Williams 4003532 Quick start guide

WINDOW WALL FURNACE
DIRECT VENT NATURAL GAS HEATER
OWNER'S OPERATION AND INSTALLATION MANUAL
25,000 and 40,000 Btu/Hr Furnaces
Model Numbers 2503532 and 4003532
WARNING: If the information in this manual is not followed exactly, a fire or
explosion may result causing property damage, personal injury, or oss 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
• 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 performed by a qualified installer, service
agency, or the gas supplier.
WARNING: Improper installation, adjustment, alteration, service, or mainte-
nance can cause injury or property damage. Refer to this manual for correct
installation and operational procedures. For assistance or additional information
consult a qualified installer, service agency, or the gas supplier.

[]
CONTENTS SECTION PAGE 1
S_etyInforma_on................................................................................................3
Local Codes .......................................................................................................... 4
Unpacking.............................................................................................................5
Product_ ...................................................................................................5
Specifications ....................................................................................................... 5
Installing Furnace ................................................................................................. 6
C-_k aas Xype.............................................................................................6
Installation Items ............................................................................................ 6
I.,ocating Furnace ............................................................................................ 6
Creating Wall Opening and Mounting Furnace ............................................. 8
Installing Thermostat ..................................................................................... 9
Connecting to Gas Supply ........................................................................... 13
Checking Gas Connections .......................................................................... 18
Connecting to Electrical Supply .................................................................. 19
Attaching Cabinet Front Cover .................................................................... 19
OperatingFurnace..............................................................................................20
For Your Safety Read Before Lighting ........................................................ 20
Operating Instructions .................................................................................. 21
To Tun_ OffGas to Furnace ......................................................................... 22
Thermostat Control Operation ..................................................................... 22
Inspecting Burner Flame .................................................................................... 22
Normal Operating Sequence ............................................................................... 23
Cleaning and Maintenance ................................................................................. 24
Troubleshooting .................................................................................................. 25
Wiring Diagrams ................................................................................................ 28
Service Hints ...................................................................................................... 28
Technical Service ............................................................................................... 28
Ordering Replacement Parts ............................................................................... 29
Illuswated Parts List ....................................................................................... 29-36
Warranty Information .......................................................................... Back Cover

SAFETY
INFORMATION WARNINGS
IMPORTANT: Read this owner's manual carefully and completely before
trying to assemble, operate, or service this furnace. Improper use of this
furnace can cause serious injury or death from burns, fire, explosion,
electrical shock, and carbon monoxide poisoning.
DANGER
Carbon monoxide poisoning may lead to death!
Carbon Monoxide Poisoning: Early signs of carbon monoxide poisoning
resemble the flu, with headaches, dizziness, and/or nausea. If you have these signs,
the furnace may not be working properly. Get fresh air at once! Have furnace
serviced. Some people are more affected by carbon monoxide than others. These
include pregnant women, people with heart or lung disease or anemia, those under the
influence of alcohol, and those at high altitudes.
Natural Gas: Natural gas is odorless. An odor-making agent is added to natural gas.
The odor helps you detect a natural gas leak. However, the odor added to natural gas
can fade. Natural gas may be present even though no odor exists.
Make certain you read and understand all Warnings. Keep this manual for reference.
It is your guide to safe and proper operation of this furnace.
1. A qualified service person must install furnace.
2. Use only natural gas. Do not convert furnace to use different fuel type.
3. If you smell gas
• Shut off gas supply.
• Do not try to light any appliance.
• Do not touch any electrical 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.
4. Do not block the flow of combustion air (outside air)_or heated air (room air)
to the furnace.
5. This furnace must have fresh air f°r pr°per °perati°n" If n°t' P°°r fuel c°mbusti°n
and improper venting of flue gases will result. Carbon monoxide poisoning from
backed-up flue gases could occur. The State of California lists carbon monoxide
as a reproductive toxin under Proposition 65.
6. Never install the furnace
• in a recreational vehicle
• on an inside wall
• in high traffic areas
• behind a door or where an open
door would block normal air flow
• in an alcove
• as a fireplace insert
• in windy or drafty areas
.Provide the following minimum furnace clearances from furnace front cover
to combustibles (as viewed from the front of furnace):
Below Front Cover: 6 inches
Adjoining Wall: 12 inches
Above Front Cover: 12 inches
Front: 8 feet
I!
201842

