Louisville Tin and Stove Furnace HEDV404 User manual

INSTALLATION
AND
OPERATING
INSTRUCTIONS
P/N 72903
MODEL
L.R GAS
HEDV403
HEDV404
If the information
2003
INSTALLER MUST LEAVE THESE INSTRUCTIONS
WITH THE CONSUMER, HAVE THEM COMPLETE,
AND RETURN THE WARRANTY CARD.
NUMBERS
NAT. GAS
WARNING:
December
in these instructions
I
I
are
not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch; do not use any
phone in your building.
hnmediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the
fire department.
INSTALLATION
AND SERVICE
MUST BE PER-
FORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
NADE iN U.$&_
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 person.
May be installed in an aftermarket, permanently located, manufactured home (mobile home) where not
prohibited by local codes. See owner's manual for details. This appliance is not convertible for use
with other gases, unless a certified kit is used.
This unit is not approved for installation
sire, or explosive conditions.
in greenhouses,
Such conditions
or environments
will invMidate
conditions.
the warranty
involving dusty, wet, corroand may create unsafe
CONTENTS
Introduction...................................
Specifications and Dimensions .............
Sat_ryRutes ...................................
Clearances.....................................
Ixx:atJ.on
.......................................
Installation....................................
Lighting Instructions ........................
Pilot Adjustment .............................
Burner Orifice................................
2
2
3
4/5
6
7
10
11
11
Wh_ilgDiagram..............................
Removing Main Burner. ....................
Proper Burner Flame ........................
Sequence of Operation ......................
OptionalKits .................................
Trouble Shooting ............................
Parts INawing ................................
PartsList ......................................
Wananty......................................
12
11
11
13
14
17
19
20
22
INTRODUCTION
THIS IS A GAS-FIRED DRAFT 1NDUCED, POWER DEPENDENT DIRECT VENT WALL FURNACE
THAT WILL OPERATE
SAFELY AND PROVIDE AN EFFICIENT
SOURCE OF HEAT WHEN
INSTALLED, OPERATED AND MAINTAINED AS RECOMMENDED
1N THESE INSTALLATION AND
OPERATING INSTRUCTIONS. READ THESE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING,
SERVICING, OR US1NG THE APPLIANCE. IF YOU DO NOT U2',TDERSTAND ANY PART OF THESE
INSTRUCTIONS
CONSULT LOCAL AUTHORITIES,
OTHER QUALIFIED INSTALLERS, SERVICE
AGENCIES, THE GAS SUPPLIER OR THE MANUFACTURER.
SPECIFICATIONS
AND DIMENSIONS
Your Direct Vent Wall Furnace is shipped complete in one carton. This carton contains the furnace, vent cap,
vent exhaust tube, air inlet tube, template with rough-in dimensions, installation and operating instructions, and
the thermostat.
MAX. WALL
Thickness
MIN. WALL
Thickness
MODEL
NO.
INPUT
BTUiHR.
WIDTH
DEPTH
HEIGHT
GAS
CO_.
TYPE
GAS
HEDV403
40,000
34-1/2"
9"
30"
1/2"
Nat.
32"
5"
HEDV404
40,000
34-1/2"
9"
30"
1/2"
L.P
32"
5"
Page 2
SAFETY
,
,
RULES
Improper installation, adjustment, alteration, service, or maintenance
injury, or death.
Use in other than a residential application may result in unsatisfactory
warranty.
Follow all applicable
codes and ordinances.
can cause property
performance
damage, bodily
and may void the
If there are none, follow the latest edition of National
Fuel
Gas Code ANSI Z223.1 A copy may be obtained from the CSA International,
or the National Fire Protection Association, Batterymarch Park, Quincy, MA. 02269. In Canada, use latest edition of CAN1-B149
installation code.
,
5.
6.
DO NOT INSTALL
THIS
FURNACE
IN A RECREATIONAL
VEHICLE
OR TRAILER.
Do not operate wall furnace unless it is connected to the supplied vent system with vent cap in place.
Check the rating label attached to the wall furnace to be sure it is equipped for the type gas you intend to
use.
,
Never use a match, candle, flame or other source of ignition to check for gas leaks.
or liquid detergent.
.
9.
10.
11.
Have your wall furnace and vent system inspected at least annually by a qualified service technician.
Before cleaning or servicing, turn off the gas and allow furnace to cool.
Do not operate wall furnace without all components properly installed (top, front, etc.).
Due to high temperatures, the wall furnace should be located out of traffic and away from furniture and
12.
Children
13.
14.
15.
avoid burns or clothing ignition.
Young children should be carefully supervised when they are in the same room with the wall furnace.
Do not place clothing or other flammable material on or near the furnace.
INSTALLATION
AND REPAIR SHOULD BE DONE BY A QUALIFIED
SERVICE PERSON.
THE
WALL FURNACE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY BY A
16.
and adults should be alerted to the hazard
of high surface temperature
Use only soapy water
and should be kept away to
PROFESSIONAL
SERVICE PERSON.
More frequent cleaning may be required
due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments,
burner, and circulating air passageways
of the furnace be kept clean.
Do not install in a closet, alcove, or small hallway where the furnace could be isolated from the space to
be heated by closing a door.
17.
Do not put anything
ventilation air.
18.
The appliance, when installed, must be electrically grounded in accordance with local codes or, in the
absence of local codes, with the latest edition of National Electrical Code, ANSI/NFPA 70. In Canada, use
CSA C22.1.
19.
20.
21.
Never operate this furnace without the sight glass in place or with the glass broken or missing.
