Louisville Tin and Stove HEDV403 User's Manual
Contents
1. eFC DUREC I CoLy VENT WALL FURNACE INSTALLATION AND OPERATING INSTRUCTIONS P N 72903 December 2003 CERTIFIED INSTALLER MUST LEAVE THESE INSTRUCTIONS WITH THE CONSUMER HAVE THEM COMPLETE AND RETURN THE WARRANTY CARD MODEL NUMBERS NAT GAS L P GAS HEDV403 HEDV404 WARNING If the information in these instructions are 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 Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building 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 PER FORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER MADE IN USA WARNING Operation of this furnace without the properly installed factory furnished vent system and vent cap could result in Carbon Monoxide CO poisoning and possible death For your safety this furnace and the vent system should be inspected at least annually by a qualified service person2. May be installed in an aftermarket permanently located manufactured home mobile home where not prohibited by local codes See owner s manual for details This appliance is not convertible for use with other gases unless a certified kit is used This unit is not approved for installation in greenhouses or environments involving dusty wet corro sive or explosive conditions Such conditions will invalidate the warranty and may create unsafe conditions CONTENTS Tntroduction sc eee eens eee aean 2 Wiring Diagram 0 cee ceeeee eee eees 12 Specifications and Dimensions 2 Removing Main Burmer 6 11 Safety RUES anra 3 Proper Burner Flame 00000 11 CETS e A 4 5 Sequence of Operation 6 0008 13 LOCaHION E E 6 Optional Kits scsersesrireniiearsie 14 Installation esor snena e 7 Trouble Shooting 0seeeeeeee ee 17 Lighting Instructions 0 45 10 Parts Drawing ccceee cence eee e eee ee 19 Pilot Adjustment 0 0 eceeee eee 11 Pats list aa aa dens cannes ane aot 20 Bummer Once s nier a os 11 Warranty eaei aiani g aai 22 INTRODUCTION THIS IS A GAS FIRED DRAFT INDUCED POWER DEPENDENT DIRECT VENT WALL FURNACE THAT WILL OPERATE SAFELY AND PROVIDE AN EFFICIENT SOURCE OF HEAT WHEN INSTALLED OPERATED AND MAINTAINED AS RECOMMENDED IN THESE INSTALLATION AND OPERATING INSTRUCTIONS READ THESE INSTRUCT
3. If any part of vent extension is vertical or local codes do not allow draining of condensate to outside you must add P N HECK 1 Condensate Kit f For cosmetic purposes the addition of the HEVK 5 Kit can be enclosed by adding a HEVE 5 Vent Enclosure Kit To completely enclose the HEVK 5 Kit one HEVE 5 will be needed for each HEVK 5 used P N 72612 2 x6 Black Flex Tubing ae P N 72532 CS Use only if connecting flex tubing of 2 or more ktis P N 72578 2 x3 Z P N 41515 Black Silicone Support Wrapped Coupling Brackets 2 P N 41520 Center Bracket P N 72575 2 x5 Black Flocked Tube P N 72593 2 Hose Clamps ae Page 14 HEVE 5 VENT ENCLOSURE KIT INSTALLATION INSTRUCTIONS STEP 1 Position end of Part No 41610 enclosure body to heater trim kit where pipes exit trim kit centering pipes inside body and attach to wall Wall anchors not provided may be required Collector box may be behind HEVE 5 Kit STEP 2 Cut to fit enclosure panel 1 beyond end of vent run Insert Part No 41620 End Cap and attach using three 8 screws provided SPECIAL INSTRUCTIONS STEP 3 If more than one HEVE 5 Kit is used attach Part No 72604 Trim Kit where ends meet STEP 4 If making a 90 turn measure 1 beyond outside turn and cut off enclosure panel Notch panel on surface of direction turn is being made to allow pipes to pass through into next HEVE 5 Kit Attach second panel to wall and
4. 00 41100 60 00 Leg Leveler 4 per unit 11 80009 1 50 80009 1 50 Draft Inducer Gasket 12 72602 11 70 72602 11 70 Draft Inducer Assembly 13 72505 135 70 72505 135 70 Sight Glass Frame 14 41215 1 60 41215 1 60 Sight Glass 15 70150 1 20 70150 1 20 Flame Sensor 16 72570 10 60 72570 10 60 Sight Glass Gasket 17 72600 2 10 72600 2 10 Ignitor 18 72550 21 10 72550 21 10 Burner Orifice 2 per unit 19 72156 3 40 72139 3 40 Manifold 20 72640 18 80 72640 18 80 Burner Box 21 41185 30 90 41185 30 90 Burner Box Top Gasket 22 72606 5 90 72606 5 90 Burner Box Top 23 41210 5 00 41210 5 00 Gas Valve 24 72540 77 30 72541 77 30 Gas Valve Bracket 25 41220 5 00 41220 5 00 Burner Box Mounting Gasket 26 72605 5 90 72605 5 90 Transformer 27 78069 23 50 78069 23 50 Control Board 28 72510 116 90 72510 116 90 Wiring Harness 29 72685 18 80 72685 18 80 Pressure Switch 30 72520 28 10 72520 28 10 Casing Back Assy 31 41120 48 50 41120 48 50 Thermostat 32 72523 72 70 72523 72 70 Control Knob 33 72633 4 40 72633 4 40 Fresh Air Intake Hose 34 72611 9 80 72611 9 80 2 Hose Clamp 4 per unit 35 72593 1 70 72593 1 70 Vent Cap Assembly 36 41300 60 20 41300 60 20 Vent Cap Gasket 37 72608 1 90 72608 1 90 Collector Box Assembly 38 41230 239 30 41230 239 30 Collector Box Gasket 39 72607 1 20 72607 1 20 Collector Box Cap 40 72587 1 50 72587 1 50 Exhaust Tube 41 72610 173 10 72610 173 10 Trim Kit Bracket 4 per unit 42 4127
