Williams 2903512, 2903511 User Manual
p
Natural Gas
Propane Gas
MODEL:
2903512
MODEL:
2903511
Installation Instructions and Owner’s Manual
Direct-Vent Wall Furnace
WARNING: Improper installation, adjustment,
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: Installation and repair must be
done by a qualified service person. The
furnace should be inspected before use and at
least annually by a professional service
person.
WARNING: If not installed, operated and
maintained in accordance with the
manufacturer’s instructions, this
product could expose you to substances in
fuel or from fuel combustion which can cause
death or serious illness and which are known
to cause cancer, birth defects or other
re
roductive harm.
WARNING: If the information in this
manual is not followed exactly; a fire
or explosion 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
performed by a qualified installer,
service agency or the gas supplier.
Williams Furnace Co., 250 West Laurel Street, Colton, CA 92324 U.S.A.
Table of Contents
General Information and Technical Data
Instructions to Installer ……………………………………………………………………………………………………………………1
Safety and General Warnings ………………………………………………………………………………………………………….. 2
Technical Data …………………………………………………………………………………………………………………………… 3
Installation
Wall Installation ….................................................................................................................................................................... 4
Outside Location for Vent Terminal …...................................................................................................................................... 6
Gas Conversions ….................................................................................................................................................................. 8
Gas Supply …........................................................................................................................................................................... 9
Electrical Wiring Diagrams …….............................................................................................................................................. 11
Operating Instructions ……………………..……………………………………………………………..……………………………... 12
Servicing
Checking and Adjusting the Gas Manifold Pressure ………………………………………………………………………….……. 14
Checking, Removing and Reassembling of the Vent Air Intake System ………………………………………………………… 14
Lubrication of Moving Parts …………………………………………………………………………………………………………… 14
Flame Visual Check ………………………………………………………………………………………………………………….... 14
Annual Maintenance Requirements ………………………………………………………………………………………………….. 15
Programmable Timer
Overview ………………………………………………………………………………………………………………………………… 16
Setting and Adjustment ………………………………………………………………………………………………………………... 17
Troubleshooting
Starting Sequence …………………………………………………………………………………………………………………….. 19
Replacement Parts ………………………………………………………………………………………………………………...………. 22
General Information and Technical Data
This furnace is design certified to ANSI Z21.86-2004 / CSA 2.32-2004 Gas–Fired Gravity and Fan-Type, Direct-Vent Wall
Furnaces as a Fan-Type Direct-Vent Wall Furnace to be installed on an outside wall according to these instructions.
Any alteration of the original design, installed other than as shown in these instructions or used with a type of gas not shown on
the rating plate is not permitted.
Instructions to Installer
Installation and repair should be done by a QUALIFIED SERVICE TECHNICIAN.
The installation must conform to local codes or in the absence of local codes; the installation must conform to the National Fuel
Gas Code ANSI Z223.1/NFPA 54, Natural Gas and Propane Installation Code CSA B149.1.
Mobile (Manufactured) home installations must conform with the “Manufactured Home Construction and Safety Standard Title 24
CFR, Part 3280” or, when such a standard is not applicable, the Standard for Manufactured Home Installations, ANSI A 225.1
NFPA/501A, Mobile Home Standard, CAN/CSA Z240 MH Series, in Canada. Installer must leave instruction manual with the
home owner after installation. Installer must show home owner how to start and operate furnace and thermostat. Installer must
provide a 1/8-inch NPT plugged tapping for test gauge connection immediately upstream of the gas supply connection of the
furnace.
During initial firing of the furnace, residual manufacturing grease will bake out and smoke will occur which is not a health danger.
To prevent nuisance and operation of fire alarms, ventilate the room for the first two hours of operation.
WARNING: Any change to this furnace or its controls can be dangerous. This is a heating appliance and any
panel, door or guard removed for servicing this furnace must be replaced prior to operating the furnace.
1
Safety Rules and General Warnings
DO NOT OPERATE THIS FURNACE WITHOUT THE FRONT PANEL INSTALLED
• Due to high temperatures, the furnace should be
located out of traffic and away from combustible
materials such as furniture and draperies.
• Children and adults should be alerted to the
hazards of high surface temperatures and should
stay away to avoid burns or clothing ignition.
• Young children should be carefully supervised
when they are in the same room as the furnace.
• Clothing or other flammable material should not be
placed on or near the furnace.
• Any safety screen or guard removed for servicing
an furnace must be replaced prior to operating the
furnace.
