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FORSAIRE COUNTERFLOW  DIRECT VENT GAS WALL HEATER  

5

INTRODUCTION

BASIC DESCRIPTION 

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 your furnace. Please read our 

instructions before you install and use your furnace. This will 

help you obtain the full value from this furnace. It could also 

help you avoid needless service costs if the answer to the 

problem is found within this instruction manual. 
Always consult your local heating or plumbing inspector, 

building department or gas utility company regarding 

regulations, codes or ordinances which apply to the 

installation of a counterflow Direct Vented wall furnace. 
Check the furnace nameplate, located in the burner 

compartment, to make sure the furnace is equipped to 

operate on the type of gas available (either natural or propane gas).  

DO NOT convert the furnace from natural gas to propane 

gas or from propane gas to natural gas without the proper 

manufacturer’s gas conversion kit.
Your Counterflow Direct Vent Furnace draws air in at the 

top of the furnace by the fan and discharged through the 

grille near the floor. It is shipped ready to install on the 

surface of a wall or recessed into a wall. Combustion air is 

drawn in from the room where the furnace is located and 

vented out the top of the furnace through listed vent piping 

to a roof Direct Vent.  Venting material is not supplied with 

this furnace. 
This appliance is equipped with a vent safety shutoff 

system designed to protect against improper venting of 

combustion products. Operation of this wall furnace when 

not connected to a properly installed and maintained 

venting system or tampering with the vent safety shutoff 

system can result in carbon monoxide (CO) poisoning and 

possible death.

1)   Seal any unused openings in the venting system.
2)   Inspect the venting system for proper size and   
      horizontal pitch, as required in the National Fuel  
      Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas  
      and Propane Installation Code, CSA B149.1 and  
      these instructions. Determine that there is no  
      blockage or restriction, leakage, corrosion and other  
      deficiencies which could cause an unsafe condition.
3)   As far as practical, close all building doors and  
      windows and all doors between the space in which  
      the appliance(s) connected to the venting system  
      are located and other spaces of the building.
4)   Close fireplace dampers.
5)   Turn on clothes dryers and any appliance not    
      connected to the venting system. Turn on  

 

      any exhaust fans, such as range hoods and  

 

      bathroom exhausts, so they are operating at    
      maximum speed. Do not operate a summer  
      exhaust fan.

      WARNING:

 

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed  
into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into 
operation, while all other appliances connected to the venting system are not in operation:

6)   Follow the lighting instructions. Place the appliance  

 

      being inspected into operation. Adjust the thermostat  
      so appliance is operating continuously.
7)   Test for spillage from draft hood equipped appliances  
      at the draft hood relief opening after 5 minutes  

 

      of main burner operation. Use the flame of a match  
      or candle.
8)   If improper venting is observed during any of the  
      above tests, the venting system must be corrected  
      in accordance with the National Fuel Gas Code,  
      ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane    
      Installation Code, CSA B149.1.
9)   After it has been determined that each appliance  

 

      connected to the venting system properly vents  
      when tested as outlined above, return doors, windows,  
      exhaust fans, fireplace dampers and any other  
      gas-fired burning appliance to their previous  
      conditions of use.

Summary of Contents for 4007331

Page 1: ...codes Not for manufactured home manufacturer factory installation Do not install any of these furnaces natural or propane gas in trailers or recreational vehicles WARNING This product can expose you...

Page 2: ...mplied warranty lasts and some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you 2 This warranty does n...

Page 3: ...SORY 9940 WIRING DIAGRAMS FURNACE ASSEMBLY REPLACEMENT PARTS 400 MODELS CONTROL ASSEMBLY REPLACEMENT PARTS 400 MODELS INTERMITTENT IGNITION CONTROL ASSEMBLY REPLACEMENT PARTS 400 MODELS STANDING PILOT...

Page 4: ...e furnace vent directly to the outdoors so that harmful combustible flue gases will not collect inside the building Follow the venting instructions for your type of installation exactly Use only the t...

Page 5: ...sult in carbon monoxide CO poisoning and possible death 1 Seal any unused openings in the venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National F...

Page 6: ...lows you to direct heated air from the side of furnace into the same room OUTLET GRILLE REGISTER 6701 Let s you route some heated air into a second room Mounts on the side wall of second room and must...

Page 7: ...l closer than 4 to intersecting wall See Page 8 Figure 4 Studs must be spaced on 16 inch centers or stud space will have to be framed in See Page 9 and 10 Recessed Mounting 2 The top of the furnace mu...