SAFETY
INFORMATION
Continued
LOCAL CODES
!1
AWARNINGS Continued
8. Provide the following minimum furnace clearances from furnace cabinet (por-
tion of cabinet extending into outside air,as viewed from the rear of furnace):
Cabinet Back: 36 inches
Cabinet Sides: 6 inches
Cabinet Bottom: Must behigh enough off thegroundto preventsnow, water,
leaves, or any other objects fromblocking cabinet vents.
9. Always follow lighting instructions. Never attemptto light burnerwith a match
orbutane torch.
10.Do not run furnace
• where flammable liquids or vapors are used orstored
•underdusty conditions
11.Never placeclothing orany flammable objects on the furnaceor venting system.
12.Furnace and venting system surfaces are very hot during operation. Keep
children and adults away from hot surfaces to avoid burns orclothing ignition.
Carefully supervise young children when they are in thesame room as furnace.
Furnace will remain hot for a time after shutdown. Let surface cool before
touching.
13.Do not use furnace as a cooking device.
14.Do not alter furnace or its controls. Any change may create a safety hazard.
15.TtLrnOfffurnace and unplug and let cool before servicing. Unless you need gas
supply for testing, shut off manual shutoff valve before servicing. Only a
qualified service person should service and repair furnace and venting system.
16.Replace any safety screen or guard removed for servicing before running
furnace.
17.DOnot use furnaceif anyparthas been underwater.Immediately call a qualified
service person toinspect the furnace and toreplace any partof thecontrol system
andany gas control which has been underwater.
Install and use furnace with care. Follow all local codes. In the absence of local
codes, use the latest edition of the following:
• National Fuel Gas Code ANSI 7-..223.1, also known as NFPA 54 *
•National Electrical Code ANSI/NFPA 70 *
•National Standard of Canada CAN/CGA-B149.2-M91 **
*Available from:
**Available from:
American National Standards Institute, Inc.
1430 Broadway
New York, N'Y"10018
National Fire Protection Association, Inc.
Batterymarch Park
Quincy, MA 02269
StandardsCouncil of Canada
350 Sparks Street
Ottawa. Ontario
KIR 7S8
This furnace must be grounded when installed. Follow all local codes. In the
absence of localcodes,refer to the National Electrical Code ANSI/NFPA No. 70
(U.S.A.) or CSA C22.1 Canadian Electrical Code, Part I (Canada).
201_

LOCAL CODES
Continued
UNPACKING
PRODUCT
FEATURES
SPECIFICATIONS
When installing furnace in a manufactured home (mobile home), follow the Manu-
factured Home Construction and Safety Standard, Title 24CFR, Part 3280 (for-
merly the Federal Standard for Mobile Home Construction and Safety, Title 24,
part 280; 1975). When such a standard is not applicable, follow the Standard for
Manufactured Home Installations, 1982 (Manufactured Home Sites, Communities
and Set-Ups), ANSI A225.1/NFPA 501A.
In Canada, install furnace in accordance with Standard CSA Z240.4 -Gas
Equipped Recreational Vehicles and Mobile Housing and any applicable local
codes and regulations.
I. Remove furnace from carton.
2. Remove all protective packaging applied to furnace for shipment.
3. Remove the following items from carton:
• Hardware package containing four large screws, two small screws, and ther-
mostat mounting plate
• Hardware package (thermostat and two screws)
• Manual shutoff valve
If any of these items are missing, promptly inform dealer where you bought
furnace.
4. Check furnace for any shipping damage. If furnace is damaged, promptly
inform dealer where you bought furnace.
Hot Surface Ignitor
This furnace has an electronic ignitor. There is no standing pilot. No matches or
batteries are required.
Thermostatic Heat Control
The thermostat is temperature sensitive. It automatically turns the furnace on and
off. This results in the greatest heating comfort. This can also result in lower gas
bills.
Limit Switch
The limit switch shuts off the gas to the main burner if the furnace becomes too hot
to operate safely.
25,000 Btu/Hr 40,000 Btu/Hr
Model Model
Rated Heating Input (Btu/Hr) 25,000 40,000
Type Gas Natural Only Natural Only
Ignition Hot Surface Ignitor Hot Surface Ignitor
Operating Amps 1.5 2
Volts/Cycles 120/60 120/60
Main Burner 1 2
Pressure Regulator Setting 3.5" W.C. 3.5" W.C.
Inlet Gas Pressure (in. of water)*
Maximum 7" 7"
Minimum 5" 5"
Dimensions, Inches (H x W x D)
Furnace 15 3/_2x 16 1/6x 23 5/8
Weight (pounds)
Furnace 53 71
Shipping 65 98
15 V3_x 21 V4x 23 V8
¢ For purposes of input adjustment.
_1_2