5. Always smell around for gas before lighting your appliance e Sniff for L P gas at floor level LP gas is heavier than air and may temporarily exist at floor level e If you smell gas do not attempt to light the pilot Do not cause a spark by turning on or off electrical switches or appliances or by using the phone Turn off the gas to the appliances and call your gas supplier from another location e If your gas control has gotten wet as the result of flooding or other wetting it must be replaced immediately by a trained gas service technician Water can lead to damage of the internal safety mechanism in the gas control and can create a hazardous condition Page 21 VAAL VV AAAAAAAAAAAAAA A AAAAAA VV VV AY AAA VAAAAAAAAAAAAAAAAAAAAAAAA 5 NII TE WARRANT Y The Louisville Tin amp Stove Co warrants to the original user the accompanying product for the period specified herein provided said product is installed operated maintained serviced and used according to the instructions and specifications accompanying the product AS OUTLINED IN OUR INSTRUCTIONS ANY WARRANTY CONSIDERATIONS ARE CONTINGENT ON INSTALLATION BY A QUALIFIED INSTALLER CONTRACTOR SELF INSTALLATION IS NOT RECOMMENDED AND MY INVALIDATE YOUR WARRANTY If within a period of one year from the date of installation of the product any part supplied by the manufacturer proves to be defective due to workmanship or material it wil
6. LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED WHETHER WRITTEN OR ORAL ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE IS EXPRESSLY LIMITED TO THE DURATION OF THE MANUFACTURER S EXPRESS WRITTEN WARRANTY UNDER NO CIRCUMSTANCES SHALL THE MANUFACTURER BE LIABLE FOR ANY SPECIAL INDIRECT OR CONSEQUENTIAL DAMANGES OR EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM ANY COMPONENT OR FROM THE USE THEREOF THE REMEDIES SET FORTH HEREIN SHALL BE THE EXCLUSIVE REMEDIES AVAILABLE TO THE USER AND ARE IN LIEU OF ALL OTHER REMEDIES SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APLY TO YOU 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 THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE TABLE A Warranty for gas appliance heat exchangers only Product Cozy Gas Fired Floor Furnace Cozy Gas Fired Wall Furnace Cozy Gas Fired Vented Console Heater Cozy Gas Fired Direct Vent Heater Cozy Gas Fired Counterflow Furnace Cozy Gas Fired Counterflow Direct Vent Furnace Cozy Gas Fired Mobile Home Direct Vent Furnace Cozy Gas Fired Hi Efficient Direct Vent Wall Furnace Warranty Period 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years LOUIS
7. Page 11 Remove burners and check for obstruc tions in throats ports and orifices Clean but do not enlarge ports or orifices 2 Make sure area around vent cap is clear be sure vent system is sealed 1 Gas leak 1 See Page 1 Delayed Ignition 1 Low gas pressure 2 Igniter not peroperly located Failure to ignite Main gas off Temperature dial or thermostat not set high enough to call for heat Clogged burner orifice Incorrect wiring Defective valve No power to unit Burner won t turn off Defective or damaged thermostat wire or thermostat Thermostat sensor location on back of heater Defective or sticking valve Ex Incorrect gas input 2 Clogged orifices Not enough heat Furnace undersized Temperature dial set too low Incorrect supply pressure Temperature dial set too high Defective flame sensor Input too high Main burner goes out during normal operation tight Vent tubes not properly installed or sealed 5 Limit switch opens 6 Exhaust or Air Intake tubes blocked Page 17 1 2 1 2 1 1 2 Clean orifices with a smooth wood toothpick 4 Check gas supply pressure Check ignitor location and correct if necessary Open all manual gas valves Set temperature dial or thermostat to higher temperature 3 Clean burner orifices do not enlarge 4 5 6 Plug in power supply cord Check 115 V Check wiring dia
8. as needed Filter can be cleaned with garden hose in bathtub sink etc Use only water or air to clean DO NOT USE ANY CLEANING SOLUTION AS THEY COULD BE FLAMMABLE AND COULD CAUSE ODORS Dry thoroughly and re install Do not operate heater without filter in place Have the furnace checked cleaned and repaired by a qualified service person Check venting system and burner operation prior to use each year Follow a regular service and maintenance schedule for safe and efficient operation Do not obstruct combustion and ventilation air Examine the venting system as a routine part of the safety perfor mance check on an annual basis If the heat exchanger is removed check the heat exchanger intake gasket and draft inducer gasket and replace if there is any sign of damage Be sure all gaskets are in place when the heat exchanger is replaced Failure to replace any gasket that has been damaged may result in property damage personal injury or loss of life Oil the bearings of the fan motor every 6 months with S A E 20 oil SERVICE RECORD Page 16 TROUBLE SHOOTING CHART SYMPTOM POSSIBLE CAUSES Flame too large 1 Defective operator section of valve 2 Burner orifice too large 3 If installed above 2 000 ft Yellow burner flame 1 Clogged burner ports 2 Obstruction around vent cap 1 2 Check with local gas company for proper 3 1 Replace valve orifice size and replace See burner orifice section
