Williams 2503531, 4003531 User Manual

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THE COMFORT PRODUCTS PEOPLE

WINDOW WALL FURNACE

DIRECT-VENT PROPANE/LP GAS HEATER

OWNER’S OPERATION AND INSTALLATION MANUAL

2503531

4003531

25,000 and 40,000 BTU/Hr Furnaces

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

FOR YOUR SAFETY

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.

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.

WARNING: Improper installation, adjustment, alteration, service, or maintenance 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.

— Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

This appliance may be installed in an aftermarket*, permanently located, manufactured (mobile) home, where not prohibited by local codes.

This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases.

* Aftermarket: Completion of sale, not for purpose of resale, from the manufacturer

Save this manual for future reference.

THE COMFORT PRODUCTS PEOPLE

DIRECT-VENT PROPANE/LP GAS HEATER

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.

Propane/LP Gas: Propane/LP gas is odorless. An odor-making agent is added to propane/LP gas. The odor helps you detect a propane/LPgasleak.However,theodoradded to propane/LP gas can fade. Propane/LP 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.

WARNING: Any change to this heater or its controls can be dangerous.

Due to high temperatures, the appliance should be located out of traffic and away from furniture and draperies.

Do not place clothing or other flammable material on or near the appliance. Never place any objects on the furnace.

Carefully supervise young children when they are in the same room with furnace.

Surface of furnace becomes very hot when running furnace. Keep children and adults away from hot surface to avoid burns or clothing ignition. Furnace will remain hot for a time after shutdown. Allow surface to cool before touching.

Turn off furnace and unplug and let cool before servicing. Unless you need gas supply for testing, shut off equipment shutoff valve before servicing. Only a qualified service person should service and repair furnace and venting system.

Replace any safety screen or guard removed for servicing before operating furnace.

You must keep control compartments, burners, and circulating air passages clean. More frequent cleaning may be needed due to excessive lint and dust from carpeting, bedding material, etc. Turn off the gas valve and unplug before cleaning furnace.

1.A qualified service person must install furnace.

2.This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases.

3.Use only propane/LP gas. Do not convert furnace to use different fuel type.

4.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.

5.Do not block the flow of combustion air (outside air) or heated air (room air) to the furnace.

6.This furnace must have fresh air for proper operation. If not, poor fuel combustion and improper venting of flue gases will result. Carbon monoxide poisoning from backedup flue gases could occur. The State of California lists carbon monoxide as a reproductive toxin under Proposition 65.

7.Never install the furnace

in a recreational vehicle

in an alcove

on an inside wall

as a fireplace insert

in high traffic areas

in windy or drafty areas

behind a door or where an open door would block normal air flow

8.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

9.Do not obstruct the flow of combustion and ventilation air in any way. Provide adequate clearances around air openings into the combustion chamber along with adequate accessibility clearance for servicing and proper operation.

10.Provide the following minimum furnace clearances from furnace cabinet (portion of cabinet extending into outside air, as viewed from the rear of furnace):

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 cabinet vents.

11.Always follow lighting instructions. Never attempt to light burner with a match or butane torch.

12.Do not run furnace

where flammable liquids or vapors are used or stored

under dusty conditions

15.Do not use furnace as a cooking device.

16.Do not alter furnace or its controls. Any change may create a safety hazard.

19.Do not use furnace if any part has been under water. Immediately call a qualified service person to inspect the furnace and to replace any part of the control system and any gas control which has been under water.

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201843

OWNER’S MANUAL

LOCAL CODES

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 ANS Z223.1, also known as NFPA 54 * (USA)

National Electric Code ANS/NFPA 70*

CAN/CGA-B149[.1 or .2] Installation Codes** (Canada).

*Available from:

American National Standards Institute, Inc.

1430 Broadway

New York, NY 10018

National Fire Protection Association, Inc.

Batterymarch Park

Quincy, MA 02269

**Available from:

Standards Council of Canada

350 Sparks Street

Ottawa, Ontario K1R 7S8

This furnace must be grounded when installed. Follow all local codes. In the absence of local codes, refer to the National Electrical Code ANS/NFPA No. 70 (U.S.A.) or CSA C22.1 Canadian Electrical Code, Part I (Canada).

