HI-EFFICIENT DIRECT

VENT WALL FURNACE

R

INSTALLATION AND

OPERATING INSTRUCTIONS

P/N 72903 / December 2006

R

MODEL NUMBERS

NAT. GAS L.P. GAS

HEDV403 HEDV404

INSTALLER: Leave this manual with the appliance.

CONSUMER: Retain this manual for future reference.

WARNING: If the information in these instructions 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.

vapors and liquids in the vicinity of this or any

Do not try to light any appliance.

- WHAT TO DO IF YOU SMELL GAS: phone in your building.

•

•

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.

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 in greenhouses, or environments involving dusty, wet, corrosive, or explosive conditions. Such conditions will invalidate the warranty and may create unsafe conditions.

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……………………………..

Clearances……………………………….

3

4/5

Location…………………………………

Installation………………………………

Lighting Instructions……………………

Pilot Adjustment………………………..

Burner Orifice…………………………..

6

7

10

11

11

CONTENTS

Wiring Diagram…………………………

Removing Main Burner…………………

Proper Burner Flame……………………

Sequence of Operation………………….

Optional Kits……………………………

Trouble Shooting……………………….

Parts Drawing…………………………..

Parts List………………………………..

Warranty………………………………..

14

17

19

20

22

12

11

11

13

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 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.

MODEL

NO.

HEDV403

HEDV404

INPUT

BTU/HR.

40,000

40,000

WIDTH DEPTH HEIGHT

34-1/2” 9” 30”

34-1/2” 9” 30”

GAS T Y P E MAX. WALL

CONN.

GAS Thickness

1/2” Nat.

32”

1/2” L.P.

32”

MIN. WALL

Thickness

5”

5”

Page 2

22.

23.

24.

16.

17.

18.

1.

2.

3.

12.

13.

14.

15.

8.

9.

10.

11.

4.

5.

6.

7.

19.

20.

21.

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 and may void the warranty.

Follow all applicable codes and ordinances. 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.

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. 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 wall furnace should be located out of traffic and away from furniture and drapes.

Children and adults should be alerted to the hazard of high surface temperature and should be kept away to 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

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.

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. In Canada, use

CSA C22.1.

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. 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.

This appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance.

Page 3

Vent Terminal

Air Supply Inlet Area where terminal is not permitted

VENT TERMINAL CLEARANCES

REFERENCE LETTER TO

DRAWING

CANADIAN

INSTALLATIONS¹

U.S. INSTALLATIONS²

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

12 Inches (30 cm)

12 Inches (30 cm)

12 Inches (30 cm)

18 Inches (46 cm)

12 Inches (30 cm)

9 Inches (23 cm)

9 Inches (23 cm)

18 Inches (46 cm)

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

18 Inches (46 cm)

12 Inches (30 cm)

12 Inches (30 cm)

3 Feet (91 cm) within a height

15 Feet (4.5m) above the meter/regulator assembly

3 Feet (91 cm)

18 Inches (46 cm)

12 Inches (30 cm)

12 Inches (30 cm)

Clearance in accordance with local installation codes and the requirements of the gas supplier

Clearance in accordance with local installation codes and the requirements of the gas supplier

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

M = Clearance under veranda, porch, deck, or balcony

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.

12 Inches (30 cm) permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides.

12 Inches (30 cm)

3 Feet (91 cm) above if within

10 Feet (3 m) horizontally

Clearance in accordance with local installation codes and the requirements of the gas supplier.

Clearance in accordance with local installation codes and the requirements of the gas 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

1.

2.

3.

4.

5.

6.

CLEARANCES

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 furnace 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 corner of building is 12”. (See Figure 5).

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 5). Do not install vent cap in a window well. Provisions must be made to prevent snow accumulation from infringing on vent cap clearances.

Ceiling or Overhang

10” (25.4 cm)

Side W

1” (2.54 cm)

FIGURE 1 FIGURE 2 FIGURE 3

Page 5

FIGURE 5

7.

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 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 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. 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

Page 6

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) where hole can be cut and to locate the wall brackets.

