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DIRECT VENT COUNTERFLOW WALL FURNACE INSTALLATION AND OPERATING INSTRUCTIONS P / N 72900 REV . 03 / 05 24 VOLT SYSTEM W / INTERMITTENT IGNITION ( IID ) 24 VOLT SYSTEM WITH LOW - BTU PILOT MODEL NUMBERS MODEL NUMBERS NAT . GAS DVCF403B - H DVCF653B - H NAT . GAS DVCF407B - H DVCF557B - H L . P . GAS DVCF404B - H DVCF654B - H L . R GAS DVCF408B - H DVCF558B - H INSTALLER MUST LEAVE THESE The coating selected to provide longer life to INSTRUCTIONS WITH THE CONSUMER the heat exchanger may smoke slightly upon HAVE THEM COMPLETE , AND RETURN initial firing . Please provide adequate THE WARRANTY CARD . ventilation if this ocurs . WARNING : If the information in this manual is not followed exactly , a fire or explosion may result causing property damage , personal injury or loss of life . - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance . - WHAT TO DO IF YOU SMELL GAS : • Do not try to light any appliance . • Do not touch any electrical switch ; do not use any phone in your building . • Immediately call your gas supplier from a neighbor's phone . Follow the gas supplier's instructions . • If you cannot reach your gas supplier , call the fire department . - INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER , SERVICE AGENCY OR THE GAS SUPPLIER . WARNING : Operation of this furnace without the properly installed , furnished vent system and vent cap I could result in Carbon Monoxide ( CO ) poisoning and possible death . For your safet ) _ this furnace and the I vent system should be inspected at least annually by a qualified service person . This unit is not approved for installation in greenhouses , or environments involving dusty , wet , I corrosive , or explosive conditions . Such conditions will invalidate the warranty and may create I unsafe conditions .
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The appliance may be installed in an aftermarket permanently located , manufactured ( mobile ) home , where not prohibited by local codes . This appliance is only for use with the type of gas indicated on the rating plate . This appliance is not convertible for use with other gases , unless a certified kit is used . CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removing Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Proper Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . 10 Specifications and Dimensions . . . . . . . . . . . . . . . 2 Optional Side Discharge Kit . . . . . . . . . . . . . . . 14 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Terminal Block Wiring . . . . . . . . . . . . . . . . . . . . . 13 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 , 5 Manual Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Maintenance Instructions . . . . . . . . . . . . . . . . . . . 13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,17 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pans Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 , 9 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,20 Pilot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 INTRODUCTION Read these installation and operating instructions carefully before you install or attempt to use this Direct Vent Counterflow Wall Furnace . If you do not understand any part of the instructions , consult local authorities , a qualified installer , service agency or the gas supplier . FAILURE TO READ OR UNDERSTAND THESE INSTRUCTIONS CAN RESULT IN MALFUNCTION , INEFFICIENT OPERATION , PROPERTY DAMAGE , SERIOUS INJURY OR DEATH . SPECIFICATIONS AND DIMENSIONS Your Direct Vent Counterflow Wall Furnace is shipped in two cartons . One carton contains the furnace , thermostat , thermostat wire and insulated staples . The second carton will have the vent tube , air intake tube and vent cap assembly . After the furnace has been removed from the carton check the rating plate to verify that the model number is correct and that the wall furnace is equipped with the type gas you intend to use . Model Type Type BtuAtr . Gas Blo , a _ Approx . Number Control Gas Input Inlet Finished Dimensions Speed Amps CFM Ship . Wt 24 VOLT SYSTEM WITH LOW - BTU STANDING PILOT DVCF403B - H 24 ¼ ) lt Nat . 40,000 ½ " 14 - 5 / 16 " Wx78 - 5 / 8 " Hxl 1 - 3 / 4 " D 1 1.95 320 128 Lbs . DVCF404B - H 24 Volt L . P 40,000 ½ " 14 - 5 / 16 " Wx78 - 5 / 8 " Hxl 1 - 3 / 4 " D 1 1.95 320 128 Lbs . DVCF653B - H 24M _ lt Nat . 62,500 ½ " 14 - 5 / 16 " Wx87 - 5 / 16 " ILxll - 3 / 4 " D 2 3.05 440 142Lbs . DVCF654B - H 24M _ lt L . P 62,500 ½ " 14 - 5 / 16 " Wx87 - 5 / 16 " ILxll - 3 / 4 " D 2 3.05 440 142Lbs . 24 VOLT SYSTEM WITH INTERMITTENT IGNITION ( I . I . D . ) DVCFdO7B - H 24 ¼ _ 1t Nat . 40,000 ½ " 14 - 5 / 16 " Wx78 - 5 / 8 " Hxll - 3 / 4 " D 1 2.2 320 130Lbs . DVCF408B - H 24 ¼ _ 1t L . P 40,000 ½ " 14 - 5 / 16 " Wx78 - 5 / 8 " Hxll - 3 / 4 " D 1 2.25 320 130Lbs . DVCF557B - H 24M _ lt Nat . 55,000 ½ " 14 - 5 / 16 " Wx87 - 5 / 16 " ILxll - 3 / 4 " D 2 3.3 440 144Lbs . DVCF558B - H 24 ¼ ) 1t L . P 55,000 ½ " 14 - 5 / 16 " Wx87 - 5 / 16 " Hxll - 3 / 4 " D 2 3.35 440 144Lbs . Page 2