The installation must conform with local codes, in the absence of local codes, with the

National Fuel Gas Code, ANS Z223.1/Canadian Installation Code, CAN/CGA B149.

When installing furnace in a manufactured (mobile) home, follow the Manufactured Home Construction and Safety Standard, Title 24CFR, Part 3280 (formerly 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), ANS 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.

Appliance input ratings are based on sea level operation and need not be changed for operation up to 2,000 feet elevation. For operation at elevations above 2,000 feet, manufactured to specified deration conditions for Canada and the United States.

UNPACKING

1.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 thermostat mounting plate

Hardware package (thermostat and two screws)

Equipment 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.

PRODUCT

FEATURES

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.

SPECIFICATIONS

 

25,000 Btu/Hr

40,000 Btu/Hr

*Rated Heating Input (BTU/Hr)

25,000

40,000

Thermal Output Capacity

 

 

(average loss calculation)

18,750 Btu/Hr

30,000 Btu/Hr

Type Gas

Propane/LP Only

Propane/LP 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

10" W.C.

10" W.C.

Inlet Connection

3/8 NPT

3/8 NPT

Inlet Gas Pressure (in. of water)*

 

 

Maximum

13"

13"

Minimum

11"

11"

Dimensions, Inches (H x W x D)

 

 

Furnace

15 3/32 x 16 1/8 x 23 5/8

15 3/32 x 21 3/4 x 23 5/8

Weight (pounds)

 

 

Furnace

53

71

Shipping

65

98

* For purposes of input adjustment.

201843

3

THE COMFORT PRODUCTS PEOPLE

DIRECT-VENT PROPANE/LP GAS HEATER

INSTALLATION

Mounting hardware needed to mount furnace into wall is included with the furnace. No venting material is needed. You must furnish tools and all gas piping from the gas source to the furnace inlet.

WARNING: 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, ANS/NFPA 70 (U.S.) or Canadian Electrical Code Part I-CSA C22.1 (Canada).

CHECK GAS TYPE

Use only propane/LP gas. If your gas supply is not propane/LP gas, do not install furnace. Call dealer where you bought furnace for proper type furnace.

INSTALLATION ITEMS

Before installing furnace, make sure you have all items below:

electric drill

drill bits

Phillips screwdriver

hammer

pipe wrench

stud locator or small finishing nails

equipment shutoff valve (supplied)

test gauge connection (see Figure 15, page 10)

piping (check local codes)

sealant (resistant to propane/LP 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.

WARNING: Do not install furnaceininteriorwallofbuilding.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 are going to install the furnace.

WARNING: Maintain the minimum clearances shown in Figure 1. If you can, provide greater clearances from floor, ceiling, and joining wall.

WARNING: Due to high temperatures,neverinstallthefurnace:

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 doorwouldblocknormalairflow

as a fireplace insert

in high traffic areas

near furniture or draperies

in windy or drafty areas

CAUTION: If you install the furnace in a home garage, locate furnace where moving vehicle will not hit it.

Forconvenienceandefficiency,installfurnace:

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 a 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 combustibles (as viewed from the front of furnace, see Figure 1):

Below Front Cover: 6 inches

Above Front Cover: 12 inches

Adjoining Wall: 12 inches

Front: 8 feet

Ceiling

12" Minimum

12" Minimum

Adjacent

Side Wall

6" Minimum

Finished Floor, Carpet, Tile, etc.

Figure 1 - Mounting Clearances as Viewed from Front of Furnace

The clearance between the cabinet and the wall it passes through is 0 inches.

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.

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201843

OWNER’S MANUAL

INSTALLATION

(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 reference for stud locations.

3.25,000 BTU/Hr Model: Cut an opening in wall between the two studs. Make opening 14 1/4" wide by 13 5/8" high (see Figure 2). IMPORTANT: You must install furnace horizontally. Do not install furnace vertically.

40,000 BTU/Hr Model: Cut a 20 5/16" wide by 14 3/8" 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. IMPORTANT: 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 propersized drill bit. Drill holes through wall and into studs at marked locations.

