORRECTIVEACTION

a. Faultypilotvalve.

b. Faultywiring.

a. Lowpilot flame.

b. Improperalignmentof sensorin

pilotflame.

c. Pilotflamebeingdrownawayfrom

sensor.

d. WhenmainburnercomesON,ensurethatpilotflame

is strong,sensorisproperlyaligned,andthatpilotflame

impingesthetop5/8inchofthesensor(Seeprocedures

forcheckingforproperpilotflameandalignmentinpro-

blem4.c.)Checkthe pilotandelectrodeassemblyfor

properelectrodegap(3/32"to 1/8") or any possible

shortingof electrodeto surroundingmetalsurfaces.

Makesurethe sparkignitorandelectrodeconnections

tothe ignitioncontrolaretight.Theignitioncontroland

pilot burnermustbothbe chassisground.If thereis

still no spark,the pilotand electrodeassemblymust

be replaced.

e, BE SUREPOWERIS OFF,BEFOREPERFORMING

THISTEST_!

Settestmeterto "ohm"scaleorusecontinuitycheeke_

Touchoneendofprobestotipofflamesensor,theother

to "SENS"terminalontheignitioncontrol.Ohmmeter

shouldread"0", continuityshouldbe evident.If you

don'tobtainareading,removewiringfromsensorand

testbothindividually.Ifcontinuityis notevident,replace

wiringand/orsensor.

Thereshouldbe NO continuitybetweensensorand

"GND" terminalonthe ignitioncontrol.Testingwiring

andsensorindividually,determinewhichis shortedon

ground.Replaceor repair.TurnON Power.

5. PilotcyclesOFFandONbyitself, a. See2.b.

b. See l.f.

6. Mainburnershutsdownbefore a. See4.C.

thermostatis satisfied. b. See4.d.

d. Improperheatanticipatorsetting.

e. Faultylimit.

c. WhenmainburnercomesON,ensurethatthe pilot

flameisstrongandthe sensoris properlyalignedand

that the pilot flameimpingesthe top 5/8 inchof the

sensor.(Seeproceduresfor checkingfor properpilot

flameandalignmentin problem4.d.)Ifthepilotflame

is drawnawayfromthe sensorwhenthe mainburner

comesON,the causecouldbethemanualvalveis not

in the full ON position.

NOTE:Lowinletgas pressureto the gas controlcan

be causedbyseveralproblemsandis notwithinthe

scopeoftheproceduresoutlinedinthisserviceguide.

Consultyourlocalutilityor gassupplier.

d. see 6.c.

Checkthe settingof the heatanticipatorin the wall

thermostat,Setitto settingspecifiedonthegasvalve,

e. Thesystemmaybecyclingona faultylimit.Usinga

testmeter,settothe110voltscale,checkfor avoltage

readingacrossthe limitwhenthemainburnershuts

OFF.If yougeta 24 voltor110voltreadingonshut-

down,replacedefectivelimit.

--34---

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--

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 •

--36--

WILLIAMS DIRECT VENT

GAS-FIRED WALL FURNACE

FOR CONTROL ASSEMBLY MODELS-

4007332 & 4007331

WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE

REPLACEMENT PARTS LIST FOR MODELS --

4007332, 4007732, 4007331 and 4007731

REF.

NO.

DESCRIPTION

Outer Casing with Air Pan

Heating Element

Element Tube

Inner Liner

Deflector Baffle Handle

Fan Shroud

Top Trim Cover

Top Front Panel

Center Front Panel

Bottom Front Panel

Element Face Cover

Limit Switch

Fan Switch

Motor

Motor Support (2 Req.)

Transformer

4007332

11 C42-2

11C67

11C37

11B46

11C63

11B86

11A40

11B102

11C62

11B103

11A103

P200300

P200200

P151101

7B46

P024200

11A152

18 P022800

19 P200600

20 11B05

21 11C68

23 11A18

24 P200900

25 P151900

26 P103100

27 11C09

28 11A07

29 11B49

,_ 4701

31 6701

Internal Wires (Except Ignition Control Wires For Models

4007332 & 4007331)

Vibration Mounts (4 Req.)