If it is suspected that rising water may enter the furnace, turn off the gas immediately.
Do not use the appliance if any part has been under water, hnmediately
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.
22.
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 iniury or loss of life.
Any safety screen or guard removed for servicing must be replaced prior to operating heater.
This appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance.
23.
24.
around the furnace or vent cap that will obstruct
Page 3
the flow of combustion
and
[_[
Vent Terminal
VENT
_
Air Supply
TERMINAL
J = Clearance
to nonmechanical
_
Area where terminalis
CLEARANCES
CANADIAN
INSTALLATIONS I
REFERENCE LETTERTO
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
E = Clearance
to unventilated
soffit
F = Clearance
to outside corner
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
Inlet
12 Inches
(30 cm)
12 Inches
(30 cm)
12 Inches
(30 cm)
18 Inches
(46 cm)
18 Inches (46 cm)
12 Inches (30 cm)
12 inches (30 cm)
3 Feet (91 cm) within a he
15 Feet (4,5m) above the
meter/regulator
assembly
3 Feet (91 cm)
12 Inches (30 cm)
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
6 Feet (1,83 m)
7 Feet (2,13m) Avent shal
not terminate
directly abc
a sidewalk or paved drive
'h
.......
Page 4
not permitted
CLEARANCES
,
2.
3.
4.
,
6.
As you face the heater, the clearance to a side wall on the right side is 0" (Fig. 1), and the left side is 1"
(Fig. 2).
The minimum clearance from the top of the heater to the ceiling or any projecting overhang is 10".
(See Figure 3).
The minimum clearance from the bottom of the heater to the floor, or the top surface of carpeting, tile, etc.
is 0". (See Figure 4).
When the tErnace is installed directly on carpeting, tile or other combustible material other than wood
flooring, the furnace shall be installed on a metal or wood panel extending the full width and depth of the
furnace.
The minimum
clearance
from the edge of the vent cap to any overhanging
obstruction,
perpendicular
side
wall, or comer of building is 12". (See Figure 5).
Vent cap must be located at least 9" ti'om any opening that would allow combustion products to enter the
building, windows, doors, etc., and 12" above the ground or shrubbery (See Figure 5). Do not install vent
cap in a window well. Provisions must be made to prevent snow accumulation
from infringing on vent cap
clearances.
--
b-----
Ceiling or Overhang
I
10" (25.4 cm)
1" (2.54 cm)
FIGURE 1
FIGURE 2
FIGURE 3
[ 30.5 cm ]
12"
[
--12"
I
',0.5 cm ]-
_:_-9"
L_
l
[22.9
12"
[ 30.5 cm]--
1
FIGURE 5
Page 5
cm]
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 whith in the grage. DO NOT locate the appliance where heated air
will be directed onto a nearby parked vehicle. Paint may discolor or rubber may harden and
crack. DO NOT allow open or closed containers of paint, gasoline or other liquids having flammane vapors to be stored or used in the same area as the heater.
7.
LOCATION
.
2.
.
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 coining into contact with the cabinet, and within
reach ofa l15V wall outlet.
If the furnace is installed in a basement, a 12" clearance must be maintained between ground level
and the bottom of the vent cap. Do not install furnace where vent cap will terminate in a window
well or any other opening below ground level. Do not allow snow accumulation to build up
within 12" of the vent cap.
OPTIONAL
KITS
HEVK-5 - To extend vent 5 foot from heater. This will allow vent cap to be installed above grade
from basement or to an outside wall. A total of 3 kits with 2 additional elbows may be used.
12" Minimum above _ade
tion
m
Page 6
INSTALLATION
Failure to follow these instructions
death.
carefully
could result in poor performance_
property
damage, personal
injury_ or
STEP 1. LOCATE VENT OPENING
(Requires 3-1/2" diameter wall opening)
a)
Select area on wall where heater will be installed. Using template (packed with heater) mark shaded area
where hole can be cut and to locate the wall brackets.
Locate studs on each side of this area.
b)
c)
d)
e)
Mark location for 3-1/2" diameter hole between studs. Hole should be of[;et to miss studs. (See Figure 6).
Check outside wall at this location for proper clearances around vent cap.
Cut vent openings
I
Template
into both the inside and outside walls, being sure to maintain
I
t
L_, /"
I
I7
t t
I I
level across both openings.
I
II
tt
t t
tt
I
Shaded
I
I
Area
I
I ..-Wall
J!Studs
[
16" O.C.
I
I
I
FIGURE
I
6
1/8" N.P.T. Plu_
for Pressure Gauge
Manual Shut
OffValve
(hound Joint
Union
Gas Supply
Inlet
' (761rnn)Min.
FIGURE 7
STEP 2. ROUGH-IN
GAS SUPPLY (See Figure 7)
a)
Install a 1/2" gas supply line. The gas line will enter the heater from the 5" spacing between
back and the wall.
b)
the heater
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.RT. plugged tapping, accessible for test gauge connection and a individual
manual shut offvalve.
The furnace and its individual shut offvalve must be disconnected from the gas
supply piping
(3.5Pa). The
shut off valve
than 1/2 psig
system during any pressure testing of that system at test pressures in excess of 1/2 psig
furnace must be isolated from the gas supply piping system by closing its individual manual
during any pressure testing of the gas supply piping system at test pressures equal to or less
(3.5Pa).
Page 7
INSTALLATION
STEP 3
a)
b)
c)
d)
- CONTINUED
INSTALLING
VENT SYSTEM 5" - 32" WALL THICKNESS
(12.7 cm - 81.3 cm)
Use only factory supplied parts. Do not attempt to modi62 in any way. To do so could cause a system
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 8).