m
INSTALLING
FURNACE
Mounting hardwareneeded to mount furnace into wall is included with the famece.
No venting material is needed. You must famish tools and all gas piping from the
gas source to the furnace inlet.
AWARNING
A qualified service person must install furnace. Have service person
inspect furnace before use and at least annually. Follow all local codes.
NOTICE
This furnace must be electrically grounded. Follow all local codes.
In the absence of local codes, follow the National Electric Code,
ANSIINFPA 70 (U.S.) or Canadian Electrical Code Part I-CSA C22.1
(Canada).
CHECK GAS TYPE
Use only naturalgas. If your gas supply is not natural gas, do not install famace.
Call dealer where you bought furnace for proper type furnace.
INSTALLATION ITEMS
Before instalfing furnace, make sureyou have all items below.
•electric drill
•drill bits
• Phillips screwdriver
• hammer
• pipe wrench
• stud locator or small finishing nails
• manual shutoff valve (supplied)
• test gauge connection (see Figure 15,
page 17)
•piping (check local codes)
• sealant (resistant to propane gas)
•ground joint union
•sediment trap
• tee joint
LOCATING FURNACE
This furnace is designed to be mounted in a wall that is 4 to 18 inches thick. You
can also mount furnace in a window.
AWARNING
DO not install furnace in Interior wall of building. You must install
furnace in exterior wall of building. Rear of furnace must extend
into open, outside air. This lets poisonous exhaust gases ventilate
to the outdoors.
WARNING
Turn off electrical circuits that pass through the wall where you
ere going to Install the furnace.
WARNING
Malntaln the mlnlmum clearances shown In Flgure I, page 7. If
you can, provlde greater clearances from floor, celllng, and
Joining wall.
2O1842

INSTALLING
FURNACE
(Continued)
201842
AWARNING
Never install the furnace
• in an inside wall
•in a recreation vehicle
• in a window recessed in a thick wall (creating an alcove)
• in an alcove
•behind a door or where an open door would block normal air flow
•as a fireplace insert
•in high traffic areas
•near furniture or draperies
•in windy or drafty areas
IACAUTION
If you install the furnace in a home garage, locate furnace where
moving vehicle will not hit it,
For convenience and efficiency, install furnace
• where there is easy access for operation, inspection, and service
• in a central location, near an electrical outlet
• where there is adequate clearance around vents outside
Before installing furnace, inspect the wall, floor, and outside areas. Make sure there
are no pipes, wiring, or anything else that would interfere with furnace installation.
If you are installing thermostat in wall, make sure there are no pipes or wiring in
the hollow wall above the furnace. The thermostat wires will pass through this wall
from the attic.
Minimum Clearances
Provide the following minimum clearances from furnace front cover to combus-
tibles (as viewed from the front of furnace, see Figure l):
Above Front Cover: 12 inches
Front: 8 feet
Below Front Cover: 6 inches
Adjoining Wall: 12 inches
Ceiling
Adjacent
Side
Well
J
T
12" Minimum
*--12"--_
_inimuml
6"Minimum
FinishedRoor, Car_t, Tile, etc.
Figure I - Mounting Clearances as Wewed from Front of Furnace
The clearance between the cabinet and the wall it passes through is 0inches.
Provide the following minimum clearances from furnace cabinet (portion of cabinet
extending into outside air, as viewed from the rear of furnace) to obstructions:
Cabinet Back: 36 inches Cabinet Sides: 6 inches
Cabinet Bottom: Must be high enough off the ground to prevent snow,
water, leaves, or any other objects from blocking vents. _l_