40,000 BTU/Hr Model: Use a propersized drill bit. On wall stud side of opening, drill holes through wall 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

 

14 1/4"

Approx.

Approx.

13

Screw

Screw

Locations

/5

Locations

"8

 

Wall

 

 

Opening

 

25,000 BTU/Hr Model

 

Wall Studs

 

Approx.

20 5/16"

 

 

14

Screw

 

Locations

 

/3

 

 

"8

Wall Opening

40,000 BTU/Hr Model

Figure 2 - Wall Openings and Screw

Locations

Installing in Masonry Wall

You can mount both models in a masonry wall. Follow the steps below to install.

1.Cut opening in wall. Make opening 14 1/4" wide by 13 5/8" high for 25,000 BTU/Hr models. Make opening 20 5/16" 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 6).

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

W

R

Red Wire

Figure 3 - Connecting Thermostat Wires to Thermostat

Continued

201843

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THE COMFORT PRODUCTS PEOPLE

DIRECT-VENT PROPANE/LP GAS HEATER

INSTALLATION

(Continued)

6.Attach thermostat to thermostat mounting plate with screws provided (see Figure 4). IMPORTANT: Note mounting plate position in Figure 4. Correctly position mounting plate for your model furnace.

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).

8.Insert screw in cabinet flange and thermostat mounting plate and tighten firmly.

IMPORTANT: Make sure thermostat wires do not touch combustion chamber.

 

.2

 

.3

 

.4

OFF

.5

 

.7

 

1.0

 

50

60

 

 

 

 

 

 

 

70

 

 

 

 

SOLID

 

 

80

90

 

 

STATE

 

 

 

 

 

 

 

 

 

 

50

60

 

 

 

IGNITION

40,000 BTU/Hr Models

 

70

 

 

90

 

 

80

 

 

 

 

 

 

 

.2

 

.3

 

.4

OFF

.5

 

.7

 

1.0

 

50

60

 

 

 

 

 

 

 

 

70

80

 

 

 

SOLID

 

 

 

90

 

 

STATE

 

 

 

 

 

 

 

 

 

 

50

60

 

 

 

IGNITION

 

 

70

 

 

 

 

 

 

80

 

 

 

 

 

 

90

25,000 BTU/Hr Models

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 4 - Attaching Thermostat to Thermostat Mounting Plate

 

 

 

00

00

 

00

00

 

00

 

 

 

40,000 BTU/Hr Models

50

60

 

 

 

 

70

80

 

 

 

 

90

25,000 BTU/Hr Models

Figure 5 - Inserting Thermostat Mounting

Plate Between Wall and Cabinet Flange

Locating Thermostat on Wall

1.Locate thermostat 4 1/2 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 Corners 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.

Routing 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 a small stiff wire through hole. This helps you locate thermostat mounting location when in attic.

3.In attic, locate stiff wire. Drill 1/2" 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 1/2" 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 1/2" 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.

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201843

OWNER’S MANUAL

INSTALLATION

(Continued)

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 connections. IMPORTANT: Make sure thermostat wires do not touch combustion chamber.

Mounting the Thermostat to Wall

1.Connect thermostat wires to the two terminal screws on back of thermostat (see Figure 6). Connect red wire to “R” terminal. Connect white wire to “W” terminal.

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

W

R

Red Wire

Wall

Anchors

.2

.3

 

.4

OFF

.5

 

.7

 

1.0

 

50

60

 

 

 

 

 

 

70

 

 

 

SOLID

 

 

80

90

 

 

 

 

 

STATE

 

 

 

 

 

 

 

 

50

60

 

 

 

IGNITION

 

70

 

 

 

 

 

80

 

 

 

 

 

90

 

 

 

 

 

 

Figure 7 - Mounting Thermostat to Wall

CONNECTING TO GAS SUPPLY

WARNING: A qualified service person must connect furnace to gas supply. Follow all local codes.

WARNING: 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 9.

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 (ANS Z223.1 NFPA No. 54), whichever applies.

You 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).

2.Connect 3/8" NPT pipe or nipple to gas inlet pipe (see Figure 8). See Providing Gas Piping to Furnace, pages 9 and 10, for correct gas pipe installation.