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 and condensation
to drain. Caulk around the edges of the vent cap mounting plate. NOTE: It may
be necessary to build a metal or wood frame to provide a flat surface for the mounting plate to be flush
against or to attain the 5" minimum wall thickness.
TRIMKITBRACI_TS
Vent Cap
CollectionBox__
Assembly
sselnbl
Vent Cap
Mounting
Plate
GAS INLET
(64 6 cm)
25-7//6"
(525
cm)
20 11/16"
"4
FLUE OUTLET
I
(/9 4 cm),
7 5/8"
1
FIGURE 9
m
m
m
irn
IW
d
i
Page 8
STEP 4. INSTALLING
a)
b)
c)
d)
e)
t)
HEATER
Screw wall brackets
to wall. Location
marked
with template.
(See Step la)
Screw trim kit brackets to back of heater. (See Figure 9).
Slide heater to within approximately
5" from wall.
Attach air intake hose to collector box outlet and burner box inlet with clamps provided. (See Figure 10).
Attach vent exhaust tube to exhaust pipe on collector box and draft inducer outlet on back of heater.
Secure with clamps provided.
(See Figure 10).
GAS CONNECTION.
Make gas connection between manual shut offvalve and furnace valve with
approved connectors.
Compounds used on threaded joints of gas piping shall be approved for use with
L.R gas. The gas lines must be checked for leaks by the installer with soapy water or liquid detergent,
never an open flame. If connections are not exposed, a pressure test must be run. Be sure to disconnect
the gas supply line from the appliance valve before pressure testing. The manifold pressure is pre-set at
the factory and should be 3.5" w.c. for Natural Gas and 10" w.c. for L.R gas. The minimum inlet
pressure for Natural Gas is 4.5" w.c. and 11" w.c. for L.R Gas, "for purpose of input adjustment".
The
maximum inlet pressure should never exceed 7.0" w.c. on Natural Gas or 14" w.c. on L.R Gas.
STEP 5. INSTALLING
a)
b)
c)
d)
e)
f)
g)
HEATER
REAR TRIM KIT
Secure right and left trim kit sides to the wall and trim kit brackets with eight #8 screws provided.
See
figure 11. The back of the heater should now be spaced 5" from the wall.
Remove the temperature sensing unit from the back of the heater. Save the nylon attachment clip and the
#8 screw.
Slide the temperature sensing unit through the 1/2" bushing located on the right trim kit side. Viewed from
the front of the heater.
Secure the temperature sensing unit to the outside of the right trim kit side using the nylon clip and #8
screw saved ti'om step B. Engagement hole provided.
Secure trim kit top panel to trim kit sides with tour #8 screws provided.
Plug power supply cord into a 115V grounded electrical outlet.
Turn the manual gas supply valve to the "on" position.
IS NOW
INSTALLED,
FOLLOW
LIGHTING
INSTRUCTIONS.
Trim Kit
Left Side
Trim Kit
(4)
FIGURE
11
Page 9
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING:
If you do not follow these instructions
causing property
damage,
• If you cannot reach your gas supplier, call
the fire department.
Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
C.
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.
B.
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.
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.
• hnmediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
Read the safety information
Set the thermostat
.
3.
4.
INSTRUCTIONS
above on
this label.
Do not use this appliance if any part has been
under water, hnmediately
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.
D.
OPERATING
STOP!
may result
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.
a.
exactly, a fire or explosion
5.
Remove front panel.
6.
Pull the gas control lever DOWN clockwise -+
to "OFF". Do not force.
Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you
smell gas, STOP! Follow "B" in the safety
information above on this label. If you don't
smell gas, go to the next step.
to lowest setting.
Turn off all electric power to the appliance.
This appliance does not have a pilot. It is
equipped with an ignition device which automatically lights the burner. Do not try to
light the burner by hand.
7.
8.
Push gas control lever UP counterclockwise
to "ON".
9.
Replace
front panel.
.F====I
knob shown
in"OFF"
11.
12.
Set thermostat to desired setting.
If the appliance will not operate, follow the
10.
instructions "To Turn Off Gas To Appliance"
and call your service technician or gas supplier.
Turn on all electric power to the appliance.
Gas
Inlet --
position
Gas control
TO TURN OFF GAS TO APPLIANCE
.
2.
.
Set the thermostat
to lowest setting.
Turn off all electric power to the appliance
if service is to be performed.
Remove front panel.
4.
5.
Page 10
Pull the gas control lever DOWN clockwise -+
to "OFF". Do not force.
Replace front panel.
PROPER
BURNER
FLAME
The burner flame may be observed by raising the sight
glass cover. A proper flame will have a dark blue inner
mantle, with a lighter blue outer mantle that extends from
the burner
into the heat exchanger tube, (see Figure 12).
There is no pmnary air adjustment on the burner, and proper
flame is assured since the correct manifold
ofificing has been done at the factory.
pressure
and
f
Primary Flame
/
C-Heat Exchanger Tube
TO
REMOVE
MAIN BURNER FOR INSPECTION AND CLEANING
Turn offall electrical
Turn offgas supply.
Remove front panel.
,
2.
3.
4.
5.
6.
,
NOTE:
NENTS
supply to heater.
Unplug wire to ignitor and sensor. (See Fig. 13.)
Disconnect vacuum hose from burner box.
Remove screws holding burner box top to burner
box. (See Figure 13.)
