Cozy HEDV40 Installation and Operating Instruction 22 Pages
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HI-EFFICIENT
DIRECT VENT
WALL FURNACE
L.P. GAS
INSTALLATION AND
OPERATING INSTRUCTIONS
P/N 72903 / JUNE 2015
MODEL NUMBERS
NAT. GAS HEDV253A HEDV403A
HEDV254A HEDV404A
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future
reference.
Remove cabinet to access gas control knob.
-
WARNING: If the information in these instructions are
not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
HEDV25
-
•
•
•
•
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.
HEDV40
INSTALLATION AND SERVICE MUST BE PER-
FORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING: Operation of this furnace without the properly installed, factory furnished vent system and vent cap could result in Carbon Monoxide (CO) poisoning and possible death. For your safety, this furnace and the vent system should be inspected at least annually by a qualified service technician.
This appliance may be installed in an aftermarket, permanently located, manufactured home (USA only) or mobile home, where not prohibited by local codes. This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used.
This unit is for residential use only and is not approved for installation in greenhouses, or environments involving dusty, wet, corrosive, or explosive conditions. Such conditions will invalidate the warranty and may create unsafe conditions.
Installation, maintenance, service, trouble shooting 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.
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.
Introduction…………………………...….. 2
Specifications and Dimensions………….
2
Safety Rules………………………............. 3
Clearances…………………………..……. 4/5
Location…………………………..….…… 6/7
Installation…………………………...…… 7/9
Lighting Instructions……………….…… 10
Burner Orifice………………………...….. 11
CONTENTS
Removing Main Burner…....…………… 11
Proper Burner Flame......………………… 11
Wiring Diagram..........…………………… 12
Sequence of Operation…………...…….
13
Optional Kits……………………….…… 14/16
Maintenance Instr./Service Record…...
17
Trouble Shooting...........………………..
18/19
Parts Drawing…….....…………………...
20
Parts List ............………………………...
21
Warranty....................................................
22
INTRODUCTION
THIS IS A GAS-FIRED DRAFT INDUCED, POWER DEPENDENT DIRECT VENT WALL FURNACE
THAT WILL OPERATE SAFELY AND PROVIDE AN EFFICIENT SOURCE OF HEAT WHEN
INSTALLED, OPERATED AND MAINTAINED AS RECOMMENDED IN THESE INSTALLATION
AND OPERATING INSTRUCTIONS. READ THESE INSTRUCTIONS THOROUGHLY BEFORE
INSTALLING, SERVICING, OR USING THE APPLIANCE. IF YOU DO NOT UNDERSTAND ANY
PART OF THESE INSTRUCTIONS CONSULT LOCAL AUTHORITIES, OTHER QUALIFIED
INSTALLER, SERVICE TECHNICIAN, THE GAS SUPPLIER OR THE MANUFACTURER.
SPECIFICATIONS AND DIMENSIONS
Your Direct Vent Wall Furnace is shipped complete in one carton. This carton contains the furnace, vent cap, collector box, vent exhaust tube, air inlet tube, wall template with rough-in dimensions, installation and operating instructions, and wall thermostat.
Model
No.
Input
BTU/HR Weight Width Depth
Type
Height Control CFM
NATURAL GAS
HEDV253A 25,000 100 Lbs.24-1/2” 9-3/4” 32-1/4” 24 V.
200
HEDV403A 40,000 120 Lbs.34-5/8” 9-3/4” 30-1/2” 24 V.
500
L.P. GAS
HEDV254A 25,000 100 Lbs.24-1/2” 9-3/4” 32-1/4” 24 V.
200
HEDV404A 40,000 120 Lbs.34-5/8” 9-3/4” 30-1/2” 24 V.
500
Gas
AMPS Conn.
Center
Vent MAX.
MIN.
to Floor Wall Wall
(Adj.) THICKNESS
1.88
3/8” 12-1/2” 32” 5”
2.18
3/8” 12-1/2” 32” 5”
1.88
3/8” 12-1/2” 32” 5”
2.18
3/8” 12-1/2” 32” 5”
Page 2
16.
17.
18.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1.
2.
3.
4.
5.
19.
20.
21.
22.
23.
24.
25.
26.
SAFETY RULES
Improper installation, adjustment, alteration, service, or maintenance can cause property damage, bodily injury, or death.
Use in other than a residential application may result in unsatisfactory performance, may create unsafe conditions and will invalidate the warranty.
The installation must conform with local codes or in the absence of local codes wtih the National Fuel
Gas Code, ANSI Z223.1/NFPA 54, Natural Gas and Propane Installation Code, CSA B149.1.
DO NOT INSTALL THIS FURNACE IN A RECREATIONAL VEHICLE OR TRAILER.
Do not operate wall furnace unless it is connected to the factory supplied vent system with vent cap in place.
Check the rating label attached to the wall furnace to be sure it is equipped for the type gas you intend to use.
Never use a match, candle, flame or other source of ignition to check for gas leaks. Use only soapy water or liquid detergent.
Have your wall furnace and vent system inspected at least annually by a qualified service technician.
Before cleaning or servicing, turn off the gas and allow furnace to cool.
Do not operate wall furnace without all components properly installed (top, front, etc.).
Due to high temperatures, the appliance should be located out of traffic and away from furniture and drapes.
Children and adults should be alerted to the hazards of high surface temperature 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 appliance.
Clothing or other flammable material should not be placed on or near the appliance.
INSTALLATION AND REPAIR SHOULD BE DONE BY A QUALIFIED SERVICE TECHNICIAN.
THE APPLIANCE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY BY A
QUALIFIED SERVICE TECHNICIAN. More frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments, burners, and circulating air passageways of the appliance be kept clean.
Do not install in a closet, alcove, or small hallway where the furnace could be isolated from the space to be heated by closing a door.