9. attach to P N 72610 orange silicone 90 elbow I with heater Secure with 2 hose clamp d Attach P N 41515 support brackets to wall Wall anchors not provided may be required Postion support brackets ii 8 from side of trim kit and end of pipe Secure flex tubing and flocked tube to brackets using 2 hose clamps e Attach P N 41520 center bracket 2 1 2 from pipe end and insert flex tube through bracket This will prevent the flex tube from touching the black flocked exhaust tube f Connect flex air intake tube and flocked exhaust tube to collection box g Complete gas connection and attach trim kit to brackets h Follow lighting instructions SPECIAL NOTES a You may use up to three HEVK 5 Kits for a total of 15 vent extension with two additional elbows DO NOT EXTEND VENT BEYOND 15 OR USE MORE THAN THREE TOTAL ELBOWS one elbow is attached to heater outlet b To connect two vent kits together use P N 72532 2 x3 steel coupling Secure with 2 hose clamps c If you are using one two or three kits after installation is complete you will discard 2 P N 72593 hose clamps and one P N 72532 steel coupling d If you need to make a 90 offset you will need to order P N HEEL 1 90 Elbow Kit Two offsets require two kits e If complete vent extension is horizontal pipes may be sloped down slightly to allow any condensate to drain through the exhaust pipe to the outside DO NOT ALLOW TO DRAIN ONTO WALKWAY
10. its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 5Pa The furnace must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 5Pa Page 7 STEP 3 INSTALLATION CONTINUED INSTALLING VENT SYSTEM 5 32 WALL THICKNESS 12 7 cm 81 3 cm a Use only factory supplied parts Do not attempt to modify in any way To do so could cause a system imbalance resulting in poor performance and or unsafe operating conditions b Slide collection box pipes through cutout and secure collection box to inside wall Anchors not supplied may be required See Figure 8 c From outside house mark collection box pipes and cut off 1 2 beyond outside wall d Slide vent cap pipes onto collection box pipes and push in until flange is flush against house Secure vent cap assembly to outside wall with a slight downward slope This will prevent water from entering and allow and condensation to drain Caulk around the edges of the vent cap mounting plate NOTE It may be necessary to build a metal or wood frame to provide a flat surface for the mounting plate to be flush against or to attain the 5 minimum wall thickness Collection Box Vent Cap TRIM KIT BRACKETS Ass
11. 5 7 50 41275 7 50 Wall Mounting Bracket 4 per unit 43 41270 2 00 41270 2 00 Casing Top Assy 44 41050 105 30 41050 105 30 Trim Kit Left Side Panel 45 41262 22 70 41262 22 70 Trim Kit Top 46 41255 27 10 41255 27 10 Trim Kit Right Side Panel 47 41260 22 70 41260 22 70 Air Filter 48 72615 25 80 72615 25 80 Burner 2 per unit 49 72533 9 20 72533 9 20 Burner Mounting Bracket 50 72534 5 90 72534 5 90 End Cap Left Side 51 72692 16 40 72692 16 40 End Cap Right Side 52 72693 16 40 72693 16 40 Wire Bracket HEDV 53 41217 2 60 41217 2 60 Ignitor Bracket HEDV 54 41212 2 50 41212 2 50 Mr Contractor we only sell parts through our wholesalers but the prices listed above are for your convenience For prompt parts service contact the wholesaler from which you purchased your Cozy heater NOTE Parts amp schematic drawings on current models are shown at www cozyheaters com IMPORTANT SAFETY BULLETIN ON YOUR GAS CONTROL AND PILOT LIGHT SYSTEM FOR HEATING EQUIPMENT WHAT YOU DON T KNOW CAN HURT YOU Your pilot light system has been designed for safe and reliable operation Although safety mechanisms are built in the potential for hazard exists This information is intended to help you avoid these hazards YOUR GAS CONTROL AND PILOT LIGHT SYSTEM Your gas control and pilot light system has a safety device whose purpose is to shut off the gas supply to the appliance if the pilot light goes out I
12. A Clearance above grade veranda porch deck or balcony B Clearance to window or door that may be opened C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 Feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner 12 Inches 80 cm 12 Inches 30 cm 12 Inches 30 cm 18 Inches 46 cm 18 Inches 46 cm 12 Inches 30 cm G Clearance to inside corner 12 Inches 30 cm H Clearance to each side of center line extended above meter regulator assembly 3 Feet 91 cm within a hel 15 Feet 4 5m above the meter regulator assembly Clearance to service regulator vent outlet 3 Feet 91 cm J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance K Clearance to a mechanical air supply inlet 12 Inches 30 cm 6 Feet 1 83 m L Clearance above paved sidewalk or paved driveway located on public property 7 Feet 2 13m A vent shal not terminate directly abc a sidewalk or paved drive Page 4 CLEARANCES As you face the heater the clearance to a side wall on the right side is 0 Fig 1 and the left side is 1 Fig 2 The minimum clearance from the top of the heater to the ceiling or any projecting overhang is 10 See Figure 3 The minimu