Remove burner plate and burner box top. Take
,
,
10.
11.
FIGURE
care not to contact, or strain lgmtor in any way
as it is extremely fragile. (See Figure 13.)
Remove 2 nuts holding burner bracket. (See
Figure 13).
Slide burners toward heat exchanger and lift up
from rear and back. (See Figure 13).
12
THE FURNACE AND ALL COMPOMUST BE INSPECTED
AT LEAST
ANNUALLY BY A QUALIFIED SERVICE PERSON.
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.
Clean or replace as needed.
Reinstall by reversing Steps 9 - 1.
_"
Burnei
Box
Top
BURNER
ORIFICE
_Mani_-
This appliance is orificed at the factory for elevations up to
2,000 ft. If installed above 2,000 ft., the BTU input must
be reduced 4% per 1,000 ft. See the following orifice chart
for the proper orifice for a specific elevation.
tbld
_V;acuulTl
Hose
SPECIFIC
MODEL
NO.
0 to
2,000'
HEDV403
45
ELEVATIONS
2000'
4,000'
NATURAL
47
4000'
6,000'
FIGURE
6000'
8,000'
8000'
10.000'
48
49
50
56
56
57
13
GAS
L.P. GAS
HEDV404
55
55
NOTE: If this heater is installed above an elevation of 8,000 feet, the Factory installed pressure switch may not
function properly. If you experience a problem with the pressure switch, contact a qualified service agency to
replace the factory installed pressure switch with a high altitude pressure switch P/N 72521. To order see your
local Cozy dealer or contact the factory.
Page 11
WIRING
This appliance is equipped with a three prong 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
FHIS IS A GAS-FIRED
APPLIANCE.
KEEP THt
AREA CLEAR OF GASOLINE AND OTHER FLAM
MABLE VAPORS AND LIQUIDS.
ALL COMBUS
FIBLE MATERIAL MUST BE KEPT CLEAR OF THI_
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 °C wire or its equivalent.
CAUTION:
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper and
dangerous operation.
Verity proper operation
after servicing.
Pressure
Switch
Circulating
Blower
Draft
Gas Valve
@]
Black
Blower
Inducer
Heat
Hmn
_._
Ignitor
Them_ostat
Sensor
115 VAC
Draft
Transformer
Transfl_rmer
Brown
Amp
_3
Thermostat
High
Limit
Black
©
24 VAC
Limit
Switch
Pressure
Switch
Gas
X_alve
MODEL
Page 12
HEDV
403,404
I
Sensor
Flmne
SEQUENCE
@F0
THERMOSTAT
CALLS FOR
HEAT
OF OPERATION
- HEDV403/4
@FX
Th_lmostat
is satisfied
F10
Sec
t 15
sec
F20
sec
F50
sec
FX
sec
tX+15
sec
FX÷120
sec
NO
STEP
#
STEP
l)
Thermostat
2}
3}
4)
5}
6)
7}
8)
Combustion
fan turns on.
Pressure switch closes.
malfunction
Power to Ignitor.
go into lockout
Ignitor warm up period.
Gas flow to burner.
This one hour mode can be bypassed
calls for heat.
Burner ignition proven.
Circulating blower on.
NOTE: If there is a malfunction
in any of the
above steps, the sequence
will stop at that point and
#
8) Continued...
return to Step 2. If after 3 attempts
by resetting
still occurs,
thermostat.
Thermostat satisfied.
Gas valve closes.
11)
Combustion
12)
Blower
Page 13
will
mode for one hour.
9)
10)
HEATER
furnace
fan off.
off.
NOW IN STAND-BY
MODE.
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 unsatis*actory performance.
CONTENTS OF KIT
1 only P/N 72532 21_x3'
,' Steel Coupling
1 only P/N 41520 Center Bracket
1 only P/N 72575 2,,x5, Black Flocked Tube
8 only P/N 72593 2" Hose Clamps
1 only P/N 72612 2 x6 Black Flex Tubing
1 only P/N 72578 2"x3" Black S_licone
2 only P/N 41515 Support Brackets _
Wrapped Coupling
STEP 1 - LOCATE VENT OPENING
a)
Select location on outside wall that vent wilt exit through.
b)
Check outside for p,roper 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.
_
Measure wall thickness. Mark and cut offboth intake and exhaust pipes to 1/2 beyond outside wall.
_)TEP 2 -Secure
collection
box to wall. Wall anchors, not provided, may be required.
INSTALL
HEATER
Using wall template supplied with heater, mark location for trim kit wall brackets.
Select
heater will
installed.may be required) and back of heater. Using screws provided on
Attach location
brackets on
to wall
wall where
(wall anchors,
not be
provided
back of heater.
d)
Slide heater into position and secure brackets togehter. This should position back of heater 5" offwall.
e)
Select direction vent will exit trim kit, left, right, or straight up.
t)
Before installing trim kit remove kalockout on this side.
STEP 3 - INSTALL VENT
}
al
Relnoveanddiscard,P/N72611
2"x24" black flex tubing tioln air inlet. (Save hgse clamp).
Attach P/N 72612 ,,2 x,6 black flex tubing to air inlet. S_cure 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 7-2610 orange silicone
90 elbo,a supplied ,aith heater. Secure ,alth 2 hose clamp7
d)
Attach P!N 41515 support brackets to wall. Wall anchors, not provided, may be required. Postion sup_grt brackets
within 8 from side of trim kit and end of pipe. Secure flex tubing and flocked tube to brackets using 2' hose
clamps.
e)
Attach P/N 41520 center bracket 2-1/2 from pipe end and insert flex tube through bracket. This will prevent the
flex tube tioln touching the black flocked exhaust robe.
t)
Connect flex air intake_mbe and flocked exhaust tube to collection box.
g)
Complete gas connection and attach trim kit to brackets.
h)
Follow ligl_ting instructions.