• Keep burner and control compartment clean.
• The outside vent cap is hot while furnace is in
operation.
• Installation and repair should be done by a
QUALIFIED SERVICE TECHNICIAN. The furnace
should be inspected before use and at least
annually by a qualified service technician.
• More frequent cleaning may be required due to excessive
lint from carpeting, bedding materials, etc. It is imperative
that control compartments, burners and circulating air
passageways of the furnace be kept clean.
• DO NOT put anything around the furnace that will obstruct
the flow of combustion and ventilation air.
• DO keep the furnace area clear and free from combustible
materials, gasoline and other flammable vapors and
liquids.
• DO examine venting system periodically and replace
damaged parts.
• DO examine burner periodically. Clean and replace
damaged parts.
• DO NOT use this furnace if any part has been under water.
Immediately call a qualified service technician to inspect
the furnace and to replace any part of the control system
and any gas control which has been under water.
Safety Information for Users of LP Gas
Propane (LP Gas) is a flammable gas which can cause fires and explosions. In its natural state, propane is odorless and
colorless. You may not know all the following safety precautions which can protect both you and your family from an accident.
Read them carefully now, then review them point by point with the members of your household. Someday, when there may
not be a minute to lose, everyone’s safety will depend on knowing exactly what to do. If, after reading the following information,
you feel you still need more information, please contact your gas supplier.
LP Gas Warning Odor
If a gas leak happens, you should be able to smell the gas because of the odorant put in the LP Gas.
That’s your signal to go into immediate action!
• Do not operate electric switches, light matches or use your phone. Do not do anything that could ignite the gas.
• IMMEDIATELY get everyone out of the building, vehicle, trailer or area.
• Close all gas tank or cylinder supply valves.
• LP Gas is heavier than air and may settle in low areas such as basements. When you have reason to suspect a gas
leak, keep out of basements and other low areas. Stay out until firefighters declare them to be safe.
• Use your neighbor’s phone and call a trained LP Gas service technician and the fire department. Even though you may
not continue to smell gas, do not turn on the gas again. Do not re-enter the building, vehicle, trailer or the area.
• Have the service technician or fire department air out the area before you return. A properly trained LP Gas service
technician must repair the leak, check and relight the gas furnace for you.
2
Some Points to Remember
• Learn to recognize the odor of LP Gas. Your local LP Gas Dealer can give you a ”Scratch and Sniff” pamphlet. Use
it to find out what the propane odor smells like. If you suspect that your LP Gas has a weak or abnormal odor, call
your LP Gas Dealer.
• If you are not qualified, do not light pilot lights, perform service, or make adjustments to furnaces on the LP Gas
system. If you are qualified, consciously think about the odor of LP Gas prior to and while lighting pilot lights or
performing service or making adjustments.
• Sometimes a basement or a closed–up house has a musty smell that can cover up the LP Gas odor. Do not try to
light pilot lights, perform service or make adjustments in an area where the conditions are such that you may not detect
the odor if there has been a leak of LP Gas.
• Odor fade, due to oxidation by rust or absorption on walls of new cylinders and tanks, is possible. Therefore, people
should be particularly alert and careful when new tanks or cylinders are placed in service. Odor fade can occur in
new tanks or reinstalled old tanks if they are filled and allowed to set too long before refilling. Cylinders and tanks
which have been out of service for a time may develop internal rust which will cause odor fade. If such conditions
are suspected to exist, a periodic sniff test of the gas is advisable. If you have any question about the gas odor,
call your LP Gas dealer. A periodic sniff test of the LP Gas is a good safety measure under any condition.
• If, at any time, you do not smell the LP–Gas odorant, and you should, assume you have a leak. Then take
the same immediate action recommended above for the occasion when you do smell the odorized LP Gas.
• If you experience a complete ”gas out” (the container is under no vapor pressure), turn the tank valve off immediately.
If the container valve is left on, the container may draw in some air through openings such as pilot light orifices.
If this occurs, some new internal rusting could occur. If the valve is left open, then treat the container as a new tank.
Always be sure your container is under vapor pressure by turning it off at the container before it goes completely
empty or having it refilled before it is completely empty.
