Product Manual
Contents
1. 5 Side amp Rear Discharge 15 16 butnace CANON ad oo ius ce EE eea P PUR p RE 6 Trouble Shooting Chart ne brc 17 19 Rough In 8 6 7 Repair Parts break down 20 25 Installation OE Repat 20 25 Controls 7 Possible Causes amp Corrective Action 19 Pile ean anne 9 hocupu 00 INTRODUCTION THIS ISAGAS FIRED GRAVITY VENTED 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 INSTRUCTIONS 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 TECHNICIAN THE GAS SUPPLIER OR THE MANUFACTURER COUNTERFLOW WALL FURNACE SPECIFICATIONS Your counterflow wall furnace is packed in a single carton that also includes thermostat thermostat wire and insulated staples The thermostat wire and staples are packed in the burner compartment and are accessible by removing the burner access door While the burner access door is open check the rating plate to verify that the model number is correct and that the wall2. 10 11 I REAR DISCHARGE KIT Recessed Use optional kit No 407RR A Cut openings in wall as shown in Figure 13 Cut out and remove embossed section on casing rear Remove knockout from inner liner Place inner boot from kit through opening matching flanges of boot and knockout Mark screw holes and remove boot Drill holes with a 1 8 drill Repeat steps 5 amp 6 for outer boot After unit has been set in wall shove the inner boot through the back wall and up against the liner Secure boot with screws provided Attach damper to inner boot with screws provided Repeat Step 9 for outer boot Place grille in place and secure to wall Final installation will appear as Figure 15 OPTIONAL KITS CONTINUED REVERSE SIDE OPTIONAL KITS CONTINUED This kit must be installed by a qualified installer or service technician SIDEDISCHARGE ON CASING Use optional kit No 306SR A Remove knockout from inner liner DUI flanges of boot to knockout on inner boot Mark screw holes and remove boot Drill holes with a 1 8 drill Attach inner boot with screws provided vec ON A attach with screws provided Cut out and remove embossed area on casing side Place 1 1 2 boot from kit through opening matching Place grille into position drill holes into casing and 90 Degree Outside Corner Pt 11 3 FT SECTION 3 FT SECTION t G Z2 A T P 4 BOTTOM SECTION av
3. FIGURE 18 Length of bottom section Ref 4 plastic raceway 8 Inches 14 Inches NOTE Above lengths terminate approximately 2 inches above floor STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 8 STEP 9 SIDE DISCHARGE With Extension Boot Use optional kit No 30SRB A Cut opening in drywall as shown in Fig 17 Position plasterground as shown in Fig 17 optional Cut out and remove embossed section on casing side Remove knockout on inner liner Put heater into position Place inner boot into position mark and cut boot flush with wall Place outer boot into position mark and cut boot flush with wall 8 Place boot trim into position slide inner boot through wall from adjacent room and attach to inner liner Slide outer boot through wall from adjacent room and attach to casing side 9 Place grille into position and secure to wall FIGURE 17 14PEK A PLUG EXTENSION KIT INSTRUCTIONS FOR NON RECESSED INSTALLATION ONLY UNITS WITH TERMINAL BOARD Turn heater off following Section 3 in Lighting Instructions and allow to cool Turn off all electricity to heater Remove top louver assembly fan shroud and fan blade Loosen two screws on romex connector Remove junction box cover plate Disconnect three power cord terminals and pull power cord out of top of heater Insert power cord provided in kit through romex connector and plug onto terminal board followin
4. disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 10 psig The appliance 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 2 pig It is required by the National Fuel Gas Code that a drip line be installed near the gas inlet This should consist of a vertical length of pipe tee connected into the gas line that is capped on the bottom in which condensation and foreign particles may collect 4 To heater gas control valve Manual cut off valve 1 8 N P T Pressure Tap Drip Leg FIGURE 4 FIGURE 5 Page 7 INSTALLATION WHEN RECESSED UP TO 9 1 4 STEP 1 Cut out floor plate between 2x4 studs so heater will set flat on floor STEP 2 Make electrical connection of 115 V wiring into junction box provided on top of header plate STEP 3 Attach the base plate purchased with the vent pipe to the header plate using two No 8 sheet metal screws through the pre punched holes See Figure B STEP 4 Square up and nail header plate in place between 2x4 studs placed on 16 centers 14 3 8 between studs For distances from top of header plate to floor see Figure 6 STEP 5 Remove double ceiling plate between studs Install one ceiling plate spacer across the cut out in ceiling plate Install ven
5. 8 55 000 88 7 8 FIGURE 6 FIGURE7 7 Page 8 Installation of B W Gas Vent for one story buildings or for Ceiling plate spacers to center first floor of multi story B W Gas Vent in stud space buildings nail securely at both ends Plate cut away for full width of stud space to provide ventilation Studs on 16 inch centers Sheet metal screw base plate to header Use manufacturer s method of fastening pipe to base plate Header plate of vented wall furnace also acts as firestop FIGURE B CONTROLS controls are pre assembled at the factory The normal manifold pressure should be 3 5 w c for Natural Gas and 10 w c for L P Gas The maximum inlet pressure in the gas supply pipe should never exceed 7 0 w c for Natural Gas or 14 w c for L P Gas The minimum inlet pressure in the gas supply pipe should never be lower than 4 5 w c for Natural Gas or 11 w c for L P Gas Pilot Adj Screw Pilot Adj Screw HONEYWELL HONEYWELL VR S200H SERIES VR8204H SERIES STANDING PILOT LLD PILOT FIGURE 10 A FIGURE 10 B PILOT ADJUSTMENT Locate the pilot adjustment screw on the valve The pilot flame should surround at least the top 3 8 of the powerpile pilot generator or flame sensor see Figure 8 The pilot is unregulated so it will be operating at inlet line pressure maximum 7 w c for Natural Gas and 11 w c for Propane Gas To decrease the pilot flame turn the screw clo
