WILLIAMS 4007732 Direct Vent Gravity Instruction Manual

WILLIAMS 4007732 Direct Vent Gravity

Product Information

The furnace is designed to expand and contract during heating and cooling cycles due to the properties of metal. Some expansion sounds are normal, but excessive noise may indicate improper installation.

Specifications

• Inlet Pressures:
  • Natural Gas: 5 – 7 inches
  • Liquid Propane Gas: 11 – 13 inches
• Manifold Pressures: 4 – 10 inches
• Altitude: Unit should be below 2,000 feet; de-rate output for elevations above 2,000 feet

Product Usage Instructions

Common Checks for Reduction of Expansion Sounds

1. Verify the combustion chamber neck is not restricted and centered within the header plate opening.
2. Avoid over-tightening screws holding the chamber in place.
3. Ensure legs are straight and not altered to fit between studs.
4. Check for proper inlet and manifold pressures.
5. Verify unit altitude and room size suitability.

Additional Instructions for Specific Models
MONTEREY, MONTEREY PLUS 25,000 35,000 50,000 BTU:

1. Always use the included header plate and ensure proper installation of the vent pipe.
2. Check furnace legs for any alterations.
3. Center the unit on a 16 stud cavity without bowing legs.
4. Ensure draft hood is centered and free-floating within the header plate.

DIRECT VENT GRAVITY 14,000 22,000 30,000 BTU:

1. Secure the furnace to the wall properly without vent tubes supporting its weight.
2. Verify accurate wall thickness and vent tube length.
3. Adjust screws on the heat exchanger for expansion allowance.

FORSAIRE TM DIRECT VENT MODELS 4007732 4007731 4007731 5507332 5507331 6007732 6007731 4007332:

1. Install the unit on a flat, level surface.
2. Avoid reshaping vent tubes; adjust length if needed.

FAQ

• Q: What should I do if the expansion sounds persist after following all instructions?
  A: If the noise continues, please contact customer support for further assistance.

Product Bulletin

FURNACE EXPANSION SOUNDS

The properties of metal cause it to expand and contract when heating and cooling. Therefore, light expansion sound is expected and considered normal. However, improper installation can cause excessive expansion/contraction sounds. Generally, the issue lies in one of these areas, so check each carefully to reduce or eliminate the sound:

1. Verify the neck of the combustion chamber is not restricted in anyway and is centered within the opening of the header plate.
2. The screws that hold the chamber in the cabinet should not be over-tightened.
3. The legs must be straight. Check to see that they were not bent to fit between the stud spacing. Legs cannot be altered in anyway.
4.  Check for proper inlet and manifold pressures.

| INLET| MANIFOLD
---|---|---
NATURAL GAS| 5 – 7 INCHES| 4 INCHES
LIQUID PROPANE GAS| 11 – 13 INCHES| 10 INCHES

•  Verify the altitude of the unit is below 2,000 feet. If not, it will need to be properly de-rated. For elevations above 2,001 feet, output should be reduced by 4% per 1,000 ft. Furnace specific high altitude kits are available from Williams.
•  Verify the room size and unit location. Make sure heater clearances meet the specification in the user’s manual and the model/BTU selected is suitable for the square footage of the room.

If the noise is still present, please follow these additional instructions.

MONTEREY, MONTEREY PLUS

25,000 ° 35,000 ° 50,000

1. Always use the header plate included with the furnace. Make sure a proper hold-down plate was installed and the vent pipe is properly secured by the hold-down plate.
2. Make sure the legs of the furnace were not cut off or bent in any way.
3. The unit must be centered on 16″ stud cavity. The legs of the furnace must not bow out.
4. Verify wall cavity dimensions of 14-3/8″ minimum with 62-¼” from the bottom of the plate to the header.
5. Make sure the neck of the draft hood is centered and not restricted in the header plate or touching either side of the header. The draft hood needs to be free floating within the header plate. Make sure there is a gap on either side between the heat exchanger neck and the heat shield. The neck should move back and forth freely without touching the heat shield on either side.
6. Make sure the screws that hold the chamber in the cabinet are not too tight. Loosen and realign chamber if necessary.
7. Make sure that the vent is at least 8-10 feet long and there are no more than two 45°offsets in the venting. The venting must extended through the ceiling and roof, terminating at least 12-feet above the finished floor on which the furnace rests.

