Understanding the proper installation and maintenance of a direct vent wall furnace is essential for both safety and performance. The EMPIRE Direct Vent Wall Furnace, designed for efficient heating in residential spaces, requires careful handling and adherence to manufacturer guidelines to ensure safe and effective operation. This article provides a detailed overview of the installation process, key safety precautions, and essential maintenance practices based on the official documentation provided by Empire Comfort Systems Inc.
The EMPIRE Direct Vent Wall Furnace is a gravity-fed, direct vent heating system designed for installation on an outside wall. It utilizes a combination of air intake and flue exhaust systems to operate safely without the need for a traditional chimney. The unit is certified to American National Standard/CSA Standard Z21.86 and CSA 2.32, ensuring compliance with industry safety and performance benchmarks. Proper installation involves several critical steps, including securing the furnace to the wall, cutting and positioning the vent tubes, and ensuring that all components are sealed and sealed to prevent air leakage.
In addition to installation, the manual emphasizes the importance of regular maintenance, such as cleaning the burner and control compartments, and annual inspections by a qualified service technician. The manual also outlines the warranty terms, which cover defects in materials or workmanship but exclude issues arising from improper installation, unauthorized modifications, or lack of maintenance.
Installation Overview
The installation of the EMPIRE Direct Vent Wall Furnace involves several critical steps that must be performed by a qualified service technician. The manual provides detailed instructions for both the initial setup and the reassembly of the vent-air intake system after servicing. These instructions emphasize the importance of precision, particularly when cutting and positioning the air inlet and flue outlet tubes.
The furnace is designed to be installed on an outside wall, and the wall studs must be located to ensure the unit is mounted securely between them. A minimum wall opening diameter of 6¼ inches (159mm) is required, though the inside and outside wall plates are designed to accommodate an 8-inch (203mm) diameter opening. A template is included in the furnace carton to assist in positioning the unit correctly on the wall.
The installation process begins with the attachment of the inside wall plate. This plate must be centered and leveled in the wall opening, and the collar must be positioned within the opening. If there is insulation above the wall opening, a barrier should be installed to prevent insulation from coming into contact with the air inlet tube. On solid walls or wall studs, the inside wall plate is secured with six #10 x 1½-inch (38mm) screws. On sheet rock walls, the plate is attached using six #10 x 1½-inch (38mm) screws and six Tinnerman nuts.
The furnace itself is then attached to the inside wall plate. Mounting clips on the furnace back are aligned with the mounting slots on the plate, and the furnace support bracket is secured to the wall. On solid walls, a single #10 x 1½-inch (38mm) screw is used, while on sheet rock walls, a toggle bolt is recommended.
Vent Tube Installation and Sealing
The vent tube installation is a critical part of the EMPIRE Direct Vent Wall Furnace setup. The manual specifies that the 5-inch (127mm) diameter air inlet tube and the 3-inch (76mm) diameter flue outlet tube must be cut precisely to ensure proper airflow and venting.
To mark and cut the air inlet tube, it must be attached to the collar of the air drop assembly and extended ½ inch (13mm) beyond the outside wall. The tube is then removed and marked at this point. Similarly, the flue outlet tube is attached to the combustion chamber collar and extended 2 inches (51mm) beyond the outside wall before being marked and cut. The manual emphasizes that the tubes should not be crimped or enlarged, and that tape should be used to mark the cutting points to ensure a clean, accurate cut.
After cutting, the tubes must be reassembled and sealed to prevent air leakage. Old furnace cement and caulking must be removed from both the flue outlet collar and the air inlet tube. New caulking is applied beneath the edge of the outside wall plate to correct any uneven surfaces, and the outside wall plate is positioned so that the air inlet tube slopes slightly downward to prevent water accumulation. The outside wall plate is secured with four #10 x 1-inch (25mm) screws.
The flue outlet tube is then attached to the combustion chamber and vent cap using furnace cement. The vent cap is secured to the outside wall plate with three #10 x ½-inch (13mm) screws. The manual also notes that the maximum wall depth can be extended to 19 inches (483mm) using vent extension kits, which are listed on page 7 of the manual.
Safety Precautions and Maintenance
Safety is a primary concern in the installation and operation of the EMPIRE Direct Vent Wall Furnace. The manual provides several critical safety guidelines that must be followed to prevent accidents and ensure safe operation.
First, the furnace must be installed in an area that is free from traffic and away from furniture, draperies, or any flammable materials. Due to the high surface temperatures, children and adults must be aware of the risks and kept at a safe distance to avoid burns or clothing ignition. Young children, in particular, should be carefully supervised when in the same room as the furnace.
The manual also emphasizes that any safety screens or guards removed for servicing must be replaced before the furnace is operated. The burner and control compartments must be kept clean to prevent the buildup of lint or other combustible materials. Additionally, the vent cap and flue outlet will be hot during operation, and users should avoid placing any objects that could obstruct the flow of combustion and ventilation air.
Installation and repair must be performed by a qualified service technician. The furnace should be inspected before use and at least annually by a qualified professional to ensure that all components are functioning correctly. More frequent cleaning may be necessary in environments with high levels of lint from carpeting or bedding materials.
Warranty and Service Information
The EMPIRE Direct Vent Wall Furnace is backed by a warranty that covers defects in materials or workmanship under normal use and service. However, the warranty does not cover issues caused by improper installation, unauthorized service, or lack of maintenance.
To make a warranty claim, the owner must provide the installing dealer with the model number, serial number, type of gas, and purchase verification. The installing dealer is responsible for initiating any warranted parts replacements and contacting the factory for assistance. Empire will provide replacement parts at the factory, but shipping expenses are not covered under the warranty.
If the service provided by the installing dealer is unsatisfactory, the owner may contact the Consumer Relations Department at Empire Comfort Systems Inc. at PO Box 529, Belleville, Illinois 62222, or via email at [email protected]. The manual also notes that users may have additional rights under state law, and it is recommended to review the warranty for full details.
Installation in Residential Garages
The manual includes specific guidelines for the installation of the EMPIRE Direct Vent Wall Furnace in residential garages. Gas utilization equipment in such environments must be installed so that all burners and ignition devices are at least 18 inches (457mm) above the floor. This ensures that the equipment is not subject to physical damage from moving vehicles and that it remains in a safe, accessible location.
Additionally, the installation must be protected to prevent damage from physical contact. The manual emphasizes that all installations in garages must follow local building codes and regulations, and it is recommended that the local Building Department be consulted for specific requirements.
Conclusion
The EMPIRE Direct Vent Wall Furnace is a reliable and efficient heating solution for residential spaces. Proper installation and maintenance are essential for safe and effective operation. The installation process involves precise cutting and sealing of vent tubes, secure mounting of the furnace and wall plates, and adherence to safety guidelines to prevent accidents.
Regular maintenance, including cleaning of the burner and control compartments, and annual inspections by a qualified service technician, are also critical for long-term performance. The warranty provides coverage for defects in materials or workmanship, but it does not extend to issues caused by improper installation or lack of maintenance.
By following the manufacturer's guidelines, homeowners and installers can ensure that the EMPIRE Direct Vent Wall Furnace operates safely and efficiently for years to come.