6. Assy Electronic w Flame Ignitor L P Blocked Flue Switch Blocked Flue Switch Wire Terminal Board Pilot Tubing w Fitting 16 Burner Pan Assembly Valve Support Bracket Assembly Pilot Mounting Bracket IID Burner Mounting Plate 58 Lighting Instructions CF Jg e NIANA A olo 5 m Oo UJ LG Lo 02 APNG BR w By A oO CA CF407D H CF408D H CF557D H CF558D H PART LIST PART LIST NUMBER PRICE NUMBER PRICE 30296 3 50 91261 N C 30296 3 50 91261 N C ATTN Contractors and Service Technicians 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 REQUIRES2 REQUIRES 4 age REV 06 2013 JUNE 2013 VENT KIT NO 31300 A ENCLOSURE TRIM KIT KIT NO KIT NO 406RR A 16VE A REAR REGISTER W BOOT FLUSH 407RR A REGIS PART DESCRIPTION REF NO PART NO LIST PRICE 16 Vent Enclosure Side 16 Vent Enclosure Front 24 Vent Enclosure Side 24 Vent Enclosure Front 36 Vent Enclosure Side 36 Vent Enclosure Front oide Rear Register oide Register Large Outer Boot Large Inner Boot Small Outer Boot S
7. CF407D H CF408D H CF557D H CF558D H LI D PILOT FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device If you cannot reach your gas supplier call the fire which automatically lights the pilot Do not try to department light the pilot by hand BEFORE OPERATING smell all around the appliance Use only your hand to push in or turn the gas control area for gas Be sure to smell next to the floor knob Never use tools If the knob will not push in or because some gas is heavier than air and will settle turn by hand don t try to repair it call a qualified service on the floor technician Force or attempted repair may result in a fire WHAT TO DO IF YOU SMELL GAS or explosion Do not try to light any appliance Do not use this appliance if any part has been under Do not touch any electric switch do not use any water Immediately call a qualified service technician to phone in your building inspect the appliance and to replace any part of the control Immediately call your gas supplier from a neighbor s system and any gas control which has been under water phone Follow the gas supplier s instructions PN 91214 02 05 LIGHTING INSTRUCTIONS STOP Read the information on the safety label 7 Wait five 5 minutes to clear out any gas Then smell for Set thermos
8. IGNITION MODULE MODELNO CF407 557D H 2 55 CF408 558D H 2 55 SELECTOR SWITCH FAN SWITCH LIMIT SWITCH s 115 TRANSEQRMER 24 V A C CF407D H CF557D H CF408D H CF558D H LADDER SCHEMATIC SPILL AUXILIARY SWITCH LIMIT SWITCH IGNITION MODULE ROUGH INS FOR REAR OR SIDE DISCHARGE Install plastergrounds as shown in Figure 12 and Figure 13 This kit must be installed bv a qualified installer or service technician NOTE When side discharge 15 being used furnace should be set exactly 4 from side wall 10 Plaster Ground FIGURE 12 S FIGURE 14 FIGURE 13 OPTIONAL ACCESSORY KITS REAR REGISTER KIT Flush Mount See Figure 14 Use optional kit No 4A06RR A Cut openings in drywall as shown in Figure 12 Position plasterground as shown in Figure 12 Optional Cut out and remove embossed section on casing rear Remove knockout on inner liner Put heater into position Place inner boot into position mark and cut boot flush with wall Place damper into cutout end of inner boot mark 4 holes from damper onto inner boot top and bottom and drill 4 1 8 hole Place outer boot into position mark and cut boot flush with wall Attach inner boot to liner Attach damper to inner boot screws provided Attach outer boot to casing back Place grill in position and secure to wall Final installation will appear as Figure 14 FIGURE 15 UA
9. Side Left Center Back Assembly Top Assembly Upper Back Assembly Lower Back Assembly Bottom Liner Assembly Header Assembly Complete Heat Exchanger Assembly Draft Diverter Assembly Fan Shroud Assembly Top Louver w Insulation Center Front Panel w Insulation Bottom Louver Assembly w Insulation Upper Front Shield Switch Box Switch Box Cover Lower Front Shield Motor Mounting Bracket Junction Box Cover Burner Valve VR8200H 1004 Natural Gas w 78089 Dis Bushing Valve VR8200H 1103 L P GAS w 78089 Dis Bushing Disappearing Bushing 1 2 x 3 8 Wiring Harness Manifold Orifice NATURAL Orifice L P Fan Motor Fan Blade Rubber Grommet Requires 4 Limit Switch 60T11 L180 Fan Switch 60T 12 F120 Speed Switch 60T 13 F160 30 Auxiliary Limit Switch 60T 15 L350 Thermostat 24 Volt Transformer Flue Pipe Adapter Plug Bracket Casing Mounting Brackets Flue Pipe Gasket 4x8 7 16 Draft Diverter Gasket 7x8 Casing Top Gasket 8 1 2x4 1 2 Element Support Gasket 9 1 2x14 1 4 Pilot NAT 0 140 512 Pilot L P 0 140 502 Cozy Handle Power Cord Snap in Outlet Thermostat Wire Thermocouple Q309A1954 Insulated Staples Door Catch Blocked Flue Switch Blocked Flue Switch Wire Terminal Board Pilot Tubing w Fittings 16 Piezo Sparker Electrode Wire Burner Pan Assembly Valve Support Bracket Assembly Pilot Mounting Bracket Burner Mounting Plate Lighting Instructions CF ATTN Contractors and S
10. for installation it is necessary to provide adequate accessibility clearances for servicing and proper operation Minimum clearance from cabinet to combustible construction Side Wall Floor 0 Ceiling 4 See Figure 2 The unit may be recessed and rest directly against side studs and the inside surface of the rear wall ELECTRICAL ROUGH IN Rough in 115 v wiring terminating inside the junction box located on top of header plate for recessed or in a receptacle box not provided for flush mount Consult local codes or ordinances See Figure 3 FIGURE 3 MODEL NUMBER AMPS CF403D CF404D 225 CF553D CF554D 229 CF407D CF557D 2 99 GAS ROUGH IN Check local codes for requirements as to the size and type of gas line required See Figure 5 for location of gas inlet holes in furnace cabinet Compounds used on threaded joints of gas pipe should be resistant to the action of liquefied petroleum gases The gas line joints must be checked for leaks This should be done with a soap solution watching for bubbles on all connections NEVER USE AN EXPOSED FLAME TO CHECK FOR LEAKS A manual valve equipped with a 1 8 NPT plugged tapping accessible for test gauge connection should be installed immediately upstream of the gas supply connection to the appliance Some codes and ordinances require that the manual valve be located outside the appliance See Figure 4 The appliance and its individual shut off valve must be
11. of the header plate the header plate or wall furnace This will lock the vent pipe down and prevent securely the draft diverter from shoving it up Loose connections on Check the connections on both the switch and the gas valve Tighten if the safety wiring necessary harness DO NOT BYPASS THE BLOCKED FLUE SWITCH TO DO SO COULD EXPOSE THE CONSUMER TO PROPERTY DAMAGE PERSONAL INJURY OR POSSIBLE DEATH Page 19 COUNTERFLOW WALL FURNACE STANDING PILOT Prices and specifications subject to USE ONLY FACTORY SUPPLIED change without notice AII REPLACEMENT PARTS prices are F O B factory MODELS NAT GAS L P GAS CF403D H CF404D H CF553D H CF554D H SS rely bo Qi PVN EL LL LI ATTN Contractors and Service Technicians 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 REV 04 13 www cozyheaters com Page 20 HOW 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 1s attached to heater REQUIRES 2 24 VOLT SYSTEM WITH LO W B T U STANDING PILOT MODEL NUMBER Z gt 9 REF PART DESCRIPTION NUMBER Casing Side Right Casing