INSTALLING
FURNACE
(Continued)
CREATING WALL OPENING AND MOUNTING FURNACE
Remove furnace front cover. Remove the two screws at the lower edges of front
cover. Lift front cover away.
Installing in Normal Frame Wall
The 25,000 Btu/Hr model is designed to fit between two wall studs set at 16 inch
on center. The 40,000 Btu/Hr model will not fit between wall studs. Follow the
steps below to install.
1. Turn off electrical circuits that pass through mounting wall. Make sure there are
no pipes or electrical wires in area you intend to cut.
2. Use stud locator or small finishing nail to find wall studs. When you locate
studs, drive a small finishing nail into each stud. This provides a visual refer-
ence for stud locations.
3. 25,000 Btu/Hr Model: Cut an opening in wall between the two studs. Make
opening 14 t/4" wide by 13 5Is" high (see Figure 2). iMPORTANT: You must
install furnace horizontally. Do not install furnace vertically.
40,000 Btu/Hr Model: Cut a 20 5h6" wide by 14 3Is" high opening in wall (see
Figure 2). Start your cut right next to stud you are going to anchor cabinet to.
Cut across wall and through the next stud. Stop cut at proper width. IMPOR-
TANT: You must install furnace horizontally. Do not install furnace vertically.
4. 25,000 Btu/Hr Model: Mark screw locations on wall (see Figure 2). Make sure
screws will anchor into studs. Make sure screw locations match screw holes on
cabinet flange.
40,000 Btu/Hr Model: Mark screw locations on wall (see Figure 2). Make sure
screws on one side will anchor into studs. Screws on other side will only anchor
in wall material. Make sure screw locations match screw holes on cabinet
flange.
5. 25,000 Btu/Hr Model: Use a proper-sized drill bit, Drill holes through wal! and
into studs at marked locations.
40,000 Btu/Hr Model: Use a proper-sized drill bit. On wal! stud side of opening,
drill holes through wail and into studs at marked locations. On other side, drill
holes through wall material.
6. Insert furnace into opening. Do this from inside the room. Secure furnace to
wall with four large screws provided.
7. On outside of wall, caulk opening between the cabinet and the rough edges of
opening. Wall Studs Wall Studs
I
14 1/4" 20 5/16"
Screw _Screw
Locations Wall _Well Opening _"
Opening !
25,000 Btu/Hr Model 40,000 Btu/Hr Model
Figure 2 -Wall Openings and Screw Locations
=z 201842

INSTALLING
FURNACE
(Continued)
201842
Installing in Masonry Wall
You can mount both models in a masonry wall. Follow the stepsbelow to install.
1. Cut opening in wall. Make opening 14 1/4" wide by 13 5Is" high for 25,000
Btu/Hr models. Make opening 20 5h6" wide by 14 3/8" high for 40,000 Btu/Hr
models. IMPORTANT'. You must install furnace horizontally. Do not install
furnace vertically.
2. Secure furnace to wall with toggle bolts or hook bolts set in mortar.
3. Insert furnace into opening. Do this from inside the room. Secure furnace to wall
with toggle bolts or hook bolts.
4. On outside of wall, caulk opening between the cabinet and the rough edges of
opening. You can also use mortar to seal opening.
INSTALLING THERMOSTAT
WARNING
Unplug furnace before installing thermostat.
Mount the thermostat directly on the furnace or on a wall in another part of the
room. If you have solid or masonry walls, mount the thermostat on the furnace.
Mounting Thermostat to Furnace
1. Unplug furnace.
2. Locate red and white thermostat wires coming out of side of furnace. These
wires are labeled "Thermostat."
3. Cut thermostat wires to desired length.
4. Route thermostat wires through slot/hole in side of thermostat mounting plate.
Then route wires through 5/8" diameter hole in center of plate (see Figure 4,
page 10).
5. Connect thermostat wires to the two terminal screws on back of thermostat (see
Figure 3). Connect red wire to "R" terminal. Connect white wire to "W"
terminal.
White Wire /_
j.
ir
Figure 3 - Connecting Thermostat Wires to Thermostat
Continued B

INSTALLING
FURNACE
(Continued)
l
6. Attach thermostat to thermostat mounting plate with screws provided (see I
Figure 4). IMPORTANT." Note mounting plate position in Figure 4. Correctly J
position mounting plate for your model furnace.
/
40,000 Btu/Hr Models
/
/
_25,000 Bt_u_'lr Models
Figure 4 -Attaching Thermostat to Thermostat Mounting Plate
7. Insert thermostat mounting plate between wall and cabinet flange. Line up top
notch on mounting plate with top screw on flange (see Figure 5).
IMPORTANT" Thermostat for 25,000 Btu/Hr model mounts on right side of
furnace (see Figure 5). Thermostat for 40,000 Btu/Hr model mounts on left side
of furnace (see Figure 5).
40,000 Btu/Hr Models 25,000 Btu/Hr Models
Figure 5 - Inserting Thermostat Mounting Plate
Between Wall and Cabinet Flange
8. Insert screw in cabinet flange and thermostat mounting plate and tighten firmly.
IMPORTANT." Make sure thermostat wires do not touch combustion chamber.
I2018_2

