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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
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Summary of Contents for Williams 6257731
- Page 1 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...
- Page 2 Contents Your Williams Warranty ......Vent Installation ......12-13 Introduction ........Mounting Your Furnace ..... 14-15 Basic Description ......Gas Supply and Piping ...... 15-16 Optional Accessories ......Electrical Wiring ......Helpful Installation Information ....Start Up Procedure ......Safety Rules .........
- Page 3 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,...
- Page 4 Safety Rules WARNING umn. The maximum inlet gas supply pressure is 13" water column. READ THESE RULES AND THE INSTRUCTIONS CAREFULLY. FAILURE FOLLOW THESE ANY SAFETY SCREEN, GUARD OR PARTS RE- RULES AND INSTRUCTIONS COULD CAUSE A MOVED FOR SERVICING AN APPLIANCE MUST BE MALFUNCTION OF THE FURNACE.
- Page 5 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.
- Page 6 Installing Your Wall Furnace 1. Properly locate the furnace within the space to be The following steps are needed for proper installation and heated. safe operation of your furnace. If you have any doubts as to any requirements, check with local authorities for local 2.
- Page 7 Locating Wall Furnace & Thermostat (ton't) 10. Be sure to provide adequate clearance and service access. The front of the furnace must face the open room. 11. Choose a location for the thermostat about 5 feet r-- -- -- _ VENT above the floor on an inside wall.
- Page 8 Recessed Mount Installation (Con't) 4. Using the hole drilled through to the outside wall as the center, cut a 91/4 inch diameter hole for the vent. It may be better to work from outside, especially when CEJUNC --F} breaking through brick, stone or tile.
- Page 9 Recessed Mount Installation (Con't) GAS AND ELECTRICAL SUPPLY OPENINGS run wires up through adjoining stud space from crawl space or basement. Holes must be drilled for the gas line and electrical sup- ply. Holes must be located from each side of furnace as Run the electrical supply with ground wire and thermostat shown in Fig.
- Page 10 Surface Mount Installation (Con't) ROUGH-IN OPTIONAL SIDE OUTLET NO. 6701 5. Fasten metal filler strips to side of furnace casing with front surface exactly opposite front of wood backup Install plasterground as shown in Figs. 11 & 12. Flanges strip. of plasterground extend the thickness of normal piaster.
- Page 11 Thermostat Installation 1. If an old thermostat is being replaced and is in a MOUNTING THE THERMOSTAT satisfactory location and the wiring appears to be 1. To remove thermostat cover, squeeze cover and pull in good condition, use existing wiring. If in doubt, use straight outward (see Fig.
-
Page 12: Vent Installation
Thermostat Installation (Con't) When all is adjusted properly, the furnace burner should shut off slightly before the desired room temperature 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. - Page 13 Vent and Inlet Tube Installation (Con't) MOUNT FURNACE THROUGH WALL NOTE Mount the furnace through the wall using surface or Each tube must overlap the collars of the vent cap a minimum of 1 1/4 inch, which is obtained when recessed mounting instructions.
- Page 14 Mounting Your Furnace FASTEN FURNACE BOTTOM To obtain adequate clearance for fastening furnace or to install gas supply fittings, it may be necessary to remove (Surface and Recessed Mount) the burner and control assembly as follows: NOTE Fasteners are not furnished because of different CAUTION requirements of various types of wall construction.
-
Page 15: Mounting Your Furnace
Mounting Your Furnace (ton't) FASTEN FURNACE TOP (Recessed Mounting) Fasten furnace top by drilling (2) holes through side flange Be careful not to damage furnace components or furnace top and securing with (2) screws or nails to wall wiring when drilling holes. CAUTION studs. - Page 16 Gas Supply and Piping (Con't) Connection between shutoff valve and burner control 4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. Drip leg must be a minimum of 3 assembly can be made with an A.G.A./C.G.A. design cer- inches long.
- Page 17 Electrical Wiring ELECTRICAL POWER SUPPLY WARNING DANGER OF PROPERTY DAMAGE, A branch circuit including this furnace must not exceed BODILY INJURY OR DEATH. 15 amperes or run a separate 115V., 60 Hz., 15 Ampere TURN OFF ELECTRIC POWER AT FUSE BOX circuit from a separate circuit breaker or fuse in your serv- OR SERVICE PANEL BEFORE...