12. of the furnace casing around the flue vent opening Remove vent collar from top of header plate and place over flue extension and fasten to matching holes in casing top using screws from header plate Install B vent type base plate not supplied to top of vent collar Install ceiling plate spacer to back wall centered between studs Install B type vent to top of furnace terminating at least 12 above the floor and at least 2 above the roof line STEP 2 Fasten furnace to wall To secure top of furnace to wall loosen top screws on back casing and raise tabs up Tighten screws Screw through hole in top of tabs into anchors not provided Secure bottom using two holes provided in bottom of casing Optional Cover exposed vent with a vent enclosure kit Part Number 16VE A or 36VE A not included STEP 3 Make electrical connection of 115 V wiring into receptacle box not provided mounted on a wall Plug power cord from top of heater into receptacle Connect thermostat wire with thermostat wires extending from top of heater According to installation instructions with thermostat do not run wires in same stud space with vent system Thermostat should be a minimum of 4 from heater and 5 from floor STEP 4 Make gas connection using connector the same size as gas connection of furnace CHECK ALL CONNECTIONS FOR GAS LEAKS WITH LEAK DETECTOR SOLUTION DO NOT USE OPEN FLAME STEP 5 Replace and fasten all front panels 40 000 82 7
13. pressure 2 B Check the rate NOTE This appliance was orificed for elevations up to 2 000 feet When installed at higher elevations refer to orifice chart in Controls section of instructions for proper orifice size 3 Improper vent system 3 Correct vent system A Vent too short A The vent should terminate a minimum of 12 feet above the floor See Figure 1 Also the top of the vent must be at least 2 foot above any obstacle within a IO foot radius including the roof See Figure A on Page 4 B Restriction in vent B Alltype B vents shall extend in a generally vertical direction with offsets not system caused by exceeding 45 degrees except that a vent system having not more than one 60 offsets degree offset may be allowed Any angle greater than 45 degrees from the vertical is considered horizontal The total horizontal run of a vent plus the horizontal vent connector shall be not greater than 75 percent of the vertical height of the vent C Incorrect vent pipe C Use listed BW type vent pipe Do not use transite or any other type of ceramic pipe for venting Do not use single wall pipe When venting into a masonry chimney the chimney must be properly lined and sized for this gas furnace The use of type B or a flexible chimney liner is recommended Incorrect header plate Consult Figure 6 for correct header plate height location Vent pipe not down on You must use a base plate obtained fromthe vent pipe manufacturer on top
14. 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 PROHIBITED AND WILL 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 will replace such part provided parts have not been subjected to misuse alteration neglect or accidents The term of the warranty for the heat exchanger and burners 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 15 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 t
15. t 1 Defective or sticking automatic valve 1 Replace valve turn off 2 Excessive gas pressure The supply gas 2 To correct this situation contact the utility pressure must not exceed 1 2 psi or supplying the gas 14 w c Incorrect Gas Input Gas input not checked Re check gas input 2 Clogged orifice 2 Check orifice for clogging If clogged clean out the hole carefully with a smooth wood toothpick Do not in any way enlarge or distort it Not enough heat Appliance undersized 1 This is especially true when a dwelling or room is enlarged Have the heat loss calculated and compare to the appliance output approx 7096 of input Your gas company or installer can supply you with this information If appliance is undersized replace with correct size unit 2 Incorrect supply pressure 2 Check supply pressure as outlined above TROUBLE SHOOTING CHART PILOT AND VALVE Burner won t Gas valve not turned on Turn gas valve to position turn on No voltage to valve Check for 24 Volts to Valve Defective thermostat Check wall thermostat No 115 Volt Line Voltage Jump fan switch to check for voltage fan will come on Auxiliary limit switch open Push on red buton to close Blocked flue switch open Push red button in to close Gas valve defective Replace gas valve Page 17 TROUBLE SHOOTING CHART FOR USE BY QUALIFIED INSTALLER OR SERVICE TECHNICIAN PILOT AND VALVE
16. AY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE TABLE A Product Warranty Period Heat Exchanger Tubes Burners 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 Cozy Gas Fired Direct Vent Baseboard Heater Cozy Fan Type Direct Vent Through The Wall Gas Heater Cozy Blue Flame Vent Free Heater Cozy Infra Red Vent Free Heater 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years N A N A 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years N A AAA AA VAVAV v LOUISVILLE TIN amp STOVE COMPANY 731 S 13 STREET LOUISVILLE KY 40210 NNN NNN NNN NNN N NV VNV VVV VeV V V
17. CONTINUED SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Pilot won t light Air in line Bleed line or stay lit STANDING PILO T Pilot won t light or stay lit LI D PILO T Manual reset switch not engaged Defective thermocouple Pilot flame too low Manual reset switch not engaged Sparker won t work Sparker won t light pilot Replace thermocouple Adjust pilot flame Push on button Check wire connections 2 a Pilot flame too lean 2 b Turn valve to on position 2 c Check for pilot restriction 3 Push on button TROUBLE SHOOTING CHART FOR INTERMITTENT IGNITION SYSTEM LI D Green LED Flash Code XxY Indicates OFF No Call for Heat Next System Action Not applicable Flash Fast Startup Flame sense Not applicable calibration Heartbeat Normal operation Not applicable 5 minute Retry Delay Pilot flame not detected during trial for for ignition Recycle Flame failed during run Flame sensed out of sequence Flame sense leakage to ground Low secondary voltage supply below 15 5 Vac 6 2 5 minute Retry Delay On every third retry on the same Call for Heat 6 3 On every 6th flame failure during run on the same Call for Heat 6 4 Flame sensed out of sequence longer than 10 seconds ON Soft lockout due to error detected during self check sequences Initiate new trial for ignition after retry delay completed Initiate new tr