13. Gas IGNITION ygs Blower Burners Combust Blower Combust Proved i Ignitor E Flow PROVED On gt ott M Fan off Off Fan NO NO NO Three YES 10 SEC 10 SEC Lockout Attempts PURGE PURGE Made NO Three YES Attempts Made STEP STEP 1 Thermostat calls for heat 8 Continued 2 Combustion fan turns on return to Step 2 If after 3 attempts 3 Pressure switch closes malfunction still occurs furnace will 4 Power to Ignitor go into lockout mode for one hour 5 Ignitor warm up period This one hour mode can be bypassed 6 Gas flow to burner by resetting thermostat 7 Burner ignition proven 9 Thermostat satisfied 8 Circulating blower on 10 Gas valve closes NOTE If there is a mal 11 Combustion fan off function in any of the 12 Blower off above steps the sequence will stop at that point and HEATER NOW IN STAND BY MODE Page 13 HEVK 5 5 VENT EXHAUST KIT INSTALLATION INSTRUCTIONS WARNING Use only Louisville Tin amp Stove Company factory supplied parts and kits Failure to do so could result in loss of life personal injury property damage or unsatisfactory performance CONTENTS OF KIT l only P N 72532 2 x3 Steel Coupling l only P N 41520 Center Bracket l only P N 72575 2 x5 Black Flocked Tube 8only P N 72593 2 Hose Clamps l on
14. IONAL VEHICLE OR TRAILER Do not operate wall furnace unless it is connected to the supplied vent system with vent cap in place Check the rating label attached to the wall furnace to be sure it is equipped for the type gas you intend to use Never use a match candle flame or other source of ignition to check for gas leaks Use only soapy water or liquid detergent Have your wall furnace and vent system inspected at least annually by a qualified service technician Before cleaning or servicing turn off the gas and allow furnace to cool Do not operate wall furnace without all components properly installed top front etc Due to high temperatures the wall furnace should be located out of traffic and away from furniture and drapes Children and adults should be alerted to the hazard of high surface temperature and should be kept away to avoid burns or clothing ignition Young children should be carefully supervised when they are in the same room with the wall furnace Do not place clothing or other flammable material on or near the furnace INSTALLATION AND REPAIR SHOULD BE DONE BY A QUALIFIED SERVICE PERSON THE WALL FURNACE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY BY A PROFESSIONAL SERVICE PERSON More frequent cleaning may be required due to excessive lint from carpeting bedding material etc It is imperative that control compartments burner and circulating air passageways of the furnace be kept clean Do not install in
15. IONS THOROUGHLY BEFORE INSTALLING SERVICING OR USING THE APPLIANCE IF YOU DO NOT UNDERSTAND ANY PART OF THESE INSTRUCTIONS CONSULT LOCAL AUTHORITIES OTHER QUALIFIED INSTALLERS SERVICE AGENCIES THE GAS SUPPLIER OR THE MANUFACTURER SPECIFICATIONS AND DIMENSIONS Your Direct Vent Wall Furnace is shipped complete in one carton This carton contains the furnace vent cap vent exhaust tube air inlet tube template with rough in dimensions installation and operating instructions and the thermostat MODEL INPUT GAS TYPE MAX WALL MIN WALL NO BTU HR WIDTH DEPTH HEIGHT CONN GAS Thickness Thickness HEDV403 40 000 34 1 2 9 30 1 2 Nat 32 mie HEDV404 40 000 34 1 2 9 30 1 2 LP 32 2 Page 2 mn 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 SAFETY RULES Improper installation adjustment alteration service or maintenance can cause property damage bodily injury or death Use in other than a residential application may result in unsatisfactory performance and may void the warranty Follow all applicable codes and ordinances If there are none follow the latest edition of National Fuel Gas Code ANSI Z223 1 A copy may be obtained from the CSA International or the National Fire Protec tion Association Batterymarch Park Quincy MA 02269 In Canada use latest edition of CAN1 B149 installation code DO NOT INSTALL THIS FURNACE IN A RECREAT
16. VILLE TIN AND STOVE COMPANY P O Box 2767 Louisville Kentucky 40201 2767 y INNNNNNNNNNNNNNNNNNNNN NVN AAA AAAA Yy AAA VAV AAAA AAA AAAAA TA AAAA Ba
17. a closet alcove or small hallway where the furnace could be isolated from the space to be heated by closing a door Do not put anything around the furnace or vent cap that will obstruct the flow of combustion and ventilation air The appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the latest edition of National Electrical Code ANSI NFPA 70 In Canada use CSA C22 1 Never operate this furnace without the sight glass in place or with the glass broken or missing If it is suspected that rising water may enter the furnace turn off the gas immediately Do not use the 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 It is necessary to replace damaged gaskets or sealing material within the vent or air intake system Failure to do so may result in property damage personal injury or loss of life Any safety screen or guard removed for servicing must be replaced prior to operating heater This appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance Page 3 Vent Terminal 4 Air Supply Inlet EJ Area where terminal is not permitted VENT TERMINAL CLEARANCES REFERENCE LETTER TO DRAWING CANADIAN INSTALLATIONS
