Cozy CF403D-H Operating instructions

Add to My manuals
26 Pages

advertisement

Cozy CF403D-H Operating instructions | Manualzz

COUNTERFLOW

WALL FURNACE

INSTALLATION AND

OPERATING INSTRUCTIONS

P/N 78111 / REV. 06/2013

R

24 VOLT SYSTEM

WITH LOW-BTU

PILOT

MODEL NUMBERS

NATURAL GAS

L.P. GAS

24 VOLT SYSTEM

WITH INTERMITTENT

NATURAL GAS

IGNITION (I.I.D.) L.P. GAS

CF403D-H CF553D-H

CF404D-H CF554D-H

CF407D-H CF557D-H

CF408D-H CF558D-H

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.

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:

Follow the gas supplier’s instructions.

This appliance is equipped with a blocked flue switch designed to protect against improper venting of combustion products.

INSTALLATION AND SERVICE MUST BE PERFORMED

BY A QUALIFIED INSTALLER, SERVICE AGENCY OR

THE GAS SUPPLIER.

THIS UNIT IS NOT TO BE

INSTALLED IN MOBILE

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 this 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.

R

The State of Massachusetts requires that installation and service of a gas appliance be performed by a plumber or gas fitter licensed in the Commonwealth of Massachusetts.

CONTENTS

Contents……………………………………………........... 2

Introduction…………………………………………. 2

Specifications……………………………………….. 2

Safety Rules………………………………………… 3

Helpful Installation Information……………….........…. 3

Connecting the Vent……………………………....…..… 3,4

Combustion and Ventilation Air...................................... 5

Furnace Location………………………………….....…. 6

Rough-In Instructions…………………………..…..…. 6,7

Installation……………………………………….......….. 8

Controls…………………………………………........….. 9

Pilot Flame Adjustment…………………………......….. 9

Lighting & Re-Lighting Instructions……………….. 10,11

Operation………………………………………….....….

12

Terminal Block Wiring Diagram……………….....…… 13

Manual Reset…………………………………....……..

13

Maintenance Instructions…………………….……… 13

Wiring Diagram……………………………….....…….. 14

Side & Rear Discharge Kits……………………...……15,16

Trouble Shooting Chart…………………………..….. 17-19

Repair Parts (break down)………………………..….. 20-25

Repair Parts List…………………………………....…. 20-25

Possible Causes & Corrective Action........................

19

Warranty………………………………………….....….

26

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 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 wall furnace is equipped for the type gas you intend to use.

Model Type Type BTU/HR.

Number Control Gas Input

Vent

Size Gas

(Oval) Inlet Finished Dimensions

Blower

Approx.

Shipping

Speed Amps CFM Weight

MODELS WITH LOW-BTU STANDING PILOT

CF403D-H 24 Volt Nat.

40,000

CF404D-H 24 Volt L.P.

40,000

CF553D-H 24 Volt Nat.

55,000

CF554D-H 24 Volt L.P.

55,000

4”

4”

4”

4”

½” 14-5/16”Wx10¼”Dx81-5/16”H 2

½” 14-5/16”Wx10¼”Dx81-5/16”H 2

½” 14-5/16”Wx10¼”Dx87-5/16”H 2

½” 14-5/16”Wx10¼”Dx87-5/16”H 2

2.25

440

2.25

440

2.25

440

2.25

440

MODELS WITH INTERMITTENT IGNITION

CF407D-H 24 Volt Nat.

40,000

CF408D-H 24 Volt L.P.

40,000

CF557D-H 24 Volt Nat.

55,000

CF558D-H 24 Volt L.P.

55,000

4”

4”

4”

4”

½” 14-5/16”Wx10¼”Dx81-5/16”H 2

½” 14-5/16”Wx10¼”Dx81-5/16”H 2

½” 14-5/16”Wx10¼”Dx87-5/16”H 2

½” 14-5/16”Wx10¼”Dx87-5/16”H 2

2.55

2.55

2.55

2.55

440

440

440

440

104 Lbs.

104 Lbs.

107 Lbs.

107 lbs.

104 Lbs.

104 Lbs.

107 Lbs.

107 Lbs.

Page 2

11.

12.

13.

14.

7.

8.

9.

10.

2.

3.

4.

5.

6.

1.

SAFETY RULES

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.

Do not install this fan type wall furnace in a recreational vehicle trailer or mobile home.

Do not operate this fan type wall furnace unless it is connected to a properly installed and maintained vent system. Do not exhaust flue gases into the room, wall or attic space for any reason.

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.

Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing ignition.

Young children should be carefully supervised when they are in the same room as the furnace.

Clothing or other flammable material should not be placed on or near the furnace.

Any safety screen guard or gill removed for servicing must be replaced prior to operating the furnace.

Locate the blocked flue switch and the auxiliary limit switch and push in the reset button. This will reset the switch in case it accidentally opened during shipping.

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/

NFPA54 or the Natural Gas and Propane Installation Code, CSA B149.1.

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 M9W 1R3.

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 “B” 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 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 must not be connected to a chimney flue serving a separate solid fuel burning appliance.

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 drafthood as possible to allow a venting action to begin before any restriction is encountered.

Page 3

Ridge

More than 10’

10’

2’ Min.

Height above any roof surface within 10’ horizontally

3’ Min.

VENTING - CONTINUED

Ridge

10’ or

Less

2’ Min.

3’ Min.

Chimney

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.

This switch, when activated, will interrupt the electrical circuit between the transformer and the gas valve causing the main burner flame to extinguish. The main burner will not re-light until the blocked flue switch has been manually reset. To reset the switch, after locating it between the bottom of the fan shroud and the top of the draft diverter, simply push the red button on top of the switch. If the homeowner experiences this problem, then the vent system must be checked and corrected.