18. COUNTERFLOW WALL FURNACE INSTALLATION AND OPERATING INSTRUCTIONS P N 78111 REV 06 2013 MODEL NUMBERS 24 VOLT SYSTEM NATURALGAS cr403p H CF553D H WITH LOW BTU l PILOT L P GAS CF404D H l crss4p H 24 VOLT SYSTEM NATURAL GAS CF407D H i CF557D H WITH INTERMITTENT l IGNITION LI D CFA08D H CF558D H 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 Donottry tolight any appliance Donottouch any electrical switch do not use any phone in your building gt Immediately call your gas supplier from neighbor s phone ena blacked fines Follow the gas supplier s instructions designed to protect against If you cannot reach your gas supplier call the fire department improper venting of combus tion products INSTALLATION AND SERVICE MUST BE PERFORMED THIS UNITI TTO BE BY A QUALIFIED INSTALLER SERVICE AGENCY OR SUL E THE GAS SUPPLIER HOMES WARNING Operation of this furnace when not connected to a properly installed and maintained venting system can result in Carbon Monoxide C O poisoning and possible death For your safety this furnace and the venting system should be inspected at least annually by a qualified service technician The coating selected to provide longer life to the heat exchanger may smoke slightly upon initial firing Please provide adequate ventilation if thi
19. IC UL Listed Vent Cap mms Listed Gas Vent Ventilation Louvers each end of attic Outlet Air Inlet Air Ventilation Louvers for unheated crawl space ALL COMBUSTION AIR FROM OUTDOORS THROUGH VENTILATED ATTIC UL Listed Vent Cap UL Listed Gas Vent Ventilation Louvers each end of attic Outlet Air Inlet Air Duct ends 1 ft 300mm above floor ALL COMBUSTION AIR FROM OUTDOORS THROUGH SINGLE COMBUSTION AIR OPENING UL Listed Vent Cap UL Listed Gas Vent Opening Alternate Opening Location USING ADJACENT STUD SPACE FORALL LOCATION AND SPECIAL PRECAUTIONS COMBUSTION AIR FROM OUTSIDE HOLES CONNECTING TO The wall furnace should be located near the center of the VENTILATED ATTIC area to be heated for optimal heat distribution If the wall furnace is installed directly on carpeting tile or any combustible material other than wood flooring the wall fur nace shall be installed on a metal plate or wood panel secured to the floor extending the full width and depth of the wall furnace If a side or rear register kit is to be installed see figures 14 18 on pages 15 and 16 HOLES CONNECTING TO VENTILATED CRAWL SPACE BASED ON 4 000 BTU OF TOTAL INPUT RATING OF ALL GAS APPLIANCES THE HEATER ONLY REQUIRES A MINIMUM FREE AREA OF SQUARE SQUARE BTU IN IN 25 000 6 25 35 000 8 75 40 000 10 00 50 000 12 50 55 000 15 75 65 000 16 25 FIGURE 2 ROUGH IN INSTRUCTIONS In selecting a location
20. Series Counterflow Page 4 COMBUSTIONAND VENTILATIONAIR When installed this gas appliance must be provided with fresh air for combustion ventilation and dilution of hot flue gases The minimum required volume of the area where the appliance is installed should be 50 cubic feet per 1 000 btu hr If installed in an area of the home that is considered an unconfined space the natural infiltration of air around windows and doors will be adequate If the area is considered a confined space less than 50 cubic feet per 1 000 btu fresh air can be supplied by providing two permanent openings into adjoining rooms Each opening shall have a minimum free area of one square inch per 1 000 btu per hour of the total input rating of all gas appliances in the confined space but not less than 100 square inches One of the openings shall be within 12 inches of the ceiling and one within 12 inches of the floor See Figure A If the home is of unusually tight construction new and remodeled homes free air must be supplied through opening s to the outdoors This can be accomplished by providing 2 permanent openings one commencing within 12 inches of the ceiling and one within 12 inches of the floor These openings shall communicate directly with the outdoors or spaces that communicate freely with the outdoors such as a ventilated attic and crawl space through galvanized or equivalent corrosion resistant ducts Exception unobstructed stud and jois
21. burner however will continue to operate and the fan cycle until the thermostat 1s satisfied TERMINAL BLOCK WIRING DIAGRAM SELECTOR FAN LIMIT SWITCH din SWITCH POWER CORD White TRANSFORMER Black LIMIT SWITCH Blue SELECTOR SWITCH Black MOTOR Black TRANSFORMER Black POWER CORD Black CF403D H CF404D H CF407D H CFA08D H CF553D H CF554D H CF557D H CF558D H CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing AUXILIARY LIMIT SWITCH For your safety this furnace is equipped with a manual reset auxiliary limit switch In case of failure by the primary limit switch this switch will shut the valve down completely before unsafe temperatures are reached After a cool down period switch must be manually reset If outages persist call a qualified service technician MAINTENANCE INSTRUCTIONS l Installation and repair must be done by a qualified service technician The appliance should be inspected before use and at least annually by a professional service technician More frequent cleaning may be required due to excessive lint from carpeting bedding material etc Itis imperative that control compartments burners pilot burners circulating air passageways and venting systems of the appliance be kept clean 2 The bearings of the motor should be oiled every six months with S A E 20 oil Ds T
22. ckwise approximately six full turns to bottom of pilot light channel until you produce sufficient flame at the minimum noise level PILOT FLAME ADJUSTMENT PILOT FLAME SHOULD ENVELOP 3 8 TO 12 INCH OF THE TIP OF THE GENERATOR Installation of B W Gas Vent Firestop spacers supplied for each subsequent ceiling or by manufacturer of B W floor level of multistory buildings Gas Vent Plate cut away to provide passage of B W Gas Vent Nail firestop spacer securely FIGURE C The appliance is orificed at the factory for elevations up to 2 000 feet If installed above 2 000 feet the BTU input must be reduced 4 per 1 000 feet Orifice change must be completed by a qualified installer or service technician See the following orifice chart for the proper orifice for a specific elevation NATURAL GAS SPECIFIC ELEVATIONS 4 000 6 000 6 000 8 000 CF403D 32 CF407D 32 CF553D 2 CF557D L P GAS SPECIFIC ELEVATIONS 0 to 2 000 i 6 000 8 000 2 000 4 000 000 8 000 10 000 49 50 49 50 2 15mm 45 2 15mm 45 STANDING PILOT LLD PILOT FIGURE 8 A FIGURE 8 B Page 9 CF403D H CF404D H CF553D H CF554D H STANDING PILOT FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance has a pilot which must be lighted by If you cannot reach your gas s