18. attach Part No 72604 Trim Kit where two bodies meet Install end cap Part No 41620 HEEL 1 90 ELBOW KIT Contains 1 only P N 72613 90 Elbow 2 HECK 1 CONDENSATE KIT INSTRUCTIONS STEP 1 Attach condensate trap to back of heater using 2 8 screws provided as shown below End of trap should extend through back of heater and into bottom of condensate pan STEP 2 Remove and discard cap from bottom of draft inducer drain tube STEP 3 Connect 1 4 plastic line from draft inducer drain tube to condensate trap Secure with 2 1 4 hose clamps provided STEP 4 Fill condensate pan with water WARNING Keep condensate pan filled with water The water provides a seal to prevent combustion products from being pushed through the drain into the house BACK OF HEATER ame PEDE cm Drain Tube Ene iw From Draft F _ 1 4 Clear Tubing Inducer 7 Condensate Trap Condensate trap empties through back of heater into a condensate pan below heat exchanger Page 15 MAINTENANCE INSTRUCTIONS For proper and safe operation keep furnace and furnace area clean At regular intervals turn control valve to off let cool and clean inside control and heat exchanger compartment To clean front panel use only a damp cloth do not use any kind of solvent or cleaning fluid that could leave a residue to burn or give off fumes when furnace is turned on Remove the blower filter from back of heater and clean
19. e is equipped with a three prong grounding plug For your protection against shock hazard this ap pliance should be plugged directly into a properly grounded three prong receptacle Do not cut or remove the ground ing prong from this plug NOTE If any of the original wire supplied with this ap pliance has to be replaced it must be replaced with type 105 C wire or its equivalent CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Pressure Switch Q Circulating Blower Thermostat Transformer TTS VEC 24 VAC Tac Transformer White Green Gas Valve Pressure Switch Limit Switch Thermostat WARNING HIS IS A GAS FIRED APPLIANCE KEEP THH REA CLEAR OF GASOLINE AND OTHER FLAM MABLE VAPORS AND LIQUIDS ALL COMBUS IBLE MATERIAL MUST BE KEPT CLEAR OF THI AREA TO AVOID FIRE OR EXPLOSION Gas Valve XFM Circulating Blower Black White od O Draft Inducer EAC LSPD Heat Hum M M2 oa Neutrals 3A Fusel White Whit Flame Sensor Brown O High Limit MODEL HEDV 403 404 Page 12 SEQUENCE OF OPERATION HEDV403 4 t 0 t X THERMOSTAT Thermostat CALLS FOR is satisfied HEAT t 10 sec t 15 sec t 20 sec t 50 sec t x sec t X 15 sec t X 120 sec Power to Fan YES Power to
20. embly Assembly Vent Cap Mounting ri GAS INLET Plate f AIR INTAKE 6 3 16 25 7 16 64 6 cm 20 1116 FLUE OUTLET 52 5 cm 7 5 8 19 4 cm FIGURE 9 Page 8 STEP 4 INSTALLING HEATER a b c d e f Screw wall brackets to wall Location marked with template See Step 1a Screw trim kit brackets to back of heater See Figure 9 Slide heater to within approximately 5 from wall Attach air intake hose to collector box outlet and burner box inlet with clamps provided See Figure 10 Attach vent exhaust tube to exhaust pipe on collector box and draft inducer outlet on back of heater Secure with clamps provided See Figure 10 GAS CONNECTION Make gas connection between manual shut off valve and furnace valve with approved connectors Compounds used on threaded joints of gas piping shall be approved for use with L P gas The gas lines must be checked for leaks by the installer with soapy water or liquid detergent never an open flame If connections are not exposed a pressure test must be run Be sure to disconnect the gas supply line from the appliance valve before pressure testing The manifold pressure is pre set at the factory and should be 3 5 w c for Natural Gas and 10 w c for L P gas The minimum inlet pressure for Natural Gas is 4 5 w c and 11 w c for L P Gas for purpose of input adjustment The maximum inlet pressure should never e
21. f you have trouble lighting the pilot or keeping it lit it may mean that this safety device is warning you that there is a problem with your system Inspection and repairs or replacement must be made by a trained gas service technician TAMPERING IS DANGEROUS The pilot safety system may also not work if you do not follow the lighting instructions carefully or if you tamper with the gas control that you use to light the pilot Tampering with the gas control particularly with tools can damage the safety mechanism in the control and can allow gas to leak This can result in a fire or explosion causing property damage personal injury or death IF YOU SMELL GAS DON T LIGHT IT IF YOU CAN T LIGHT IT DON T FIGHT IT ATOM LEGAR AGA Gas Association gama THIS IS NOT AN ADVERTISEMENT WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from al 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 Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance CRITICAL SAFETY POINTS TO REMEMBER e Your gas has been odorized so that you can smell it