Do not put anything around the furnace or vent cap that will obstruct the flow of combustion and ventilation air.
The appliance, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, with the latest edition of National Electrical Code, ANSI/NFPA 70, or Canadian
Electrical Code, CSA C22.1, if an external electrical source is utilized.
Never operate this furnace without the sight glass in place or with the glass broken or missing.
If it is suspected that rising water may enter the furnace, turn off the gas immediately.
Do not use 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.
It is necessary to replace damaged gaskets or sealing material within the vent or air intake system. Failure to do so may result in property damage, personal injury or loss of life.
Any safety screen or guard removed for servicing must be replaced prior to operating heater.
A gas appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance.
The appliance area must be kept clear and free from combustilbe materials, gasoline and other flammable vapors and liquids.
Any safety screen or guard removed for servicing an appliance must be replaced prior to operating the appliance.
Page 3
Vent Terminal
Air Supply Inlet
FIGURE 1
Area where terminal is not permitted
VENT TERMINAL CLEARANCES
REFERENCE LETTER TO
DRAWING
A = Clearance above grade, veranda, porch, deck, or balcony
B = Clearance to window or door that may be opened
C = Clearance to permanently closed window
D = Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 Feet (61 cm) from the center line of the terminal
CANADIAN
INSTALLATIONS¹
12 Inches (30 cm)
12 Inches (30 cm)
12 Inches (30 cm)
18 Inches (46 cm)
U.S. INSTALLATIONS²
12 Inches (30 cm)
9 Inches (23 cm)
9 Inches (23 cm)
18 Inches (46 cm)
E = Clearance to unventilated soffit
18 Inches (46 cm)
F = Clearance to outside corner 12 Inches (30 cm)
18 Inches (46 cm)
12 Inches (30 cm)
G = Clearance to inside corner
H = Clearance to each side of center line extended above meter/ regulator assembly
I = Clearance to service regulator vent outlet
12 Inches (30 cm)
3 Feet (91 cm) within a height
15 Feet (4.5m) above the meter/regulator assembly
3 Feet (91 cm)
12 Inches (30 cm)
Clearances are in accordance with local installation codes and the requirements of the gas supplier
Clearances are in accordance with local installation codes and the requirements of the gas supplier
12 Inches (30 cm) J = Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance
K = Clearance to a mechanical air supply inlet
L = Clearance above paved sidewalk or paved driveway located on public property
12 Inches (30 cm)
6 Feet (1.83 m)
7 Feet (2.13m) A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
3 Feet (91 cm) above if within
10 Feet (3 m) horizontally
Clearances are in accordance with local installation codes and the requirements of the gas supplier.
M = Clearance under veranda, porch, deck, or balcony
12 Inches (30 cm) permitted only if veranda, porch, deck, or balcony is fully open on a
Clearances are in accordance with local installation codes and the requirements of the gas minimum of two sides. supplier.
¹ In accordance with the current CSA-B149.1 Natural Gas and Propane Installation Code
² In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code
Page 4
ATTENTION ALL CANADIAN CONTRACTORS/INSTALLERS: Before install-
ing this heater into a multi-family hi-rise exceeding four stories, contact the local building code inspector to verify the building construction complies with the Progressive
Collapse requirements as listed in the National Building Code of Canada 2005.
7.
8.
3.
4.
1.
2.
5.
6.
CLEARANCES
As you face the heater, the clearance to a side wall on the right side is 0” (Fig. 2), and the left side is 1” (Fig. 2).
The minimum clearance from the top of the heater to the ceiling or any projecting overhang is
10”. (See Figure 2).
The minimum clearance from the bottom of the heater to the floor, or the top surface of carpeting, tile, etc. is 0”. (See Figure 2).
When the appliance is installed directly on carpeting, tile or other combustible material other than wood flooring, the appliance shall be installed on a metal or wood panel extending the full width and depth of the appliance.
The minimum clearance from the edge of the vent cap to any overhanging obstruction, perpendicular side wall, or corner of building is 12”. (See Figure 1).
Vent cap must be located at least 9” from any opening that would allow combustion products to enter the building, windows, doors, etc., and 12” above the ground or shrubbery (See Figure 1).
Do not install vent cap in a window well. Provisions must be made to prevent snow accumulation from infringing on vent cap clearances.
Clearances around vent cap must be maintained to assure adequate combustion and ventilation air.
Clearances listed are minimum. Adequate accessibility clearances for servicing must be maintained.
Left
Side
Wall
CEILING OR OVERHANG
1”
0”
Right
Side
Wall
Left
Side
Wall
CEILING OR OVERHANG
1”
0”
Right
Side
Wall
HEDV40
HEDV25
FIGURE 2
Page 5
9.
1.
2.
3.
1.
CLEARANCES
RESIDENTIAL GARAGE INSTALLATION: Gas utilization equipment in residential garages shall be installed so that all burners and burner ignition devices are located not less than 18 inches
(46 cm) above the floor. You must build a platform 18” above floor, the full width and depth of the heater, including the rear trim kit. HEATER IS NOT DESIGNED TO HANG ON WALL.
Unit should be located or protected so it is not subject to damage by a moving vehicle. Use care in selecting a good location within the garage. DO NOT locate the appliance where heated air will be directed onto a nearby parked vehicle. Paint may discolor or rubber may harden and crack. DO
NOT allow open or closed containers of paint, gasoline or other liquids having flammable vapors to be stored or used in the same area as the heater.
LOCATION
The wall furnace must be installed on an outside wall, unless optional Kit No. HEVK-5 is used.
For most efficient performance, locate furnace as centrally as possible in the area to be heated and where occupants may move about freely without coming into contact with the cabinet, and within reach of a 115V wall outlet.
If the furnace is installed in a basement, a 12” clearance must be maintained between ground level and the bottom of the vent cap. Do not install furnace where vent cap will terminate in a window well or any other opening below ground level. (See Figure 3). Do not allow snow accumulation to build up within 12” of the vent cap.
