gas-fired vented w all furnace all furnace
Contents
1. See Page 7 and 5C CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing WIRING INSTRUCTIONS GRAVITY WALL FURNACE WARNING Failure to locate the thermostat properly or to wire the furnace correctly may result in continuous operation control damage or failure to operate This can cause property damage personal injury or loss of life Follow the instructions included with the thermostat Locate the thermostat approximately five 5 feet above the floor and four feet 4 from appliance Always mount the thermostat on an inside wall where it won t be affected by heat or cold sources such as direct sunlight televisions fireplaces hidden hot or cold water pipes drafts etc The thermostat must never be installed in an adjoining room where a door can be closed between the thermostat and wall furnace This wall furnace is equipped with a self generating control system Never connect to a 24 volt transformer or to the household electrical system Do not use more thermostat wire than is included with the wall furnace Do not run thermostat wire in same stud space with vent Conceal wire inside wall or secure to wall with insulated staples that are included YOUR FURNACE MAY BE EQUIPPED WITH EITHER A WALL THERMOSTAT Figure 2 OR SNAP BULB BUILT IN THERMOSTAT Figure 1 CONTROL CHECK THE CONTROL ASSEMBLY2. by installer gas supplier or qualified serviceman ORDER KIT 49820 45 1 HIGH ALTITUDE KIT WSOIF 43 44 45 47 48 WS505F 43 44 45 47 48 ORDER KIT 49850 2287 2 HIGH ALTITUDE KIT L P GAS Model 0 to 2 000 4 000 6 000 8 000 No 2 000 4 000 6 000 000 10 000 145mm 54 145mm 54 52 52 52 52 ORDER KIT 49820 45 1 HIGH ALTITUDE KIT W502F 145mm 54 54 55 55 W506F 1 45mm 54 54 55 55 ORDER KIT 49850 2287 2 HIGH ALTITUDE KIT COMBUSTION AND VENTILATION AIR 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 th
3. instructions slight yellow tipping is allowable on L P Gas See Page 12 6 Drafts around appliance 6 Eliminate drafts 7 Bad venting 7 See Venting 2 Defective gas valve 2 Replace gas valve water vapor Burner won t 1 Defective or sticking automatic valve 1 Clean or 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 14 supplying the gas water column Incorrect gas input Gas input not checked 1 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 70 of input Your gas company or installer can supply you with this information If appliance is undersized replace with correct size unit Temperature dial set too low Bulb Raise setting of Temperature Dial See type valves Lighting and Shutting Down Instructions Incorrect supply pressure Check supply pressure as outlined above Too much heat Temperature dial set too high Lower setting of temperature dial See Lighting and Shutting Down Instructions Combination control valve sticks open Replace combination control valve Page
4. 60 Pilot Generator Thermostat Wire Thermostat Thermocouple Carry Over Shield Installation Instructions Lighting Instr Bulb Lighting Instr Wall VALVES Ref No 36 7000SRLC Nat 7O0OSRLC L P 70093 f 6003H L P 143 90 7000MVRLC Nat 6003 Nat 129 20 7O0O0MVRLC L P 6003 L P 137 60 7000SRLC Nat 6003H Nat 7O00SRLC L P 6003H L P 7000MVRLC Nat 6003 Nat 7O00MVRLC L P 6003 L P 7000SRLC Nat 70092 6003H Not 84087 134 40 W501F 84128 7O00SRLC L P 70093 f 6003H L P 84088 143 90 W502F 84127 7000MVRLC Nat 70090 6003 Nat 84085 129 20 W505F 84128 7O00MVRLC L P 70091 6003 L P 84086 137 60 W506F 84127 9 30 9 30 9 30 9 30 9 30 9 30 9 30 Q350A1867 L P Q350A 1545 NAT Q358A1867 L P Q350A 1545 NAT Q350A 1867 L P Q350A 1545 NAT Q350A 1867 L P Q350A 1545 NAT Q350A1867 L P Q350A 1545 NAT Q350A1867 L P Ike e PART DESCRIPTION PART Part Desc PART LIST MODEL PART LIST PART LIST 70092 f 6003H Nat 84087 134 40 W251F 84128 9 30 Q350A1545 NAT 84639 3 20 95274 84648 95274 84648 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 TWO REQUIRED Page 18 AUGUST 2004 REVISED 11 22 04 IMPORTANT S
5. 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 LOUISVILLE TIN AND STOVE COMPANY P O BOX 2767 Vv LOUISVILLE KY 40201 2767 AAAAAAAAAAAAAAAAAAAAAAAZ AAA VeVe Ve V V VeVe V V V V V V VVV VN A vy A Y A Vv A Y A AAAA y A Yy AAAA