INSTALLING
FURNACE
(Continued)
201842
Locating Thermostat on Wall
I. Locate thermostat 4 Ih to 5 feet above the floor on an inside wall away from
any heat sources. The thermostat needs to sense average room temperature.
Avoid the following:
HOT SPOTS
Concealed pipes or ducts
Fireplaces
Registers
TV sets and radios
Lamps or direct sunlight
Kitchen
COLD SPOTS
Concealed pipes or ducts
Stairwells (drafts) or doors (drafts)
Unheated rooms on other side of wall
DEAD SPOTS
Behind doors
Comers and alcoves
2. Before installing thermostat, inspect the wall, floor, and attic areas. Make sure
there are no pipes, wiring, or anything else that would interfere with installing
thermostat. Do not mount thermostat to stud. If there are any obstructions, choose
a new location.
3. Provide two 18-gauge insulated stranded wires for the thermostat wire. Also
provide two wire nuts, and two wall anchors. There is a red and a white thermostat
wire coming from the furnace. The extra thermostat wires you furnish attach to
these wires. Make sure you furnish a red and a white wire. This will insure correct
hookup. Purchase enough thermostat wire to go from the furnace to the thermostat
location. Do not cut and splice this wire. The thermostat wire must be unbroken.
Routino Thermostat Cable
All wiring must meet local codes. The following instructions cover routing the wire
through the attic. You can run wiring from a basement or crawl space.
1. Unplug furnace.
2. Before drilling hole in wall, drive a small finishing nail through ceiling directly
above thermostat location. Pull nail out and push asmall stiff wire through hole.
This helps you locate thermostat mounting location when in attic.
3. In attic, locate stiff wire. Drill liT' hole in center of ceiling wall plate next to stiff
wire. Remove wire.
4. Probe through drilled hole in wall plate with a stiff wire to make sure there are no
pipes, wiring, or anything else blocking the way for thermostat wires, If you find
blockage, choose new location for thermostat.
5. Drill a liT' hole through the wall at thermostat mounting location.
6. From attic, feed thermostat wires through hole in ceiling plate until wires reach
thermostat location.
7. Make a small hook with a piece of stiff wire. Run wire hook through liT' hole in
wall. Hook thermostat wires. Pull wires through hole in wall. Make sure 6" of wires
stick out.
8. Drive a small finishing nail in ceiling above furnace.
25,000 Btu/Hr Model - Drive nail above right side of furnace.
40,000 Btu/Hr Model - Drive nail above left side of furnace.
Pull nail out and push a small stiff wire through hole. This helps you locate
wire routing location when in attic.
9. Repeat steps 3 and 4 above.
10. Feed thermostat wires from attic to furnace through 1/2" hole in ceiling wall plate.
11.Connect thermostat wires from attic to thermostat wires on furnace. Connect red
wires together, then connect white wires together. Use wire nuts to make connec-
tions. IMPORTANT: Make sure thermostat wires do not touch combustion
chamber. Continued _

[]
INSTALLING
FURNACE
(Continued)
Mountina the Thermostat to Wall
1. Connect thermostat wLmsto the two terminal screwson back of thermostat (see
Figure 6). Connect red wire to "R" terminal. Connect white wire to "W" termi-
nal.
2. Push any excess wire back through hole in wall and plug hole with insulation to
prevent drafts. Drafts affect the thermostat operation.
3. Use thermostat base to mark mounting screw locations.
4. Drill proper-sized holes for wall anchors.
5. Attach thermostat to wall using screws provided (see Figure 7).
White Wire\
Figure 6 - Connecting Thermostat Wires to Thermostat
Figure 7- Mounting Thermostat to Wall
201842