Technical Data
OUTPUT HEATING CAPACITY
INPUT RATING (High Input)
MINIMUM INPUT RATING
(Low Input)
THERMAL EFFICENCY % 82 mbar 16.2
LENGTH
HEIGHT
DEPTH
WEIGHT
GAS CONNECTION NPT /h 8.7
WALL HOLE DIAMETER
AIR INLET DIAMETER LP
EXHAUST PIPE DIAMETER
MAX WALL THICKNESS
MIN WALL THICKNESS
kW 6.98 8.0
kBTU/hr 23,817
kW 8.5 mbar 26.5
MAX
kBTU/hr 29,000
kW 5.89 mbar 4.6
kBTU/hr 20,100
mm 1006 6.5
MANIFOLD PRESSURE
MIN
in 39-5/8” m
mm 715 ft3/h 30.1
in 28-1/8” m
MAX
mm 208
in 8-1/4” m
kg 42
lbs. 93 m
½”
FEMALE
mm 50 mbar 17.4
in 2”
mm 49 mbar 27.4
in 1-7/8” in
mm 35 m³/h 450
in 1-3/8”
mm 500 m³/h 330
in 19-5/8”
GAS RATE
MIN
MINIMUM INLET
PRESSURE
AIR FLOW
MINIMUM AIR FLOW
mm 150
in 5-7/8”
NATURAL
GAS
LP
NATURAL
GAS
LP
NATURAL
GAS
LP
NATURAL
GAS
LP
NATURAL
GAS
mbar
in
W.C.
in
W.C.
in
W.C.
in
W.C.
3
3
3
/h 11.6
ft
3
3
/h 21.3
ft
3
3
ft
in
W.C.
W.C.
3.2
10.6
1.8
/h .9
/h .3
/h .6
/h .2
7.0
11.0
cfm 265
cfm 194
3
Installation
Installation should be done by a QUALIFIED SERVICE TECHNICIAN.
The furnace must be located on an outside wall.
Wall Installation
Minimum clearances from combustible materials:
• Furnace to the top surface of carpeting, tile:
2-inches (50 mm)
• Furnace to back wall (0” to spacers):
0-inch (0 mm).
• Vent to wall enclosure:
0-inch (0 mm)
• Furnace to sidewalls:
3.15-inches (80 mm)
• Furnace to ceiling:
10-inches (254 mm)
See Figure 1 showing clearance for installation of vent cap.
Leave at least three-feet in front of the wall furnace for servicing and proper operation. The wall furnace must be installed in such
a way that the external casing can be completely removed for servicing.
If there is a shelf above the furnace, it must be be noncombustible. A minimum clearance of 12-inches (300 mm) is
recommended between the furnace and the noncombustible shelf above it.
Gas equipment in residential garages must be installed so that all burners and burner ignition devices are located not less than
18-inches (460 mm) above the floor. Such equipment must be located, or protected, so it is not subject to physical damage by a
moving vehicle.
The vent terminal of this direct-vent furnace must be located at least 9-inches (230 mm) from any opening through which flue
gases could enter a building. The bottom of the vent terminal and the air intake must be located at least 12-inches (300mm)
above grade.
DO NOT cover the furnace.
Make sure that the correct gas supply is available.
The furnace requires a 120V, 60 Hz electrical supply.
The furnace must be electrically grounded in accordance with local codes or in the absence of local codes, with the National
Electrical Code ANSI/NFPA 70 (latest edition) or in Canada with CAN/CSA-C22.2 No. 3.
WARNING: For the installation of this furnace, the
following items must be used as a vent air intake
External Vent Cap
(Part Number: WFR–TRM000)
Flanged Air Inlet Tube
(Part Number: WFR–TBO002)
(Part Number: WFN–RNG003)
Flue Outlet Tube
(Part Number: WFR-795)
(All the above items are supplied with the furnace)
system:
O-Ring
WARNING: The nearest point of the vent cap should be a minimum horizontal distant of six (6) feet (1,830 mm)
from any pressure regulator. In case of regulator malfunction, the six (6) feet (1,830 mm) distance will reduce
the chance of gas entering the vent cap.
4
(
Figure 1
1 = Fixed/Closed 2 = Openable V = Vent Terminal A = Air Supply 1 = Fixed/Closed 2 = Openable V = Vent Terminal A = Air Supply
A. Clearance above grade, veranda, porch, deck or
balcony 12-inches (30 cm) minimum.
B. Clearance to window or door that may be opened 12-
inches (30 cm) minimum.
C. Clearance to permanently closed window (minimum 12-
inches (30 cm) recommended to prevent condensation
on window.