NOTE: An existing vent that has worked for years may not be adequate for today’s appliances because of higher efficiency requirements that result in lower stack temperatures.

WARNING: Operation of this wall furnace when not connected to a properly installed and maintained venting system or tampering with the blocked flue switch can result in Carbon Monoxide (CO) poisoning and possible death.

(SEE LIST OF POSSIBLE CAUSES AND CORRECTIONS ON PAGE 19).

12’

Min.

3’

Ceiling

Plate

Spacer

Lances

Chimney

2’ Min.

FIG. 1 - VENT INSTALLATION

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 drafthood as possible to allow a venting action to begin before any restriction is encountered.

Red

Button

Blocked

Flue

Switch

Listed

Vent Top

Storm Collar

Roof

Flashing

Oval to round

adapter

Listed “BW”

Vent Pipe

Base Plate

Header

Plate

2x4 Wall

Stud

Draft Diverter

Relief Opening

“CF40/55-D” Series Counterflow

Page 4

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 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 corrosionresistant 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 fireplaces.

Additional information can be found in the latest edition of ANSI

Z223.1 (National Fuel Gas Code).

Page 5

F

I

G

U

R

E

ALL COMBUSTION AIR FROM ADJACENT INDOOR

SPACES THROUGH INDOOR COMBUSTION AIR

OPENINGS

UL Listed Vent Cap

UL Listed Gas Vent

Opening

A

Opening

F

I

G

U

R

E

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

B

F

I

G

U

R

E

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)

Inlet

Grille

Inlet

Grille

Outlet Air

Inlet Air Duct (ends 1 ft.

[300mm] above floor)

C

F

I

G

U

R

E

ALL COMBUSTION AIR FROM OUTDOORS

THROUGH SINGLE COMBUSTION AIR OPENING

UL Listed Vent Cap

UL Listed Gas Vent

Opening

Alternate Opening

Location

D

USING ADJACENT STUD SPACE FOR ALL

COMBUSTION AIR FROM OUTSIDE

HOLES CONNECTING TO

VENTILATED ATTIC

CEILING

PLATE

LOCATION AND SPECIAL PRECAUTIONS

The wall furnace should be located near the center of the 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 furnace 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.

AIR

GRILLE

FLOOR

PLATE

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:

BTU

SQUARE

IN.

25,000 6.25

35,000 8.75

40,000 10.00

50,000 12.50

55,000 13.75

65,000 16.25

HOLE SQUARE

SIZE = IN.

1” .785

1.5”

1.75”

2”

2.5”

3”

1.76

2.4

3.14

4.90

7.065

4” Minimum

FIGURE 2

ROUGH-IN INSTRUCTIONS

In selecting a location 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

-

-

4”

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.

MODEL NUMBER AMPS

CF403D, CF404D

CF553D, CF554D

2.25

2.25

CF407D, CF557D

CF408D, CF558D

2.55

2.55

Page 6

FIGURE 3

115 V.A.C.

Line

In

B-W Vent

Pipe

Header Plate

Wire Nut (not provided)

Switch Box Cover Plate

4” Minimum

2x4

Stud

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 disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of

½ 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 ½ 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.

FIGURE 4

To heater gas control valve

Manual cut off valve

Drip

Leg

1/8 N.P.T.

Pressure Tap

5 ”

1-1/2” Dia.

Knockout

8”

4 ”

1-1/2” Dia.

Gas Inlet

Hole

2 ”

Gas

Supply

Line

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 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

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.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.Replace and fasten front panels to furnace.

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 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.

B-W Vent

Header

Plate

40,000 - 82-7/8”

55,000 - 88-7/8”

NOTE: FOR PROPER COMBUSTION, MAKE

SURE UNITS ARE LEVEL FRONT TO BACK

AND SIDE TO SIDE.

FIGURE 6

Page 8

FIGURE 7

Installation of B-W Gas Vent for one-story buildings or for first floor of multi-story buildings.

Ceiling plate spacers to center

B-W Gas Vent in stud space nail securely at both ends.

Installation of B-W Gas Vent for each subsequent ceiling or floor level of multistory buildings.

Firestop spacers supplied by manufacturer of B-W

Gas Vent

Plate cut away to provide passage of B-W Gas Vent

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

All 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

HONEYWELL

VR8200H SERIES

STANDING PILOT

FIGURE 10-A

Pilot Adj.

Screw

HONEYWELL

VR8204H SERIES

I.I.D. PILOT

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 clockwise (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 ½ INCH

OF THE TIP OF THE GENERATOR.

STANDING PILOT

FIGURE 8-A

Page 9

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

Model 0 to 2,000 - 4,000 - 6,000 - 8,000 -

No. 2,000’ 4,000’ 6,000’ 8,000’ 10,000’

CF403D 32 34 35

CF407D 32 34 35

CF553D 29 30 30

CF557D 29 30 30

36

36

40

40

31 32

31 32

ORDER KIT #49840 2287-1 HIGH ALTITUDE KIT

L.P. GAS

SPECIFIC ELEVATIONS

Model 0 to 2,000 - 4,000 - 6,000 - 8,000 -

No. 2,000’ 4,000’ 6,000’ 8,000’ 10,000’

CF404D 49 50 51 52 52

CF408D 49 50 51 52 52

CF554D 2.15mm 45 47 48

CF558D 2.15mm 45 47 48

49

49

ORDER KIT #49840 2287-1 HIGH ALTITUDE KIT

3/8” TO 1/2”

3/8” TO 1/2”

I.I.D. PILOT

FIGURE 8-B

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.