DIRECT VENT GRAVITY
14,000 ° 22,000 ° 30,000 BTU

1. Use the template provided with the unit to draw the 9-¼” diameter circle on the wall. Then mark the location of the gas supply line. Make sure the unit is installed on a flat, plumb surface, and the legs and/or wall brackets are not bent or cut off.
2. Make sure the furnace is properly secured to the wall. Verify the vent tubes are not supporting the weight of the furnace on the wall.
3. Verify wall thickness and vent tube length are accurate. Make sure the vent cap is installed on a plumb surface.
4. Remove the heat shield and loosen the screws on the corners of the heat exchanger, then hand tighten the screws to allow for expansion.
5. When replacing a direct vent unit make sure to use the venting supplied with the unit. Do not reuse existing venting.

FORSAIRE ™ DIRECT VENT
MODELS 4007732 ° 4007731 ° 6007732 ° 6007731 ° 4007332 4007731 ° 5507332 ° 5507331

1. Make sure the unit is installed on a flat, level surface.
2. Verify the vent tubes are not supporting the weight of the furnace. Vent tube cannot be reshaped, but the length can be altered.
3. Verify wall thickness and vent tube length, making sure the vent cap is installed on a plumb surface. The vent cap securing screws should be tightened just snug enough to allow expansion of the metal and to ensure the vent cap does not put pressure on the vent tubes in any direction.

FORSAIRE ™ TOP VENT
MODELS 6008832 ° 6008831 ° 3508632 ° 3508632 ° 5008632 ° 5008631 6508632 ° 6508631

1. Always use the header plate provided with the furnace. Make sure a proper hold-down plate was installed and the vent pipe is properly secured by the hold-down plate.
2.  Verify the furnace is mounted on a flat, level surface. The bottom of the furnace may rest directly on a wood or concrete floor. If floor is other than wood or concrete, there must be a piece of wood or sheet metal under the furnace that is at least the same size as the bottom of the furnace.
3.  Make sure that all top vent is at least 8-10 feet long and there are no more than two 45° angles in the venting. The venting must extended through the ceiling and roof terminating at least 12-feet above the finished floor on which the furnace rests.
4.  Make sure the neck of the draft hood is centered and not restricted in the header plate or touching either side of the header. The draft hood needs to be free floating within the header plate.

ROOM HEATER

1. Make sure unit is sitting on a flat, level surface.

2. Check that the weight of the venting is not being supported by the draft diverter on the back of the unit.

3. Larger units have multiple heat exchangers that may shift in transit. Check for proper alignment of the interconnecting tubes:
   Remove the top

4. Remove the three (3) brackets on the rear of the heater that secure the cabinet top to the back plate

5. Pull the cabinet top forward and lift up.

6.  Reinstall the cabinet top by reversing the procedures noted on figure below.
   NOTE: TO REMOVE CABINET TOP REMOVE THE 3 BRACKETS FROM THE REAR OF THE CABINET. PULL CABINET TOP FORWARD AND LIFT UP.

7. ake sure nothing is touching the blower duct that is directly below the heat exchangers.

8. Hand tighten heat exchanger bracket screws and replace the top. (see above)

9. Make sure that all venting is at least 8-10 feet long and at least a ¼” rise for every foot of horizontal run.
   The venting must extend through the ceiling and roof terminating at least 12-feet above the surface on which the furnace rests.
   Note: Take special care to engage the six (6) clips located on the bottom of the cabinet top into the top flange of the heater sides.

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