SPECIAL NOTES
a)
You may use up to three HEVK-5 Kits for a total of 15' vent extension with two additional elbows. DONOT
EXTEND VENT BEYOND 15 OR USE MORE THAN THREE TOTAL ELBOWS (one elbow is attached to
heater outlet).
cl
bl
Toyou
connect
two vent
2"x3" steel
coupling.you Secure
with 2"2 P/N
hose 72593hose
clamps.
If
are using
one, kits
two,together
or three use
kits,P/N
after72532
installation
is complete
will discard
one P/N 72532_steel co%ling.
_
d_
If complete
you need vent
to make
a 90 • otl_et
you willpipes
need may
to order
P/N HEEL-1
90' Elbow
Kit. any
Twocondensate
ofl;ets require
If
extension
is horizontal,
be sloped
down slightly
to allow
to two ldts.
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 HECK-1
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.
t)
PiN 72612
2"x6" Black
Flex Tubing
72532
e only if connecting
flex tubing of 2 or
_2_3 _
P 'BNlaTck57_i
•
Wrapped Coupling
lnore
151_/
Support
Brackets (2)
C 2Nr
ktis
/
,
_'J"
'4B15_Oe
t-_
Z/j
PiN 72575
Black
2"x5'
PiN 72593
2" Hose Clamps
Page 14
clamps and
.
HEVE-5
VENT
ENCLOSURE
INSTALLATION
HECK-1
KIT
CONDENSATE
INSTRUCTIONS
KIT
INSTRUCTIONS
STEP 1)Position end of Part No. 41610 enclosure body to
heater trim kit where pipes exit trim kit, centering
pipes inside body and attach to wall. Wall anchors,
not provided, may be required. Collector box may
be behind HEVE-5 Kit.
STEP 2)Cut to fit enclosure panel 1" beyond end of vent
ran. 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 Triln Kit where ends meet.
STEP 4)If making a 90 ° turn, measure 1" beyond outside
mm 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 walt and attach Part No.
72604 Trim Kit where two bodies meet. Install
STEP 1)Attach
screws
should
bottom
condensate trap to back of heater using 2 #8
provided, as shown below. End of trap
extend through back of heater and into
of condensate pan.
STEP 2)Remove and discard cap from bottom of draft
inducer drain tube.
STEP 3)Connect 1/4" plastic line from draft inducer drain
tube to condensate trap. Secure with 2 1/4" hose
clamps, provided.
STEP 4)Fill condensate pan with water.
WARNING:
Keep condensate pan filled with water.
The water provides a seal to prevent combustion products
from being pushed through the drain into the house.
BACK OF HEATER
end cap Part No. 41620.
Drain Tube
FromDraft
Inducer
_- -_xh--aust -__'!ii_ .....
_--
__.1
(;learTubing
-_>'_i_ Condensate
-n[_
Trap
Condensate trap empties through back
of heater into a condensate pan below
heat exchanger.
HEEL-1
90 ° ELBOW
Contains
KIT
1 only P/N 72613 90 ° Elbow 2"
Page 15
MAINTENANCE
INSTRUCTIONS
For proper and sate operation keep furnace and furnace area clean. At regular intervals turn control valve to otL 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 offfumes when furnace is turned
on.
Remove the blower filter from back of heater and clean as needed. Filter can be cleaned with garden hose, in bathtub,
sink, etc. Use only water or air to clean. DO NOT USE ANY CLEANING SOLUTION AS THEY COULD BE
FLAMMABLE
AND COULD CAUSE ODORS. Dry thoroughly and re-install. Do not operate heater without filter
in place.
Have the furnace checked, cleaned,
operation prior to use each year.
and repaired
Follow a regular service and maintenance
schedule
Do not obstruct combustion and ventilation
mance check on an annual basis.
If the heat exchanger
is any sign of damage.
is removed,
by a qualified
service person.
for sate and efficient
air. Examine
check the heat exchanger
the venting
system,
and burner
operation.
system as a routine part of the safety perfor-
intake gasket and draft inducer gasket and replace if there
Be sure all gaskets are in place when the heat exchanger
Failure to replace any gasket that has been damaged may result in property
Oil the bearings of the t:an motor every 6 months with S.A.E. 20 oil.
SERVICE
Check venting
RECORD
Page 16
is replaced.
damage, personal
injury or loss of life.
TROUBLE
SYMPTOM
Flame
too large
SHOOTING
POSSIBLE
i.
Defective
2. Bumer
operator
CAUSES
section
of valve,
orifice too large.
CHART
CORRECTIVE
i. Replace
2. Check
with local gas company
orifice
3. If installed
Yellow burner flame
i. Clogged
above
2,000
ft.
i. Remove
section,
burners
tions in throats,
Gas odor
Delayed Ignition
Failure
i.
around
vent cap.
Clean
-
1. See Pa_e 1.
located.
Main gas off.
Temperature
dial or thermostat
enough
and orifices.
ports or orifices.
2. Make sure area around vent cap is clear, be
sure vent svstem is sealed.
Gas leak.
I. Low gas pressure,
2. Igniter not peroperly
to ignite
Page 11.
and check for obstrucports,
but do not enlarge
Obstruction
for proper
- size and replace.