22. gram Replace valve wall outlet Can be checked by removing wire from con trol board terminal If burner goes off replace thermostat 2 Thermostat sensor attached to back of heater to re locate out of drafts hot or cold spots t utility supplying gas a e thermo Re check gas input do not enlarge This is especially true when a dwelling or room is enlarged Have the heat loss calculated and compare to furnace output Your gas company can supply you with this information If furnace is undersized replace with correct size unit Raise temperature setting Check suppl pressure Check voltage and replace if low 2 Check input rate Cover around pilot lighter hole not air 3 Tighten wing nuts securing cover and sight glass Check and replace gasket if needed Follow instructions Check both exhaust and air intake tubes and vent cap Be sure all gaskets are in place and properly sealed Use only tubes and vent cap supplied Do not alter vent tubes or cap Clean air filter Remove obstruction Check for snow accumulation around vent cap TROUBLE SHOOTING CONTROL BOARD To improve diagnosing and servicing this control board is equipped with a self diagnosing green status light see wiring diagram To indicate stand by mode and proper operation this light will remain on If there should be a malfunction the light will flash a varying number of times with a pause between each series of flas
23. he floor You must build a platform 18 above floor the full width and depth of the heater including the rear trim kit HEATER IS NOT DESIGNED TO HANG ON WALL Unit should be located or protected so it is not subject to damage by a moving vehicle Use care in selecting a good location whith in the grage DO NOT locate the appliance where heated air will be directed onto a nearby parked vehicle Paint may discolor or rubber may harden and crack DO NOT allow open or closed containers of paint gasoline or other liquids having flam mable vapors to be stored or used in the same area as the heater LOCATION The wall furnace must be installed on an outside wall unless optional Kit No HEVK S is used For most efficient performance locate furnace as centrally as possible in the area to be heated and where occupants may move about freely without coming into contact with the cabinet and within reach of a 115V wall outlet If the furnace is installed in a basement a 12 clearance must be maintained between ground level and the bottom of the vent cap Do not install furnace where vent cap will terminate in a window well or any other opening below ground level Do not allow snow accumulation to build up within 12 of the vent cap OPTIONAL KITS HEVK 5 To extend vent 5 foot from heater This will allow vent cap to be installed above grade from basement or to an outside wall A total of 3 kits with 2 additional elbows may be used 12 Mini
24. hes indicate the circuit to check Reason for Indication Failed ignition attempts 3 times This puts heater into one hour lockout mode This one hour lockout can be bypassed by resetting the thermostat Pressure switch stuck closed Pressure switch failed to close Limit switch circuit open Gas valve energized with no call for heat Polarity reversal Possible Causes Hot Surface Ignitor a Broken b Loose or damaged wire No Gas to Burner a Valve in OFF position b Gas supply turned OFF c Loose or damaged wire to valve d Defective or dirty flame sensor Defective switch a Vacuum hose disconnected or damged b Defective switch c Wire disconnected or damaged d Obstruction in vent pipe a Defective limit switch b Disconnected or damaged wire a Defective gas valve b Sensor defective c Short in sensor wire a Hot and neutral electrical supply wire reversed in junction box Page 18 The number of flashes will Corrective Action Hot Surface Ignitor a Replace b Connect or replace wire No Gas to Burner a Turn to ON b Open gas supply valve c Connect or replace wire d Replace or clean sensor Replace switch a Reconnect or replace vacuum hose b Replace switch c Connect or replace wire d Remove obstruction a Replace limit switch b Replace or connect wire a Replace gas valve b Replace sensor c Replace sen
