Owner’s Manual Save this manual for future reference. Top-Vent Gravity Wall Furnace Model Numbers: 2509622; 2539622; 2559622; 3509622; 3539622; 3559622; 5009622; 5039622; 5059622 FOR USE WITH NATURAL GAS ONLY Model Numbers: 2509621; 2539621; 2559621; 3509621; 3539621; 3559621; 5009621; 5039621; 5059621 FOR USE WITH PROPANE GAS ONLY READ THIS OWNER’S MANUAL CAREFULLY BEFORE YOU INSTALL YOUR NEW WILLIAMS WALL FURNACE.
Warranty & Installation Record – 2 Warranty The manufacturer, Williams Furnace Co., warrants this wall furnace or heater to the original purchaser under the following conditions: LIMITED ONE-YEAR WARRANTY 1. Any part thereof which proves to be defective in material or workmanship within one year from date of original purchase for use will be replaced at the Manufacturer’s option, FOB to its factory. 2.
Contents Your Williams Warranty .................................................................2 Installation Record .........................................................................2 Table of Contents ..........................................................................3 Safety Rules ..................................................................................4 Introduction....................................................................................5 Basic Materials Needed.......
Safety Rules WARNING: Read these rules and the instructions carefully. Failure to follow these rules and instructions could cause a malfunction of the furnace. This could result in death, serious bodily injury and/or property damage. INSTALLATION MUST CONFORM TO LOCAL CODES. IN THE ABSENCE OF LOCAL CODES, INSTALLATION MUST CONFORM TO THE NATIONAL FUEL GAS CODE, ANSI Z223.1.
Introduction – 5 Introduction The following steps are all needed for proper installation and safe operation of your furnace. If you have any doubts as to any requirements, check with local authorities. Obtain professional help where needed. All of the checks and adjustments in the Start-Up Procedures are vital to the proper and safe operation of the furnace. Please read the instructions before you install and use your furnace. This will help you obtain the full value from this furnace.
Installing Your Furnace The following steps are needed for proper installation and safe operation of your furnace. If you have any doubts as to any requirements, obtain professional help. Remember to ALWAYS consult your local heating or plumbing inspector, building department or gas utility company regarding regulations, codes, or ordinances which apply to the installation and location of a vented wall furnace. 2. Install the furnace in accordance with local codes or ordinances and instructions provided.
Installing Your Furnace Locating Wall Furnace & Thermostat (continued) The thermostat should be sensing average room temperature; avoid the following: HOT SPOTS: Concealed pipes or ducts Fireplaces Registers TV sets Radios Lamps Direct sunlight Kitchen COLD SPOTS: Concealed pipes or ducts Stairwells – drafts Doors – drafts Unheated rooms on other side of wall After picking a location that meets the requirements, check the walls, attic and roof to make sure there are no obstructions such as pipes, electric
Installing Your Furnace Combustion & Ventilation Air (continued) LOUVERS / GRILLES AND SCREENS COVERING FREE AREA OPENINGS If a screen is used to cover the opening(s), it must not be smaller than 1/4-inch mesh. Use the free area of a louver or grille to determine the size opening required to provide the free area specified. If the free area is not known, assume a 20% free area for wood and a 60% free area for metal louvers or grilles.
Installing Your Furnace Combustion & Ventilation Air (continued) FURNACE LOCATED IN UNCONFINED SPACE A. Air From Inside the Building An unconfined space must have a volume of a minimum 50 cubic feet per 1,000 Btu/hr. of the total combined input of all appliances in the area. Adjoining rooms may be included only if there are no doors between the rooms or if special provisions are made such as ventilation grilles installed between connecting rooms.
Installing Your Furnace Recessed Wall Mount Installation On models 2509621, 2539621, 2559621, 2509622, 2539622, 2559622, 3509621, 3539621, 3559621, 3509622, 3539622, and 3559622, the maximum recess depth from rear of furnace forward is 4½ inches. FIND THE STUDS AND CEILING JOINTS Use a stud locator or small finishing nails. Repeatedly drive and remove a nail into the wall in the area of the stud until it is located. Then find the inside edge of the stud. Leave the nail at this location.
Installing Your Furnace Recessed Wall Mount Installation (continued) CLOSE OFF STUD SPACE (If Required) INSTALL VENT BASE PLATE (HOLD-DOWN PLATE) If studs are not on 16-inch centers, cut the hole for the furnace next to an existing stud and frame in the other side using a 2x4 and spacer blocks as required. (Figure 6). Position base plate on top of header plate and fasten with screws. Note: Hold down plate is not included.