Page 8: ...age room temperature AVOID THE FOLLOWING HOT SPOTS COLDSPOTS Concealed pipes or ducts Concealed pipes or ducts Fireplaces Stairwells drafts Registers Doors drafts TV sets Unheated rooms Radios on the...

Page 9: ...tion 3 Make the required cutout in inside wall Figure 8 4 Using the hole drilled through to the outside wall as the center cut a 9 inch diameter hole for the vent It may be better to work from outside...

Page 10: ...THE STUDS 1 Find two studs at spot where furnace is to be placed Use a stud indicator or small finishing nails Repeatedly drive and remove a nail into the wall in the area of the stud until you find i...

Page 11: ...opening in furnace outer casing where marked See Page 10 Figure 10 2 Place the outer boot against casing with inner flanges exactly on edges of cut hole mark screw location re move boot and drill 33...

Page 12: ...a basement or crawl space using similar methods 4 Before drilling a hole in the wall at selected location drive a small finishing nail through the ceiling in the corner of the wall and ceiling above...

Page 13: ...ting from end with collar and holes Cut off evenly File off any burrs resulting Vent tube B Add 2 inches to dimension X Mark on tube starting from end with collar and holes Cut off evenly File off any...

Page 14: ...into place until the stops are contacted If the stops prevent the mounting plate from reaching the wall refer back to DETERMINE PROPER LENGTHS Page 13 NOTE The smaller tube in the vent cap must slide...

Page 15: ...OTTOM SURFACE AND RECESSED MOUNT NOTE Fasteners are not furnished because of different requirements of various types of wall construction Fasten the furnace to the floor through the holes provided in...

Page 16: ...put and pressure shown on the rating plate On Natural Gas the manifold pressure should be 4 inches water column The manifold pressure should be 10 5 inches water column for propaned gas See page 19 fo...

Page 17: ...rtion or mal function may result from excess pipe within control Apply moderate amount of good quality dope to pipe only leaving 2 end threads bare If propane gas installation use compound resistant t...

Page 18: ...ch diameter knockout into the burner control assembly area and insert it into the nylon plug attached to the outer casing bottom If desired you may route the thermostat wire alongside of the service c...

Page 19: ...ge 25 Figure 30 CHECK THE MANIFOLD GAS PRESSURE A tapped opening is provided in the gas valve to facilitate measuring the manifold gas pressure A U Tube manometer having a scale range from 0 to 12 inc...

Page 20: ...t be adjusted WARNING Danger of bodily injury or death Do not operate the furnace with a broken or missing pilot observation door FOR MODELS EQUIPPED WITH WILLIAMS GAS VALVE P321704 OR P321705 Models...

Page 21: ...y light the pilot Continue to hold the red reset button in for about 1 minute after the pilot is lit Release button and it will pop back up Pilot should remain lit If it goes out repeat steps 5 throug...

Page 22: ...eep children clothing furniture and flammable material away from it Do not store or use gasoline or other flammable liquids or vapors near the furnace WARNING Danger of bodily injury or death Do not o...

Page 23: ...ight in approximately 45 seconds NOTE On initial start up or after prolonged shut down several ignition cycles may be required to purge the gas lines To accomplish the recycle repeat steps 6 through 1...

Page 24: ...ront panel Clean any lint or dirt from fan blades fan motor and exposed air passages Use a brush Put 5 drops of SAE 20 oil in each of the two cups or oil tubes on the fan motor See Figure 36 below PIL...

Page 25: ...the pilot A change in its adjustment could be made if struck during cleaning WARNING A BUILDUP OF ANY DUST LINT OR FOREIGN MATERIAL IN THE PRIMARY AIR OPENING OF THE BURNER CAN INTERFERE WITH THE PRO...

Page 26: ...ly one service switch services both the appliance and the carbon monoxide detector b Have battery back up power INSTALLATIONS IN THE STATE OF MASSACHUSETTS c Meet ANSI UL 2034 Standards and comply wit...

Page 27: ...the service power cord disconnect the cord at the receptacle connector located at the base of the furnace and remove the cord completely from the furnace Following the wiring diagram below make all th...

Page 28: ...28 FORSAIRE COUNTERFLOW DIRECT VENT GAS WALL HEATER WIRING DIAGRAMS MODELS 4007332 4007331 MODELS 5507332 5507331...

Page 29: ...FORSAIRE COUNTERFLOW DIRECT VENT GAS WALL HEATER 29 MODELS 4007732 4007731 MODELS 6007732 6007731...

