Williams 2903512, 2903511 User Manual

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MODEL:

Natural Gas 2903512

MODEL:

Propane Gas 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 reproductive 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.

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Safety Rules and General Warnings

DO NOT OPERATE THIS FURNACE WITHOUT THE FRONT PANEL INSTALLED

• Due to high temperatures, the furnace should be

• More frequent cleaning may be required due to excessive

located out of traffic and away from combustible

lint from carpeting, bedding materials, etc. It is imperative

materials such as furniture and draperies.

that control compartments, burners and circulating air

• Children and adults should be alerted to the

passageways of the furnace be kept clean.

• DO NOT put anything around the furnace that will obstruct

hazards of high surface temperatures and should

stay away to avoid burns or clothing ignition.

the flow of combustion and ventilation air.

• Young children should be carefully supervised

• DO keep the furnace area clear and free from combustible

when they are in the same room as the furnace.

materials, gasoline and other flammable vapors and

• Clothing or other flammable material should not be

liquids.

• DO examine venting system periodically and replace

placed on or near the furnace.

• Any safety screen or guard removed for servicing

damaged parts.

• DO examine burner periodically. Clean and replace

an furnace must be replaced prior to operating the

furnace.

damaged parts.

• Keep burner and control compartment clean.

• DO NOT use this furnace if any part has been under water.

• The outside vent cap is hot while furnace is in

Immediately call a qualified service technician to inspect

the furnace and to replace any part of the control system

operation.

and any gas control which has been under water.

 

• 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.

 

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.

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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

kW

6.98

kBTU/hr

23,817

 

INPUT RATING (High Input)

kW

8.5

kBTU/hr

29,000

 

MINIMUM INPUT RATING

kW

5.89

(Low Input)

kBTU/hr

20,100

THERMAL EFFICENCY

%

82

 

 

 

LENGTH

mm

1006

in

39-5/8”

 

 

 

 

HEIGHT

mm

715

in

28-1/8”

 

 

 

 

DEPTH

mm

208

in

8-1/4”

 

WEIGHT

kg

42

lbs.

93

 

 

 

 

GAS CONNECTION

NPT

½”

FEMALE

 

 

 

 

 

WALL HOLE DIAMETER

mm

50

 

 

in

2”

 

AIR INLET DIAMETER

mm

49

 

 

in

1-7/8”

 

EXHAUST PIPE DIAMETER

mm

35

 

 

in

1-3/8”

 

MAX WALL THICKNESS

mm

500

in

19-5/8”

 

MIN WALL THICKNESS

mm

150

in

5-7/8”

 

 

 

 

PRESSURE

 

 

NATURAL

mbar

8.0

 

MAX

GAS

in W.C.

3.2

 

LP

mbar

26.5

 

 

 

 

in W.C.

10.6

 

 

 

MANIFOLD

 

 

NATURAL

mbar

4.6

 

MIN

GAS

in W.C.

1.8

 

LP

mbar

16.2

 

 

 

 

 

 

 

 

in W.C.

6.5

 

 

 

 

 

 

 

NATURAL

m3/h

.9

 

 

MAX

GAS

ft3/h

30.1

RATE

 

LP

m3/h

.3

 

 

 

 

ft3/h

11.6

 

 

 

 

 

NATURAL

m3/h

.6

GAS

 

 

GAS

 

 

 

 

ft3/h

21.3

 

 

MIN

 

m3/h

.2

 

 

 

LP

ft3/h

8.7

 

 

 

 

 

 

 

 

 

 

 

 

 

NATURAL

mbar

17.4

MINIMUM INLET

GAS

in W.C.

7.0

 

PRESSURE

LP

mbar

27.4

 

 

 

 

 

 

 

 

in W.C.

11.0

 

 

 

 

AIR FLOW

 

m³/h

450

 

 

 

 

cfm

265

 

 

 

 

MINIMUM AIR FLOW

 

m³/h

330

 

cfm

194

 

 

 

 

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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.

WARNING: For the installation of this furnace, the following items must be used as a vent air intake system:

External Vent Cap

(Part Number: WFR–TRM000)

Flanged Air Inlet Tube

(Part Number: WFR–TBO002)

O-Ring

(Part Number: WFN–RNG003)

Flue Outlet Tube

(Part Number: WFR-795)

(All the above items are supplied with the furnace)

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: 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.

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Figure 1

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. (3)

B.Clearance to window or door that may be opened 12inches (30 cm) minimum. (3)

C.Clearance to permanently closed window (minimum 12inches (30 cm) recommended to prevent condensation on window.

K.Clearance to a mechanical air supply inlet 6-feet (1.8 m) minimum. (3)

L.Clearance (1) above paved sidewalk or a paved driveway located on public property 7-feet (2.1 m) minimum. (3)

M.Clearance under veranda, porch, deck or balcony 12inches (30 cm) minimum. (2), (3)

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.

Notes:

(1)A vent must not terminate directly above a sidewalk or paved driveway which is located between two single family dwellings and serves both dwellings.

(2)Only permitted if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

(3)As specified in CGA B149 installation codes (1991).

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. (3)

I.Clearance to service regulator vent outlet 6-feet (1.8 m) minimum. (3)

J.Clearance to nonmechanical air supply inlet to building

or the combustion air inlet to any other furnace 12inches (30 cm) minimum. (3)

Note: Local codes or regulations may require different clearances.

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Outside Location for Vent Terminal

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

Flue Outlet Tube Length

= Wall Thickness + 1-5/16 inches

Figure 2

A + 33.3 mm

A + 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.

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Figure 4

O-Ring Gasket

Figure 5

Figure 6

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.

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