Locate studs on each side of this area.

d) e)

Mark location for 3-1/2” diameter hole between studs. Hole should be offset to miss studs. (See Figure 6).

Check outside wall at this location for proper clearances around vent cap.

Cut vent openings into both the inside and outside walls, being sure to maintain level across both openings.

Template

Shaded

Area

Wall

Studs

16” O.C.

FIGURE 6

Manual Shut

Off Valve

1/8” N.P.T. Plugged Hole for Pressure Gauge

Gas

Valve

Gas Supply

Inlet

Ground Joint

Union

3” (76mm) 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 the heater back and the wall.

b) 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 a individual manual shut off valve. The furnace 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 furnace 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).

Page 7

INSTALLATION - CONTINUED

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) c) d) 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.

Collection Box

Assembly

Vent Cap

Assembly

BRACKETS

Vent Cap

Mounting

Plate

FIGURE 9

Page 8

c) d) e)

STEP 4. INSTALLING HEATER a) b)

Screw wall brackets to wall. Location marked with template. (See Step 1a)

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).

f)

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 off valve and furnace valve with approved connectors. Compounds used on threaded joints of gas piping shall be approved for use with

L.P. 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.P. gas. The minimum inlet pressure for Natural Gas is 4.5” w.c. and 11” w.c. for L.P. 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.P. Gas.

e) f) g)

STEP 5. INSTALLING REAR TRIM KIT a) b)

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 c) d)

#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 from step B. Engagement hole provided.

Secure trim kit top panel to trim kit sides with four #8 screws provided.

Plug power supply cord into a 115V grounded electrical outlet.

Turn the manual gas supply valve to the “on” position.

HEATER IS NOW INSTALLED, FOLLOW LIGHTING INSTRUCTIONS.

Trim Kit Top

Temperature Sensing Unit

Trim Kit

Right Side

1/2” Bushing

Trim Kit

Bracket (4)

FIGURE 11

Trim Kit

Left Side

Page 9

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.

A.

B.

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.

C.

D.

• If you cannot reach your gas supplier, call

the fire department.

Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

1.

2.

3.

4.

Gas

Inlet

OPERATING INSTRUCTIONS

STOP! Read the safety information above on 5.

this label.

Set the thermostat 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.

6.

7.

8.

Gas control knob shown in “OFF” position

9.

10.

11.

12.

Remove front panel.

Pull the gas control lever DOWN clockwise

6

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.

Push gas control lever UP counterclockwise

7

to “ON”.

Replace front panel.

Turn on all electric power to the appliance.

Set thermostat to desired setting.

If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

1.

2.

3.

TO TURN OFF GAS TO APPLIANCE

Set the thermostat to lowest setting.

4.

Pull the gas control lever DOWN clockwise

6

Turn off all electric power to the appliance to “OFF”. Do not force.

if service is to be performed.

Remove front panel.

5.

Replace front panel.

Page 10

PROPER BURNER FLAME

Primary 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 primary air adjustment on the burner, and proper flame is assured since the correct manifold pressure and orificing has been done at the factory.

Burner

TO REMOVE MAIN BURNER FOR INSPEC-

TION AND CLEANING

Secondary Flame

Heat Exchanger Tube

FIGURE 12

1.

2.

3.

4.

5.

6.

7.

8.

9.

Turn off all electrical supply to heater.

Turn off gas supply.

Remove front panel.

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 care not to contact, or strain ignitor 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).

Clean or replace as needed.

Reinstall by reversing Steps 9 - 1.

NOTE: THE FURNACE AND ALL COMPO-

NENTS MUST BE INSPECTED AT LEAST

ANNUALLY BY A QUALIFIED SERVICE PER-

SON. 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.

Valve

10.

11.

BURNER ORIFICE

Burner

Box

Plate

Sensor

Burner

Burner

Box

Top

Manifold

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.

Nut

Burner Bracket

Ignitor

Vacuum

Hose

MODEL

NO.