A. This appliance has a pilot, which must be lighted by hand. When lighting the pilot, follow these instructions exactly.

B. 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.

If you cannot reach your gas supplier, call the fire department.

C. 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.

D. 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.

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.

Remove lower front panel.

5.

Push in gas control knob slightly and and turn clockwise to “OFF”.

Gas Control Knob

NOTE: Knob can not be turned from

“PILOT” to

“OFF” unless knob is pushed in slightly.

Do not force.

Pilot Control Knob

6.

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.

7.

Locate red piezo ignitor button. Locate pilot. (Follow metal pilot tube from gas control).

8.

Turn gas control knob counterclockwise to

“PILOT”.

9.

Push in pilot control knob and hold in. Immediately begin a series of pushing and releasing the red piezo ignitor button, while observing the pilot. Continue to spark until pilot is lit. Continue to hold the pilot control knob in for about one (1) minute after the pilot is lit.

Release the pilot control knob and it will pop back up.

Pilot should remain lit. If pilot goes out, repeat steps 5 thru 9.

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.

10. Turn gas control knob counterclockwise to “ON”.

11. Replace lower front panel.

12. Turn on all electric to the appliance.

13. Set thermostat to desired setting.

PN 91217 02/05

TO TURN OFF GAS TO APPLIANCE

1.

Turn thermostat to lowest setting.

2.

Turn off all electric power to the appliance if service is to be performed.

3.

Remove lower front panel.

Page 10

4.

Push in gas control knob slightly and turn clockwise

to “OFF”. Do not force.

5.

Replace lower front panel.

PN 91217 02/05

CF407D-H, CF408D-H, CF557D-H, CF558D-H - - I.I.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.

If you cannot reach your gas supplier, call the fire department.

A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

B.

BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

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.

C. 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.

D. 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.

PN 91214 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.

This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

5.

Remove lower front panel.

6.

Push in gas control knob slightly and turn clockwise

to “OFF”.

7.

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.

8.

Turn gas control knob counterclockwise to “ON”.

GAS CONTROL

KNOB

Gas Control Knob

NOTE: Knob cannot be turned to

“OFF” unless knob is pushed in slightly. Do not force.

9.

Replace lower front panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. 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

1.

Turn thermostat to it’s lowest setting.

2.

Turn off all electric power to the appliance if service is to be performed.

3.

Remove lower front panel.

4.

Push in gas control knob slightly and turn clockwise to “OFF”. Do not force.

5.

Replace 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 and 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.

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 is 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 burner, however, will continue to operate and the fan cycle until the thermostat is satisfied.

5” to 7”

Approx.

1”

FIGURE 11

Page 12

TERMINAL BLOCK WIRING DIAGRAM

SELECTOR

SWITCH

(Red)

FAN/LIMIT SWITCH (Brown)

POWER CORD (White)

TRANSFORMER(Black)

MOTOR

(Red)

POWER

CORD

(Green)

TERMINAL BOARD

GROUND (Green)

MOTOR (Green)

MOTOR (White)

MOTOR (Black)

TRANSFORMER (Black)

POWER CORD (Black)

P/N 91123

LIMIT

SWITCH

(Blue)

SELECTOR

SWITCH

(Black)

CF403D-H, CF404D-H, CF407D-H, CF408D-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

1.

2.

3.

4.

5.

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. It is imperative that control compartments, burners, pilot burners, circulating air passageways and venting systems of the appliance be kept clean.

The bearings of the motor should be oiled every six months with S.A.E. 20 oil.

The appliance area must be kept clear and free of any combustible materials, gasoline and other flammable vapors and liquids.

It is essential that the flow of combustion and ventilation air not be obstructed.

Periodic examination of the entire ventilation system as a routine part of the safety performance check is 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 any 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

POWER

CORD

THERMOSTAT

SPILL

SWITCH

RED

BLACK

WHITE

RED

BLACK

BLACK

BROWN

BLUE

TRANSFORMER

MOTOR

GREEN

BLUE

BLACK

RED

BROWN

I.I.D.

CF407/408D-H, CF557/558D-H

THERMOSTAT

CF407/8D-H, CF557/8D-H

PICTORIAL

SCHEMATIC

POWER

CORD

RED

BLACK

WHITE

RED

BLACK

BLACK

BROWN

BLUE

MOTOR

GREEN

SPILL

SWITCH

TRANSFORMER

BLUE

BLACK

RED

BROWN

LIMIT

SWITCH

SELECTOR

SWITCH

BLACK

FAN

SWITCH

AUXILIARY

LIMIT SWITCH

TH

TR

CF403D-H, CF404D-H

CF553D-H, CF554D-H

PICTORIAL

SCHEMATIC

GAS VALVE

FAN

SWITCH

AMPS

2.25

SELECTOR

SWITCH

MOTOR

LIMIT

SWITCH

THERMOSTAT

SPILL

SWITCH

115 V.A.C.

TRANSFORMER

24 V.A.C.

CF403D-H,

CF404D-H

CF553D-H,

CF554D-H

LADDER

SCHEMATIC

AUXILIARY

LIMIT SWITCH

GAS

VALVE

AUXILIARY

LIMIT SWITCH

BLACK

IGNITION MODULE

Spark

Sense

24 V

24 V

Gnd.

Gnd.(Burner)

P V

MV/PV

MV

LIMIT

SWITCH

PILOT

SELECTOR

SWITCH

BLACK

FAN

SWITCH

GAS VALVE

MODEL NO.