23. 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 24 VOLT SYSTEM WITH LOW B T U I D D NATURAL REF NUMBER Casing Side Right Casing Side Left Center Back Assembly Top Assembly Upper Back Assembly Lower Back Assembly Bottom Liner Assembly Header Assembly Complete Heat Exchanger Assembly Draft Diverter Assembly Fan Shroud Assembly Top Louver w Insulation Center Front Panel wInsulation Bottom Louver Assembly w Insulation Upper Front Shield Switch Box Switch Box Cover Lower Front Shield Motor Mounting Bracket Junction Box Cover Burner Wiring Harness Valve Nat LI D VR8204H 1006 w 78089 Disappearing Bushing Valve L P L I D VR8204H 1006 w 78089 Dis Bushing Disappearing Bushing 1 2 x 3 8 Manifold Orifice Natural Orifice L P Fan Motor Fan Blade Rubber Grommet Requires 4 Limit Switch 60T11 L180 Fan Switch 60T 12 F120 Speed Switch F160 30 Auxiliary Limit Switch 60T G15 350 Deg Lower Thermostat 24 Volt Transformer Flue Pipe Adapter Plug Bracket Casing Mounting Brackets Flue Pipe Gasket 4x8 7 16 Draft Diverter Gasket 7x8 Casing Top Gasket 8 1 2x4 1 2 Element Support Gasket 9 1 2x14 1 4 Cozy Handle Power Cord Snap in Outlet Thermostat Wire Ignition Control Box S8600B Pilot Assy Electronic w Flame Ignitor NAT Pilot
24. ervice Technicians 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 REQUIRES 4 la NON NY NPN NY NO e me AIO N RK o CONN VR WN KOO uA tn A UTIN N 29 Oo m 32 32b 32c w val G N Aujla vlu aN nA bf HH HW GW NW NM BIW N QN tA own DN U Page 21 LIST PRICE REV 06 2013 JUNE 2013 COUNTERFLOW WALL FURNACE LI D PILOT Prices and specifications subject to change without notice prices are F O B factory MODELS GAS L P GAS CF407D H 408 CF557D H 558 Cis i A T FOL I 1i T CONTROL ASSEMBLY USE ONLY FACTORY SUPPLIED REPLACEMENT PARTS ATTN Contractors and Service Technicians 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 f REV 04 2013 Page 22 HOW PROPERLY ORDER PARTS In addition to part
25. eset button This will reset the switch in case it accidentally opened during shipping QN tA N READ CAREFULLY BEFORE INSTALLING UNIT The installation must conform with local codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 54 or the Natural Gas and Propane Installation Code CSA 149 1 The appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes the latest edition of the National Electrical Code ANSI NFPA 70 In Canada see latest edition of CSA C22 1 if an external electrical source is utilized The ANSI standards are available from the American Gas Association 1515 Wilson Blvd Arlington Virginia 22209 The NFPA standards are available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 Canadian standards are available from International Approval Services 178 Rexdale Blvd Etobicoke Ontario Canada MOW R3 VENTING This appliance must be properly connected to a venting system Consult local ordinances governing venting Install only UL listed type BW 4 oval gas vent When the vent enters the attic a listed type B 1 round flue pipe may be used See Figure 1 Page 4 Vent pipe must connect to the wall furnace or header plate with a vent base plate and terminate with a cap at a point at least 12 ft above the bottom of the wall furnace and two feet above any obstacle w
26. furnace is equipped for the type gas you intend to use Vent Approx Model Type Type BTU HR Size Gas Blower Shipping Number Control Gas Input Oval Inlet Finished Dimensions Speed Amps Weight MODELS WITH LOW BTU STANDING PILOT CF403D H 24 Volt Nat 40 000 4 14 5 16 Wx10 4 Dx81 5 16 H 2 25 104 Lbs CF404D H 24 Volt L P 40 000 4 4 5 16 Wx104 Dx81 5 16 H 2 25 104 Lbs CF553D H 24 Volt Nat 55 000 4 4 5 16 Wx104 Dx87 5 16 H 2 25 107 Lbs CF554D H 24 Volt L P 55 000 4 4 5 16 Wx104 Dx87 5 16 H 2 29 107 Ibs MODELS WITH INTERMITTENT IGNITION CF407D H 24 Volt Nat 40 000 4 4 5 16 Wx10 4 Dx 81 5 16 H 2 99 104 Lbs CF408D H 24 Volt L P 40 000 4 14 5 16 Wx10 4 Dx81 5 16 H 2 99 104 Lbs CF557D H 24 Volt Nat 55 000 4 14 5 16 Wx10 4 Dx87 5 16 H 2 99 107 Lbs CF558D H 24 Volt L P 55 000 4 4 5 16 Wx10 4 Dx87 5 16 H 2 99 107 Lbs Page 2 SAFETY RULES 1 Improper installation adjustment alteration service or maintenance can cause property damage bodily injury or death If you do not understand these instructions or your local codes call local authorities a qualified installer service agency gas supplier or the manufacturer 2 Do not install this fan type wall furnace in a recreational vehicle trailer or mobile home 3 Do not operate this fan type wall furnace unless it is connected to a properly installed and maintained vent system Do not exhaust fl
27. g wiring diagram found in lighting and operating instructions Tighten two screws on romex connector Replace junction box cover plate STEP 10 Replace fan blade fan shroud and top louver assembly STEP 11 Snap 90 Degree outside corner Ref 1 onto 3 ft section Ref 2 plastic raceway Insert power cord and remove blue backing from adhesive strip on raceway and apply to side of heater See Figure 18 STEP 12 Insert power cord into second 3 ft section of raceway Ref 3 and remove blue backing and apply to side of heater butting up agianst bottom of other section See Fig 18 STEP 13 Cut 14 inch long bottom section to required length see chart insert power cord remove backing and apply to side of heater See Fig 18 STEP 14 Plug power cord into wall receptacle see Fig 18 STEP 15 Light the heater following lighting instructions Page 16 TROUBLE SHOOTING CHART for qualified service technician MAIN BURNER SYMPTOM POSSIBLECAUSEES 4CORRECTVEACTION 2 Flame too large Defective operator section of gas valve Replace complete valve Burner orifice too large 2 Check with local gas company for proper orifice size and replace If installed above 2 000 ft 3 Refer to orifice chart on Page 9 Noisy Flame Noisy pilot Reduce pilot gas with adjusting screw on combination gas control valve Burr in orifice if it whistles or resonates 2 Remove burr or replace orifice do not enlarge or