OPTIONAL KITS
HEVK-5 - To extend vent 5 foot from heater. This will allow vent cap to be installed above grade from basement or to an outside wall. A total of 3 kits with 2 additional elbows may be used.
12” Minimum above grade
without excavation
FIGURE 3
Page 6
ATTENTION ALL CANADIAN CONTRACTORS/INSTALLERS: Before installing
this heater into a multi-family hi-rise exceeding four stories, contact the local building code inspector to verify the building construction complies with the Progressive Col-
lapse requirements as listed in the National Building Code of Canada 2005.
INSTALLATION
Failure to follow these instructions carefully could result in poor performance, property damage, personal injury, or death.
STEP 1. LOCATE VENT OPENING (Requires 3-1/2” diameter wall opening) a) Select area on wall where heater will be installed. Using template (packed with heater) mark shaded area b) c) d) e) where hole can be cut and to locate the wall brackets. (See Figure 4).
Locate studs on each side of this area.
Mark location for 3-1/2” diameter hole between studs. Hole should be offset to miss studs. (See Fig. 4).
Check outside wall at this location for proper clearances around vent cap. (See Fig. 1).
Cut vent openings into both the inside and outside walls, being sure to maintain level across both openings.
Template
Manual shut-off valve must be accessible in room where heater is installed
Wall
Gas Valve
Back of heater
Wall
Studs
16” O.C.
Shaded
Area
FIGURE 4
Manual shut off valve with
1/8” NPT plugged tapping
Must be accessible in room where heater is installed
3/8” Black iron pipe
Gas Supply
Drip
Leg
FIGURE 5
STEP 2. ROUGH-IN GAS SUPPLY (See Figure 5)
Install at least 3/8” gas supply line. Contact local gas supplier if any questions.
Install a drip leg in gas supply line immediately upstream from the gas connection to heater (see local codes), and provide a 1/8” N.P.T. plugged tapping, accessible for test gauge connection and an individual manual shut off valve accessible within room where heater is installed. (See Figure 5). The heater 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 1/2 psig (3.5Pa). The heater must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5Pa).
Test all connections for leaks using a soapy solution. NEVER USE AN OPEN FLAME TO TEST FOR
LEAKS.
The maximum inlet gas supply pressure for Natural or L.P./Propane gas is 1/2 p.s.i. or 14” w.c.
The minimum inlet gas supply pressure for the purpose of adjustment is 4.5” w.c. for Natural gas or 11.0” w.c. for
L.P./Propane gas.
Page 7
STEP 3 INSTALLING VENT SYSTEM 5” - 32” WALL THICKNESS (12.7 cm - 81.3 cm) a) Use only factory supplied parts. Do not attempt to modify in any way. To do so could cause a system b) imbalance resulting in poor performance and/or unsafe operating conditions.
Slide collection box pipes through cutout and secure collection box to inside wall. Anchors (not supplied) may be required. (See Figure 5).
c) d)
From outside house, mark collection box pipes and cut off 1/2” beyond outside wall.
Slide vent cap pipes onto collection box pipes and push in until flange is flush against house. Secure vent cap assembly to outside wall with a slight downward slope. This will prevent water from entering and allow condensation to drain. Caulk around the edges of the vent cap mounting plate. NOTE: It may be necessary to build a metal or wood frame to provide a flat surface for the mounting plate to be flush against or to attain the 5” minimum wall thickness.
6-3/8”
(16.2 cm)
INSTALLATION - CONTINUED
Trim Kit Brackets
6-1/4”
(15.9 cm)
4”
(10.2 cm)
4-1/8”
(10.2 cm)
Trim Kit Brackets
Gas Inlet
Air Intake
Gas Inlet
Air Intake
Flue Outlet
Flue Outlet
6-1/8”
(15.6 cm)
5-7/8”
(14.9 cm)
HEDV25 - Figure 6
FIGURE 5
HEDV40 - Figure 6
Collection Box
Assembly
Vent Cap
Assembly
Vent Cap
Mounting
Plate
FIGURE 7
FIGURE 8
Page 8
c) d) e)
STEP 4. INSTALLING HEATER a) b)
Locate (and mark) wall mounting bracket location on wall using template supplied.
Secure wall brackets to wall, anchors (not provided) may be required.
Secure trim kit brackets to back of heater using eight #8 screws provided. (See Figure 9).
Slide heater to approximately 5” of wall.
f)
Secure air intake hose to back of heater and the collector box assembly using hose clamps provided. (See
Figure 8).
Secure vent exhaust tube to exhaust tube on back of heater and the exhaust tube on the collection box g) h) i) j) k) assembly using hose clamps provided. (See Figure 8).
Connect 3/8” minimum gas supply line to manual cut-off valve on back of the heater. (See Figure 5).
Locate factory installed thermostat wires extending from rear of the heater. Connect 24 V. thermostat wall thermostat (provided) using a maximum 20’ of thermostat wire. Do NOT splice thermostat wire.
Secure right and left trim side panels to the wall and trim kit brackets with eight #8 screws provided.
(See Figure 9). This will space the back of the heater 5” from the wall.
Secure trim top to trim sides using four #8 screws provided.
l)
Plug three-pronged factory wired power cord into a properly grounded 115 Volt electrical outlet. NEVER use an extension cord. If homeowner desires, heater can be hard wired by a licensed electrician. See local electrical codes.
Turn the manual gas control valve on. Check all connections for leaks using a soapy solution. NEVER check for leaks with an open flame.
HEATER IS NOW INSTALLED, FOLLOW LIGHTING INSTRUCTIONS TO PLACE HEATER INTO SER-
VICE. FRONT PANEL MUST BE REMOVED FOR ACCESS TO LIGHTING INSTRUCTIONS AND GAS
CONTROL.