3. See burner orifice
burner ports,
ACTION
valve.
not set high
to call for heat.
i. Check
gas supply
2. Check
ignitor
necessa_.
i. Open all manual
2. Set temperature
higher
Clogged burner orifice.
4. Ineon'ect wiring.
5. Defective valve.
6. No power to unit.
4. Check
and con'ect
gas valves.
dial or themmstat
if
to
temperature.
3. Clean burner
3.
pressure.
location
orifices
(do not enlarge).
wiring diagram.
5. Replace valve.
6. Plug in power supply
cord.
Check
115 V.
wall 0ml_r,
Burner won't
mm off
Defective
or damaged
thermostat
wire,
or themlostat,
Thermostat
1. Can be checked
sensor
location
on back of heater.
2.Thermostat
sensor
to re-locate
Defective or sticking valve.
4. Excessive gas pressure.
Flefoetivenr_{nmnoecl
vonanr
gas
input
Not
enough
heat
wire from con-
If burner
attached
out of &afts,
goes oft', replace
to back of heater
hot, or cold spots.
3. R, _lace valve.
3.
Incon'ect
by removing
trol board terminal.
thermostat.
4. Contact utility supplying
q Renlm-e themanat_t
i. Gas input not checked,
2. (:logged orifices.
i. Re-check
i. Furnace
1. This is especially
gas input.
2. (;lean orifices
do not enlarge.
undersized.
gas.
with a smooth
wood
toothpick,
true when a dwelling
or
room is enlarged.
Have the heat loss
calculated and compare to A_rnace output.
Your gas company can supply you with this
information.
If furnace is undersized,
replace
Too much
heat
Main burner
goes out
duringnormal
operation
with con'ect
size unit.
Temperature
dial set too lox_:
3. Incon'ect supply pressure.
I. Temperature
dial set too high.
9 (_nmhinatinn
enntrnl valve _tuek nnen
2. Raise temperature
setting.
3. Check supply pressure.
i. Defective
flame sensor,
2. Input too high.
3. Cover around pilot lighter
i. Check voltage and replace
2. Check input rate.
2.
hole not air
tight.
Vent robes not properly installed or
sealed.
i. Lower temperature
setting.
9 Renlaee enmhinatinn
enntrnl
3. Tighten
wing nuts securing
cover and sight
air intake tubes, and vent cap. Be sure all
gaskets are in place and properly sealed. Use
and vent cap supplied.
alter vent tubes
5. Clean air filter.
6. Remove
Do not
or cap.
obstruction.
accumulation
Page 17
if low.
glass. Check and replace gasket if needed.
4. Follow instructions.
Check both exhaust and
only mbes
5. Limit switch opens.
6. Exhaust or Air Intake robes blocked.
valve
around
Check
for snow
vent cap.
TROUBLE
To improve
diagnosing
SHOOTING
and servicing,
green status light (see wiring
CONTROL
BOARD
this control board is equipped
diagram).
To indicate
with a self diagnosing
stand by mode and proper
operation
this light will remain on. If there should be a malfunction,
the light will flash a varying
number of times with a pause between each series of flashes. The number of flashes will
indicate the circuit to check.
# of
Reason
Possible Causes
for Indication
Corrective
Action
Flashes
1
Failed
ignition
Hot Surface
attempts
I_nitor:
Hot Surface
a) Broken
This puts heater into one hour
lockout mode. This one hour
b) Loose
lockout
can be bypassed
No Gas to Burner:
No Gas to Burner:
resetting
the thermostat.
a)
b)
c)
d)
a) Tum to "ON"
b) Open gas supply
by
a) Replace
or damaged
wire.
Valve in "OFF" position.
Gas supply turued OFF.
Loose or damaged wire to valve.
Defective or dirty flame sensor.
Pressure
switch
stuck closed
Defective
Pressure
switch
failed
a) Vacuum hose disconnected
b) Defective switch.
to close
b)
switch.
switch
circuit
Gas valve energized
call for heat
6
Polarity
reversal
open
with no
or replace
wire
valve.
c) Connect
or replace
d) Replace
or clean
wire.
sensor.
or damged.
a) Reconnect
or replace
vacuum
b) Replace
c) Connect
switch.
or replace
d) Remove
obstruction.
a) Defective limit switch.
a) Replace
limit switch.
b) Disconnected
b) Replace
or connect
d)
Limit
Connect
Replace switch.
c) Wire disconnected or damaged.
very
rapid
I_nitor:
(3 times)
Obstruction in vent pipe.
or damaged wire.
wire reversed
electrical
in junction
Page 18
wire.
wire.
a) Replace gas valve.
b) Replace sensor.
c) Replace sensor wire.
a) Defective gas valve.
b) Sensor defective.
c) Short in sensor wire.
a) Hot and neutral
hose.
supply
box.
a) Unplug
socket.
switch
supply
cord from wall
Open junction box and
the hot and neutral wires.
MODEL
NUMBERS
HEDV403
- NAT. GAS
HEDV404
- L.P. GAS
HI-EFFICIENT DIRECT VENT
WALL FURNACE
Prices and specifications
to change without
subj ect
notice.
All prices are F.O.B. factory.
Mr. Contractm; we only sell parts through our wholesalers, but the prices listed are f_r your convenience. For prompt parts
service, contact the wholesaler fiom which you purchased your Cozy heater. NOTE: Parts & schematic drawings on current
models are shown at _vw.cozyheaters.com.