28. he appliance area must be kept clear and free of any combustible materials gasoline and other flammable vapors and liquids 4 It is essential that the flow of combustion and ventilation air not be obstructed D Periodic examination of the entire ventilation system as a routine part of the safety performance check 15 recommended on an annual basis IMPORTANT Keep burner and control compartment clean Vacuum burner compartment at the start of the heating season or as often as needed NOTE It is advised that the burner flames be checked at least twice during the heating season for changes in burner flame characteristics 115 VAC 60 HZ Less than 12 Amps If any of the original wire as supplied with this appliance must be replaced it must be replaced with type thermoplastic 105 degree C wire or its equivalent Page 13 STANDING PILOT CF403 404D H CF553 554D H SWITCH 48 YELLOW LIMIT SELECTOR FAN SWITCH SWIICH SWITCH AUXILIARY LIMIT SWITCH CF403D H CF404D H CF553D H CF554D H PICTORIAL SCHEMATIC GAS VALV 5 2 23 SELECTOR SWITCH SWITCH LIMIT SWITCH CF403D H CF404D H CF553D H CF554D H LADDER SCHEMATIC SPILL AUXILIARY SWITCH LIMIT SWITCH Page 14 CF407 408D H CF557 558D H CF407 8D H CF557 5D H PICTORIAL SCHEMATIC POWER CORD 17 P BLA k Sy Lt i dit SPILL SWITCH YELLOW AUXILIARY LIMIT SWITCH
29. he 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 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 THE MANUFACTURER S EXPRESS WRITTEN WARRANTY UNDER NO CIRCUMSTANCES SHALL THE MANUFACTURER BE LIABLE FOR ANY SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES 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 APPLY 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 M
30. ial for ignition Flash code wi ill remain through the ignition trial until flame is proved If situation self corrects w ithin 10 seconds control returns to normal sequence If flame out of sequence remains longer than 10 seconds control goes to Flash Code 6 4 see below Control remains in w ait mode When the fault corrects control resumes normal operation after a one minute delay Control remains in w ait mode When the fault corrects control resumes normal operation after a one minute delay Initiate new trial for ignition after retry delay completed 5 minute retry delay then initiate new trial for ignition Control w aits until flame is no longer sensed and then goes to soft lockout Flash code continues Control auto resets from soft lockout after one hour Control auto resets from soft lockout after one hour Recommended Service Action If system fails to light on next trial for ignition check gas supply pilot burner spark and flame sense w iring flame rod contaminated or out of position burner ground connection f system fails to light on next trial ignition check gas supply pilot burner flame sense w iring contamination of flame rod burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Check flame sense lead w ire for damage or shorting Check that flame rod is in proper
31. ifices Excessive gas input 3 See Flame Too Large above Yellow tip flame some Clogged main burner ports Clean main burner ports Do not enlarge ports yellow tipping on LP Clogged draft hood 2 Clean draft hood gas is permissible Linted up mixer opening 3 Check for dust or lint at air mixer opening Floating Flame Gas Odor 1 Gas leak Shut off gas service immediately Check piping Call gas company See Your Safety Page 1 Chimney or flue obstruction 2 Clean flue Drafts around appliance 3 Eliminate drafts Delayed Ignition Pilot flame too small Check pilot orifice Increase pilot gas flow if necessary by adjusting inlet pressure from gas source meter if natural gas or second stage regulator if propane maximum 7 w c for Natural and 11 w c for propane Burner ports clogged near pilot 2 Clean burner ports do not enlarge ports Low gas pressure 3 Check gas supply inlet pressure Check gas outlet manifold pressure for minimum step pressure for step pressure chart see Operation 4 Pilot decreases in size when main 4 Supply piping inadequately sized or incorrect burners come on inlet pressure 5 Drafts around appliance 5 Eliminate drafts 6 Bad venting 6 See Venting Failure to Ignite Open all manual gas valves 2 Defective gas valve 2 Replace gas valve Condensation of Improper venting 1 See Venting Water Vapor Burner won
32. ithin a 10 foot radius and at least 3 foot above the roof Provisions must be made for adequate combustion and ventilation air This appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance All type vents shall extend in a generally vertical direction with offsets not exceeding 45 degrees except that a vent system having not more than one 60 degree offset may be allowed Any angle greater than 45 degrees from the vertical is considered horizontal The total horizontal run of a vent plus the horizontal vent connector shall be not greater than 75 percent of the vertical height of the vent Any offsets used should be as far above the drafthood as possible to allow a venting action to begin before any restriction is encountered Page 3 VENTING CONTINUED Height above any 10 or roof surface Less within 10 i horizontally 2 Min E ZA N 3 Min 3 Min Chimney W Listed Vent Top FIGURE A This appliance is equipped with a blocked flue switch WARNING Do not bypass the blocked flue switch To do so could expose the consumer to property damage personal injury or possible death Flashing Oval to round This switch when activated will interrupt the electrical circuit between adapter the transformer and the gas valve causing the main burner flame to ry A extinguish The main burner will not re light until the blocked flue switch 22 Li
33. mall Inner Boot Boot Trim Plaster Ground oide Boot Cabinet Side Trim Angle Cabinet Top Trim is 31320 5 70 Damper Assembly 16 31675 25 20 REPLACEMENT WIRING STANDING PILOT COUNTERFLOW MODELS CF403D CF404D CF553D and CF554D Black 17 1 2 Fork Term with stripped end Transformer 24 V to Thermostat Black 32 Flag Terminal Flag Terminal Auxiliary Limit Switch Valve Black 6 Flag Terminal Flag Termial Selector Switch Fan Switch Wiring Harness i i 1 OM o NIO O A OIN N REPLACEMENT WIRING 11 0 INTERMITTENT IGNITION COUNTERFLOW MODELS CF407D CF408D CF557D and CF558D Black 17 1 2 Fork Term with stripped end Transformer 24V to Thermostat Black 38 Flag Terminal Straight Terminal Auxiliary limitto ignition control box Black 6 Flag Terminal Flag Terminal Selector Swith Fan Switch Wiring Harness ATTN Contractors and Service Technicians 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 REV 04 13 Page 25 APRIL 2013 VAAAAAAAAAAAAAAAAAAAAAAAA S OU ANA NANANA MAVAVA AA VA VA VA VAVAVAVA VA VA VA VA VA VA WVAVA VA VA VA VA V AD LIMITED WARRANTY The Louisville Tin amp Stove Co warrants to the original user the accompanying product for the period