Trim Kit Top
1/2”
Bushing
Trim Kit
Right Side
Trim Kit
Bracket (4)
FIGURE 9
Trim Kit
Left Side
Page 9
A.
B.
FOR YOUR SAFETY READ BEFORE OPERATING
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 does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
- 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.
1.
2.
3.
4..
5.
6.
OPERATING INSTRUCTIONS
STOP! Read safety information on this label.
7.
Set the thermostat to the lowest setting.
Turn off all electric power to the appliance.
This appliance is equipped with an ignition device which automatically lights the burner. Do not try 8.
to light the burner by hand.
Remove cabinet to access gas control knob.
9.
Turn gas control knob clockwise to
“off”. Do not force.
10.
11.
Wait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow “B” in safety information on this label. If you don’t smell gas, go to next step.
Turn gas control knob counterclockwise to “ON”.
Turn on all electric power to the appliance.
Set thermostat to desired setting.
If the appliance does not operate, follow instructions “To Turn Off Gas To Appliance” and call your service technician or gas
12.
supplier.
Replace cabinet.
Gas control knob shown in “OFF” position
1.
2.
3.
TO TURN OFF GAS TO APPLIANCE
Set the thermostat to lowest setting.
Turn off all electric power to the appliance if service is to be performed.
Turn gas control knob clockwise to “OFF”. Do not force.
Page 10
8.
9.
10.
11.
1.
2.
3.
4.
5.
6.
7.
PROPER BURNER FLAME
The burner flame may be observed by raising the sight glass cover. A proper flame will have a dark blue inner mantle, with a lighter blue outer mantle that extends from the burner into the heat exchanger tube, (see Figure 10).
There is no primary air adjustment on the burner, and proper flame is assured since the correct manifold pressure and orificing have been done at the factory.
TO REMOVE MAIN BURNER FOR
INSPECTION AND CLEANING
Turn off all electrical supply to heater.
Turn off gas supply.
Remove front panel.
Unplug wire to direct spark ignitor and sensor.
(See Fig. 11.)
Disconnect vacuum hose from burner box.
Remove screws holding burner box top to burner box. (See Figure 11.)
Remove burner plate and burner box top. Take care not to contact, or strain ignitor in any way as it is extremely fragile. (See Figure 11.)
Remove 2 nuts holding burner bracket. (See
Figure 11).
Slide burners toward heat exchanger and lift up from rear and back. (See Figure 11).
Clean or replace as needed.
Reinstall by reversing Steps 9 - 1.
BURNER ORIFICE
This appliance equipped only for altitudes 0 - 2,000 ft.
Appliance input ratings are based on sea level operation and need not be changed for operation up to 2,000 feet
(609.9 m) elevation. For operation at elevations above
2,000 feet (609.9 m).
The BTU input must be reduced 4% per 1,000 ft. Orifice change must be completed by a qualified installer or service technician. See the following orifice chart for the proper orifice drill size for a specific elevation.
MODEL
NO.
HEDV253A
HEDV403A
HEDV254A
HEDV404A
SPECIFIC ELEVATIONS
0 to
51
45
58
55
2,000’
52
47
4,000’
2,000’ 4,000’ 6,000’
NATURAL GAS
52
48
L.P. GAS
60
55
62
56
6,000’
8,000’
53
49
63
56
8,000’ -
10,000’
54
50
64
57
Primary Flame
Burner
Secondary Flame
Heat Exchanger Tube
FIGURE 10
NOTE: THE FURNACE AND ALL COMPO-
NENTS MUST BE INSPECTED AT LEAST
ANNUALLY BY A QUALIFIED SERVICE
TECHNICIAN. THIS SHOULD INCLUDE THE
BURNER, HEAT EXCHANGER, AND VENT
SYSTEM. BE SURE THAT THE FLOW OF
COMBUSTION AND VENTILATION AIR ARE
NOT OBSTRUCTED AND THAT ALL HOSES
ARE UNDAMAGED, AND ALL CLAMPS ARE
SECURELY TIGHTENTED.
Maxitrol
Gas Valve
Burner
Burner
Bracket
Direct Spark Ignitor
FIGURE 11
Burner
Box Top
Manifold
Page 11
WIRING
This appliance is equipped with a three prong power cord with grounding plug. For your protection against shock hazard, this appliance should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug.
WARNING
THIS IS A GAS-FIRED APPLIANCE. KEEP THE
AREA CLEAR OF GASOLINE AND OTHER FLAM-
MABLE VAPORS AND LIQUIDS. ALL COMBUS-
TIBLE MATERIAL MUST BE KEPT CLEAR OF THIS
AREA TO AVOID FIRE OR EXPLOSION.
NOTE: If any of the original wire supplied with this appliance has to be replaced, it must be replaced with type 105
º
C wire or its equivalent.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing.
Pressure
Switch
Black
Thermostat
Gas
Valve
HEDV25-A,
Blue
R G W C
Yellow
24
VAC
CMB Blower
Limit
Switch
L1
ACC
Ground
24 V AC8 COOL
C i r c u i t
Board
Transformer
Brown
Black
Draft
Inducer
HEDV40-A
PICTORIAL
Circulating
Blower
Black
Green
HEDV25-A,
HEDV40-A
LADDER
Gas Valve
P r e s s u r e
Switch
Limit Switch
Thermostat
24 VAC
CIRCUIT BOARD
115 VAC
Draft Inducer
Circulating
Blower
HEDV253A, HEDV254A, HEDV403A, & HEDV404A
WIRING DIAGRAM
Page 12
SEQUENCE OF OPERA
YES
NO
YES
NO
Page 13
HEVK-5 5’ VENT EXHAUST KIT
INSTALLATION INSTRUCTIONS
WARNING: Use only Louisville Tin & Stove Company factory supplied parts and kits. Failure to do so could result in loss of life, personal injury, property damage, or unsatisfactory performance. This kit must be installed by a qualified installer or service technician.