-
Page 18: Operating Your Furnace
Start-Up Procedure Start the furnace using procedures in section CHECK THE GAS INPUT (NATURAL GAS ONLY) OPERATING YOUR FURNACE. Pages 19 thru 24. WARNING WARNING NATURAL GAS HEATING VALUE (BTU PER CUBIC FOOT) CAN VARY SIGNIFICANTLY, THEREFORE, DANGER OF PROPERTY DAMAGE, IT IS THE INSTALLER'S RESPONSIBILITY TO SEE BODILY INJURY OR DEATH. - Page 19 THE FURNACE WITH BROKEN MISSING PILOT OBSERVATION NOTE: DOOR. 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 For models equipped with WILLIAMS gas valve APPLIANCE."...
- Page 20 FOR YOUR SAFETY, READ BEFORE LIGHTING I 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 a pilot which must be lighted • If you cannot reach your gas supplier, call the fire hand,...
- Page 21 FOR YOUR SAFETY, READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life, • If you cannot reach your gas supplier, call the fire This appliance has a pilot which must be lighted department.
- Page 22 FURNACE WITH BROKEN MISSING PILOT OBSERVATION NOTE: DOOR. For models equipped with WILLIAMS gas valve P322043 or P322044 refer to this sheet and sheet 23 for "SAFETY & LIGHTING INSTRUCTION" and "TURN GAS OFF TO For models equipped with WILLIAMS gas valve APPLIANCE."...
- Page 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. • if you cannot reach your gas supplier, call the fire This appliance is equipped with an ignition...
- Page 24 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 • If you cannot reach your gas supplier, call the fire department.
-
Page 25: How To Care For Your Furnace
How To Care For Your Furnace WARNING PILOT BURNER DANGER OF BODILY INJURY OR DEATH Light pilot using instructions in OPERATING YOUR FURNACE (on Pages 19 thru 24, depending on your TURN ELECTRIC POWER SUPPLY model). DISCONNECT SWITCH, FUSE BOX OR SERVICE PANEL BEFORE REMOVING ANY DOORS OR... - Page 26 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 SUPPLY ARE OFF BEFORE REMOVING PANELS OR DOORS, ETC.
-
Page 27: Wiring Diagrams
WIRING DIAGRAMS FOR MODELS 4007732 and 4007731 6257732 and 6257731 FOR 62.5M B.T.U. FOR 40M B.T.U. FAN TYPE DIRECT VENT WALL FURNACE FAN TYPE DIRECT VENT WALL FURNACE WITH CONTINUOUS PILOT CONTROL SYSTEM WITH CONTINUOUS PILOT CONTROL SYSTEM L1 __ 115v 60HZ HOT| NEUT... - Page 28 WIRING DIAGRAMS FOR MODELS 4007332 and 4007331 5507332 and 5507331 FOR 40M B.T.U. FOR 55M BT.U. FAN TYPE DIRECT VENT WALL FURNACE FAN TYPE DIRECT VENT WALL FURNACE WITH INTERMtTFENT IGNITION CONTROL SYSTEM WITH INTERMITI-ENT IGNITION CONTROL SYSTEM 1.1 |. 115V8ONZ .| L2 HOTi_...
- Page 29 Troubleshooting Chart for Models 4007732, 6257732, 4007731 and 6257731 SYMPTOM CORRECTIVE ACTION POSSIBLE CAUSE(S) 1. Pilotwill not staylit afterfollow- a. Thermocoupleproducinginsuffi- Checkpilot flame-- mustimpingeon thermocouple. ing lighting instructions. cient millivoltage. Pilotflame maybe lowor blowing(high)causingsafe- ty todropout.Pilotorificeoraerating holemaybeplugg- ed (checkforspiders,websor otherorganicmaterial). Besurethe thermocouple is fully insertedin bracket.
- Page 30 Troubleshooting Chart for Models 4007732, 6257732, 4007731 and 6257731 (Continued) CORRECTIVE ACTION SYMPTOM POSSIBLE CAUSE(S) 2 Mainburnerwill notcomeon -- b Electric powerto furnaceturned b. Checkfor linevoltage atfurnace-- if okayandnomain gas flow,proceedto Step"c". pilotburningandthermostatset for heat (continued) c. Low voltage transformeror limit Checkfor 24 volts at the lowvoltageterminalsof the switch defective transformer.
- Page 31 Troubleshooting Chart for Models 4007732, 6257732, 4007731 and 6257731 (Continued) CORRECTIVE ACTION SYMPTOM POSSIBLE CAUSE(S) e. Detective f an switch. 3. Burner comes ON, but goes e. If, after checking above possibilities,problem still OFF before blower turns ON exists,replacefan switch (continued).