34. nd burner flame meet 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 NOTE It is advised that the burner flames be checked at least twice during the heating season for any changes in burner flame characteristics The appliance area must be kept clear and free from combustible materials gasoline and other flammable vapors and liquids This heater comes from the factory with the proper burner orifice for elevations up to 2 000 feet Heaters installed above 2 000 feet must be derated 4 for every 1 000 feet For the proper orifice size find the Model Number and elevation on the orifice chart See CONTROLS Replace burner orifice FIGURE 11 Page 12 OPERATION This heater is equipped with a slow opening gas control On a call for heat the gas valve does not snap open to full manifold pressure but opens with a gradual increase to normal manifold pressure The time lapse from the call for heat to normal operating pressure 15 two to five seconds The slow open feature assures a safe less noisy ignition After the heat exchanger has warmed sufficiently the fan will automatically come on to efficiently transfer the heat into the room NOTE All models have an automatic two speed fan In a new installation or on fall start up in a very cold room some on off cycling of the fan may occur if the heat exchanger cools too much The
35. position Check flame rod ceramic for cracks damage or tracking Check transformer and AC line for proper input voltage to the control Check w ith full system load on the transformer Check gas supply pilot burner spark and flame sense w iring flame rod contaminated or out of position burner ground connectiion Check gas supply pilot burner flame sense w iring contamination of flame rod burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Heset by cycling Call for Heat If error repeats replace the control POSSIBLE CAUSES amp CORRECTIVE ACTIONS SEE PAGE 19 Page 18 THE FOLLOWING IS A LIST OF POSSIBLE CAUSES AND CORRECTIVE ACTIONS FOR BLOCKED FLUE SWITCH PROBLEMS FOR USE BY A QUALIFIED INSTALLER OR SERVICE TECHNICIAN POSSIBLE CAUSES CORRECTIVE ACTION 1 Blockage in vent pipe 1 A Check vent pipe for blockage such as bird nest wasp nest twigs leaves etc 1 B Check inside the bottom of the vent pipe to make sure the top of the draft diverter did not rip the inner liner causing it to block part of the vent opening 1 C Check that no insulation from the header plate got caught on top of the draft diverter when the heater was inserted into the wall 1 D Check that the vent is properly installed not shoved too far down on the vent pipe 2 Burner is overfiring 2 A Check the manifold
36. rving the pilot Continue to OFF unless spark until pilot is lit Continue to hold the pilot control knob is pushed knob in for about one 1 minute after the pilot 1s lit in slightly Release the pilot control knob and it will pop back up i SITE 73 Do not force i MN remain lit If pilot goes out repeat steps 5 u9 Pilot Control Knob e If knob does not pop up when released STOP and 6 Waitfive 5 minutes to clear out any gas Then smell immediately call your service technician or gas supplier for gas including near the floor If you smell gas e Ifthe pilot will not stay lit after several tries turn the STOP Follow B in the information on the safety gas control knob to OFF and call your service label If you don t smell gas go to the next step technician or gas supplier 7 Locate red piezo ignitor button Locate pilot Follow 10 Turn gas control knob counterclockwise to ON metal pilot tube from gas control Replace lower front panel 8 Turn gas control knob counterclockwise y w to 12 Turn on all electric to the appliance PILOT 13 Set thermostat to desired setting PN 91217 02 05 TO TURN OFF GAS TO APPLIANCE Turn thermostat to lowest setting 4 Push in gas control knob slightly and turn clockwise Turn off all electric power to the appliance if service is 7 OFF Do not force to be performed 5 Replace lower front panel Remove lower front panel PN 91217 02 05 Page 10
37. s occurs This unit is for residential use only and is not approved for installation in mobile homes greenhouses or environments involving dusty wet corrosive or explosive conditions Such conditions will invalidate the warranty and may create unsafe conditions Installation maintenance service troubleshooting and repairs must be performed by a qualified service agency Mr Mrs Homeowner DO NOT attempt any of these procedures yourself as this could expose you to property damage personal injury or loss of life and will invalidate all warranties INSTALLER Leave this manual with the appliance CONSUMER Retain this manual for future reference The State of Massachusetts requires that installation and service of a gas appliance performed by a plumber or gas fitter licensed in the Commonwealth of Massachusetts CONTENTS SII NETTE E o 22 Lighting amp Re Lighting Instructions 10 11 Introd tollo EE 2 Operation TR 10 2222 2 Terminal Block Dum n 13 SUELE ES SUI 5 EE E AA 3 Manual Reset T P 12 Helpful Installation Information 3 Maintenance E P E TEER E 13 Connectine 34 14 Combustion and Ventilation Air
38. sted BW has been manually reset To reset the switch after locating it between Vent Pipe the bottom of the fan shroud and the top of the draft diverter simply 12 push the red button on top of the switch If the homeowner experiences i this problem then the vent system must be checked and corrected Ceiling NOTE Anexisting vent that has worked for years may not be adequate Plate for today s appliances because of higher efficiency requirements that Spacer result in lower stack temperatures Lances 4 2x4 Wall WARNING Operation of this wall furnace when not connected to a Stud properly installed and maintained venting system or tampering with the blocked flue switch can result in Carbon Monoxide CO poisoning and possible death SEELIST OF POSSIBLE CAUSES AND CORRECTIONS ON PAGE 19 type vents shall extend in a generally vertical direction with offsets not exceeding 45 degrees except that a vent system having not more than one 60 degree offset may be allowed Button Any angle greater than 45 degrees from the vertical is considered horizontal The total horizontal run of a vent plus the horizontal vent connector shall be not greater Blocked than 75 percent of the vertical height of the vent E x Flue Switch Any offsets used should be as far above the drafthood as possible to allow a venting action to begin before any restriction is encountered Draft Diverter Relief Opening CF40 55 D