AMPS

CF407/557D-H 2.55

CF408/558D-H 2.55

FAN

SWITCH

SELECTOR

SWITCH

MOTOR

Page 14

LIMIT SWITCH

115 V.A.C.

TRANSFORMER

24 V.A.C.

THERMOSTAT

SPILL

SWITCH

CF407D-H / CF557D-H

CF408D-H / CF558D-H

LADDER

SCHEMATIC

AUXILIARY

LIMIT SWITCH

IGNITION

MODULE

GAS

VALVE

ROUGH-INS FOR REAR OR SIDE DISCHARGE

Install plastergrounds as shown in Figure 12 and Figure 13.

This kit must be installed by a qualified installer or service technician.

NOTE: When side discharge is being used, furnace should be set exactly 4” from side wall.

14-1/2”

Plaster

Ground

1/2”

14-3/8”

Plaster

Ground

14-11/16”

10-3/

16”

REAR

SIDE

1.

2.

3.

5.

6.

7.

FIGURE 12

4.

8.

9.

10.

FIGURE 13

OPTIONAL ACCESSORY KITS

REAR REGISTER KIT (Flush Mount)

(See Figure 14)

REAR DISCHARGE KIT (Recessed)

Use optional kit No. 406RR-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.

4.

5.

6.

7.

8.

9.

1.

2.

3.

10.

11.

12.

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 & 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)

FIGURE 14

FIGURE 15

Page 15

5.

6.

7.

8.

1.

2.

3.

4.

OPTIONAL KITS - CONTINUED

This kit must be installed by a qualified installer or service technician.

SIDE DISCHARGE ON CASING

SIDE DISCHARGE (With Extension Boot)

Use optional kit No. 306SR-A.

Cut out and remove embossed area on casing side.

Remove knockout from inner liner.

Place 1-1/2” boot from kit through opening, matching 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.

Place grille into position, drill holes into casing, and attach with screws provided.

5.

6.

7.

1.

2.

3.

4.

8.

9.

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.

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.

Place grille into position and secure to wall.

18”

Min.

FIGURE 16

90 Degree

Outside Corner

W

ALL

3 FT.

SECTION

3 FT.

SECTION

BOTTOM SECTION

FIGURE 18

MODEL

NUMBER

CF40

CF55

Length of bottom section

(Ref. 4) plastic raceway

8 Inches

14 Inches

NOTE: Above lengths terminate approximately 2 inches above floor.

FIGURE 17

14PEK-A PLUG EXTENSION KIT INSTRUCTIONS

FOR NON-RECESSED INSTALLATION ONLY

UNITS WITH TERMINAL BOARD

STEP 1. Turn heater off following Section 3 in “Lighting Instructions” and allow to cool.

STEP 2. Turn off all electricity to heater.

STEP 3. Remove top louver assembly, fan shroud and fan blade.

STEP 4. Loosen two screws on romex connector.

STEP 5. Remove junction box cover plate.

STEP 6. Disconnect three power cord terminals and pull power cord out of top of heater.

STEP 7. Insert power cord provided in kit through romex connector and plug onto terminal board following wiring diagram found in lighting and operating instructions.

STEP 8. Tighten two screws on romex connector.

STEP 9. 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

Flame too large

Noisy Flame

Yellow tip flame (some yellow tipping on LP gas is permissible

Floating Flame

Gas Odor

Delayed Ignition

Failure to Ignite

Condensation of

Water Vapor

Burner won’t turn off

POSSIBLE CAUSES

1. Defective operator section of gas valve.

2. Burner orifice too large.

3. If installed above 2,000 ft.

1. Noisy pilot.

2. Burr in orifice (if it whistles or resonates).

2. Remove burr or replace orifice (do not enlarge orifices).

3. Excessive gas input.

3. See “Flame Too Large” above.

1. Clogged main burner ports.

2. Clogged draft hood.

3. Linted up mixer opening.

1. Clean main burner ports. (Do not enlarge ports).

2. Clean draft hood.

3. Check for dust or lint at air mixer opening.

1. Blocked venting.

1. Gas leak.

2. Chimney or flue obstruction.

3. Drafts around appliance.

1. Pilot flame too small.

1. Clean flue passageways to remove blockage.

1. Shut off gas service immediately. Check piping.

Call gas company. See “For Your Safety”, Page 1.

2. Clean flue.

3. Eliminate drafts.

1. 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).

2. Burner ports clogged near pilot.

3. Low gas pressure.

CORRECTIVE ACTION

1. Replace complete valve.

2. Check with local gas company for proper orifice size and replace.

3. Refer to orifice chart on Page 9.

1. Reduce pilot gas with adjusting screw on combination

gas control valve.

4. Pilot decreases in size when main

burners come on.

5. Drafts around appliance.

6. Bad venting.

1. Main gas off.

2. Defective gas valve.

1. Improper venting.

2. Clean burner ports (do not enlarge ports).

3. Check gas supply inlet pressure. Check gas outlet

(manifold) pressure for “minimum step” pressure

(for “step” pressure chart see “Operation”).

4. Supply piping inadequately sized or incorrect

inlet pressure.

5. Eliminate drafts.

6. See “Venting”.

1. Open all manual gas valves.

2. Replace gas valve.

1. See “Venting”.

Incorrect Gas Input

Not enough heat

Too much heat

Burner won’t turn on

1. Defective or sticking automatic valve.

2. Excessive gas pressure (The supply gas

pressure must not exceed 1/2 psi or

14” w.c.

1. Gas input not checked.

2. Clogged orifice.

1. Appliance undersized.

2. Incorrect supply pressure.

1. Combination control valve sticks open.

1. Replace valve.

2. To correct this situation contact the utility

supplying the gas.

1. Re-check gas input.

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).

1. This is especially true when a dwelling or room is

enlarged. Have the heat loss calculated and compare

to the appliance output (approx. 70% of input).