- Page 32 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.
- Page 33 Troubleshooting Chart for Models 4007332, 5507332, 4007331 and 5507331 (Continued) CORRECTIVE ACTION SYMPTOM POSSIBLE CAUSE(S) a. Faultyignitioncontrol With power ON, turnthermostatto the lowestsetting, 3. Pilot gas-- but no spark. wait 10seconds and returnto high setting. W ith power ON and thermostatset at its highest position, set voltmeterto 24Vscaleand attachprobesto terminals "TR"...
- Page 34 Troubleshooting Chart for Models 4007332, 5507332, 4007331 and 5507331 SYMPTOM CORRECTIVE ACTION POSSIBLE CAUSE(S) 4. Pilotlit -- but mainburnerwon't d. WhenmainburnercomesON,ensurethat pilotflame d, Improperalignment of sensor in is strong, s ensorisproperly aligned, a ndthatpilotflame pilot flame. come ON(continued). impinges thetop5/8inchofthesensor(Seeprocedures forchecking forproperpilotflameandalignment i n pro- blem4.c.)Checkthe pilotand electrode assemblyfor properelectrodegap (3/32"...
-
Page 35: Repair Parts
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--... - Page 36 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 ONLY MANUFACTURER'S AUTHORIZED PARTS • WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE FOR CONTROL ASSEMBLY MODELS- 4007332 &...
- Page 37 WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE REPLACEMENT PARTS LIST FOR MODELS 4007332, 4007732, 4007331 and 4007731 PART NO. FOR MODEL: REF. 4007731 4007332 4007732 4007331 DESCRIPTION 11C42-2 11 C42-2 11C42-2 11C42-2 Outer Casing with Air Pan 11C67 11C67 11C67 11C67...
- Page 38 P101600 P101600 P101600 Burner Spacer, Cast Iron Burner P018100 P018100 P018100 P018100 Thermostat P322017 P322017 P322017 P322017 Ignition Control Unit, Williams P321910 P321910 Piezo Gas Lighter (Manual Spark Lighter) P285500 P285500 Manifold Adapter P321887 P321888 P321887 P321808 Ignition Shield 7C79...
- Page 39 WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE FURNACE ASSEMBLY FOR MODELS 5507332 and 5507331 CABINET and BODY ASSEMBLY FOR PARTS LIST SEE PAGE 41 USE ONLY MANUFACTURER'S AUTHORIZED PARTS --39--...
- Page 40 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...
- Page 41 WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE REPLACEMENT PANTS LIST FOR MODELS 5507332 and 5507331 PART NO. FOR MODEL: REF. DESCRIPTION 5507332 5507331 11C42-1 Outer Casing with Air Pan 11C42-1 Heating Element 11C66 11C66 Element Tube 11C37 11C37 Inner Liner 7B79...
- Page 42 P101600 P018100 P018100 P018100 P018100 Burner Spacer, Cast Iron Burner Thermostat P322017 P322017 P322017 P322017 P321910 P321910 Ignition Control Unit, Williams P285500 P285500 Piezo Gas Lighter (Manual Spark Lighter) P321887 P321688 P321887 P321866 Manifold Adapter 7C79 7C79 Ignition Shield 31B036...
- Page 43 WILLIAMS DIRECT VENT GAS-FIRED WALL FURNACE FURNACE ASSEMBLY FOR MODELS 6257732 and 6257731 CABINET and BODY ASSEMBLY FOR PARTS LIST SEE PAGE 44 USE ONLY MANUFACTURER'S AUTHORIZED PARTS --43--...
- Page 44 WILLIAMS DIRECT VENT WALL FURNACE REPLACEMENT PARTS LIST FOR MODELS- 6257732 6257731 REF. PART MODEL: DESCRIPTION 6257732 6257731 11C42-1 OUTER CASING 11C42-1 AIR PAN TUNNEL GASKET P151900 P151900 INNER LINER 11B120 11B120 HEATING ELEMENT 11C66 11C66 PEEPHOLE COVER 12B40 12B40...
- Page 45 Service Record DATE MAINTENANCE PERFORMED COMPONENTS REQUIRED .--45 m...
- Page 46 Notes --46--...
- Page 47 Notes...
- Page 48 All parts listed herein may be ordered from your equip- information: ment supplier. 1. MODELNUMBER The Model Number of your Williams wall furnace will be 2. MFG.DATE CODE found on the rating plate near gas valve, inside control 3. PART NUMBER compartment.