HEDV403

HEDV404

SPECIFIC ELEVATIONS

0 to 2,000’ 4,000’ 6,000’ 8,000’ -

2,000’ 4,000’ 6,000’ 8,000’ 10,000’

4 5

5 5

NATURAL GAS

4 7 4 8

L.P. GAS

5 5 5 6

4 9

5 6

5 0

5 7

FIGURE 13

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

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

EC 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

Circulating

Blower

Draft

Inducer

Ignitor

Flame

Sensor

115 VAC

Primary

Transformer

3 Amp

Fuse

Secondary

24 VAC

Black

Black

Yellow

Yellow

White

Red

Thermostat

Black

White

Green

Transformer

24 VAC

White

Black

W

C

R

Y

Yellow

Yellow

Gas Valve

XFMR

L 1

EAC/LSPD

Heat

Hum

M 1

M 2

Black

White

Circulating

Blower

High

Limit

Neutrals

White

Draft

Inducer

Flame

Sensor

White

Brown

Thermostat Limit Pressure Gas

Switch Switch Valve

MODEL HEDV 403, 404

Page 12

@t=0

THERMOSTAT

CALLS FOR

HEAT

Power to

Combust.

Fan

10 SEC

PURGE

NO

Three

Attempts

Made?

YES

Fan

Proved

YES

SEQUENCE OF OPERATION - HEDV403/4

t=10 sec.

Power to

Ignitor t=15 sec.

Gas

Flow

t=20 sec.

IGNITION

PROVED?

YES t=50 sec.

Blower

On

@t=X

Thermostat is satisfied t=x sec.

Burners

Off

t=X+15 sec.

Combust.

Fan Off

NO

NO

NO

Lockout

YES

Three

Attempts

Made?

10 SEC

PURGE t=X+120 sec.

Blower

Off

STEP #

1) Thermostat calls for heat.

2) Combustion fan turns on.

3) Pressure switch closes.

4) Power to Ignitor.

5) Ignitor warm up period.

6) Gas flow to burner.

7) Burner ignition proven.

8) Circulating blower on.

NOTE: If there is a malfunction in any of the above steps, the sequence will stop at that point and

STEP #

8) Continued...

return to Step 2. If after 3 attempts malfunction still occurs, furnace will go into lockout mode for one hour.

This one hour mode can be bypassed by resetting thermostat.

9) Thermostat satisfied.

10) Gas valve closes.

11) Combustion fan off.

12) Blower off.

HEATER NOW IN STAND-BY MODE.

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.

a) b) c)

1 only P/N 72532 2”x3” Steel Coupling

1 only P/N 72575 2”x5’ Black Flocked Tube

1 only P/N 72612 2”x6’ Black Flex Tubing

2 only 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.

Check outside for proper clearances around vent cap. See installation instructions.

b) c) d) e)

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 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) b) c)

Select location on wall where heater will be installed.

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 back of heater.

d) e)

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.

f) Before installing trim kit remove knockout on this side.

STEP 3 - INSTALL VENT

d) e)

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

90

E elbow supplied with heater. Secure with 2” hose clamp.

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 f) g) h) a) 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

b) c) d) e) f)

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 is attached to heater outlet).

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.

If you need to make a 90

E 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 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.

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

HECK-1

CONDENSATE 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 1) Attach condensate trap to back of heater using 2 #8 screws provided, as shown below. End of trap should extend through back of heater and into bottom of condensate pan.

STEP 2) Remove and discard cap from bottom of draft inducer drain tube.

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.

STEP 3) Connect 1/4” plastic line from draft inducer drain tube to condensate trap. Secure with 2 1/4” hose clamps, 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 90

E 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.

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

Drain Tube

From Draft

Inducer

Exhaust

1/4” Clear Tubing

Condensate

Trap

Condensate trap empties through back of heater into a condensate pan below heat exchanger.

HEEL-1

90

EEEEE ELBOW KIT

Contains 1 only P/N 72613 90

///// Elbow 2”

Page 15

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.