6. a solid fuel burning wood or coal appliance or a multi vent system Page 3 CONTROLS All controls are preassembled at the factory If integral snap bulb type thermostat is used make sure that sensing bulb is located on the bottom of gas valve with clips provided DO NOT KINK the connecting tubing Do not bend the capillary bulb The normal manifold pressure should be 3 5 w c on Natural Gas and 10 w c on L P Gas The maximum inlet pressure in the gas supply pipe should never exceed 14 w c on L P Gas or 7 0 w c on Natural Gas The appliance and its individual shutoff 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 The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig The minimum inlet pressure in the gas supply pipe should be 5 0 w c on Natural Gas or 11 w c on L P Gas for purpose of input adjustment 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 See the following orifice chart for the proper orifice for a specific elevation A blank orifice is shipped in the high altitude kit which will have to be drilled to correct size
7. bracket must be up and threaded nut sert aligned with the small vertical line Note Anchors not provided may be required STEP 4 Remove junction box and connect 115v power supply in accordance with the wiring diagram Replace junction box STEP 5 Set fan kit on top of wall furnace front panel Slot should align with the nut sert Secure fan kit to wall mounting bracket with thumb screw provided Thumb Screw Threaded Nut a Slot Sert Fan Attachment Bracket z Wall Mounting Z 5 Bracket aeae p r One Inch mer Screw 4 Junction Box Fan Kit woe tee fae eee eae Wall Furnace See ee Front Panel AFEFE ET ee a el ee at gel we Sr TH Ei n a F Al aP aP gal EERE ee Page 13 WFFSI C WIRING SCHEMATIC L1 Black 115 VAC GREEN GROUND WIRE 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 14 TROUBLE SHOOTING CHART for qualified serviceman MAIN BURNER POSSIBLE CAUSES CORRECTIVE ACTION Flame too large 1 Defective operator section of gas valve 1 Replace complete valve 2 Burner orifice too large 2 Check with local gas company for proper orifice size and replace 3 If installed above 2 000 ft 3 Refer to orifice chart Page 3 Noisy Flame 1 Too much primary air 1 Adjust air shutter See Page 12 2 Noisy pilot 2 Reduce pilot gas with a
8. fireplaces Additional information can be found in the latest edition of ANSI Z223 1 National Fuel Gas Code 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 FIGURE C Page 4 ALL COMBUSTION AIR FROM ADJACENT INDOOR SPACES THROUGH INDOOR COMBUSTION AIR OPENINGS UL Listed Vent Cap UL oe Gas Vent Opening Opening FIGUREA ALL COMBUSTION AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE AND OUTLET AIR TO VENTILATED ATTIC UL Listed Vent Cap UL Listed Gas Vent Ventilation Louvers each end of attic Outlet Air Inlet Air Ventilation louvers for unheated crawl space FIGURE B ALL COMBUSTION AIR FROM OUTDOORS THROUGH SINGLE COMBUSTION AIR OPENING UL Listed Vent Cap UL Listed Gas Vent Opening Alternate Opening Location FIGURE D USING ADJACENT STUD SPACE FOR ALL COMBUSTION AIR FROM OUTSIDE HOLES CONNECTING TO VENTILATED ATTIC 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 BIU ___IN __IN 25 000 6 25 i 785 35 000 8 75 1 76 50 000 12 50 j 3 14 VENTING This appliance must be properly connected to a venting system Consult local ordinances governing venting Install o
9. 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 information on the safety label If you don t smell gas go to the next step Locate the pilot Follow metal pilot tube from gas control Turn gas control knob counterclockwise KN to PILOT Pilot is located on side of burner Depress gas control knob and hold in Immediately light the pilot with a match Continue to hold the gas control knob in for about one 1 minute after the pilot is lit Release gas control knob and it will pop back up Pilot should remain lit If pilot goes out repeat steps 4 through 8 If knob does not pop up when released STOP and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn the gas control knob to OFF and call your service technician or gas supplier Turn gas control knob counterclockwise KN to ON Turn temperature control knob to desired setting usually a setting of 5 or 6 is satisfactory Close the cabinet door TO TURN OFF GAS TO APPLIANCE Open the cabinet door Turn temperature control knob clockwise y7y to LO Page 11 3 Push in gas control knob slightly and turn clockwise f 4 to OFF Do not force 4 Close cabinet door PILOT ADJUSTMENT MAINTENANCE INSTRUCTIONS Locate the pilot adjustment screw on the valve The pilot L Installatio