1 only
1 only
1 only
2 only
P/N 72532 2”x3” Steel Coupling
P/N 72575 2”x5’ Black Flocked Tube
P/N 72612 2”x6’ Black Flex Tubing
P/N 41515 Support Brackets
CONTENTS OF KIT
1 only P/N 41520 Center Bracket
8 only P/N 72593 2” Hose Clamps
1 only P/N 72578 2”x3” Black Silicone
Wrapped Coupling
STEP 1 - LOCATE VENT OPENING
a) Select location on outside wall that vent will exit through.
b) c)
Check outside for proper clearances around vent cap. See installation instructions.
Mark and cut 3-1/2” hole through both inside and outside walls, being sure to maintain level across both openings.
d) e)
Measure wall thickness. Mark and cut off both intake and exhaust pipes to 1/2” beyond outside wall.
Secure collection box to wall. Wall anchors, not provided, may be required.
STEP 2 - INSTALL HEATER
a) Select location on wall where heater will be installed.
a) b) c) b) c)
Using wall template supplied with heater, mark location for trim kit wall brackets.
Attach brackets to wall (wall anchors, not provided may be required) and back of heater. Using screws provided on d) e) f) back of heater.
Slide heater into position and secure brackets togehter. This should position back of heater 5” off wall.
Select direction vent will exit trim kit, left, right, or straight up.
Before installing trim kit remove knockout on this side.
STEP 3 - INSTALL VENT
Remove and discard P/N 72611 2”x24” black flex tubing from air inlet. (Save hose clamp).
Attach P/N 72612 2”x6’ black flex tubing to air inlet. Secure with P/N 72593 2” hose clamp.
Slide P/N 72575 2”x5’ flocked tube through trim kit opening (knockout) and attach to P/N 72610 orange silicone
90E elbow supplied with heater. Secure with 2” hose clamp.
d) Attach P/N 41515 support brackets to wall. Wall anchors, not provided, may be required. Postion support brackets within 8” from side of trim kit and end of pipe. Secure flex tubing and flocked tube to brackets using 2” hose clamps.
Attach P/N 41520 center bracket 2-1/2’ from pipe end and insert flex tube through bracket. This will prevent the e) f) g) h) flex tube from touching the black flocked exhaust tube.
Connect flex air intake tube and flocked exhaust tube to collection box.
Complete gas connection and attach trim kit to brackets.
Follow lighting instructions.
SPECIAL NOTES
a) You may use up to three HEVK-5 Kits for a total of 15’ vent extension with two additional elbows. DO NOT
EXTEND VENT BEYOND 15’ OR USE MORE THAN THREE TOTAL ELBOWS (one elbow comes with the b) c) heater).
To connect two vent kits together use P/N 72532 2”x3” steel coupling. Secure with 2” hose clamps.
If you are using one, two, or three kits, after installation is complete you will discard 2 P/N 72593 hose clamps and one P/N 72532 steel coupling.
d) e) f)
If you need to make a 90E offset you will need to order P/N HEEL-1 90E Elbow Kit. Two offsets require two kits.
If complete vent extension is horizontal, pipes may be sloped down slightly to allow any condensate to drain through the exhaust pipe to the outside. DO NOT ALLOW TO DRAIN ONTO WALKWAY. If any part of vent extension is vertical or local codes do not allow draining of condensate to outside you must add P/N 18900
Condensate Kit.
For cosmetic purposes, the addition of the HEVK-5 Kit can be enclosed by adding a HEVE-5 Vent Enclosure Kit.
To completely enclose the HEVK-5 Kit one HEVE-5 will be needed for each HEVK-5 used.
P/N 72612
2”x6’ Black
Flex Tubing
P/N 72532
Use only if connecting flex tubing of 2 or more ktis
P/N 72578 2”x3”
Black Silicone
Wrapped Coupling
P/N 41515
Support
Brackets (2)
P/N 41520
Center Bracket
P/N 72575 2”x5’
Black Flocked Tube
P/N 72593
2” Hose Clamps
Page 14
HEVE-5
VENT ENCLOSURE KIT
INSTALLATION INSTRUCTIONS
This kit must be installed by a qualified installer or service technician.
STEP 1) Position end of Part No. 41610 enclosure body to heater trim kit where pipes exit trim kit, centering pipes inside body and attach to wall. Wall anchors,
not provided, may be required. Collector box may be behind HEVE-5 Kit.
STEP 2) Cut to fit enclosure panel 1” beyond end of vent run. Insert Part No. 41620 End Cap and attach using three #8 screws provided.
SPECIAL INSTRUCTIONS
STEP 3) If more than one HEVE-5 Kit is used, attach Part
No. 72604 Trim Kit where ends meet.
STEP 4) If making a 90º turn, measure 1” beyond outside turn and cut off enclosure panel. Notch panel on surface of direction turn is being made to allow pipes to pass through into next HEVE-5 Kit.
Attach second panel to wall and attach Part No.
72604 Trim Kit where two bodies meet. Install end cap Part No. 41620.
HEEL-1
90º ELBOW KIT
Contains 1 only P/N 72613 90º Elbow 2”
Page 15
18900 CONDENSATE KIT
INSTRUCTIONS
HI-EFFICIENT DIRECT-VENT WALL FURNACE
Always use this kit when the vent has a vertical run, or where local codes prohibit draining condensate to the outside. Use only Cozy Heating Systems supplied parts. Failure to use factory supplied parts or to follow these instructions may result in unsatisfactory performance, property damage, personal injury and/or loss of life.
Before beginning kit installation, open carton and identify the following components.
A) P/N 18910 Condensate Pan Assembly
B)
C)
P/N 72618 Condensate Trap Assembly
P/N 72538 3/8” Tubing
D)
E)
P/N 72539 3/8” Hose Clamp (2)
P/N 50606 #8 x ½” screws (2)
Step 1. Set thermostat to “off” and allow heater to cool.