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, and repaired by a qualified service person. 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 16

SYMPTOM

Flame too large

Yellow burner flame

Gas odor

Delayed Ignition

Failure to ignite

Burner won’t

turn off

Incorrect gas

input

Not enough heat

Too much heat

Main burner

goes out

during normal

operation

TROUBLE SHOOTING CHART

POSSIBLE CAUSES

1. Defective operator section of valve.

2. Burner orifice too large.

CORRECTIVE ACTION

1. Replace valve.

2. Check with local gas company for proper

orifice - size and replace.

3. See burner orifice section, Page 11.

3. If installed above 2,000 ft.

1. Clogged burner ports.

2. Obstruction around vent cap.

1. Gas leak.

1. Low gas pressure.

2. Igniter not peroperly located.

1. Main gas off.

2. Temperature dial or 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 sensor location on back of heater.

3. Defective or sticking valve.

4. Excessive gas pressure.

5. Defective or damaged sensor.

1. Gas input not checked.

2. Clogged orifices.

1. Furnace undersized.

2. Temperature dial set too low.

3. Incorrect supply pressure.

1. Temperature dial 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 all manual gas valves.

2. Set temperature dial or 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.Thermostat sensor attached to back of heater

to 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 temperature setting.

3. Check supply pressure.

1. Lower temperature setting.

2. Replace combination control valve.

1. Defective flame sensor.

2. Input too high.

3. Cover around pilot lighter hole 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 wing nuts securing cover and 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. Clean air filter.

6. Remove obstruction. Check for snow

accumulation around vent cap.

Page 17

TROUBLE SHOOTING CONTROL BOARD

To improve diagnosing and servicing, this control board is equipped with a self diagnosing green status light (see wiring diagram). To indicate 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 for Indication

Flashes

1 Failed ignition attempts

(3 times)

This puts heater into one hour lockout mode. This one hour lockout can be bypassed by resetting the thermostat.

Possible Causes

Hot Surface Ignitor: a) Broken b) Loose or damaged wire.

No Gas to Burner: a) Valve in “OFF” position.

b) Gas supply turned OFF.

c) Loose or damaged wire to valve.

d) Defective or dirty flame sensor.

Corrective Action

Hot Surface Ignitor: a) Replace b) Connect or replace wire

No Gas to Burner: a) Turn to “ON” b) Open gas supply valve.

c) Connect or replace wire.

d) Replace or clean sensor.

2

3

Pressure switch stuck closed

Pressure switch failed to close

4 Limit switch circuit open

5 Gas valve energized with no call for heat

6

very

rapid

Polarity reversal

Defective switch.

a) Vacuum hose disconnected or damged.

b) Defective switch.

c) Wire disconnected or damaged.

d) Obstruction in vent pipe.

a) Defective limit switch.

b) Disconnected or damaged wire.

a) Defective gas valve.

b) Sensor defective.

c) Short in sensor wire.

a) Hot and neutral electrical supply

wire reversed in junction box.

Replace switch.

a) Reconnect or replace vacuum hose.

b) Replace switch.

c) Connect or replace wire.

d) Remove obstruction.

a) Replace limit switch.

b) Replace or connect wire.

a) Replace gas valve.

b) Replace sensor.

c) Replace sensor wire.

a) Unplug supply cord from wall

socket. Open junction box and

switch the hot and neutral wires.

Page 18

1

MODEL NUMBERS

HEDV403 - NAT. GAS

HEDV404 - L.P. GAS

2

3

5

4

HI-EFFICIENT DIRECT VENT

WALL FURNACE

Prices and specifications subject to change without notice.

All prices are F.O.B. factory.

51

6

45

44

7

46

8

34

37

52

48

33

43

35

41

40

39

38

29

32

28

30

31

42

47

27

50

26

24

25

53

23

22

21

49

20

9

10

11

12

13

14

15 16

17

54

19

5

18

36

Mr. Contractor, we only sell parts through our wholesalers, but the prices listed are for your convenience. For prompt parts service, contact the wholesaler from which you purchased your Cozy heater. NOTE: Parts & schematic drawings on current models are shown at www.cozyheaters.com.

Page 19

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 DESCRIPTION

Bottom Louver Panel

Center Front Panel

Upper Front Panel

Left Side Panel Ins ulation

Cabinet Side Panel

Circulating Blower As s em bly

Lim it Switch

Front Heat Shield As s y.