39. t pipe into position be sure to lock bottom of vent pipe into the base plate Nail second ceiling plate spacer in place See Figure B STEP 6 If the vent continues through additional stories within the 2x4 stud space then fire stop spacers must be installed at the second and subsequent ceiling levels See Figure C STEP 7 To place furnace into position grasp furnace and lift so furnace flue vent and header plate vent opening engage Plug power cord from top of heater into receptacle on bottom of the header plate see Figure 3 Run thermostat wire through a drilled hole into an adjacent stud space Do not route it behind the header plate To do so may cause the thermostat wiring to chaff resulting in the appliance operating continually Connect thermostat wire with thermostat wires extending from top of heater Lift furnace upward and swing bottom into wall see Figure 7 Secure furnace in place using 2 holes provided in bottom of casing STEP 8 gas connection using connector the same size as gas connection of furnace CHECK ALL CONNECTIONS FOR GAS LEAKS WITH LEAK DETECTOR SOLUTION DO NOT USE OPEN FLAME STEP 9 Replace and fasten front panels to furnace NOTE FOR PROPER COMBUSTION MAKE SURE UNITS ARE LEVEL FRONT TO BACK AND SIDE TO SIDE INSTALLATION WHEN INSTALLED FLUSH TO WALL STEP 1 After locating furnace cut 3 1 2 x12 rectangular hole in ceiling between ceiling joists Make sure gasket is in position on the top
40. t spaces are acceptable ducts provided that not more than one fire block is removed Special provisions must be taken to insure that these stud and joist spaces cannot be blocked with insulation or other objects Each of these openings using vertical ducts shall have a minimum free area of one square inch per 4 000 btu hr of total input rating of all gas appliances See Figure B and C If horizontal ducts are used the minimum free area shall be one square inch per 2 000 btu hr of total input rating of all gas appliances Fresh make up air can also be provided through a duct to one permanent opening commencing within 12 inches of the ceiling The minimum free area of this opening shall be one square inch per 3 000 btu hr of the total input rating of all gas appliances but not less than the sum of the areas of all vent connectors in the space See Figure D When calculating the amount of fresh air needed you must include make up air requirements for the operation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces Additional information can be found in the latest edition of ANSI 7223 1 National Fuel Gas Code Page 5 gt AACA Ss aycan g mxco A mxco h ALL COMBUSTION AIR FROM ADJACENT INDOOR SPACES THROUGH INDOOR COMBUSTION AIR OPENINGS UL Listed Vent Cap uL Een Gas Vent Opening Opening ALL COMBUSTION AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE AND OUTLET AIR TO VENTILATED ATT
41. tat to lowest setting gas including near the floor If you smell gas STOP Turn off all electric power to the appliance Follow in the information on the safety label If you This appliance is equipped with an ignition device don t smell gas go to the next step which automatically lights the pilot Do not try to gas control knob counterclockwise K to ON light the pilot by hand Remove lower front panel GAS CONTROL Push in gas control knob slightly and turn clockwise to OFF Gas Control Knob NOTE Knob cannot be turned to OFF unless knob is pushed in slightly Do not force Replace lower front panel Turn on all electric power to the appliance 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 PN 91214 02 05 TO TURN OFF GAS TO APPLIANCE Turn thermostat to it s lowest setting 4 Push in gas control knob slightly and turn clockwise Turn off all electric power to the appliance if to OFF Do not force service is to be performed 5 Replace lower front panel Remove lower front panel PN 91214 02 05 Page 11 PROPER BURNER FLAME A proper flame will have a dark blue inner mantle that sits right on top of the burners with a lighter blue outer mantle rising above the burner See Figure 11 There may be some yellow where the pilot flame a
42. ue gases into the room wall or attic space for any reason 4 Locate the thermostat in a room or space that cannot be separated by a door or other means from the room or space in which the front outlet grill is installed Adequate air for combustion and venting must be provided If rising water may enter the wall furnace turn off the gas immediately and disconnect the electric service Do not use the wall furnace if any part has been under water Immediately call a qualified service technician to inspect the wall furnace and to replace any part of the control system or any gas control which has been under water Have your fan type wall furnace and vent system inspected at least annually by a qualified service technician Before cleaning or servicing the wall furnace turn off the gas and allow it to cool This will prevent burns Due to high temperatures the furnace should be located out of traffic and away from furniture and draperies 10 Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing ignition 11 Young children should be carefully supervised when they are in the same room as the furnace 12 Clothing or other flammable material should not be placed on or near the furnace 13 Any safety screen guard or gill removed for servicing must be replaced prior to operating the furnace 14 Locate the blocked flue switch and the auxiliary limit switch and push in the r
43. upplier call the fire hand When lighting the pilot follow these instruc department tions exactly BEFORE LIGHTING smell all around the appliance Use only your hand to push in or turn the gas control area for gas Be sure to smell next to the floor because knob Never use tools If the knob will not push in or some gas is heavier than air and will settle on the turn by hand don t try to repair it call a qualified floor service technician Force or attempted repair may result WHAT TO DO IF YOU SMELL GAS in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under Do not touch any electric switch do not use any phone water Immediately call a qualified service technician to in your building inspect the appliance and to replace any part of the Immediately call your gas supplier from a neighbor s control system and any gas control which has been phone Follow the gas supplier s instructions under water PN 91217 02 05 LIGHTING INSTRUCTIONS 1 STOP Read the information on the safety label 2 Set thermostat to lowest setting 3 Turn off all electric power to the appliance 4 Removelower front panel 5 Push in gas control knob slightly and and turn clockwise 7 to OFF Gas Control Knob NOTE Knob can not be 9 Pushin pilot control knob and hold in Immediately turned from begin a series of pushing and releasing the red piezo PILOT to ignitor button while obse
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