10. 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 CRITICAL SAFETY POINTS TO REMEMBER e Your gas has been odorized so that you can smell it Always smell around for gas before lighting your injury or death appliance e Sniff for L P gas at floor level LP gas is heavier than IF YOU SMELL GAS DON T LIGHT IT air and may temporarily exist at floor level 9 e If you smell gas do not attempt to light the pilot Do 9 IF YOU CAN T LIGHT IT not cause a spark by turning on or off electrical DON T FIGHT IT switches or appliances or by using the phone Turn off the gas to the appliances and call your gas supplier from another location maT e If your gas control has gotten wet as the result of LP GAS R 3 s AGA Gas flooding or other wetting it must be replaced Association gama 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 THIS IS NOT AN ADVERTISEMENT hazardous condition AKA y A y A V A y A V VAAAAA NNN Vv NNA y A NANANA Z y A y A NANANA Z AAA AAAAA AAAA AAAA AAAA ANANA ANANAS AOMDEIPIEID W feet et AAN IE Y The Louisville Tin amp Stove Co warrants to the original user the accompanying product for the period specified herein pro
11. 15 TROUBLE SHOOTING CHART AUTOMATIC PILOT amp VALVE Burner won t Pilot flame too large or too small Re adjust pilot flame using adjustment on turn on combination control valve Dirt in pilot orifice Clean pilot orifice with air or solvent do not ream Defective automatic pilot section in Replace entire combination control valve combination control valve Defective thermocouple Replace thermocouple Defective combination control valve Replace valve Wall thermostat models manual reset Reset switch see Page 6 and blocked flue blocked flue switch tripped section below 1 Blockage in Check vent pipe for blockage such as bird nest wasp nest twigs leaves etc vent pipe 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 Check that no insulation from the header plate got caught on top of the draft diverter when the heater was inserted into the wall Check that the vent cap is properly installed not shoved too far down on the vent pipe 2 Burner is Check the manifold pressure overfiring 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 and re orifice accordingly 3 Improper vent Correct vent system system A Vent too short A The vent s
12. 40033 Motor Mounting Brk 15 Body Assembly 4 157 50 157 50 40103 Motor 16 Draft Diverter Assembly 7 37 20 37 10 40141 Fan Blade 17 Draft Diverter Assembly 7A N A N A 40140 Heyco Strain Relief 18 Heat Exchanger 8 129 20 127 10 40260 Fan Switch 19 Upper Shield 9 2 90 2 90 40068 Wiring Diagram label 20 Header Assembly 10 25 90 25 90 40150 Fan Housing 21 Lower Front Shield 11 13 10 13 10 f 40065 Fan Switch Wire 48 Gasket Flue Pipe 12 Wall Mtg Bracket 49 40317 Blocked Flue Sw 350 Deg 46 Installation Manual N A 84511 Wiring Harness Bulb 47 Wiring Harness Wall 47 E C O Fitting Bulb 34 BURNER ASSY PARTS W251 252 255 256F W501 502F 40542 A REAR REGISTER FOR MODELS _ wastyase vase yosce wean soot qwonvastar snes only REF PART LIST PART LIST REF PART LIST PART DESCRIPTION NO NO PRICE NO PRICE PART DESCRIPTION NO NO PRICE Burner Support Assy 28 40212 Damper 22 Burner Steel 29 84070 Damper Spring 23 Burner Steel WITH Frame Assembly 24 Carry Over Tapping 29A 84071 Register Chain 25 Burner Restrictor Plate N A 40220 Bell Pull 26 for W502F and W506F Register Assembly 27 Orifice Coupling 30 Installation Manual N A Elbow 3 8 90 Degree 3 FSK A Manifold 33 Floor Plate Assembly 55 Pipe Nipple N A Right Side Assembly 56 Pilot Tubing w Fittings 44 74452 Upper Left Side 5 7 Air Shutter 35 84078 Upper Right Side 58 Valves 36 SEE VALVES Upper Front 59 Pilots 38 SEE PILOTS Left Side Assembly
13. AFETY 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 SYSTEM Do not try to light any appliance Your gas control and pilot light system has a safety De nottouch any lectica aiot device whose purpose is to shut off the gas supply to h buildi the appliance if the pilot light goes out If you have any phone in your Duuding trouble lighting the pilot or keeping it lit it may mean Immediately call your gas supplier from a that this safety device is warning you that there is a neighbor s phone Follow the gas supplier s problem with your system Inspection and repairs or instructions replacement must be made by a trained gas service technician 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 TAMPERING IS DANGEROUS Do not store or use gasoline or other flammable The pilot safety system may also not work if you do vapors and liquids in the vicinity of this or any not follow the lighting instructions carefully or if you other appliance tamper with the gas control that you use to light the pilot Tampering with the gas control particularly with