Page 30: ...1 P151101 14 Motor Support 2 Req 7B46 7B46 7B46 7B46 15 Transformer P024200 P024200 P024200 P024200 16 Internal Wires except for 4007332 4007331 11A152 11A152 11A152 11A152 17 Vibration Isolator 4 Req...

Page 31: ...FORSAIRE COUNTERFLOW DIRECT VENT GAS WALL HEATER 31 EXPLODED VIEW REPLACEMENT PARTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 16 18 19 20 21 22 23 24 25 26 28 29 27...

Page 32: ...22044 7 Pilot Natural P323418 Pilot Propane P323419 8 Thermocouple Flame Sensor P271100 P271100 9 Pilot Tube Gasket P151800 P151800 10 Pilot Tube Seal 11A41 11A41 11 Gasket 44 inch P101600 P101600 12...

Page 33: ...133 6 Williams Valve P323209 P322042 7 Pilot Natural P323418 Pilot Propane P323419 8 Thermocouple P254000 Flame Sensor P271100 9 Pilot Tube Gasket P151800 P151800 10 Pilot Tube Seal 11A41 11A41 11 Gas...

Page 34: ...200400 P200400 13 Fan Switch P200200 P200200 14 Motor P062101 P062101 15 Motor Support 2 Req 7B46 7B46 16 Transformer P024200 P024200 17 Vibration Isolator 4 Req P022800 P022800 18 Fan Blade P200600 P...

Page 35: ...FORSAIRE COUNTERFLOW DIRECT VENT GAS WALL HEATER 35 EXPLODED VIEW REPLACEMENT PARTS 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 20 17 18 19 21 25 23 24 25 26 27 28 29 11...

Page 36: ...acket P323649 P323649 6 Burner Pan 11B134 11B156 7 Williams Valve P323210 P322042 8 Pilot Natural P323418 Pilot Propane P323419 9 Thermocouple P254000 Flame Sensor P271100 10 Pilot Tube Gasket P151800...

Page 37: ...FORSAIRE COUNTERFLOW DIRECT VENT GAS WALL HEATER 37 1 2 3 4 5 6 10 11 13 14 15 EXPLODED VIEW REPLACEMENT PARTS 3 7 8 9 12...

Page 38: ...11B119 11 Selector Switch P200400 P200400 12 Fan Switch P200200 P200200 13 Switch Box Cover 11C68 11C68 14 Switch Box 11B05 11B05 15 Seal Gasket P103100 P103100 16 Element Baffle 11B116 11B116 17 Limi...

Page 39: ...T Diffusing Grille Two Way 6703 6703 KIT Diffusing Grille One Way 6704 6704 Thermostat not included with these models REF NO REPLACEMENT PARTS DESCRIPTION 6007732 6007731 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 40: ...323948 5 50 mm Burner Without pilot bracket P32649 P323649 6 Burner Pan 11B156 11B156 7 Williams Valve P323209 P322042 8 Pilot Natural P323418 Pilot Propane P323419 9 Thermocouple P254000 P254000 10 P...

Page 41: ...FORSAIRE COUNTERFLOW DIRECT VENT GAS WALL HEATER 41 EXPLODED VIEW REPLACEMENT PARTS 1 2 3 3 4 5 6 7 8 9 10 11 14 13 12...

Page 42: ...ectric power turned ON if no voltage replace transformer NOTE Before replacing the transformer or limit switch check wiring for loose connections or broken wires and repair as needed If voltage is pre...

Page 43: ...ath of warm air discharge from the furnace near a lamp or above a TV set or stereo Check the thermostat calibration or replace Check the thermostat wiring from furnace to the thermostat may be shorted...

Page 44: ...onnect one end of a jumper wire to terminal GND DO NOT REMOVE EXISTING WIRE Attach the other end of the jumper wire to the metal blade of a small screwdriver Position the end of metal blade approx 1 8...

Page 45: ...the sensor See procedures for checking for the proper pilot flame and alignment in problem 4d If the pilot flame is drawn away from the sensor when the main burner comes ON the cause could be that the...

Page 46: ...46 FORSAIRE COUNTERFLOW DIRECT VENT GAS WALL HEATER SERVICE RECORD DATE MAINTENANCE PERFORMED COMPONENTS REQUIRED...

Page 47: ...ir parts always give the following Information 1 MODEL NUMBER 2 MFG DATE CODE 3 PART NUMBER 4 PART DESCRIPTION All parts listed herein may be ordered from your equipment supplier The Model Number of y...

Page 48: ...P321004_RV 06 21 www williamscomfortprod com 888 444 1212 250 West Laurel Street Colton CA 92324 USA Subject to change without notice 2021 TM...

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