Installing Your Furnace Surface Mount Installation The use of the optional Free Standing Accessory No. 4901 allows single-sided furnaces to be surface mounted instead of recessed into a wall. This is ideal for remodeling existing masonry wall construction or when studding is substandard. This kit drastically cuts installation time and eliminates the expense of cutting into the walls and ceiling plates. Be sure this accessory is of the type and design required for the use with your furnace.
Installing Your Furnace Surface Mount Installation (continued) FIGURE B FIGURE C FIGURE D Vent Installed Front panel installed
Installing Your Furnace Vent Installation The vent installation must comply with all local codes and ordinances. If in doubt, consult your local codes or inspector. Figure 8 – Typical Vent Installation The furnace vent must be directed to the outdoors so that harmful combustion gases will not collect inside the building. This furnace must not be connected to a chimney flue serving a separate solid-fuel burning appliance. This product is design certified to ANSI Z21.86. It must be installed with a U.L.
Installing Your Furnace Attaching Your Furnace Clear the wall recess of all debris, remove any wood or plaster. Stand the furnace in front of recess, holding the furnace body at an angle. Insert flue collar into the opening in the header plate and raise furnace carefully (Figure 9). Swing bottom of furnace into wall recess with front edges of legs flush with 2x4 floor plate. In the holes provided, nail through the legs into studs or floor plate (Figure 10).
Installing Your Furnace Attaching Your Furnace (continued) After furnace is in position, install rear outlet register as shown in Figure 12. Have damper in open position when inserting the assembly. Secure the rear outlet register to speed nuts with the machine screws furnished. FIGURE 12 – Mounting Rear Outlet Register Gas Supply and Piping GAS PIPING The gas control valve, in the furnace, is shipped with a seal over the gas inlet tapping.
Installing Your Furnace Gas Supply and Piping (continued) GAS PIPING The gas supply line must be of adequate size to handle the Btu/hr. requirements and length of the run for the unit being installed. FIGURE 14 – Gas Piping Determine the minimum pipe size from Figure 13, based on the length of the run from the gas meter to the unit. FIGURE 13 – Pipe Capacity Pipe Capacity – Btu/hr. with Fittings All piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.
Installing Your Furnace Gas Supply and Piping (continued) CHECKING THE GAS PIPING Test all piping for leaks. When checking gas piping to the furnace with gas pressure less than 1/2 PSI, shut off manual gas valve to the furnace. If gas piping is to be checked with the pressure at or above 1/2 PSI, the furnace and manual shutoff valve must be disconnected during testing. (SEE WARNING). Apply soap solution (or a liquid detergent) to each joint. Bubbles forming indicate a leak.
Installing Your Furnace Thermostat Installation Williams’ furnaces are operated by a millivolt type thermostat. Current to the thermostat is supplied by the pilot generator. Do not connect it to electricity. Anticipator settings are not required. 7. Use the 18-gauge wire as supplied for a maximum length of 20-feet. If a longer length is needed, use 16-gauge wire to a maximum length of 25-feet. 1. Use of existing wire is acceptable if it is in a satisfactory location and the wire is in good condition.
Installing Your Furnace Start-Up Procedure WARNING: Danger of property damage, bodily injury or loss of life. Liquefied Petroleum (L.P.) Gas is heavier than air and may settle in any low area, including open depressions and may remain there unless area is ventilated. Never attempt start-up of unit before thoroughly ventilating the area. Check the furnace operation as outlined in the following instructions. If any sparking, odors or unusual noises are encountered, shut off electric power immediately.
Operating Your Furnace Start-Up Procedure (continued) CHECK PILOT BURNER NORMAL APPEARANCE The pilot flame must surround the generator tip from 1/4 to 3/8inches. Pilot flame is preset at the factory, so ordinarily it does not require field adjustment. (Figure 19). On new installations, the gas lines will be filled with air and may take several minutes to establish a pilot flame. Natural Gas: 1. Inner coneblue in color3/8 to 5/8-inches above ports. 2.
Operating Your Furnace FOR YOUR SAFETY, READ BEFORE LIGHTING THE PILOT WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. 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. E.
Operating Your Furnace FOR YOUR SAFETY, READ BEFORE LIGHTING THE PILOT (continued) TO TURN OFF GAS TO APPLIANCE 1. 2. 3. 4. 5. Set the thermostat to lowest setting. Turn off all electric power to the appliance if service is to be performed (if applicable). Remove control access panel. Push in gas control knob slightly and turn clockwise to "OFF". Do not Force. Replace control access panel. IMPORTANT: KEEP BURNER AND CONTROL COMPARTMENT CLEAN.
Caring for Your Furnace How to Care for Your Furnace WARNING: Danger of bodily injury or death. Turn off electric power supply at disconnect switch, fuse box or service panel before removing any doors or access service panels from unit. PILOT BURNER Using the instructions in "Lighting the Pilot”, leave thermostat at its lowest setting. Pilot flame should surround the generator tip 1/4 to 3/8-inches. If flame needs adjusting, do so as follows: ANNUAL UPKEEP NEEDED 1.