14. D INSTALLERS SERVICE AGENCIES THE GAS SUPPLIER OR THE MANUFACTURER SPECIFICATIONS Your vented wall furnace comes packed in a single carton For wall thermostat models that includes the thermostat thermostat wire and insulated staples Before installing the wall furnace check the rating plate to verify that the Model Number is correct and that the wall furnace is equipped for the type gas you intend to use Model Type Type BTU Hr Vent Gas Shpg REAR REG KIT FAN KIT No Control Gas Input Size Inlet FINISHED DIMENSIONS Wt Model Weight Model Wt SINGLE WALL FURNACE W251F Snap Bulb a j 1 2 Wx68 Hx6 1 2 D W255F Wall Stat j 1 2 Wx68 Hx6 1 2 D W252F Snap Bulb P 7 1 2 Wx68 Hx6 1 2 W256F Wall Stat a j 1 2 Wx68 Hx6 1 2 W351F Snap Bulb 4 j 1 2 Wx68 Hx6 1 2 W355F Wall Stat z j 1 2 Wx68 Hx6 1 2 W352F Snap Bulb ep z j 1 2 Wx68 Hx6 1 2 W356F Wall Stat i 2 1 2 Wx68 Hx6 1 2 DUAL WALL FURNACE WS501F Snap Bulb k j 16 1 2 Wx68 Hx6 1 2 D W505F Wall Stat a 7 16 1 2 Wx68 Hx6 1 2 D W502F Snap Bulb Me 2 16 1 2 Wx68 Hx6 1 2 D WS506F Wall Stat 4 i 16 1 2 Wx68 Hx6 1 2 D One or two fan kits may be used on dual wall furnace Page 2 SAFETY RULES A The wall furnace should be located near the center of the house for best heat distribution B Due to high temperatures the appliance should be located out of traffic and away from furniture and d
15. INCH OF THE TIP OF THE GENERATOR BURNER FLAME ADJUSTMENT STAINLESS STEEL BURNER 1 FLAME TOO SOFT Yellow 2 FLAME TOO HARD Deep Blue 3 NORMAL FLAMES Flame Open air shutters until Coloration Closing air shutters yellow tipping disappears to a point where yellow tipping begins re open slightly to eliminate yellow tipping Air shutter adjustment is now correct NOTE It is advised that the burner flames be checked at least twice during the heating season for any changes in burner characteristics Vacuum burner compartment at start of heating season or as often as needed Page 12 MODEL WFF81 C OPTIONAL FAN KIT INSTALLATION INSTRUCTIONS NOTE This fan kit is to be installed after installation of wall furnace and with the wall furnace front panel in place STEP 1 This appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the latest edition of the National Electric Code ANSI NFPA No 70 In Canada see the current Canadian Electrical Code CSA C22 1 STEP 2 Set fan kit on top of the wall furnace front panel Using the back top edge of the fan kit cabinet as a guide mark a horizontal line across the wall Mark a small vertical line which aligns with the slot located toward the rear of the fan kit casing STEP 3 Using the four one inch screws provided secure the wall mounting bracket to wall 1 8 below the horizontal line Fan attachment
16. TO DETERMINE WHICH WIRING EXAMPLE TO USE Manual Reset Blocked Flue Switch Thermo BULB MODELS NAT LP W251F W252F W351F W352F WSOILF W502F FIGURE 1 Thermostat Manual Reset Blocked Flue Switch TT THERMOSTAT MODELS W255F W256F W355F W356F W505F W506F FIGURE 2 Gas Valve SPECIAL INSTRUCTIONS FOR REAR REGISTER KIT APPLICATION Figures 6 and 7 line drawings of rear register opening STEP 1 Cut hole in the back wall 8 1 4 high by 12 5 8 wide The lower edge of the hole to be 45 3 4 above the floor plate as shown in Figure 6 STEP 2 Install frame for rear register in hole and nail frame to stud as shown in Figure 7 STEP 3 Install rough in header and follow instructions for installation of regular furnace NOTE See Supplement No 84504 packaged with Rear Register Kit a 14 1 8 Mi me Plaster Hole for back register E Opening 7 8 from each stud Plaster FIG 6 ROUGH IN DIMENSION FOR REAR REGISTER Page 9 Nail to stud A Stud Plaster FIG 7 PLACING FRAME FOR REAR REGISTER LIGHTING INSTRUCTIONS MODELS W255F W256F W355F W356F W505F W506F 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 e If you cannot reach your gas supplier call the fire by hand When lighting th
17. and side to side Dry Wall B W Type Vent k Plaster B W Type Vent p Screw Plaster Ground FIGURE 5B PLASTER WALL Page 7 STEP 4 Remove double ceiling plate between studs Install one ceiling plate spacer across the cut out in ceiling plate Install vent pipe into position be sure to lock bottom of vent pipe into the base plate Nail second ceiling plate spacer in place See Figure C Page 6 STEP 5 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 D Firestop spacers supplied by manufacturer of B W gas vent Installation of B W gas vent for each subsequent ceiling or floor level of multi story buildings Plate cut away to provide passage of B W gas vent Nail firestop spacer securely FIGURE D VENT INSTALLATION LISTED 2 FT MIN f m per a FLASHING Te OVAL TO 7 ae ROUND ADAPTER CEILING PLATE SPACERS LISTED BW VENT PIPE BASE PLATE CEILING PLATE SPACER LANCES HEADER PLATE _ 2X 4 WALL STUDS FIGURE 2 VENT INSTALLATION FIGURE 4 Front Panel FIGURE 5C Page 8 INSTALLATION STEP 6 To place furnace into position grasp furnace and lift so furnace flue vent and header plate vent opening engage Do not use burner or gas control to lift heater Lift furnace upward and swing bottom into wall openin