25. l replace such part provided parts have not been subjected to misuse alteration neglect or accidents The term of the warranty for the heat exchanger is covered in Table A below Any claim not made within ten 10 days after the expiration of the warranty period shall be deemed waived by the user The manufacturer shall have no liability or be required to perform any obligation under this warranty unless when requested the user returns at the user s expense the component or product claimed defective to the manufacturer for inspection to enable the manufacturer to determine if the claimed defect is covered by this warranty No charges for freight labor or other expenses incurred in the repair removal or replacement of any product or component claimed to be defective will be paid by the manufacturer to the user and the manufacturer will not be liable for any expenses incurred by the user in remedying any defect in the product Service under this warranty is the responsibility of the installer In the event service under this warranty is needed the user of the product shall request such service directly from the installer If the user is unable to locate the installer the user should write directly to the manufacturer and the name of an alternative service source will be supplied The product safety registration card packed inside the appliance must be completed and returned to the factory THIS WARRANTY IS EXPRESSLY IN
26. ly P N 72612 2 x6 Black Flex Tubing l only P N 72578 2 x3 Black Silicone 2only P N 41515 Support Brackets Wrapped Coupling STEP 1 LOCATE VENT OPENING a Select location on outside wall that vent will exit through b Check outside for proper clearances around vent cap See installation instructions c Mark and cut 3 1 2 hole through both inside and outside walls being sure to maintain level across both openings d Measure wall thickness Mark and cut off both intake and exhaust pipes to 1 2 beyond outside wall e Secure collection box to wall Wall anchors not provided may be required STEP 2 INSTALL HEATER a Select location on wall where heater will be installed b Using wall template supplied with heater mark location for trim kit wall brackets c Attach brackets to wall wall anchors not provided may be required and back of heater Using screws provided on back of heater d Slide heater into position and secure brackets togehter This should position back of heater 5 off wall e Select direction vent will exit trim kit left right or straight up f Before installing trim kit remove knockout on this side STEP 3 INSTALL VENT a Remove and discard P N 72611 2 x24 black flex tubing from air inlet Save hose clamp b Attach P N 72612 2 x6 black flex tubing to air inlet Secure with P N 72593 2 hose aed c Slide P N 72575 2 x5 flocked tube through trim kit opening knockout and
27. m clearance from the bottom of the heater to the floor or the top surface of carpeting tile etc is 0 See Figure 4 When the furnace is installed directly on carpeting tile or other combustible material other than wood flooring the furnace shall be installed on a metal or wood panel extending the full width and depth of the furnace The minimum clearance from the edge of the vent cap to any overhanging obstruction perpendicular side wall or corner of building is 12 See Figure 5 Vent cap must be located at least 9 from any opening that would allow combustion products to enter the building windows doors etc and 12 above the ground or shrubbery See Figure 5 Do not install vent cap in a window well Provisions must be made to prevent snow accumulation from infringing on vent cap clearances y Ceiling or Overhang 1 2 54 cm 10 25 4 cm FIGURE 1 FIGURE 2 FIGURE 3 30 5 cm L 12 l A j 00 5cm KO 22 9 L30 FIGURE 5 Page 5 CLEARANCES RESIDENTIAL GARAGE INSTALLATION Gas utilization equipment in residential garages shall be installed so that all burners and burner ignition devices are located not less than 18 inches 46 cm above t
28. mum above grade Pa eevee is L Page 6 INSTALLATION Failure to follow these instructions carefully could result in poor performance property damage personal injury or death STEP 1 LOCATE VENT OPENING Requires 3 1 2 diameter wall opening a Select area on wall where heater will be installed Using template packed with heater mark shaded area where hole can be cut and to locate the wall brackets b Locate studs on each side of this area c Mark location for 3 1 2 diameter hole between studs Hole should be offset to miss studs See Figure 6 d Check outside wall at this location for proper clearances around vent cap e Cut vent openings into both the inside and outside walls being sure to maintain level across both openings Template _ Shaded Area I l Wall Studs 16 O C Ll FIGURE 6 1 8 N P T Plugged Hole for Pressure Gauge Manual Shut Off Valve Gas Supply Inlet FIGURE 7 STEP 2 ROUGH IN GAS SUPPLY See Figure 7 a Install a 1 2 gas supply line The gas line will enter the heater from the 5 spacing between the heater back and the wall b Install a drip leg in gas supply line immediately upstream from the gas connection to heater see local codes and provide a 1 8 N P T plugged tapping accessible for test gauge connection and a individual manual shut off valve The furnace and
29. not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion 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 OPERATING INSTRUCTIONS STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance does not have a pilot It is equipped with an ignition device which auto matically lights the burner Do not try to light the burner by hand Gas control knob shown in OFF position Remove front panel Pull the gas control lever DOWN clockwise gt to OFF Do not force Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step Push gas control lever UP counterclock