Fan Blade

Switch Box

Switch Box Cover

Peep Hole Cover

Element Face Gasket

Air Pan Tunnel Gasket

Seal Gasket

Vent Cap

Flue Extension -- 9801 Kit

Air Inlet Extension

,it 4701 Trim Strip Kit

* Inner Boot

* Outer Boot -- 6701 Side Outlet Kit 10" Boots

* Plaster Ground

6702 Side Casing Grille Kit

* 6703 Diffusing Grille Kit - Two-Way

* 6704 Diffusing Grille Kit -One-Way

Gasket, Burner Pan (2 Req.)

Owner's Manual

PART NO. FOR MODEL:

4007732 4007331

11C42-2 11C42-2

11C67 11C67

11C37 11C37

11B46 11B46

11C63 11C63

11B86 11B86

11A40 11A40

11B102 11B102

11C62 11C62

11B103 11B103

11A103 11A103

P200300 P200300

P200200 P200200

P151101 P151101

7B46 7B46

P024200 P024200

11A152 11A152

P022800 P022800

P200600 P200600

11B05 11B05

11C68 11C68

12B40 11A18

P200900 P200900

P151900 P151900

P103100 P103100

11C09 11C09

11A97 11A97

11B49 11B49

4701 4701

6701

33 6702 6702

34 6703 6703

6704 6704

34A P321020 P321020

._ P321004 P321004

* Not available separately, in kit form only

NOTE: Screws and bolts are standard hardware items, available locally.

Not shown. Continued

4007731

11C42-2

11C67

11C37

11B46

11C63

11B86

11A40

11B102

11C62

11B103

1tA103

P200300

P200200

F151101

7B46

P024200

11A152

P022800

P200600

11B05

11C68

12B40

P200900

P151900

P103100

tlC09

11A97

11B49

4701

6701 6701

6702 6702

6703 6703

6704 6704

P321020 P321020

P321004 P321004

For paM illu_ration see page 35,

--37--

WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE

REPLACEMENT PARTS LIST FOR MODELS (Con't) --

4007332, 4007732, 4007331 and 4007731

REF.

NO.

4007332

11S58

P151700

P090500

P025600

P026200

11C64-2

DESCRIPTION

Manifold

Manifold Gasket

Orifice Fitting, Specify Model & Gas

Burner, Cast Iron, Nat. or L.P.G.

Locknut (2 Req.)

Burner Pan

Valve, Williams Nat.

Valve, Williams L.P.G,

Valve, Williams Nat.

Valve, Williams L.P.G.

Pilot, Cast Iron Burner, L.P,G.

Pilot, Cast Iron Burner, Nat.

Thermocouple

Flame Sensor

Pilot Tube Gasket

Pilot Tube Seal

Gasket 44 inch

Burner Spacer, Cast Iron Burner

Thermostat

Ignition Control Unit, Williams

Piezo Gas Lighter (Manual Spark Lighter)

Manifold Adapter

Ignition Shield

Ignition Control Wires

4007731

11B58

P151700

P090500

P025600

P026200

11C64-2

PART NO. FOR MODEL:

4007732 4007331

11B58 11B58

P151700 P151700

P090500 P090500

P025600 P025600

P026200 P026200

11C64-2 11C04-2

P322041

-- P322044

-- P229200

P229100

P254000

-- P271100

P151800 P151000

11A41 11A41

P101600 P101600

P018100 P018100

P322017 P322017

-- P321910

P285500

P321888 P321887

-- 7C79

-- 31 B036

41 m _

-- P322042

P322043

42 -- P229200

P229100

43 -- P254000

P271100

44 P151800 P151800

45 11A41 11A41

46 P101600 P101600

47 P018100 P018100

48 P322017 P322017

49 P321910 --

50 -- P285500

53 P321887 P321808

54 7C79 --

31B036 --

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--

WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE

FURNACE ASSEMBLY FOR MODELS --

5507332 and 5507331

CABINET and BODY

ASSEMBLY

USE ONLY MANUFACTURER'S

AUTHORIZED PARTS

FOR PARTS LIST

SEE PAGE 41

--39--

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--

WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE

REPLACEMENT PANTS LIST FOR MODELS --

5507332 and 5507331

REF.