Heat Exchanger As s em bly

Cabinet Bas e As s em bly

Leg Leveler (4 per unit)

Draft Inducer Gas ket

Draft Inducer As s em bly

Sight Glas s Fram e

Sight Glas s

Flam e Sens or

Sight Glas s Gas ket

Ignitor

Burner Orifice (2 per unit)

Manifold

Burner Box

Burner Box Top Gas ket

Burner Box Top

Gas Valve

Gas Valve Bracket

Burner Box Mounting Gas ket

Trans form er

Control Board

Wiring Harnes s

Pres s ure Switch

Cas ing Back As s y.

Therm os tat

Control Knob

Fres h Air Intake Hos e

2" Hos e Clam p (4 per unit)

Vent Cap As s em bly

Vent Cap Gas ket

Collector Box As s em bly

Collector Box Gas ket

Collector Box Cap

Exhaus t Tube

Trim Kit Bracket (4 per unit)

Wall Mounting Bracket (4 per unit)

Cas ing Top As s y.

Trim Kit Left Side Panel

Trim Kit Top

Trim Kit Right Side Panel

Air Filter

Burner (2 per unit)

Burner Mounting Bracket

End Cap, Left Side

End Cap, Right Side

Wire Bracket, HEDV

Ignitor Bracket, HEDV

42

43

44

45

46

47

48

34

35

36

37

38

39

40

41

49

50

51

52

53

54

27

28

29

30

31

32

33

22

23

24

25

26

17

18

19

20

21

REF.

NO.

12

13

14

15

16

9

10

7

8

11

4

5

6

1

2

3

72611

72593

41300

72608

41230

72607

72587

72610

41275

41270

41050

41262

41255

41260

72615

72533

72534

72692

72693

41217

41212

72600

72550

72156

72640

41185

72606

41210

72540

41220

72605

78069

72510

72685

72520

41120

72523

72633

HEDV403

PART NO.

72690

LIST

PRICE

$ 41.80

41080

72691

72665

41085

72500

$

$

$

$

40.70

41.80

$ 2.10

25.70

255.20

80091

41165

72530

41100

80009

72602

72505

41215

70150

72570

$

$

$ 141.10

$

$

$

$

10.40

28.90

66.80

$

$

1.70

13.00

151.10

$ 1.80

1.40

11.80

$ 2.30

$ 23.50

$ 3.80

$ 20.90

$ 34.30

$ 6.60

$ 5.60

$ 86.10

$ 5.60

$ 6.60

$ 26.20

$ 130.10

$ 20.90

$ 31.30

$ 54.00

$ 80.90

$ 4.90

$ 10.90

$ 1.90

$ 67.00

$ 2.10

$ 266.40

$ 1.40

$ 1.70

$ 192.70

$ 8.40

$ 2.20

$ 117.20

$ 25.20

$ 30.20

$ 25.20

$ 28.70

$ 10.30

$ 6.60

$ 18.20

$ 18.20

$ 2.90

$ 2.80

72611

72593

41300

72608

41230

72607

72587

72610

41275

41270

41050

41262

41255

41260

72615

72533

72534

72692

72693

41217

41212

72600

72550

72139

72640

41185

72606

41210

72541

41220

72605

78069

72510

72685

72520

41120

72523

72633

HEDV404

PART NO.

72690

LIST

PRICE

$ 41.80

41080

72691

72665

41085

72500

$

$

$

$

40.70

41.80

$ 2.10

25.70

255.20

80091

41165

72530

41100

80009

72602

72505

41215

70150

72570

$

$

$ 141.10

$

$

$

$

10.40

28.90

66.80

$

$

1.70

13.00

151.10

$ 1.80

1.40

11.80

$ 2.30

$ 23.50

$ 3.80

$ 20.90

$ 34.30

$ 6.60

$ 5.60

$ 86.10

$ 5.60

$ 6.60

$ 26.20

$ 130.10

$ 20.90

$ 31.30

$ 54.00

$ 80.90

$ 4.90

$ 10.90

$ 1.90

$ 67.00

$ 2.10

$ 266.40

$ 1.40

$ 1.70

$ 192.70

$ 8.40

$ 2.20

$ 117.20

$ 25.20

$ 30.20

$ 25.20

$ 28.70

$ 10.30

$ 6.60

$ 18.20

$ 18.20

$ 2.90

$ 2.80

Mr. Contractor, we only s ell parts through our wholes alers , but the prices lis ted above are for your convenience. For prom pt parts s ervice, contact the wholes aler from which you purchas ed your Cozy heater.