Page 19
HOW TO PROPERLY ORDER PARTS: In addition to part description and part nulnber, please give model nulnber, serial
nmnber, and type of gas used. This inforlnation can be found on the rating plate that is attached to heater.
Model
Number
HEDV403
REF.
PART DESCRIPTION
Bottom Louver Panel
Center Front Panel
NO.
1
2
Upper Front Panel
Left Side Panel Insulation
Cabinet Side Panel
3
4
5
Circulating Blower Assembly
Limit Switch
6
7
Front Heat Shield Assy.
Heat Exchanger Assembly
Cabinet Base Assembly
Leg Leveler (4 per unit)
Draft Inducer Gasket
8
9
!0
11
12
Draft Inducer Assembly
Sight Glass Frame
Sight Glass
Flame Sensor
13
14
15
16
Sight Glass Gasket
Ignitor
Burner Orifice (2 per unit)
Manifold
Burner Box
17
18
19
20
21
Burner Box Top Gasket
Burner Box Top
Gas Valve
Gas Valve Bracket
22
23
24
25
Burner Box Mounting Gasket
Transformer
Control Board
26
27
28
Wiring Harness
Pressure Switch
29
30
Casing Back Assy.
Thermostat
Control Knob
Fresh Air Intake Hose
3!
32
33
34
2" Hose Clamp (4 per unit)
Vent Cap Assembly
Vent Cap Gasket
Collector Box Assembly
Collector Box Gasket
35
36
37
38
39
Collector Box Cap
Exhaust Tube
40
4!
Trim Kit Bracket (4 per unit)
Wall Mounting Bracket (4 per unit)
Casing Top Assy.
Trim Kit Left Side Panel
42
43
44
45
Trim Kit Top
Trim Kit Right Side Panei
Air Filter
46
47
48
Burner (2 per unit)
Burner Mounting Bracket
End Cap, Left Side
End Cap, Right Side
Wire Bracket, HEDV
49
50
51
52
53
Ignitor Bracket, HEDV
54
HEDV404
LIST
PART NO.
72690
41080
72691
72665
41085
72500
80091
41165
72530
41100
80009
72602
72505
41215
70150
72570
72600
72550
72156
72640
41185
72606
41210
72540
41220
72605
78069
72510
72685
72520
41120
72523
72633
72611
72593
41300
72608
41230
72607
72587
72610
41275
41270
41050
41262
41255
41260
72615
72533
72534
72692
72693
41217
41212
PRICE
$37.50
$36.60
$37.50
$1.90
$23.00
$229.30
$9.30
$26.00
$126.80
$60.00
$1.50
$11.70
$135.70
$1.60
$1.20
$10.60
$2.10
$21.10
$3.40
$!8.80
$30.90
$5.90
$5.00
$77.30
$5.00
$5.90
$23.50
$!16.90
$18.80
$28.10
$48.50
$72.70
$4.40
$9.80
$1.70
$60.20
$1.90
$239.30
$1.20
$1.50
$173.10
$7.50
$2.00
$105.30
$22.70
$27.10
$22.70
$25.80
$9.20
$5.90
$16.40
$16.40
$2.60
$2.50
LIST
PART
NO.
PRICE
72690
41080
72691
72665
41085
72500
$37.50
$36.60
$37.50
$1.90
$23.00
229.30
80091
41165
72530
$9.30
$26.00
126.80
41100
80009
72602
72505
$60.00
$1.50
$11.70
135.70
41215
70150
72570
72600
72550
72139
72640
41185
72606
41210
72541
41220
72605
78069
72510
$1.60
$1.20
$10.60
$2.10
$21.10
$3.40
$18.80
$30.90
$5.90
$5.00
$77.30
$5.00
$5.90
$23.50
;116.90
72685
72520
41120
72523
72633
72611
72593
41300
72608
41230
$18.80
$28.10
$48.50
$72.70
$4.40
$9.80
$1.70
$60.20
$1.90
239.30
72607
72587
72610
$1.20
$1.50
173.10
41275
41270
41050
$7.50
$2.00
105.30
41262
41255
41260
72615
72533
72534
72692
72693
41217
41212
$22.70
$27.!0
$22.70
$25.80
$9.20
$5.90
$16.40
$16.40
$2.60
$2.50
Ml: Contractm;
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. NO]E:
Parts & schematic drawings on
current models are shown at w_v.cozyheaters.com
Page 20
MARCH
2005
IMPORTANT
SAFETY
BULLETIN
SYSTEM
WHAT
ON YOUR
FOR
YOU
HEATING
DON'T
KNOW
GAS
CONTROL
AND
PILOT
LIGHT
EQUIPMENT
CAN
HURT
YOU.
Your pilot light system has been designed for safe and reliable operation. Although safety mechanisms are built-in, the
potential for hazard exists. This information is intended to help you avoid these hazards.
YOUR
GAS
CONTROL
AND
PILOT
LIGHT
SYSTEM
Your gas control
device
whose
and pilot light system
purpose
to the appliance
have
trouble
may
mean
that
there
if the pilot
lighting
that
light
the pilot
this safety
and
repairs
by a trained
If you
or keeping
it lit, it
is warning
with
your
•
you
must
be
•
technician.
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
instructions.
system.
or replacement
gas service
•
•
the gas supply
goes out.
device
is a problem
Inspection
made
is to shut-off
WHAT TO DO IF YOU SMELL
has a safety
If you cannot
department.
phone.
reach
Follow
the
gas
your gas supplier,
[nstallation
and service
qualified installer, service
supplier's
call the fire
must be performed
by a
agency or the gas supplier.