18. b cannot be turned from PILOT to OFF unless the pilot is lit Release gas control knob and it will knob is pushed in slightly Do not force pop back up Pilot should remain lit If pilot goes 5 Wait five 5 minutes to clear out any gas Then out repeat steps 4 through 8 smell for gas including near the floor If you smell e If knob does not pop up when released STOP and gas STOP Follow B in the information on the immediately call your service technician or gas supplier safety label If you don t smell gas go to the next e Ifthe pilot will not stay lit after several tries turn the gas step control knob to OFF and call your service technician 6 Locate the pilot Follow metal pilot tube from gas or gas supplier control 9 Turn gas control knob counterclockwise WN to ve Turn gas control knob counterclockwise K to ON l PILOT 10 Close the cabinet door 11 Set thermostat to desired setting TO TURN OFF GAS TO APPLIANCE Set the thermostat to it s lowest setting gt Push in gas control knob slightly and turn clockwise Open cabinet door ft to OFF Do not force Close cabinet door Page 10 Outlet Manifold Pressure Tap LIGHTING INSTRUCTIONS MODEL W251F W252F W351F W352F W501F W502F 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 li
19. d O ZY GAS FIRED VENTED INSTALLATION AND OPERATING INSTRUCTIONS P N 84502 REV 11 04 NATURAL W251F W351F W501F L P W252F W352F W502F GAS W255F W355F W505F GAS W256F W356F W506F WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life CERTIFIED 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 PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER 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 person This appliance is equipped with a blocked flue switch designed to protect against a blocked flue condition The coating selected to provide longer life to the heat exchanger may smoke slightly upon initial firing Please provide adequate ventila
20. djusting screw on combination gas control valve 3 Burr in orifice if it whistles or resonates 3 Remove burr or replace orifice Do not enlarge orifices 4 Excessibe gas input 4 See Flame Too Large above Yellow tip flame 1 Too little primary air 1 Adjust air shutter See Page 12 some yellow tipping 2 Clogged main burner ports 2 Clean main burner ports Do not enlarge ports on L P gas is 3 Clogged draft hood 3 Clean draft hood permissible 4 Linted up air shutter 4 Check for dust or lint at air mixer opening and around the shutter Clean as ne ary Floating Flame 1 Blocked venting 1 Clean flue passageways to remove blockage 2 Insufficient primary air 2 Adjust air shutter to increase primary air supply See Page 12 Gas Odor 1 Gas leak 1 Shut off gas service immediately Check piping Call gas company See Page 1 2 Chimney or flue obstruction 2 Clean flue 3 Drafts around appliance 3 Eliminate drafts Delayed Ignition 1 Pilot flame too small 1 Check pilot orifice increase pilot gas flow if necessary by adjusting inlet pressure 2 Burner ports clogged near pilot 2 Clean burner ports Do not enlarge ports 3 Low gas pressure 3 Check gas supply pressure 4 Pilot decreases in size when main burners 4 Supply piping is inadequately sized Consult local come on gas utility or competent installer 5 Air shutter open too far 5 Close air shutter to proper setting as outlined in these
21. e it complies with all phases of the local heating codes Or in the absence of local codes with the latest edition of the National Fuel Gas Code ANSI Z223 1 In Canada see the current installation code CAN1 B149 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 the National Electrical Code ANSI NFPA No 70 In Canada see the current Canadian Electrical Code C5AC22 1 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 M9W IR3 NOTE If optional rear register kit is to be used see supplemental installation instructions No 84504 and section marked Special Instructions for Rear Register Kit Application prior to installation of Rough In INTRODUCTION THIS IS A GAS 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 QUALIFIE