Step 2. Turn off gas supply to heater.
Step 3. Turn off electric power to heater.
Step 4. Remove the cabinet.
Step 5. Loosen the two wing nuts located in the heater base. See Figure 1.
Step 6. Slide the condensate pan into the bottom of the heater with slots in tabs onto the weld studs and under the wing nuts. Use care to not rip the insulation in bottom of heater. Tighten the wing nuts to secure condensate pan.
See Figure 1.
Step 7. Remove and discard the button plug located at center lower area of heater back.
Step 8. Attach condensate trap to heater back so bottom of trap is inside the bottom of the condensate pan. Secure using the (2) #8 screws provided. Fill trap with water. See Figure 2.
Step 9. Remove and discard plastic cap from bottom of the draft inducer drain tube. See Figure 2.
Step 10. Connect the tubing to the draft inducer drain tube and the condensate trap. Secure both ends with two 3/8” hose clamps provided. See Figure 2.
Step 11. Fill the condensate pan with water.
Step 12. Reverse steps 4 – 1. Follow lighting instructions to place heater in operation.
WARNING: The water level in the condensate pan must be checked and maintained to completely cover the condensate trap. The water provides a seal to prevent combustion products from coming through the condensate trap and entering the living area.
Weld
Pin (2)
Wing Nuts (2)
FIGURE 1
Form No. 72936
Condensate Pan
Assembly
Page 16
72618 -
Condensate Trap
80190 - Casing
Black Plug
Inducer
Drain Cap
72538 -
Flex
Hose
72539 - Hose
Clamp (2)
50606 - #8x12 Screw
(2)
FIGURE 2
MAINTENANCE INSTRUCTIONS
For proper and safe operation keep furnace and furnace area clean. At regular intervals turn control valve to off, let cool and clean inside control and heat exchanger compartment. To clean front panel use only a damp cloth, do not use any kind of solvent or cleaning fluid that could leave a residue to burn or give off fumes when furnace is turned on.
Have the furnace checked, cleaned, and repaired by a qualified service technician. Check venting system, and burner operation prior to use each year.
Follow a regular service and maintenance schedule for safe and efficient operation.
Do not obstruct combustion and ventilation air. Examine the venting system as a routine part of the safety performance check on an annual basis.
If the heat exchanger is removed, check the heat exchanger intake gasket and draft inducer gasket and replace if there is any sign of damage. Be sure all gaskets are in place when the heat exchanger is replaced.
Failure to replace any gasket that has been damaged may result in property damage, personal injury or loss of life.
Oil the bearings of the fan motor every 6 months with S.A.E. 20 oil.
SERVICE RECORD
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Page 17
TROUBLE SHOOTING CHART - For use by a qualified service technician.
SYMPTOM
Flame too large
CORRECTIVE ACTION
POSSIBLE CAUSES To be taken by Contractor
1. Defective operator section of valve.
2. Burner orifice too large.
3. If installed above 2,000 ft.
1. Replace valve.
2. Check with local gas company for proper
orifice - size and replace.
3. See burner orifice section, Page 11.
Yellow burner flame 1. Clogged burner ports.
Gas odor
Delayed Ignition
Failure to ignite
Burner won’t
turn off
Incorrect gas
input
Not enough heat
Too much heat
2. Obstruction around vent cap.
1. Gas leak.
1. Low gas pressure.
2. Igniter not properly located.
1. Main gas off.
2. Thermostat not set high enough to call
for heat.
3. Clogged burner orifice.
4. Incorrect wiring.
5. Defective valve.
6. No power to unit.
1. Defective or damaged thermostat wire,
or thermostat.
2. Thermostat location.
3. Defective or sticking valve.
4. Excessive gas pressure.
5. Defective or damaged thermostat.
1. Gas input not checked.
2. Clogged orifices.
1. Furnace undersized.
2. Thermostat temperature set too low.
3. Incorrect supply pressure.
1. Temperature set too high.
2. Combination control valve stuck open.
1. Remove burners and check for obstruc-
tions in throats, ports, and orifices. Clean -
but do not enlarge ports or orifices.
2. Make sure area around vent cap is clear, be
sure vent system is sealed.
1. See Page 1.
1. Check gas supply pressure.
2. Check ignitor location and correct if
necessary.
1. Open manual gas valve.
2. Set thermostat to higher temperature.
3. Clean burner orifices (do not enlarge).
4. Check wiring diagram.
5. Replace valve.
6. Plug in power supply cord. Check 115 V.
wall outlet.
1. Can be checked by removing wire from con-
trol board terminal. If burner goes off, replace
thermostat.
2.Re-locate out of drafts, hot, or cold spots.
3. Replace valve.
4. Contact utility supplying gas.
5. Replace thermostat.
1. Re-check gas input.
2. Clean orifices with a smooth wood toothpick,
do not enlarge.
1. This is especially true when a dwelling or
room is enlarged. Have the heat loss
calculated and compare to furnace output.
Your gas company can supply you with this
information. If furnace is undersized,
replace with correct size unit.
2. Raise thermostat temperature setting.
3. Check supply pressure.
1. Lower temperature setting.
2. Replace combination control valve.
Main burner
goes out
during normal
operation
1. Defective flame sensor.
2. Input too high.
3. Sight glass not air tight.
4. Vent tubes not properly installed or
sealed.
5. Limit switch opens.
6. Exhaust or Air Intake tubes blocked.
1. Check voltage and replace if low.
2. Check input rate.
3. Tighten screws securing sight glass. Check
and replace gasket if needed.
4. Follow instructions. Check both exhaust and
air intake tubes, and vent cap. Be sure all
gaskets are in place and properly sealed. Use
only tubes and vent cap supplied. Do not
alter vent tubes or cap.