Your gas company or installer can supply you with

this information. If appliance is undersized, replace

with correct size unit.

2. Check supply pressure as outlined above.

1. Replace combination control valve.

TROUBLE SHOOTING CHART - PILOT AND VALVE

1. Gas valve not turned on.

2. No voltage to valve.

3. Defective thermostat.

4. No 115 Volt Line Voltage.

5. Auxiliary limit switch open.

6. Blocked flue switch open.

7. Gas valve defective.

1. Turn gas valve to “on” position”.

2. Check for 24 Volts to Valve.

3. Check wall thermostat.

4. Jump fan switch to check for voltage (fan will

come on).

5. Push on red buton to close.

6. Push red button in to close.

7. Replace gas valve

Page 17

TR OUB LE SHOOTIN G CHAR T - FOR USE B Y QUALIFIED IN STALLER OR

SER VICE TECHN ICIAN - PILOT AN D VALVE - CON TIN UED

SYM PTOM

Pilot w on't light or stay lit

(S TAN D IN G

PILO T)

Pilot w on't light , or stay lit

(I.I.D . PILO T)

POSSIB LE CAUSES

1. A ir in line.

2. D efective t hermocoup le

3. Pilot flame too low .

4. M anual reset sw itch not engaged.

1. Sp arker w on't w ork.

2. Sp arker w on't light p ilot.

3. M anual reset sw itch not engaged.

COR R ECTIVE ACTION

1. Bleed line.

2. Rep lace t hermocoup le.

3. A djust p ilot flame.

4. P ush on butt on.

1. Check w ire connections.

2.a. Pilot flame too lean.

2.b. T urn valve to "on" p osit ion.

2.c. Check for p ilot rest rict ion.

3. P ush on butt on.

TROUBLE SHOOTING CHART FOR INTERMITTENT IGNITION SYSTEM (I.I.D)

Green LED

Flash Code

(XxY )ª

OFF

Indicates

No "Call f or Heat"

Flash Fast Startup - Flame sense calibration

Heartbeat Normal operation

2 5 minute Retry Delay

Next System Action

Not applicable

Not applicable

None

None

Recommended Service Action

3

4

7

8

6 + 2

6 + 3

6 + 4

ON

Pilot f lame not detected during trial f or f or ignition

Recycle

Flame f ailed during run

Flame sensed out of sequence

Flame sense leakage to ground

Low secondary voltage supply - (below 15.5 Vac)

5 minute Retry Delay - On every third retry on the same "Call f or Heat"

On every 6th f lame f ailure during run on the same

"Call f or Heat"

Flame sensed out of sequence - longer than 10 seconds

Sof t lockout due to error detected during self check sequences

Not applicable

Initiate new trial f or ignition af ter retry delay completed.

Initiate new trial f or ignition. Flash code w ill remain through the ignition trial until f lame is proved.

None

If system f ails to light on next trial f or ignition check gas supply, pilot burner, spark and f lame sense w iring, f lame rod contaminated or out of position, burner ground connection.

If system f ails to light on next trial ignition check gas supply, pilot burner, f lame sense w iring, contamination of f lame rod, burner ground connection.

If situation self corrects w ithin 10 seconds, Check f or pilot f lame. Replace gas control returns to normal sequence. If valve if pilot f lame present. If no f lame out of sequence remains longer than pilot f lame, cycle "Call f or Heat".

10 seconds, control goes to Flash Code If error repeats, replace control.

6+4 (see below ).

Control remains in w ait mode. When the f ault corrects, control resumes normal operation af ter a one minute delay.

Control remains in w ait mode. When the f ault corrects, control resumes normal operation af ter a one minute delay.

Initiate new trial f or ignition af ter retry delay completed.

Check f lame sense lead w ire f or damage or shorting. Check that f lame rod is in proper position. Check f lame rod ceramic f or cracks, damage or tracking.

Check transf ormer and A C line f or proper input voltage to the control. Check w ith f ull system load on the transf ormer.

Check gas supply, pilot burner, spark and f lame sense w iring, f lame rod contaminated or out of position, burner ground connectiion.

5 minute retry delay, then initiate new trial f or ignition.

Check gas supply, pilot burner, f lame sense w iring, contamination of f lame rod, burner ground connection.

Control w aits until f lame is no longer Check f or pilot f lame. Replace gas valve if sensed and then goes to sof t lockout. Flash pilot f lame present. If no pilot f lame, cycle code continues. Control auto resets f rom sof t lockout af ter one hour.

"Call f or Heat". If error repeats, replace control.

Control auto resets f rom sof t lockout af ter one hour.

Reset by cycling "Call f or Heat". If error repeats, replace the control.

POSSIBLE CAUSES & 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

1. Blockage in vent pipe

CORRECTIVE ACTION

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 cap is properly installed, not shoved too far down on the

vent pipe.

2. Burner is overfiring

3. Improper vent system.

A) Vent too short

B) Restriction in vent

system caused by

offsets

C) Incorrect vent pipe

2. A) Check the manifold 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. Correct vent system.

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

10 foot radius, including the roof. See Figure A on Page 4.

B) 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.

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.

4. Incorrect header plate

location

4. Consult Figure 6 for correct header plate height.

5. Vent pipe not down on 5. You must use a base plate (obtained from the vent pipe manufacturer) on top 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.

6. Loose connections on

the safety wiring

harness

6. Check the connections on both the switch and the gas valve. Tighten if

necessary.

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 change without notice. All prices are F.O.B. factory.