NO.

36A

DESCRIPTION

Outer Casing with Air Pan

Heating Element

Element Tube

Inner Liner

Deflector Baffle Handle

Fan Shroud

Top Trim Cover

Top Front Panel

Center Front Panel

Bottom Front Panel

Element Face Cover

Limit Switch

Selector Switch

Fan Switch

Motor

Motor Support (2 Req.)

Transformer

Internal Wires (Except ignition control wires)

Vibration Mounts (4 Req,)

Fan Blade

Switch Box

Switch Box Cover

Peep Hole Cover

Element Face Gasket

Air Pan Tunnel Gasket

Seal Gasket

Vent Cap

Flue Extension -- 9801 Kit

Air Inlet Extension

*4701 Trim Strip Kit

_r Inner Boot

* Outer Boot

* Plaster Ground

6702 Side Casing Grille Kit

6703 Diffusing Grille Kit -Two-Way

6704 Diffusing Grille Kit -One-Way

Gasket, Burner Pan (2 Req.)

-- 6701 Side Outlet Kit

PART NO. FOR MODEL:

5507332

11C42-1

11C66

11C37

7B79

11C63

11B86

11A40

11B102

11C59

ttB103

11A103

P296001

P200400

P200200

P062101

7B46

P024200

7A194

P022800

P200600

11B05

11C68

12B40

P200900

P151900

P103106

11C09

11A97

11B49

4701

6701

5507331

11C42-1

11C66

11C37

7B79

11C63

11B86

11A40

11Bt02

11C59

11B103

11A103

P296001

P2OO400

P200200

P062101

7B46

P024200

7A194

P022800

P200600

11B05

11C68

12B40

P2O090O

P151900

P103100

11C09

11A97

11B49

4701

6701

6702 6702

6703 6703

6704 6704

P321020 P321020

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--

WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE

REPLACEMENT PARTS LIST FOR MODELS (Con't) --

5507332, 6257732, 5507331 and 6257731

RER

NO, DESCRIPTION

43 P322043

P229100

P271100

46 P151800

47 11A41

48 P101600

49 P018100

50 P322017

51 P321910

56 P321887

57 7C79

31B036

,* Not available separately, in kit form only

NOTE: Screws and bolts are standard hardware items, available locally.

_r Not shown.

Manifold

Manifold Gasket

Orifice Fitting, Specify Model &Gas

Burner, Cast Iron, Nat. or L.P.G, (2 req.)

Locknut (2 Req)

Burner Pan

Valve, Williams Nat.

Valve, Williams L.P.G.

Valve, Williams Nat.

Valve, Williams L.P.G

Pilot, Cast Iron Burner, L.P.G.

Pilot, Cast Iron Burner, Nat

Thermocouple

Flame Sensor

Pilot Tube Gasket

Pilot Tube Seal

Gasket 44 inch

Burner Spacer, Cast Iron Burner

Thermostat

Ignition Control Unit, Williams

Piezo Gas Lighter (Manual Spark Lighter)

Manifold Adapter

Ignition Shield

Ignition Control Wires

5507332

11B57

P151700

P090500

P025600

P026200

11C64-1

PART NO. FOR MODEL:

6257732 5507331

11B57 t1B57

P151700 P151700

P090500 P090500

P025600 P025600

P026200 P026200

11C64-1 11C64-1

P322041

P229100

P254000

P151800

11A41

P101600

P018100

P322017

P285500

P321688

6257731

11B57

P151700

P090500

P025600

P026200

11C64-1

-- P322042

P322044

P229200 P229200

-- P254000

P271100

P151800 P151800

11A41 11A41

P101600 P101600

P018100 P018100

P322017 P322017

P321910

-- P285500

P321887 P321866

7C79

31B036

For pad illustr_ion see page 40.

--42--

WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE

FURNACE ASSEMBLY FOR MODELS --

6257732 and 6257731

CABINET and BODY

ASSEMBLY

USE ONLY MANUFACTURER'S

AUTHORIZED PARTS

FOR PARTS LIST

SEE PAGE 44

--43--

WILLIAMS DIRECT VENT WALL FURNACE

REF.

NO.