5. Check for blockage of discharge air.
6. Check for and remove any obstruction to
incoming circulating air.
Page 18
TROUBLE SHOOTING CHART - for use by a qualified service technician.
To assist in diagnosing and servicing, this heater is equipped with a self-diagnosing control module. Should a malfunction occur, the green indicator light on the control module will flash a varying number of times indicating the circuit in which malfunction is located.
# OF
FLASHES
Slow Flash
Fast Flash
2
REASON FOR
INDICATION
Normal operation,
no call for heat
Normal operation, call for heat
System lockout failed to detect or sustain flame
POSSIBLE CAUSES
CORRECTIVE ACTION
TO BE TAKEN BY CONTRACTOR
3
4
5
Pressure switch
Open or Closed
Limit Switch opens
Flame sensed gas valve not energized a.) Defective ignitor.
b.) Ignitor cable defective.
a.) Replace ignitor.
b.) Replace ignitor cable.
c.) Ignitor cable disconnected.
c.) Connect ignitor cable.
d.) Manual gas valve in “OFF” d.) Turn manual gas valve to “ON”.
position. No gas to valve.
e.) Defective wire to gas valve.
e.) Replace defective wire.
f.) Wire to gas valve disconnected. f.) Connect gas valve wire.
g.) Obstruction to vent outlet.
g.) Remove obstruction.
h.) Obstruction to air inlet.
h.) Remove obstruction.
a.) Defective pressure switch.
b.) Pressure switch tubing
damaged, kinked or collapsed.
c.) Pressure switch tubing
disconnected.
d.) Defective draft inducer.
e.) Pressure switch tubing to
wrong connection.
a.) Replace pressure switch.
b.) Replace damaged tubing.
c.) Connect pressure switch tubing.
d.) Replace draft inducer.
e.) Reverse tubing connections on
pressure switch.
a.) Defective limit switch.
a.) Replace limit switch.
b.) Damaged limit switch wire.
b.) Replace damaged wire.
c.) Limit switch wire c.) Connect limit switch wire.
disconnected.
d.) Blockage in front of front
panel.
e.) Heater over rate.
d.) Remove blockage.
e.) Check orifice, pressures, rate.
a.) Defective gas valve.
b.) Defective control module.
a.) Replace gas valve.
b.) Replace control module.
Steady light Internal failure
No Flashes (control module failure and power on self-check) a.) Defective control module.
a.) Replace control module.
Page 19
1
MODEL NUMBERS
HEDV253A - NAT. GAS
HEDV403A - NAT. GAS
HEDV254A - L.P. GAS
HEDV404A - L.P. GAS
HI-EFFICIENT DIRECT VENT
WALL FURNACE
Prices and specifications subject to change without notice.
All prices are F.O.B. factory.
4
44
40
3
2
45
6
42
7
5
26
25
9
29
47
28
8
24
27
31
30
35
39
38
41
23
22
43
36
37
34
33
32
17
19
21
20
15
14
10
12
16
13
11
18
46
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 20
Rev. 05/2012
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.
HEDV253A
REF.
PART
NO.
NO.
LIST
PRICE PART DESCRIPTION
Cabinet
Circulating Blower
Limit Switch
Front Heat Shield
Tubular Heat Exchanger
Cabinet Base Assembly
Leg Leveler (4 Per)
Draft Inducer Gasket - 7-3/4x9"
Draft Inducer Mounting Plate Gasket
Draft Inducer
Sight Glass Frame
Sight Glass
Sight Glass Gasket - 2-5/8x1-3/8"
Ignitor
Ignitor Cable
Burner Orifice (Requires 2)
Burner
Manifold
17 *72528
18 72640
Burner Box Assembly 19 18150
Burner Box Top Gasket - 6-3/4x6-1/2" 20 72567
Burner Box Top
Gas Valve
21 18165
22 64590
Gas Valve Support Bracket 23 18180
Burner Box Mounting Gasket - 7¾x3½" 24 72566
Transformer 25 78069
1 18020
2 72501
3 72671
4 18100
5 72531
6 18120
7 80009
8 72565
9 72563
10 72506
11 18185
12 70150
13 72564
14 64009
15 64210
16 *95251
Circuit Board
Wiring Harness
Pressure Switch
Casing Back
Air Intake Hose
2" Hose Clamp (4 Per)
Vent Cap Assembly
Vent Cap Gasket - 4-3/32x4-3/32"
26 64625
27 72675
28 72517
29 18090
30 72611
31 72593
32 18250
33 72608
Collection Box Assembly 34 18225
Collection Box Gasket -
5-7/16x5-7/16"
35 72607
Collection Box Cap
Vent Exhaust Tube
36 72587
37 72610
Trim Kit Bracket (Requires 4)
Wall Mounting Bracket (Requires 4)
Trim Kit, Left Side Panel
Trim Kit, Right Side Panel
38
39
40
41
18320
18315
18310
18305
Trim Kit Top
HEDV Wire Bracket
Liner, Left Side
Liner Top
Wall Thermostat, 24 Volt
Draft Inducer Mounting Plate
Thermostat Wire 20'
Power Cord
Manual Shut-off Valve (Off-On)
Condensate Kit
42 18300
43 18190
44 18110
45 18075
46 78355
47 18200
N/A 74518
N/A 64205
N/A 64074
N/A 18900
HEDV254A
PART
NO.
LIST
PRICE
18320
18315
18310
18305
18300
18190
18110
18075
72611
72593
18250
72608
18225
72607
72587
72610
78355
18200
74518
64205
64074
18900
*72528
72640
18150
72567
18165
64591
18180
72566
78069
64625
72675
72517
18090
72563
72506
18185
70150
72564
64009
64210
*95258
18020
72501
72671
18100
72531
18120
80009
72565
HEDV403A
PART
NO.