22. e pilot follow these in department structions exactly BEFORE LIGHTING smell all around the Use only your hand to push in or turn the gas control appliance area for gas Be sure to smell next to the knob Never use tools If the knob will not push in floor because some gas is heavier than air and will or turn by hand don t try to repair it call a qualified settle on the floor service technician Force or attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under Do not try to light any appliance water Immediately call a qualified service technician Do not touch any electric switch do not use any phone to inspect the appliance and to replace any part of the in your building control system and any gas control which has been Immediately call your gas supplier from a neighbor s under water phone Follow the gas supplier s instructions LIGHTING INSTRUCTIONS 1 STOP Read the information on the safety label 2 Set thermostat to it s lowest setting Pilot is 3 Open cabinet door cated 4 Depress and turn gas control knob clockwise anade to OFF of burner Gas Control Knob gE E F Manifold 1D g Pressure Tap 8 Push gas control knob and hold in Immediatel Pilot Adjustment 8 y GGe Cap Internal Manifold light the pilot with a match Continue to hold the Pressure Regulator gas control knob in for about one 1 minute after NOTE Kno
23. ect 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 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
24. fe This appliance has a pilot which must be lighted by hand When lighting the pilot follow these instruc tions exactly BEFORE LIGHTING 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 Do not try to light any appliance Do not touch any electric 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 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 LIGHTING INSTRUCTIONS STOP Read the information on the safety label Open cabinet door Turn temperature control knob to LO Depress and turn gas control knob clockwise fs to OFF Temp Control Knob Internal Outlet Pressure Regulator Gas Control Knob NOTE Knob can not be turned from PILOT to OFP unless knob is pushed in slightly Do not
25. g until legs rest on floor plate and are flush to finished wall For proper combustion level heater front to back and side to side Nail legs to studs DO NOT BEND LEGS as this will put the entire unit into a bind and cause expansion noises See Figure 3 STEP 7 A drip leg and a manual valve equipped with a 1 8 N P T 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 STEP 8 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 9 For wall thermostat units see Wiring section for thermostat connections Make sure all connections are correct and connector stems are not touching STEP 10 To fasten front panel to furnace be sure exposed portion of header is free of debris and plaster Place outer panel over furnace with top of panel about one inch above header and centered in opening Keep front panel flush to finished wall and slide down until rear flange of top outer panel is wedged tight with header and flush with wall Open bottom door of front panel and place sheet metal screw into locking latch Secure top of front panel to header plate with screw provided This will hold front panel securely to wall See Figures SA 5B
26. hould terminate a minimum of 12 feet above the floor See Figure 2 Also the top of the vent must be at least 2 foot above any obstacle within a 10 foot radius including the roof See Figure A B Restriction in All type B vents shall extend in a generally vertical direction with offsets not exceeding 45 vent system degrees except that a vent system having not more than one 60 degree offset may be allowed caused by offsets 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 C Incorrect vent pipe C Use listed BW type vent pipe Do not use tansite 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 flexible chimney liner is recommended 4 Incorrect header 4 The header plate must be 65 3 4 above the floor plate See rough in instructions plate location 5 Vent pipe not down 5 Use a base plate obtained from the vent pipe manufacturer on top of our header plate on the header plate This will lock the vent pipe down and prevent the draft diverter from shoving it up securel 6 Loo