NOTE: Parts & s chem atic drawings on current m odels are s hown at w w w .cozyheaters.com

.

Page 20

MARCH 2009

IMPORTANT SAFETY BULLETIN ON YOUR GAS CONTROL AND PILOT LIGHT

SYSTEM FOR HEATING EQUIPMENT

WHAT YOU DON’T KNOW CAN HURT YOU.

Your pilot light system has been designed for safe and reliable operation. Although safety mechanisms are built-in, the potential for hazard exists. This information is intended to help you avoid these hazards.

YOUR GAS CONTROL AND PILOT LIGHT

SYSTEM

Your gas control and pilot light system has a safety device whose purpose is to shut-off the gas supply to the appliance if the pilot light goes out. If you have trouble lighting the pilot or keeping it lit, it may mean that this safety device is warning you that there is a problem with your system.

Inspection and repairs or replacement must be made by a trained gas service technician.

WHAT TO DO IF YOU SMELL GAS . . .

••••• Do not try to light any appliance.

••••• Do not touch any electrical switch; do not use any

phone in your building.

••••• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s instructions.

••••• If you cannot reach your gas supplier, call the fire

department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

TAMPERING IS DANGEROUS

The pilot safety system may also not work if you do not follow the lighting instructions carefully or if you tamper with the gas control that you use to light the pilot. Tampering with the gas control, particularly with tools, can damage the safety mechanism in the control and can allow gas to leak. This can result in a fire or explosion causing property damage, personal injury or death.

CRITICAL SAFETY POINTS TO REMEMBER . . .

••••• Your gas has been odorized 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.

IF YOU SMELL GAS, DON’T LIGHT IT

IF YOU CAN’T LIGHT IT,

DON’T FIGHT 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 wet as the result of

flooding or other wetting, it must be replaced immediately by a trained gas service technician.

Water can lead to damage of the internal safety mechanism in the gas control and can create a hazardous condition.

THIS IS NOT AN ADVERTISEMENT

Page 21

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 NOT RECOMMENDED

AND MY INVALIDATE YOUR WARRANTY.

If within a period of one year from the date of installation of the product, any part supplied by the manufacturer proves to be defective due to workmanship or material, it will replace such part, provided parts have not been subjected to misuse, alteration, neglect, or accidents. The term of the warranty for the heat exchanger 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.

Service under this warranty is the responsibility of the installer. In the event service 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.

SPECIFIC LEGAL RIGHTS, AND YOU MAY

ALSO HAVE OTHER RIGHTS, WHICH VARY, under this warranty is needed, the user of the product FROM STATE TO STATE.

TABLE A

Product

Cozy Gas Fired Floor Furnace

Cozy Gas Fired Vented Console Heater

Cozy Gas Fired Direct Vent Heater

Cozy Gas Fired Counterflow Furnace

Cozy Gas Fired Counterflow Direct Vent Furnace

Cozy Gas Fired Mobile Home Direct Vent Furnace

Cozy Gas Fired Hi-Efficient Direct Vent Wall Furnace

Cozy Gas Fired Direct Vent Baseboard Heater

Cozy Fan-Type, Direct Vent Through-The-Wall Gas Heater

Cozy Blue Flame Vent Free Heater

Cozy Infra-Red Vent Free Heater

Warranty Period

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

N/A

N/A

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

10 Years

N/A

LOUISVILLE TIN & STOVE COMPANY

P.O. BOX 2767 - LOUISVILLE, KY. 40201-2767