30. sor wire a Unplug supply cord from wall socket Open junction box and switch the hot and neutral wires MODEL NUMBERS HI EFFICIENT DIRECT VENT HEDV403 NAT GAS WALL FURNACE HEDV404 L P GAS Prices and specifications subject to change without notice All prices are F O B factory Mr Contractor we only sell parts through our wholesalers but the prices listed are for your convenience For prompt parts service contact the wholesaler from which you purchased your Cozy heater NOTE Parts amp schematic drawings on current models are shown at www cozyheaters com Page 19 HOW TO PROPERLY ORDER PARTS In addition to part description and part number please give model number serial number and type of gas used This information can be found on the rating plate that is attached to heater Model Number HEDV403 HEDV404 REF LIST LIST PART DESCRIPTION NO PART NO PRICE PART NO PRICE Bottom Louver Panel 1 72690 37 50 72690 37 50 Center Front Panel 2 41080 36 60 41080 36 60 Upper Front Panel 3 72691 37 50 72691 37 50 Left Side Panel Insulation 4 72665 1 90 72665 1 90 Cabinet Side Panel 5 41085 23 00 41085 23 00 Circulating Blower Assembly 6 72500 229 30 72500 229 30 Limit Switch 7 80091 9 30 80091 9 30 Front Heat Shield Assy 8 41165 26 00 41165 26 00 Heat Exchanger Assembly 9 72530 126 80 72530 126 80 Cabinet Base Assembly 10 41100 60
31. t See Figure 13 9 Slide burners toward heat exchanger and lift up from rear and back See Figure 13 10 Clean or replace as needed 11 Reinstall by reversing Steps 9 1 BURNER ORIFICE This appliance is orificed at the factory for elevations up to 2 000 ft If installed above 2 000 ft the BTU input must be reduced 4 per 1 000 ft See the following orifice chart for the proper orifice for a specific elevation SPECIFIC ELEVATIONS 0 to 2 000 4 000 6 000 8 000 2 000 4 000 6 000 8 000 10 000 NATURAL GAS HEDV403 45 47 48 L P GAS HEDV404 55 55 56 Secondary Flame Heat Exchanger Tube FIGURE 12 NOTE THE FURNACE AND ALL COMPO NENTS MUST BE INSPECTED AT LEAST ANNUALLY BY A QUALIFIED SERVICE PER SON THIS SHOULD INCLUDE THE BURNER HEAT EXCHANGER AND VENT SYSTEM BE SURE THAT THE FLOW OF COMBUSTION AND VENTILATION AIR ARE NOT OBSTRUCTED AND THAT ALL HOSES ARE UNDAMAGED AND ALL CLAMPS ARE SECURELY TIGHTENTED Vacuum Hose FIGURE 13 NOTE If this heater is installed above an elevation of 8 000 feet the factory installed pressure switch may not function properly If you experience a problem with the pressure switch contact a qualified service agency to replace the factory installed pressure switch with a high altitude pressure switch P N 72521 To order see your local Cozy dealer or contact the factory Page 11 WIRING This applianc
32. wise to ON Replace front panel Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Pull the gas control lever DOWN clockwise gt to OFF Do not force Replace front panel Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove front panel Page 10 PROPER BURNER FLAME The burner flame may be observed by raising the sight glass cover A proper flame will have a dark blue inner mantle with a lighter blue outer mantle that extends from the burner into the heat exchanger tube see Figure 12 There is no primary air adjustment on the burner and proper flame is assured since the correct manifold pressure and orificing has been done at the factory TO REMOVE MAIN BURNER FOR INSPEC TION AND CLEANING Turn off all electrical supply to heater Turn off gas supply Remove front panel Unplug wire to ignitor and sensor See Fig 13 Disconnect vacuum hose from burner box Remove screws holding burner box top to burner box See Figure 13 7 Remove burner plate and burner box top Take care not to contact or strain ignitor in any way as it is extremely fragile See Figure 13 OG SNe 8 Remove 2 nuts holding burner bracke
33. xceed 7 0 w c on Natural Gas or 14 w c on L P Gas STEP 5 INSTALLING REAR TRIM KIT a b c d e f g Secure right and left trim kit sides to the wall and trim kit brackets with eight 8 screws provided See figure 11 The back of the heater should now be spaced 5 from the wall Remove the temperature sensing unit from the back of the heater Save the nylon attachment clip and the 8 screw Slide the temperature sensing unit through the 1 2 bushing located on the right trim kit side Viewed from the front of the heater Secure the temperature sensing unit to the outside of the right trim kit side using the nylon clip and 8 screw saved from step B Engagement hole provided Secure trim kit top panel to trim kit sides with four 8 screws provided Plug power supply cord into a 115V grounded electrical outlet Turn the manual gas supply valve to the on position HEATER IS NOW INSTALLED FOLLOW LIGHTING INSTRUCTIONS Trim Kit Top FIGURE 11 Page 9 FOR YOUR SAFETY READ T BEFORE OFERALING This appliance does not have a pilot Itis equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do
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