27. n and repair should be done by a qualified flame should surround at least the top 3 8 of the powerpile service person The appliance should be inspected before pilot generator or thermocouple see below The pilot is use and at least annually by a professional service person unregulated so it will be operating at inlet line pressure Max More frequent cleaning may be required due to excessive 7 w c for natural gas and 11 w c for propane To decrease lint from carpeting bedding material etc It is the pilot flame turn the screw clockwise approximately seven imperative that control compartments burners pilot to nine full turns to bottom of pilot light channel until you burners circulating air passageways and venting systems produce sufficient flame at the minimum noise level of the appliance be kept clean 2 If the appliance has been equipped with the optional PILOT FLAME ADJUSTMENT WFF81 C fan kit assembly the bearings of the motor should be oiled every six months with approximately 2 drops of S A E 20 oil 3 8 TO 1 2 INCH 3 The 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 5 Periodic examination of the entire ventilation system as a routine part of the safety performance check is recommended on an annual basis PILOT FLAME SHOULD ENVELOP 3 8 TO 1 2
28. nly 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 2 Page 7 Vent pipe must connect to the wall furnace header plate with a B vent base plate and terminate with a cap at a point at least 12 foot above the bottom of the wall furnace two feet above any obstacle within a 10 foot radius and at least 3 foot above the roof Provisions must be made for adequate combustion and ventilation air This appliance is equipped with a manual reset blocked flue switch designed to protect against a blocked flue condition which would cause combustion products to spill back into the living quarters NOTE A partially blocked inadequate or disconnected vent system may not activate the switch Discoloration of the grille is an indication of a bad vent If this occurs the vent can be checked by a qualified serviceman using a draft gauge After 15 minutes the gauge should read between 02 up to 04 inches w c Vent must be checked at the beginning of each heating season The switch when activated on a bulb control burner will extinguish the pilot flame on a thermostat controlled burner the thermostat circuit will be broken turning off the main burner flame Before the heater can be relit the reset button must be activated See Figure B for location of the manual reset blocked flue switch To reset the switch insert a slender rigid object 1 e screwdriver through the f
29. raperies C Children and adults should be alerted to the hazards of high surface temperature and should stay away to avoid burns or clothing ignition D Young children should be carefully supervised when they are in the same room as the appliance E Do not place clothing or other flammable material on or near the appliance Precautions should be taken so as not to place furniture drapes or other articles directly in front of grille or lower access door that would obstruct air openings as proper air flow is critical to proper operation of unit F Any safety screen guard or casing front removed for servicing an appliance must be replaced prior to operating the appliance G If the area where the appliance is to be installed contains carpeting tile or combustible materials other than wood flooring the appliance shall be installed on a metal plate a wood panel or other non combustible materials The use of ceramic or quarry tile is acceptable and will provide a surface that is easily cleaned This material is to extend the full width and depth of the appliance CLEARANCES As viewed from front of heater the minimum clearance from cabinet to combustible construction Side Wall 1 Floor 2 Ceiling 11 In selecting a location for installation it is necessary to provide adequate accessibility clearances for servicing and proper operation This appliance must not be connected to a chimney flue that serves to vent
30. ront panel louvers and push the reset button down See Figure B 1 However you may have to remove the front panel then reset the switch and reinstall the front panel to relight heater If homeowner experiences this problem the vent system must be checked and corrected NOTE A pre existing vent that has worked for years may not be adequate for todays design because of higher efficiency requirements that result in lower stack temperatures See Possible Causes and Corrective Action on Page 16 All type B 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 dratthood as possible to allow a venting action to begin before any restriction is encountered Page 5 ROUGH IN INSTRUCTIONS NOTE Maximum wall thickness for a dual wall W501 W502 W505 W506 installation is 5 3 8 WARNING Do not bypass the blocked flue switch To do so could expose the consumer to property damage personal injury or possible death STEP 1 Attach the base plate purchased ge ey with the vent pipe to the header plate FIGURE A sed using two No 8 sheet metal screw