Do not store or use gasoline or other flammable
vapors
and liquids in the vicinity of this or any other appliance.
TAMPERING
The
pilot
safety
do not follow
system
the
or if you tamper
particularly
with
mechanism
in the
damage,
IF YOU
also not work
instructions
the gas control
Tampering
This can result
property
may
lighting
with
to light the pilot.
leak.
IS DANGEROUS
SMELL
tools,
control
that
IS NOT
CRITICAL
•
you use
with the gas control,
can
damage
and
can
the
personal
injury
GAS,
DON'T
safety
allow
in a fire or explosion
gas
•
to
SAFETY
POINTS
Your gas has been odorized
TO REMEMBER...
so that you can smell
it. Always smell around for gas before lighting your
appliance.
Sniff for L.P.-gas at floor level. LP-gas is heavier
than air and may temporarily
exist at floor level.
causing
or death.
LIGHT
IF YOU CAN'T LIGHT IT,
DON'T FIGHT IT!
THIS
if you
carefully
IT
•
If you smell gas, do not attempt to light the pilot.
Do not cause a spark by turning on or off electrical
switches or appliances or by using the phone. Turn
off the gas to the appliances
and call your gas
supplier from another location.
•
If your gas control has gotten
flooding or other wetting,
it
immediately
by a trained gas
Water can lead to damage of
mechanism
in the gas control
hazardous
condition.
AN ADVERTISEMENT
Page 21
wet as the result of
must be replaced
service technician.
the internal
safeD T
and can create a
LIIN TIIIIWAIit AI1T$
The Louisville
original
user
specified
herein,
operated,
Tin & Stove
the accompanying
provided
maintained,
Co. warrants
product
said
serviced,
to the
for the period
product
is installed,
and used according
to the
instructions
and specifications
accompanying
the product.
AS OUTLINED
IN OUR INSTRUCTIONS,
ANY
WARRANTY
CONSIDERATIONS
ARE
CONTINGENT
ON
INSTALLATION
BY
Q[ ALIFIED
INSTALLER
(CONTRACTOR).
INSTALLATION
IS NOT RECOMMENDED
MY INVALIDATE
YO[R
If within
a period
installation
_ARRANTY.
of one year from the date of
of the product,
manufacturer
proves
A
SELFAND
any part
to be defective
supplied
by the
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 wan'anty
is covered
in Table A below.
ten (10) days
after
shall be deemed
not made
of the warranty
within
period
by the user.
The manufiacturer
shall have no liability or be
to perform
any obligation
under this wan'anty
required
unless,
the expiration
waived
for the heat exchanger
Any claim
when
expense,
requested,
the user
the component
returns,
or product
at the user's
claimed
defective,
to
the manufiacturer
for inspection, to enable the manufacturer
to determine
if the claimed
defect is covered
by this
warranty.
No charges
incurred
product
for freight,
in the repair,
or component
labor or other expenses
removal,
claimed
or replacement
to be defective,
of any
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
Service
in the product.
under
this warranty
is the responsibility
of the installer.
In the event service under this warranty is
needed, the user of the product shall request such service
directly
from the installer.
If the user is unable
the installer, the user should write directly to the
manufacturer, and the name of an alternative service source
will be supplied.
The product safety registration card (packed
inside the appliance) must be completed and returned to
the factory.
THIS WARRANTY IS EXPRESSLY IN LIEU
OF ANY OTHER WARRANTIES,
EXPRESS OR
IMPLIED (WHETHER WRITTEN OR ORAL). ANY
IMPLIED WARRANTY OF MERCHANTABILITY
OR
OF FITNESS FOR A PARTICULAR
PURPOSE IS
EXPRESSLY LIMITED TO THE DURATION OF THE
MANUFACTURER'S
EXPRESS,
WRITTEN
WARRANTY.
UNDER NO CIRCUMSTANCES SHALL THE
MANUFACTURER BE LIABLE FOR ANY SPECIAL,
INDIRECT OR CONSEQUENTIAL
DAMANGES OR
EXPENSES ARISING DIRECTLY OR INDIRECTLY
FROM ANY COMPONENT
OR FROM THE USE
THEREOF.
THE REMEDIES SET FORTH HEREIN
SHALL BE THE EXCLUSIVE REMEDIES AVAILABLE
TO THE USER AND ARE IN LIEU OF ALL OTHER
REMEDIES.
SOME
STATES
DO
NOT
ALLOW
LIMITATIONS
ON HOW LONG AN IMPLIED
WARRANTY LASTS, SO THE ABOVE LIMITATIONS
MAY NOT APLY TO YOU.
SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL
DAMAGES,
SO THE ABOVE
LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO
YOU.
THIS WARRANTY GIVES YOU SPECIFIC
LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER
RIGHTS, WHICH VARY, FROM STATE TO STATE.
to locate
TABLE A
Warranty for gas appliance heat exchangers only.
Product
Cozy
Cozy
Cozy
Cozy
Cozy
Cozy
Cozy
Cozy
Gas
Gas
Gas
Gas
Gas
Gas
Gas
Gas
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Floor Furnace
Wall Furnace
Vented Console Heater
Direct Vent Heater
Counterflow Furnace
Counterflow Direct Vent Furnace
Mobile Home Direct Vent Furnace
Hi-Efficient Direct Vent Wall Furnace
LOUISVILLE
RO. Box 2767
TIN AND STOVE
Wananty Period
10 Years
10 Years
10 Years
10 Years
10 Years
10 Years
10 Years
10 Years
COMPANY
Louisville, Kentucky 40201-2767