USE ONLY FACTORY SUPPLIED

REPLACEMENT PARTS

MODELS:

NAT. GAS

CF403D-H

CF553D-H

L.P. GAS

CF404D-H

CF554D-H

32

15

52

1a

32c

39

6

46

45

7

25

34

14

24

26

2

37

REV. 04/13

8

9

1c

1d

1b

33

3

32b

34b

32d

1

10

5

19

11

4

27

12

30

29 28

13

1e

1f

31

35

22/

16

16

CONTROL

ASSEMBLY

Page 20

21

42

36

59

17/18

60

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 & schematic drawings on current models are shown at

www.cozyheaters.com.

HOW TO PROPERLY ORDER PARTS: In addition to part description and part number, please give model number, serial number, and type of gas used. This information can be found on the rating plate that is attached to heater.

MODEL NUMBER

PART DESCRIPT ION

Casing Side, Right

Casing Side, Left

Center Back Assembly

T op Assembly

Upper Back Assembly

Lower Back Assembly

Bot tom

Liner Assembly

Header Assembly Complete

Heat Exchanger Assembly

Draft Divert er Assembly

Fan Shroud Assembly

T op Louver w/Insulation

Center Front Panel w/Insulation

Bot tom Louver Assembly w/Insulation

Upper Front Shield

Swit ch Box

Swit ch Box Cover

Lower Front Shield

Mot or Mount ing Bracket

Junction Box Cover

Burner

Valve, VR8200H-1004 Natural Gas w/78089 Dis. Bushi ng

Valve, VR8200H-1103 L.P. GAS w/78089 Dis. Bushi ng

Disappearing Bushing 1/2 x 3/8

Wiring Harness

Manifold

Orifice,NATURAL

Orifice, L.P.

Fan Mot or

Fan Blade

Rubber Grommet (Requires 4)

Limit Swit ch 60T 11-L180

Fan Switch 60T 12-F120

Speed Swit ch 60T 13-F160-30

Auxiliary Limit Switch 60T 15-L350

T hermostat 24 Volt

T ransformer

Flue Pipe Adapt er

Plug Bracket

Casing Mount ing Brackets

Flue Pipe Gasket - 4x8-7/16"

Draft Divert er Gasket - 7x8"

Casing T op 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

T hermostat Wire

T hermocouple Q309A1954

Insulated Staples

Door Cat ch

Blocked Flue Swit ch

Blocked Flue Swit ch Wire

T erminal Board

Pilot T ubing w/Fitt ings - 16"

Piezo Sparker

Electrode Wire

Burner Pan Assembly

Valve Support Bracket Assembly

Pilot Mount ing Bracket

Burner Mount ing Plate

Light ing Instructions "CF"

24 VO LT SYSTEM W ITH LO W-B.T.U. STANDING PILO T

46

52

--

59

42

43

44

45

60

53

56

57

--

58

32b

32c

32d

33

34

34b

35

36

36

37

38

39

41

24

25

26

27

19

21

22

23

28

29

30

31

32

NAT URAL

L.P.

CF403D-H

CF404D-H

REF.

PART

NUMBER NUMBER

LIST

PRICE

1

1a

1b

1c

30325

30330

30364

30025

$

$

$

$

60.20

60.20

42.00

16.30

5

6

7

3

4

1d

1e

1f

2

30070

30219

30246

30370

31399

30378

30400

30200

30087

$

$

$

$

$

$

$

$

27.30

37.50

12.00

90.80

47.30

258.40

$ 52.00

26.60

21.60

16

17

18

12

13

14

15

10

11

8

9

78006

72147

72149

78111

78101

**78010

78065

78067

78066

78086

78355

78069

40061

30047

*30260

78050

30359

30100

30250

30450

30253

30256

*30079

30033

72107

78090

78091

78089

78257

78051

78155

78052

72020

72021

84003

78213

78058

74518

$ 32.80

$ 38.90

$ 4.30

$ 8.90

$ 3.50

$ 6.30

$ 2.50

$ 4.50

$ 46.80

$ 153.50

$ 158.60

$ 2.40

$ 33.00

$ 15.10

$ 4.20

$ 4.20

$ 105.30

$ 29.60

$ 3.80

$ 7.20

$ 7.50

$ 10.90

$ 11.40

$ 24.60

$ 28.90

$ 2.40

$ 2.30

$ 1.60

$ 1.60

$ 1.60

$ 1.60

$ 5.40

$ 27.80

$ 27.80

$ 2.70

$ 5.80

$ 5.80

$ 1.70

78095

74209

80005

78107

78230

78300

78452

80016

72022

30286

30290

30299

30296

91272

$ 14.00

$ 1.60

$ 1.60

$ 11.40

$ 1.90

$ 6.20

$ 6.60

$ 7.00

$ 5.80

$ 19.50

$ 5.80

$ 2.90

$ 3.50

N/C

78006

78161

78168

78111

78101

**78010

78065

78067

78066

78086

78355

78069

40061

30047

*30260

78050

30534

30100

30250

30450

30253

30256

*30079

30033

72107

78090

78091

78089

78257

78051

78155

78052

72020

72021

84003

78213

78058

74518

CF553D-H

CF554D-H

PART

NUMBER

LIST

PRICE

30525

30530

30544

30025

$

$

$

$

63.90

63.90

45.00

16.30

30070

30219

30246

30550

31399

30577

30400

30200

30087

$

$

$

$

$

$

$

$

27.30

37.50

12.00

98.50

47.30

265.10

$ 52.00

26.60

21.60

78095

74209

80005

78109

78230

78300

78452

80016

72022

30286

30290

30299

30296

91272

$ 14.00

$ 1.60

$ 1.60

$ 11.40

$ 1.90

$ 6.20

$ 6.60

$ 7.00

$ 5.80

$ 19.50

$ 5.80

$ 2.90

$ 3.50

N/C

$ 35.30

$ 38.90

$ 4.30

$ 8.90

$ 3.50

$ 6.30

$ 2.50

$ 4.50

$ 46.80

$ 153.50

$ 158.60

$ 2.40

$ 33.00

$ 15.10

$ 4.20

$ 4.20

$ 105.30

$ 29.60

$ 3.80

$ 7.20

$ 7.50

$ 10.90

$ 11.40

$ 24.60

$ 28.90

$ 2.40

$ 2.30

$ 1.60

$ 1.60

$ 1.60

$ 1.60

$ 5.40

$ 27.80

$ 27.80

$ 2.70

$ 5.80

$ 5.80

$ 1.70

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 & schematic drawings on current m odels are shown at www.cozyheaters.com.