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SAFETY RULES 1 . Follow all applicable local codes and ordinances . If there are none , follow the latest edition of the National Fuel Gas Code , ANSI . Z223 . 1 . A copy may be obtained from American Gas Association , 1515 Wilson Blvd . , Arlington , Virginia 22209 , or the National Fire Protection Association , Batterymarch Park , Quincy , MA . 02269 . In Canada , see the current CAN1 - B 149 installation code , available from International Approval Services , 55 Scarsdale Road , Don Mills , Ontario , Canada M3B - 2R3 . 2 . 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 / NFPAT0 . In Canada , see the current CSA C22 . 2 Canadian Electrical Code , available from International Approval Services , 178 Rexdale Boulevard , Etobicoke , Ontario , Canada M9W 1R3 . 3 . Do not install this furnace in a recreational vehicle or trailer . 4 . Do not operate this furnace unless it is connected to the supplied vent system with vent cap in place . Do not attempt to extend vent pipes . 12 inches is maximum length . 5 . Never use a match , candle , flame or other source of ignition to check for gas leaks . Use only soapy water or liquid detergent . 6 . Before cleaning or servicing , turn offthe gas and allow furnace to cool . 7 . Do not operate furnace without grilles and front panel in place . 8 . Due to high temperatures , locate furnace out of traffic and away from furniture and drapes . 9 . Children and adults should be alerted to the hazard of high surface temperature and should be kept away to avoid burns or clothing ignition . 10 . Young children should be carefully supervised when they are in the same room with the furnace . 11 . Do not place clothing or other flammable material on or near the furnace . 12 . Installation and repair should be done by a qualified service person . The 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 caLt _ eting , bedding material , etc . It is imperative that control compartments , burners , and circulating air passageways of the furnace be kept clean . 13 . Do not put anything around the furnace or vent cap that will obstruct the flow of combustion and ventilation air . 14 . When installing the furnace allow adequate accessibility clearances for servicing and proper operation . ( See Figure 1 - Page 5 ) . 15 . 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 . 16 . Do not use this heater if any part has been under water , hnmediately call a qualified service technician to inspect the heater and to replace any part of the control system which has been under water . 17 . For your safety , this furnace is equipped with a manual reset auxiliary limit switch . In case of failure by the primary limit switch , this switch will shut the valve down completely before unsafe temperatures are reached . After a cool down period , switch must be manually reset . If outages persist , call a qualified service person . 18 . Side discharge kit boots must not exceed 10 inches . 19 . Locate the auxiliary limit switch and push in the red reset button . This will reset the switch in case it accidentally opened during shipping . Page 3
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Vent Terminal _ . _ Air Supply Inlet [ ] Area where terminal is not permitted VENT TERMINAL CLEARANCES REFERENCE LETTERTO CANADIAN INSTALLAI DRAWING A : Clearance above grade , veranda , 12 Inches ( 30 cm ) ) orch , deck , or balcony B : Clearance to window or door that 12 Inches ( 30 cm ) may be opened C = Clearance to permanently closed 12 Inches ( 30 cm ) window D = Vertical clearance to ventilated 18 Inches ( 46 cm ) 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 24 Inches ( 61 cm ) F : Clearance to outside corner 12 Inches ( 30 cm ) G : Clearance to inside corner 12 Inches ( 30 cm ) H : Clearance to each side of center 3 Feet ( 91 cm ) within a height line extended above meter / regulator 15 Feet ( 4,5m ) above the meter , assembly assembly 3 Feet ( 91 cm ) I : Clearance to service regulator vent outlet J = Clearance to nonmechanical air 12 Inches ( 30 cm ) supply inlet to building or the combustion air inlet to any other appliance K : Clearance to a mechanical air 6 Feet ( 1,83 m ) supply inlet I . = Clearance above paved sidewalk or 7 Feet ( 2,13m ) A vent shall not l - paved driveway located on public directly above a sidewalk or pa _ property driveway that is located betwe _ single family dwellings and serve dwellings , M = Clearance under veranda , porch , 12 Inches ( 30 cm ) permiffed onl ! deck , or balcony veranda , porch , deck , or balcon open on a minimum of two side _ In accordance with the current CSA - B149 , 1 Natural Gas and Prep ( Page 4