Gas Inlet Pipe

3/8" NPT Pipe or Nipple

Figure 8 - Connecting Gas from Inside of Room

Figure 6 - Connecting Thermostat Wires to Thermostat

Continued

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THE COMFORT PRODUCTS PEOPLE

DIRECT-VENT PROPANE/LP GAS HEATER

INSTALLATION

(Continued)

Connecting Furnace 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).

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 22, for location). Removing two screws will detach bottom shield.

3.Slide furnace out of furnace cabinet.

4.Locate gas inlet pipe on lower, right front of furnace.

5.40,000 BTU/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).

7.Rotate the 3/8" manifold elbow 90° so the opening is pointing downward (see Figure 12).

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.

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 BTU/Hr 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 9 and 10 for correct gas pipe installation.

12.Check connections for gas leak.

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.

13.Caulk around pipe or nipple. This prevents cold air entering knockout hole.

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)

Furnace

Furnace Flange

Cabinet

Flange

Figure 11 - Removing Screws on Lower Flange (40,000 BTU/Hr Model Shown)

Remove Screw,

40,000 BTU/Hr

Model Only

Gas Inlet

Pipe

Manifold Elbow

Figure 12 - Disconnecting Gas Inlet Pipe

(40,000 BTU/Hr Model Shown)

Knockout Plug

Figure 13 - Location of Knockout Plug

3/8" NPT

Figure 14 - Inserting Pipe through Knockout Hole

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201843

OWNER’S MANUAL

INSTALLATION

(Continued)

Providing Gas Piping to Furnace

You must provide gas piping from gas source to furnace. The gas piping 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 furnace 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 2500. This will give you the approximate cubic feet per hour needed.

Example:

40,000 BTU/Hr

+15,000 BTU/Hr for other gas appliances

55,000 BTU/Hr total

55,000 ÷ 2500 = 22

Locate 22 or higher on chart below.

According to the chart below, you should use 40 feet or less of 3/8" pipe, 125 feet or less of 1/2" pipe, etc...

MINIMUM

 

 

 

 

 

 

 

 

 

 

 

 

 

IRON PIPE

 

 

 

 

 

 

 

 

 

 

 

 

 

SIZE

 

 

 

 

LENGTH OF PIPE (FEET)

 

 

 

 

 

10

20

30

40

50

60

70

80

90

100

125

150

175

200

3/8"

47

32

26

22

19

18

16

15

14

13

12

11

10

1/2"

87

61

48

42

37

33

30

28

26

25

22

20

18

17

3/4"

184

126

100

86

76

69

63

59

55

52

48

42

39

36

1"

344

232

189

162

142

129

119

112

106

99

86

79

73

66

11/4"

696

484

391

331

291

265

245

232

212

202

182

166

149

139

11/2"

1060

729

590

504

444

404

371

351

324

305

272

252

232

212

2"

2022

1392

1094

961

842

762

696

656

616

576

517

470

430

404

21/2"

3182

2188

1790

1524

1326

1226

1127

1060

994

928

829

749

969

649

3"

5635

3911

3116

2718

2387

2154

1989

1856

1724

1657

1458

1326

1226

1127

4"

11602

7956

6431

5503

4906

4508

4110

3845

3580

3381

2983

2718

2519

2320

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

IMPORTANT:Check gas line pressure at gas meter before connecting furnace to gas line. Gas line pressure must be no less than 11 inches of water and no greater than 13 inches of water. Gas pressures and input to the burners must not exceed the rated input and pressure shown on the rating plate. For propane/LP gas, manifold pressure should be 10 inches of water. For elevations above 2000 feet, reduce rating 4% for each 1000 feet above sea level (U.S.A. only).

CAUTION: Never connect heater directly to the propane/LP supply. This heater requires an external regulator (not supplied). Install the external regulator between the heater and propane/LP supply.

The installer must supply an external regulator. The external regulator will reduce incoming gas pressure. You must reduce incoming gas pressure to between 11 and 14 inches of water. If you do not reduce incoming gas pressure, heater regulator damage could occur. Install external regulator with the vent pointing down. Pointing the vent down protects it from

freezing rain or sleet.

Continued

201843

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