INSTALLING
FURNACE
(Continued)
201842
CONNECTING TO GAS SUPPLY
lAWARNING
A qualified service person must connect furnace to gas supply.
Follow all local codes.
AWARNING
Never connect furnace to private (non-utility) gas wells. This gas is
commonly known as well-head gas.
WARNING t
Unplug furnace before connecting to gas supply.
CAUTION
Use only new, black iron or steel pipe. Copper tubing may be
acceptable in certain areas. Check local codes. Use pipe large enough
in diameter to allow proper gas volume to furnace. If pipe is too small,
undue loss of pressure will occur. Refer to chart on page 16.
CAUTION
Lightly apply pipe joint sealant to male threads before connecting.
Use pipe joint sealant that is resistant to liquid petroleum (LP) gas.
All piping must comply with local codes and ordinances or with the National Fuel
Gas Code (ANSI Z223.1 NFPA No. 54), whichever applies.
Yon can connect furnace to gas supply at front of furnace (inside) or at rear of
furnace (outside).
Connecting Furnace to Gas Supply at Front of Furnace
1. Locate gas inlet pipe on lower, right front of furnace (see Figure 8).
3/8" Pipe
Nipple
Gas Inlet Pipe
Figure 8 - Connecting Gas from Inside of Room
2. Connect 3/8" pipe or nipple to gas inlet pipe (see Figure 8). See Providing Gas
Piping to Furnace, pages 16 and 17 for correct gas pipe installation.
Continued []

m
INSTALLING
FURNACE
(Continued)
Connecting Fumace to Gas Supply at Rear of Furnace
1. Remove the two screws in back of furnace cabinet located by the exhaust
vent(s) (see Figures 9 and 10).
Figure 9 -Locations of Screws in
Back of Furnace Cabinet
(25,000 Btu/Hr Model)
Figure 10 - Locations of Screws in
Back of Furnace Cabinet
(40,000 Btu/Hr Model)
2. Remove two screws on front lower flange that attach furnace flange to furnace
cabinet flange (see Figure 11). Note: 40,000 Btu/Hr model has a bottom shield
(see parts list, page 31, for location). Removing two screws will detach bottom
shield.
Furnace
Cabinet Flange-
Flange
=a
Figure 11 -Removing Screws on Lower Flange (40,000 Btu/Hr Model Shown)
3. Slide furnace out of furnace cabinet.
4. Locate gas inlet pipe on lower, right front of furnace.
5. 40,000 Stu/Hr Model Only: Remove screw holding gas inlet pipe clamp to
furnace.
6. Disconnect gas inlet pipe from 3/8" manifold elbow. Turn gas inlet pipe counter
clockwise to disconnect (see Figure 12).
Remove Screw,__"
40,000 Btu/I-Ir
Model Only Gas Inlet
Pipe Aanifold Elbow
Rgure 12 - Disconnecting Gas Inlet Pipe (40,000 Btu/Hr Model Shown)
7. Rotate the 318" manifold elbow 90 °so the opening is pointing downward (see
Figure 12).

INSTALLING
FURNACE
(Continued)
201842
8. Locate knockout plug in furnace cabinet. Knockout plug is in lower left rear of
furnace cabinet (as viewed from rear, see Figure 13). Remove knockout plug.
J
Knockout Plug
J
Figure 13 - Location of Knockout Plug
9. Slide furnace back into furnace cabinet. Make sure exhaust tube gaskets are in
place. Make sure exhaust and intake vent tubes extend into vent caps on back of
cabinet. Replace two screws by exhaust vent(s) removed in step 1.
10.25,000 Btu/Hr Model: Replace two screws removed in step 2. Attach furnace
flange and furnace cabinet lower flange together.
40,000 BttdHr Model: Place bottom shield back in place. Replace two screws
removed in step 2. Attach bottom shield, furnace flange, and furnace cabinet
lower flange together.
11.Run 3/8" pipe or nipple through knockout hole. Connect 3/8" pipe or nipple to
manifold elbow (see Figure 14). See Providing Gas Piping to Furnace, pages 16
and 17 for correct gas pipe installation.
Figure 14 - Inserting Pipe through Knockout Hole
12.Cheek connections for gas leak.
AWARNING
Never use an open flame to check for a leak. Apply a mixture of
liquid soap and water to all joints. Bubbles forming show a leak.
Correct all leeks at once.
13. Caulk around pipe or nipple. This prevents cold air entering knockout hole.