Care – 25 Caring for Your Furnace How to Care for Your Furnace (continued) CLEANING THE BURNER COMPARTMENT Because cold air is attracted to the flame during furnace operation, a buildup of lint from carpeting, bedding, dust, etc. in the burner area will occur. It is necessary to clean this area regularly. Use a vacuum cleaner with a narrow attachment to reach small areas. Be careful in and around the pilot. A change in its adjustment could be made if moved during cleaning.
Installing Your Blower Accessory Blower Accessory 2901 and 2907 (continued) FIGURE A – Install Electrical Outlet FIGURE B – Install Blower Body FIGURE D – Wiring for Model 2907 FIGURE C – Wiring for Model 2901 26
Accessories– 27 Blower Accessory Replacement Parts
Care – 28 Blower Accessory Replacement Parts Blower Accessory 2901 and 2907 (continued) BLOWER ACCESSORY PARTS - MODEL 2901MODEL 2901 Ref. No. Description Part No.
Installing Your Motorized Rear Outlet Accessory Motorized Rear Outlet Register 6919 and 6920 WARNING: Danger of property damage, bodily injury or death. Turn off all electrical power supply at disconnect switch, fuse box or service panel before removing or working on fan. For your protection against shock hazard, this appliance is equipped with a three-prong (grounding) plug and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the prong.
Installing Your Motorized Rear Outlet Accessory Motorized Rear Outlet Register 6919 and 6920 (continued) 30 FIGURE C – Surfaced Mounted Installation FIGURE D – Recessed Mounted Installation FIGURE E – Surface Mounted Installation FIGURE F - Wiring
Motorized Rear Outlet Replacement Parts Motorized Rear Outlet – Models 6919 and 6920 -- and 6920
Motorized Rear Outlet Replacement Parts Motorized Rear Outlet Replacement Parts (continued) Motorized Rear Outlet Replacement Parts List – Models 6919 and 69206919 and 6920 Ref. No. Description 1 2 3 4 5 6 7 8 9 10 11 Register Assembly Strain Relief Bushing J-Box Cover Strain Relief Bushing Heat Sensor Switch Fan Switch Motor and Blower Motor cover Motor Housing Back Plate Cord and Plug Bushing Use only manufacturer’s authorized parts.
Furnace Replacement Parts Control Assembly – 250, 350, and 500 Series
Furnace Replacement Parts Furnace Replacement Parts (continued) Cabinet and Body Parts - 250 and 350 Series 34
Furnace Replacement Parts Furnace Replacement Parts (continued) Cabinet and Body Parts – 500 Series
Furnace Replacement Parts Furnace Replacement Parts (continued) Control Assembly – 250, 350 & 500 Series REF. NO.
Furnace Replacement Parts Furnace Replacement Parts (continued) Cabinet and Body Parts – 500 Series DESCRIPTION 5009621 5039621 5059621 5009622 5039622 5059622 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Face Panel (2 Required) Front Heat Shield (2 Required) Carryover Shell Combustion Chamber (2 Required) Shield Assembly Deflector (2 Required) Header Vent Limit Switch Draft Hood (2 Required) Non-Vision Shield Inner Shield Top (2 Required) Burner Pan Blower Heat Deflector Manual Spark Igniter Igniter Bracket
Troubleshooting Your Furnace SYMPTOM 1. 2. Pilot will not stay lit after following lighting instructions. POSSIBLE CAUSE(S) c. d. Grounded thermostat wire. e. Defective gas valve. a. a. Turn gas valve knob to the “ON.” b. Set thermostat to a position calling for heat. c. d. Checkclean or replace. Check connections at valve terminals. If valve operates, check thermostat wires. e. See 1a and 1c above. f. g. Gas valve not turned to the “ON” position after lighting pilot.
Troubleshooting Your Furnace Troubleshooting Your Furnace (continued) SYMPTOM 6. Pilot outage. POSSIBLE CAUSE(S) a. CORRECTIVE ACTION a. b. Pilot flame may be low or blowing (high). Drafts or drafty areas. b. Adjust pilot flame. Pilot orifice may be plugged (check for spider webs or other material). Check for doorway and high movement areas. 7. Noisy blower. a. b. c. Housing rattling. Blower dirty. Blower wheel bent. a. b. c. Tighten blower screws. Clean blower wheel. Straighten or replace.
Hints and Information Service Hints If your furnace fails to work correctly, you may avoid the inconvenience and cost of a service call by checking the troubleshooting section on pages 38 and 39 before you call for service. 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 or this or any other appliance.