* REQUIRES 2 ** REQUIRES 4 Page 21

REV. 06/2013

JUNE 2013

COUNTERFLOW WALL FURNACE / I.I.D. PILOT

Prices and specifications subject to change without notice. All prices are F.O.B. factory.

MODELS:

NAT. GAS L.P. GAS

CF407D-H CF408D-H

CF557D-H CF558D-H

6

51

50

32

15

52

14

24

26

7

25

34

5

17

8

10

11

4

27

28

12

30

13

9

37

35

1a

32c

39

2

22/

23

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 & schematic drawings on current models are shown at

www.cozyheaters.com.

Page 22

21

16

1

1c

1d

1b

33

3

32b

34b

32d

1e

1f

31

46

19 20

49

47/

48

REV. 04/2013

HOW TO PROPERLY ORDER PARTS: In addition to part description and part number, please give model number, serial number, and type of gas used. This information can be found on the rating plate that is attached to heater.

MODEL NUMBERS

P ART DESCRIP T ION

24 VOLT SYST EM WIT H LOW-B.T .U. I.D.D

NAT URAL

L.P.

CF407D-H

CF408D-H

REF.

PART

NUMBER NUMBER

LIST

PRICE

Casing Side, Right

Casing Side, Left

Cent er Back Assembly

T op Assembly

Upper Back Assembly

Lower Back Assembly

Bot t om

Liner Assembly

Header Assembly Complet e

Heat Exchanger Assembly

Draft Divert er Assembly

Fan Shroud Assembly

T op Louver w/Insulat ion

Cent er Front Panel w/Insulat ion

Bot t om Louver Assembly w/Insulat ion

Upper Front Shield

Swit ch Box

Swit ch Box Cover

Lower Front Shield

Mot or Mount ing Bracket

Junct ion Box Cover

Burner

Wiring Harness

Valve, Nat. - I.I.D. VR8204H-1006 w/78089 Disappearing Bushing

Valve, L.P.. - I.I.D. VR8204H-1006 (Conv.) w/78089 Dis. Bushing

Disappearing Bushing 1/2 x 3/8

Manifold

Orifice, Natu ral

Orifice, L.P.

Fan Mot or

Fan Blade

Rubber Grommet (Requires 4)

Limit Swit ch 60T 11-L180

Fan Switch 60T 12-F120

Speed Swit ch F160-30

Auxiliary Limit Swit ch 60T G15 350 Deg., Lower

T hermost at 24 Volt

T ransformer

Flue Pipe Adapt er

P lug Bracket

Casing Mount ing Brackets

Flue Pipe Gasket - 4x8-7/16"

Draft Divert er Gasket - 7x8"

Casing T op Gasket - 8-1/2x4-1/2"

Element Support Gasket - 9-1/2x14-1/4"

Cozy Handle

P ower Cord

Snap-in Out let

T hermost at Wire

Ignit ion Cont rol Box S8600B

P ilot Assy., Elect ronic w/Flame Ignit or, NAT.

P ilot Assy., Elect ronic w/Flame Ignit or, L.P.

Blocked Flue Swit ch

Blocked Flue Swit ch Wire

T erminal Board

P ilot T ubing w/Fit t ing - 16"

Burner Pan Assembly

Valve Support Bracket Assembly

P ilot Mount ing Bracket , IID

Burner Mounting P lat e

Light ing Inst ruct ions "CF"