INSTALLING
FURNACE
(Continued)
Providing Gas Piping to Fumace
You must provide gaspiping from gas sourceto furnace. The gaspiping must be in
a vertical position where it connects to the furnace. This prevents interference with
front cover installation.
Consult your local gas company for proper routing of the gas lines.
Pipe size is determined by the length of pipe from the gas source to the fumaee and
the total Btu load on the gas source.
Add the total Btus required for all appliances connected to the gas source including
this furnace. Divide this number by 1030. This will give you the approximate cubic
feet per hour needed.
Example:
40,000 Btu/Hr for furnace
+_Btu/Hr for other gas appliances
55,000 Btu/Hr total
55,000 +1030 = 53.4
Locate 53.4 or higher on chart below.
According to the chart below, you should use 50 feet or less of liT' pipe,
200 feet or less of 3/4" pipe, etc...
MINIMUM
IRON PIPE
SIZE LENGTH OF PIPE (FEET)
10 20 30 40 50i 60 70 80 gO 100 125 150 175 200
3/8" 72 49 40 34 30 27 25 23 221 21 18 17 15 14
I/2" 132 92 73 63 56 50 46 43 401 38 34 31 28 26
3/4" 278 190 152 130 115 105 96 90 84 79 72 64 59 55
1" 520 350 285 245 215 195 180 170 160 150 130 120 110 100
1 V4" 1050 730 590 500 440 400 370 350 320i 305 275 250 225 210
1_h" 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320
2" 3050 2100 1650 1450 1270 1150 1050 990 930 870 780 710 650 610
2lh" 4800 3300 2700 2300 2000 1850 1700 160011500 1400 1250 1130 1050 980
3" 8500 5900 4700 4100 !3600 3250 3000 2800 2600 2500 2200 2000 1850 1700
4" 17500 12000 9700 8300 ?400 6800 6200 5800 5400 5100 4500 4100 3800 3500
IMPORTANT: Check gas line pressure at gas meter before connecting furnace to
gas line. Gas line pressure must be no less than 5 inches of water and no greater
than 7 inches of water. Gas pressures and input to the burners must not exceed the
rated input and pressure shown on the rating plate. For natural gas, manifold
pressure should be 3.5 inches of water. For elevations above 2000 feet, reduce
rating 4% for each 1000 feet above sea level (U.S.A. only).
m201842

INSTALLING
FURNACE
(Continued)
201842
Installation must include amanual shutoff valve (supplied), ground joint union,
plugged I/8" NPT tap, and a sediment trap. Locate NPT tap within reach for test
gauge hook up. NPT tap must be upstream from furnace (see Figure 15).
Apply pipe joint sealant lightly to male threads. Prevent excess sealant from going
into pipe. Excess sealant in pipe could result in clogged furnace valves.
CAUTION
Use pipe joint sealant that is resistant to liquid petro-
leum (LP) gas.
Install sediment trap in supply line as shown in Figure 15. Locate sediment trap
where it is within reach for cleaning. Asediment trap traps moisture and contami-
nants. This keeps them from going into furnace controls. If sediment trap is not
installed or is installed wrong, furnace may not run properly.
IMPORTANT." Locate sediment trap where trapped matter will not freeze. Install
sediment trap in a vertical run of pipe. If gas piping enters furnace from rear
(outside), you must locate sediment trap in crawl space (see Figure 15). If you
install furnace in structure with slab foundation, you must install gas piping to
front of furnace (inside) (see Figure 15).
Gas Piping Gas Piping
Manual Shutoff Entering Entering
Valve Furnace Furnace
Front Rear
Test Gauge (Inside) (Inside)
3" Min.
Trap
Slab Floor Installation
Manual
To Gas Supply ,, \ _. Shutoff
Valve
To Gas
Test Gauge
Connection Sediment
Trap
Crawl Space Installation
Figure 15 -Gas Connection m