LIST
PRICE
72611
72593
18650
72608
18225
72607
72587
72610
18320
18315
18310
18305
18700
18190
18610
N/A
78355
18200
74518
64205
64074
18900
*72528
72640
18150
72567
18165
64590
18180
72566
78069
64625
72675
72518
18590
72563
72506
18185
70150
72564
64009
64210
*72156
18520
72500
72670
18595
72530
18620
80009
72565
HEDV404A
PART
NO.
LIST
PRICE
72611
72593
18650
72608
18225
72607
72587
72610
18320
18315
18310
18305
18700
18190
18610
N/A
78355
18200
74518
64205
64074
18900
*72528
72640
18150
72567
18165
64591
18180
72566
78069
64625
72675
72518
18590
72563
72506
18185
70150
72564
64009
64210
*72139
18520
72500
72670
18595
72530
18620
80009
72565
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
.
* Requires 2
Page 21
JUNE 2015
LIMITED W
ARRANT
Cozy Heating Systems LLC warrants to the original user the accomp anying product for the p eriod specified h erein, p rovided said produ ct is installed, under this warranty is needed, the user of the product shall request such service d irectly from the installer. If the user is unable to locate the installer, the u ser operated, maintained, serviced, and used according to the in structions and specificatio ns accompanying the product. AS OU TLINED IN OUR
INSTRUCTIONS, ANY WA RRANTY
CONSIDERATIONS ARE CONTINGENT ON
INSTALLATION BY A QUALIF IED INSTALLER
(CONTRACTOR ). SELF-INSTALLATION IS
PROHIBITED A ND WILL INVALIDATE Y OUR
WARRANTY.
If within a period of one year from the date of installation of th e product, any part supp lied by the manu facturer p roves to be defective due to workmanship or material, it will rep lace su ch part, provided parts have n ot been subjected to misuse, alteration, neglect, o r accid ents. The term of the warranty for the heat exch anger and burn ers is covered in Tab le A below. Any claim not made within ten (10) days after th e exp iration of the warranty period shall be deemed waived by the u ser.
The manu facturer shall have no liability or be required to p erform any ob ligation under this warranty unless, when requested, the user retu rns, at the user’s exp ense, the component o r product claimed defective, to the manufacturer for inspectio n, to enab le the manu facturer to determine if the claimed defect is co vered by this warranty.
No charges fo r freight, labor o r o th er exp enses incurred in the repair, removal, or replacement of any product or compon ent claimed to be defective, will be p aid by the man ufacturer to the user, an d the manufactu rer will no t be liable for any exp enses incurred, b y the user, in remed ying any d efect in the p roduct.
Service under this warranty is the responsibility of the installer. In the event service
Cozy Gas Fired Floo r Furnace
T ABLE A
Cozy Gas Fired Wall Furnace
Cozy Gas Fired Vented Co nsole Heater
Cozy Gas Fired Direct Vent Heater
Cozy Gas Fired Counterflow Furnace
Cozy Gas Fired Counterflow Direct Ven t Furnace
Cozy Gas Fired Mobile Home Direct Vent Furnace
Cozy Gas Fired Hi-E fficient Direct Vent Wall Fu rnace
Cozy Gas Fired Direct Vent Baseboard Heater
Cozy Fan-Type, Direct Vent Th rough-The-Wall Gas Heater
Cozy Blue Flame Vent Free Heater should write directly to the manufacturer, and the name o f an altern ative service source will b e supplied.
T he product safety registratio n card (p acked inside the applian ce) must be completed and returned to the factory.
T HIS WARRANTY IS EXPRESSLY IN
LIE U OF ANY OTHE R WARRANTIES, EXPRESS
OR IM PLIED (WHETHER WRIT TEN OR ORAL).
ANY IMPLIE D WARRANTY OF
MERCHANTABILITY OR OF FITNE SS FOR A
PARTICUL AR PURPOSE IS EXPRESSLY LIMIT ED
TO T HE DURATION OF THE MANUFACTURER’S
EXPRESS, WRITTE N WARRANTY.
UNDE R NO CIRCUMSTANCES SHALL
THE MANUFACTURER BE LIABLE FOR ANY
SPECIAL, INDIRECT OR CONSEQUENTIAL
DAM AGES OR EXPENSE S ARISING DIRE CTLY
OR INDIRECTLY FROM ANY COMPONENT OR
FROM THE USE TH EREOF. THE REMEDIES SET
FORTH HEREIN SHALL BE THE EXCLUSIVE
REMEDIES AVAILABLE TO THE USE R AND ARE
IN LIEU OF ALL OTHE R REMEDIES.
SOM E STATES DO NOT ALLOW
LIMITATIONS ON HOW LONG AN IMPLIED
WARRANTY L ASTS, SO THE ABOVE
LIMITATIONS MAY NOT APPLY TO YOU.
SOM E STATES DO NOT ALL OW T HE
EXCLUSION OR LIMITATION OF INCIDENT AL
OR CONSEQUENTIAL DAMAGE S, SO T HE
ABOVE LIMIT ATIONS OR EXCLUSIONS M AY
NOT APPLY TO YOU.
T HIS WARRANTY GIVES YOU SPECIFIC
LEGAL RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS, WHICH VARY, FROM STATE
TO STATE.
Warranty Period
10 Years
10 Years
10 Years
10 Years
10 Years
10 Years
10 Years
10 Years
10 Years
10 Years
N/A
1 0 Years
1 0 Years
1 0 Years
1 0 Years
1 0 Years
1 0 Years
1 0 Years
1 0 Years
1 0 Years
1 0 Years
1 0 Years
COZY HEATING SYSTEMS LLC
3230 INDUST RIAL PARKWAY. – JEFFERSONVILLE, IN 47130
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Table of contents
- 2 Introduction
- 3 Safety Rules
- 5 Clearances
- 7 Location
- 9 Installation
- 11 Burner Orifice