31. rough 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 joist 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
32. s through the pre punched holes The heater may not vent properly without a base plate to anchor and seal the vent system See Figure C or for first floor of multi Ceiling plate spacers to story buildings center B W gas vent in stud space nail securely at both ends Plate cut away for ful width of stud space to provide ventilation Studs on 16 inch centers Man Reset Blocked Sheet metal screw base plate Flue Switch aes Use manufacturer s method of Draft fastening pipe to base plate Diverter Header plate of vented wall furnace Relief also acts as firestop Opening FIGURE C Combustion STEP 2 Cut out an opening between the studs of 14 3 8 x 66 1 2 above the floor FIGURE B FIGURE B 1 plate Embed the rear flange of the channel on top of header into either the drywall or the plastered wall This provides part of the required fire stop Square up and nail the header in place with the top front of header located 65 3 4 above floor plate See arrow on right side of header and Figure 1 5A and 5B on Page 7 STEP 3 Rough in 2 gas supply on center line of left stud either 4 above top of floor plate or 4 to right of left stud through floor plate See Figure 1 located on Page 7 Page 6 ROUGH IN INSTRUCTIONS FIGURE 1 ROUGH IN DIMENSIONS 65 3 4 This measurement must be taken from top of floor plate NOTE For proper combustion make sure units are level front to back
33. se connections 6 Check the connection on both the switch and the gas valve Tighten if necessary on the vent safety wiring harness DO NOT BYPASS THE BLOCKED FLUE SWITCH To do so could expose the consumer to property damage personal injury or possible death Page 16 Prices and specifications subject GRAVITY WALL FURNACE to change without notice All LIST PRICES JUNE 2004 prices are F O B factory SINGLE WALL FURNACE DUAL WALL FURNACE Model Numbers Model Numbers Nat L P Nat LE W251F W252F oe WS501F W502F W352F WS05F W506F W256F oN W356F oe xe z a ae t EP WFF81 C FAN KIT Used on Single and Dual Wall models BURNER ASSEMBLY DUAL WALL FURNACE REAR REGISTER KIT Used NOTICE When ordering any component in the Burner Assembly specify on Single Wall models only either Honeywell or Robertshaw components REV 08 02 Page 17 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 FRONT PANEL DOOR amp BODY ASSEMBLY WFF81 C FAN KIT FORMODES J o Fits all Models REF PART LIST PART LIST PART LIST REF PART LIST Front Panel Assembly 121 80 121 80 40025 Fan Cabinet 13 Lower Door 2 9 60 9 60 f 40032 Junction Box 14 Handle Assembly 3 4 40 4 40
34. tion if this occurs This heater may be installed without recessing 1 This unit 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 THIS UNIT IS NOT TO BE INSTALLED IN MOBILE HOMES CONTENTS Iod UCU ON enap aen 2 Rear Register Kit Instructions cccssecessseseseeeeees 9 SPECHICAIONS c2csicnasa ni ada a 2 Lighting Instr Cti nS issnin 10 11 Sary RUES 3 PIAS Da Ascension 12 Clearances tensions aries ete annie 3 Burner Flame Adjustment cccceceeseeseceseesreeeeees 12 CONT OLS soa ee me re reenter ee ncn meee 3 Maintenance Instructions cceessceessstecessseeeeesnees 12 Combustion amp Ventilation Ait 06 4 WEF81 Fan Instructions c ccccsssecesscesssseessneeesenes 13 14 VOS eaa sens ieou ueecdoueseade 5 6 Trouble Shooting Chart cccccscecsscsssesssesseessseeesees 15 16 Rough In Instructions ccccesceeeseeesees 6 Parts DAWNS oses tesa nt aus 17 TAS CAMA OM ssc canecnstasesennsssccmsetanasssattvatcsanatectds 8 Fan ESTaren ann a mass areas e 18 Wiring Instructions ccceceseeseesseeesnees 9 WAAN N aut ee naa ees 20 READ CAREFULLY BEFORE INSTALLING UNIT These installation instructions are a general guide and do not supersede applicable local codes and ordinances Before planning or making the installation be sur
35. vided 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 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 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 def
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