!
INSTALLING
FURNACE
(Continued)
CHECKING GAS CONNEC_ONS
AWARNING
Test all gas piping and connections for leaks after Installation or
servicing. Correct aU leaks at once.
,WARNING
Never use an open flame to check for a leak. Apply a mixture of
liquid soap and water to all joints. Bubbles forming show a leak.
Correct all leaks at once.
1
Pressure Testing Gas Supply Piping System
Test Pressures In Excess Of 1/2 PSIG
1. Disconnect furnaceand its individual manual shutoff valve from gas supply
piping system.
2. Cap off open end of gas pipe where manual shutoff valve was connected.
3. Pressurize supply piping system by either using compressed air or
opening main gas valve located on or near gas meter.
4. Check all joints of gas supply piping system. Apply mixture of liquid soap and
water to gas joints. Bubbles forming show a leak.
5. Correct all leaks at once.
Test Pressures Equal To or Less Than 1/2 PSIG
1. Close manual shutoff valve (see Figure 16).
2. Pressurize supply piping system by either using compressed air or opening main
gas valve located on or near gas meter.
3. Check all joints from gas meter to manual shutoff valve. Apply mixture of liquid
soap and water to gas joints. Bubbles forming show a leak.
4. Correct all leaks at once.
Pressure Testing Furnace Gas Connections
1. Open manual shutuff valve (see Figure 16).
2. Open main gas valve located on or near gas meter.
3. Make sure control knob of furnace is in the OFF position.
4. Check all joints from manual shutoff valve to gas inlet pipe. Apply mixture of
liquid soap and water to gas joints. Bubbles forming show a leak.
5. Correct all leaks at once.
6, Turn on furnace (see Operating Furnace, page 20). Check the rest of the internal
joints for leaks.
7. Turn off furnace (see To Turn OffGas to Furnace, page 22).
On Position
Off Position
Figure 16 -Manual Shutoff Valve
20f8A2

INSTALLING
FURNACE
(Continued)
CONNECTING TO ELECTRICAL SUPPLY
IMPORTANT." Follow all local codes when connecting electricity to furnace. In
the absence of local codes, refer to the latest edition of the National Electrical Code
ANSI/NFPA No. 70. If you are not familiar with wiring codes, have a qualified
electrician do the wiring.
It is best to plug furnace into a separate and permanent electrical line circuit.
1. Supply a 120-volt, 60-cycle, grounded outlet at furnace location.
2. The furnace has a three-pronged (grounded) plug. Use only a grounded, three-
prong outlet.
IMPORTANT." Some local codes require rigid or semi-rigid conduit or metallic
sheathe cable. When using a metallic sheathe cable, the installer must terminate the
supply wire in the terminal box opening.
Performance Check
Plug furnace into three-pronged outlet. If ignitor remains on after main burner
ignition or if the valve chatters, you may have reversed polarity.
1. Unplug furnace.
2. Turn off electricity to outlet.
3. Reverse 120-volt connections inside outlet.
4, Turn on electricity to outlet.
5. Plug in furnace. Ignitor should turn off after main burner ignites. If ignitor does
not turn off, or if valve continues to chatter, turn off furnace and unplug. Call a
qualified service person.
A'n'ACHING CABINET FRONT COVER
ACAUTION
Do not operate furnace with front cover removed or mounted
wrong. If front cover is mounted wrong, you cannot secure it to
cabinet with screws.
1. Hook top of front cover over top cabinet flange.
2. Secure the sides of front cover to lower sides of furnace cabinet with two screws
provided (see Figure 17).
IMPORTANT: You may have removed furnace from furnace cabinet during
installation. You must correctly install furnace within cabinet. If not, front cover
will not properly attach to cabinet. Make sure gaskets for intake and exhaust tubes
are in place. Make sure intake and exhaust tubes extend into vent caps on cabinet
back and are secured with screws. Make sure you secured flange on bottom of
furnace to flange on bottom front of cabinet.
[]
Figure 17 -Attaching Front Cover to Cabinet
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OPERATING
FURNACE AWARNING
Furnace burner, combustion chamber, and exhaust port are very
hot during operation. Keep children and adults away from hot
surfaces to avoid burns and clothing ignition. Carefully supervise
young children when they are in the same room as furnace. Furnace
will remain hot for a time after shutdown. Let surface cool before
touching.
AWARNING
Do not operate furnace with front cover removed. Unsafe operation
could result.
CAUTION
Do not block circulating air openings in the louver of the front
cover. This is necessary for furnace to operate properly.
NOTICE
If operating furnace for the first time, a slight odor will occur. This
odor will go away after afew hours of operation.
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 does not have a pilot. It is equipped with an ignition device
which automatically lights the burner. Do not try to light the burner by hand.
B. BEFORE OPERATING smell all 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.
• 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.
C. Use only your hand to mm the handle on the manual shutoff valve. Never use
tools. If the handle will not turn by hand, don't try to repair it. Call a qualified
service technician. Force or attempted repair may result in a fire or explosion.
D. 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.
m201842