D. Vertical clearance to ventilated soffit located above the
terminal within a horizontal distance of 2-feet (60 cm)
from the centerline of the terminal 18-inches (46 cm)
minimum.
E. Clearance to unventilated soffit 12-inches (30 cm)
minimum clearance to vinyl soffit 36-inches (90 cm)
minimum.
F. Clearance to outside corner 12-inches (30 cm)
minimum.
G. Clearance to inside corner 18-inches (46 cm) minimum.
H. Not to be installed above a meter/regulator assembly
within 3-feet (90 cm) horizontally from the centerline of
the regulator.
I. Clearance to service regulator vent outlet 6-feet (1.8 m)
minimum.
J. Clearance to nonmechanical air supply inlet to building
or the combustion air inlet to any other furnace 12inches
(3)
(3)
30 cm) minimum.
(3)
(3)
(3)
K. Clearance to a mechanical air supply inlet 6-feet (1.8 m)
minimum.
L. Clearance
located on public property 7-feet (2.1 m) minimum.
M. Clearance under veranda, porch, deck or balcony 12-
inches (30 cm) minimum.
Notes:
(1)
A vent must not terminate directly above a sidewalk
(2)
Only permitted if veranda, porch, deck or balcony is
(3)
As specified in CGA B149 installation codes (1991).
Note: Local codes or regulations may require different
clearances.
5
(3)
(1)
above paved sidewalk or a paved driveway
(2), (3)
or paved driveway which is located between two
single family dwellings and serves both dwellings.
fully open on a minimum of two sides beneath the
floor.
(3)
Outside Location for Vent Terminal
A
Upon delivery, check to make sure the packaging has not been damaged.
1. Remove the furnace from box/packaging taking care not to damage the paper template to be used to mark the holes for
mounting the furnace.
2. After marking the appropriate holes using the above mentioned template, make a 2-inch diameter hole.
3. Cut the combustion exhaust and fresh air inlet tubes according to the wall thickness (Figure 2):
Air Inlet Tube Length = Wall Thickness + 3/32-inch
F Flue Outlet Tube Length = Wall Thickness + 1-5/16 inches
Figure 2
A + 33.3 mm
+ 2.3 mm
Ø 49.2
4. Drill the mounting holes “A” (8 holes) in the wall. If possible, use self-tapping screws, drill 1/8-inch diameter holes. If
self-tapping screws cannot be used, drill 1/4-inch diameter holes and use the plastic anchors provided.
5. Install the supporting bracket to the wall; insert the air pipe in the wall through the hole provided in the support bracket.
Place the round adhesive gasket around the hole, so that the air pipe remains in its position.
6. Attach the supporting bracket with the screws provided. If possible, use self-tapping screws, drill 1/8-inch diameter
holes. If self-tapping screws cannot be used, use the plastic anchors provided.
7. Remove the casing loosening the screws and disconnect the casing grounding cable.
8. Place the adhesive spongy lining behind the furnace. (Figure 3)
Figure 3
9. Attach the flue exhaust flue pipe end (diameter 1” 3/8) on the furnace pipe male connection (Figure 5).
BE SURE THAT THE RUBBER SILICONE O–RING GASKET IS IN POSITION.
10. Remove the front panel by loosing the lateral screws (Figure 4).
11. Install the furnace to the wall leaning the bottom edge of panel “C” (where the fan is located) on the supporting frame, as
shown in Figure 6. Attach the furnace to the matching hooks “A”, with light pressure against the wall). Install the
heating body of the furnace to the supporting bracket with the two lateral screws.
6
Figure 4
Figure 6
O-Ring Gasket
Figure 5
12. When the inside installation is complete, proceed to the outside location of the aluminium vent cap on the external wall.
The vent cap should perfectly match the pipe end. Mark the location of the three holes for the screw anchors. (Figure 7)
The flue grid must be vertical.
13. Remove the vent cap and drill all the necessary holes (diameter 1/4 in. for the screw fittings provided with the furnace).
14. Position the vent cap and attach it with the screws (Figure 7).
15. Connect the female end of the three-prong plug to the furnace connection on the bottom of the furnace.
16. Connect the gas supply line. A gas tap must before the connection to the furnace must be installed.
17. Reattach the front panel. (Figure 4)
18. Reconnect the grounding wire to the casing and reinstall the casing then tighten the screws.
19. Turn on gas supply and check for gas leaks with soapy water on all gas connections. Seal any leaks prior to operating
the furnace.
7
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