46

47 & 49

48 & 49

50

51

52

--

53

56

57

58

--

32c

32d

33

34

34b

35

37

38

39

41

28

29

30

31

32

32b

25

26

27

22

23

24

15

16

17

19

20

N/A

21

12

13

14

9

10

11

2

3

4

1d

1e

1f

1

1a

1b

1c

7

8

5

6

72147

72149

78111

78101

**78010

78065

78067

78066

78086

78355

78069

40061

30047

*30260

78050

78051

78155

78052

84003

78213

78058

74518

78097

78098

78099

78107

78230

78300

78452

30286

30290

30299

30296

91261

30100

30250

30450

30253

30256

*30079

30033

72107

78257

78092

78093

78089

78006

30325

30330

30364

30025

30070

30219

30246

30370

31399

30378

30400

30200

30087

30359

$ 4.20

$ 4.20

$ 105.30

$ 29.60

$ 3.80

$ 7.20

$ 7.50

$ 10.90

$ 11.40

$ 24.60

$ 28.90

$ 2.40

$ 2.30

$ 1.60

$ 1.60

$ 1.60

$ 1.60

$ 5.40

$ 2.70

$ 5.80

$ 5.80

$ 1.70

$ 157.10

$ 36.60

$ 36.60

$ 11.40

$ 1.90

$ 6.20

$ 6.60

$ 19.50

$ 5.80

$ 2.90

$ 3.50

N/C

$ 38.90

$ 4.30

$ 8.90

$ 3.50

$ 6.30

$ 2.50

$ 4.50

$ 46.80

$ 33.00

$ 150.70

$ 150.70

$ 2.40

$ 15.10

$ 63.90

$ 60.20

$ 42.00

$ 16.30

$ 27.30

$ 37.50

$ 12.00

$ 90.80

$ 47.30

$ 258.40

$ 52.00

$ 26.60

$ 21.60

$ 32.80

CF557D-H

CF558D-H

PART

NUMBER

LIST

PRICE

78161

78168

78111

78101

**78010

78065

78067

78066

78086

78355

78069

40061

30047

*30260

78050

78051

78155

78052

84003

78213

78058

74518

78097

78098

78099

78109

78230

78300

78452

30286

30290

30299

30296

91261

30100

30250

30450

30253

30256

*30079

30033

72107

78257

78092

78093

78089

78006

30525

30530

30544

30025

30070

30219

30246

30550

31399

30577

30400

30200

30087

30534

$ 4.20

$ 4.20

$ 105.30

$ 29.60

$ 3.80

$ 7.20

$ 7.50

$ 10.90

$ 11.40

$ 24.60

$ 28.90

$ 2.40

$ 2.30

$ 1.60

$ 1.60

$ 1.60

$ 1.60

$ 5.40

$ 2.70

$ 5.80

$ 5.80

$ 1.70

$ 157.10

$ 36.60

$ 36.60

$ 11.40

$ 1.90

$ 6.20

$ 6.60

$ 19.50

$ 5.80

$ 2.90

$ 3.50

N/C

$ 38.90

$ 4.30

$ 8.90

$ 3.50

$ 6.30

$ 2.50

$ 4.50

$ 46.80

$ 33.00

$ 150.70

$ 150.70

$ 2.40

$ 15.10

$ 63.90

$ 63.90

$ 45.00

$ 16.30

$ 27.30

$ 37.50

$ 12.00

$ 98.50

$ 47.30

$ 265.10

$ 52.00

$ 26.60

$ 21.60

$ 35.30

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 wholes aler from which you purchased your Cozy heater.

NOTE: Parts & schematic drawings on current models are shown at www.cozyheaters.com.

*REQUIRES 2 **REQUIRES 4

Page 23

REV. 06/2013

JUNE 2013

KIT NO.

306SR-A

SIDE

REGISTER -

FLUSH

KIT NO. 31300-A

TRIM KIT

15

VENT

ENCLOSURE

2

4

1

3

14

KIT NO. 406RR-A

REAR REGISTER W/

BOOT - FLUSH

KIT NO.

16VE-A

or

36VE-A

13

5

16

8

7

7

8

12

12

11

5

16

5

10

9

12

KIT NO.

407RR-A

REAR REGISTER -

RECESS

6

KIT NO.

30SRB-A

SIDE REGISTER

W/BOOT

Page 24

For description of above reference numbers, see reverse side.

REV. 04/2013

PART DESCRIPTION

16" Vent Enclosure Side

16" Vent Enclosure Front

24" Vent Enclosure Side

24" Vent Enclosure Front

36" Vent Enclosure Side

36" Vent Enclosure Front

Side / Rear Register

Side Register

Large Outer Boot

Large Inner Boot

Small Outer Boot

Small Inner Boot

Boot Trim

Plaster Ground

Side Boot

Cabinet Side Trim Angle

Cabinet Top Trim

Damper Assembly

REF. NO. PART NO. LIST PRICE

9

10

11

12

7

8

4

5

6

13

14

15

16

1

2

1

2

3

31360

31355

31367

31366

31385

31380

31630

31525

31580

31560

31720

31710

31615

31595

31510

31310

31320

31675

$ 10.10

$ 12.60

$ 15.40

$ 19.00

$ 18.80

$ 23.20

$ 22.10

$ 22.10

$ 28.80

$ 26.10

$ 11.90

$ 11.20

$ 19.40

$ 14.20

$ 11.30

$ 6.50

$ 5.70

$ 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

78200

78216

78208

78257

$ 1.90

$ 2.30

$ 2.00

$ 33.00

REPLACEMENT WIRING - I.I.D. (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 limit to ignition control box

Black 6" Flag Terminal/Flag Terminal Selector Swith - Fan Switch

Wiring Harness

78200

78258

78208

78257

$ 1.90

$ 2.70

$ 2.00

$ 33.00

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 & schematic drawings on current models are shown at www.cozyheaters.com.

REV. 04/13

Page 25

APRIL 2013

LIMITED WARRANTY

The Louisville Tin & Stove Co. warrants to the original user the accompanying product for the period specified herein, provided said product is installed, operated, maintained, serviced, and used according to the instructions and specifications accompanying the product. AS OUTLINED IN

OUR INSTRUCTIONS, ANY WARRANTY

CONSIDERATIONS ARE CONTINGENT ON

INSTALLATION BY A QUALIFIED

INSTALLER (CONTRACTOR). SELF-

INSTALLATION IS 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 is covered by this warranty.

No charges for freight, labor or other expenses incurred in the repair, removal, or replacement of any product or component claimed to be defective, will be paid by the manufacturer to the user, and the manufacturer will not be liable for any expenses incurred, by the user, in remedying any defect in the product. 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

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 MAY

Service under this warranty is the responsibility of the installer. In the event service under this warranty is needed, the user of the product

TABLE A

Warranty Period

Vented 10

Cozy Gas Fired Direct Vent Heater

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 Infra-Red Vent Free Heater

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

N/A

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

N/A

ALSO HAVE OTHER RIGHTS, WHICH VARY,

FROM STATE TO STATE.

LOUISVILLE TIN & STOVE COMPANY

737 S. 13

TH

STREET - LOUISVILLE, KY. 40210

advertisement

Related manuals

Download PDF

advertisement