37A

REPLACEMENT PARTS LIST FOR MODELS-

6257732 and 6257731

DESCRIPTION

OUTER CASING W/. AIR PAN

AIR PAN TUNNEL GASKET

INNER LINER

HEATING ELEMENT

PEEPHOLE COVER

BURNER PAN GASKET (2 RE(;}.)

BOTTOM FRONT PANEL

CENTER FRONT PANEL

BOTTOM AIR DEFLECTOR

PART

6257732

11C42-1

P151900

11B120

11C66

12B40

P521020

11B103

11C59

11B125

CENTER AIR DEFLECTOR

SELECTOR SWITCH

FAN SWITCH

SWITCH BOX COVER

SWITCH BOX

SEAL GASKET

ELEMENT BAFFLE

LIMIT SWITCH

TOP AIR DEFLECTOR

TOP FRONT PANEL

FAN SHROUD

11Bl19

P20O40O

P200200

11C68

11B05

P105100

11Bl16

P521942

11Bl19

11B102

11B86

NO. FOR MODEL:

6257731

11C42-1

P151900

11B120

11C66

12B40

P321020

11B105

11C59

11B125

11Bl19

P200400

P200200

11C68

11B05

P103100

11Bl16

P521942

11Bl19

11B102

11B86

ELEMENT FACE GASKET

FAN BLADE

MOTOR

MOTOR SUPPORT (2 REQ.)

VIBRATION MOUNTS (4 REQ.)

TRANSFORMER

INTERNAL WIRES

ELEMENT TUBE

TOP TRIM COVER

VENT CAP

FLUE EXTENSION - 9801 KIT

AIR INLET EXTENSION

_" INNER BOOT

_'OUTER BOOT 6701 SIDE

PLASTERGROUND OUTLET KIT

"_6702 SIDE CASING GRILLE KIT

_'6705 DIFFUSING GRILLE KIT - 2 WAY

_'6704 DIFFUSING GRILLE KIT - 1 WAY

_'4701 TRIM STRIP KIT (NOT SHOWN)

P304000

P200600

P321601

7B46

P022800

P024200

6257752

11C57

11A40

11C09

11A97

11B49

6701

6702

6705

6704

4701

_" Not available separately, in kit form only. For parts Illustration

NOTE: Screws and bolts are standard hardware Items, available locally.

P504000

P200600

P321601

7B46

P022800

P024200

6257751

11C37

11A40

11C09

11A97

11B49

6701

6702

6703

6704

4701

see page 45

--44--

Service Record

DATE MAINTENANCE PERFORMED COMPONENTS REQUIRED

.--45 m

-- Notes --

--46--

-- Notes --

owners

manual

SERVICE

MODEL NOS.

4007332

4007732

5507332

6257732

4007331

4007731

5507331

6257731

Service Hints

If your furnace fails to work right, you may avoid inconvenience and the cost

of a service call by checking the following points before you call for service.

FOR YOUR SAFETY FOR YOUR SAFETY

Do not store or use gasoline If you smell gas:

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.

POSSIBLE CAUSE WHAT TO DO

If fan motor is noisy --

Housing rattling.

Fan dirty.

Fan blade bent.

Motor bearings need oiling.

Tighten screws.

Clean fan blade.

Replace fan blade.

Oil motor.

If fan does not run -

Fuse blown or tripped circuit

breaker.

Motor bearings need oiling.

Replace fuse or reset breaker.

Oil motor.

If burner is noisy --

Pilot observation door loose or

missing. (peep hole cover)

Tighten wingnut or replace

door.

If your furnace is not heating or not giving enough heat --

Replace fuse or reset breaker,Fuse blown or tripped circuit

breaker.

Thermostat is not set correctly.

Air flow restricted.

Reset thermostat to desired

setting.

Check that doors, drapes or

furniture are not blocking

furnace louvers.

If your furnace short cycles --

Thermostat anticipator not set

correctly.

Set anticipator (See Page 11).

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

225 Acacia Street

Colton, CA 92324 USA

(909) 825-0993

MANUFACTURED

IN THE U.S.A.

Established 1916

FAX: (909) 824-8009

WILLIAMS Furnace/Heater, Gas Manual L0408178

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