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CLEARANCES 1 . The minimum clearance to a side wall is 4 " . ( See Fig . 1 ) . NOTE : The unit may be recessed and rest directly against side studs and the inside surface of the rear wall . 2 . The minimum clearance to the ceiling is 4 " . ( See Figure 1 ) . 3 . The minimum clearance to the floor is 0 " . ( See Figure 1 ) . 4 . The minimum clearance from the side of the vent cap to any protruding obstructions , or corners is 12 " . ( See Figure 2b ) . 5 . The minimum clearance from any window to the side of the vent cap is 9 " for DVCF403 , 404 , 407 and 408 ( See Figure 2 ) , and 12 " for DVCF557 , 558 , 653 , and 654 ( See Figure 2b ) . 6 . The minimum clearance from any overhanging projection is 24 " to top of vent cap ( See Figure 2 ) . 7 . 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 . Such equipment shall be located , or protected so it is not subject to damage by a moving vehicle . Use care in selecting a good location within the garage . DO NOT locate the appliance where heated air will be directed onto a nearby parked vehicle . Paint may discolor or rubber may harden FIGURE 1 and crack . DO NOT allow heated discharge air to blow directly onto open or closed containers of paint , gasoline or other liquids having flammable vapors . 24 " ] / iin . [ - - ] [ - - ] 24 ' { Mln . DD DD , ff ] D - 12 " _ _ , , ) ) FIGURE 2 / DVCF403B , 404B , 407B , AND 408B FIGURE 2B / DVCF557B , 558B , 653B , AND 654B Page 5
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LOCATIONS 1 . This furnace must be installed on an outside wall and vented to the outside . If possible , this wall should be on the side of the house that receives the least amount of wind since strong gusting winds could cause pilot outage . 2 . For most efficient performance , locate furnace as centrally - - _ l _ - - - 3 - 1 / 2 " as possible in the area to be heated . 3 . The furnace can be installed flush against a wall or recessed up to 10 " maximum . For proper combustion , make sure unit is level front to back and side - to - side . _ v - - _ - l - 1 / 20A 4 . Do not install the furnace in a closet , alcove or small hallway where the furnace could be isolated from the space to be FIGURE 3 heated by closing a door . 5 . Be sure the vent cap will have the proper clearances ( See Figure 2 ) . 6 . Check inside the wall to make sure there are no obstacles such as water pipes , electric wiring , etc . which could interfere with the installation of the furnace or vent tubes . 7 . Be sure to maintain adequate accessibility clearances for servicing and proper operation . 8 . 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 Gas terminate in a window well or any other opening below ground level . - - ; Supply II Line INSTALLATION Drip _ _ - Leg - * Cut off - 1 / 8 N . P . T . ELECTRICAL ROUGH - IN Valve Pressure Tap For convenience , this furnace is equipped with a three - prong FIGURE 4 power cord located on the top left of heater . The 115V wiring should be brought in on the left side terminating in a receptacle box ( not provided ) . Consult local codes or ordinances . ( For II I Alnps , see Page 2 / Specifications and Dimensions ) . II I II I ROUGH - IN GAS SUPPLY Install a 1 / 2 inch diameter gas supply line . The gas line can 9 - 1 / 4 I enter the cabinet through the right side or bottom ( See Figure DIA . I 3 ) . The gas line must have an individual manual shut offvalve . I 1 I Also , you must install a drip leg and provide a 1 / 8 " N . RT . plugged tapping , accessible for test gauge connection , ' DVC _ I40 - 59 " immediately upstream of the gas supply connection to the WALL _ DVCF , 55 / 65 - 68 - 1 / T furnace ( See Figure 4 ) . sTuD } si II The furnace and its individual shut off valve must be II II disconnected from the gas supply piping system during any II pressure testing of that system at test pressures in excess of * / 2 II psig ( 3.5kPa ) . The furnace must be isolated from the gas supply FINISHED II piping system by closing its individual manual shut off valve , , FLOOR , I , I , , during any pressure testing of the gas supply piping system at FIGURE 5 test pressures equal to or less than 1 / 2psig ( 3.5kPa ) . Page 6
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LOCATE VENT OPENING After the location of the heater has been determined , the opening for the vent pipe should be cut . If the heater is to be recessed , cut out opening tbr heater between studs on the interior wall and cut out the floor plate bepvveen the studs , so heater will set flat on floor as all dimensions are given from a finished floor . The height of the cut out for a 40,000 BTUcut model is 78 - 5 / 8 " , for the 55,000 and 62,500 models the out height is 87 - 5 / 16 " . NOTE : This dimension may be increased to allow more room t \ ) r installation and making the wiring connection , then refinished . I Next , cut out a 9 - 1 / 4 " opening in exterior wall t \ ) r the vent tubes to pass through . The center of opening for the 40,000 BTU furnace is 59 " , the center for opening tbr 55,000 and Vent J get 62,500 BTU furnaces is 68 - 1 / 2 " . See Figure 5 , on Page 6 . Collar Cap Vent Cap If the heater is to be surfaced mounted , cut out 9 - 1 / 4 " opening Spacer through the interior and exterior wall . The center of cut out Plate will be 59 " for 40,000 BTU and 68 - 1 / 2 " for 55,000 and 62,500 BTU models . Be sure both cutouts are level with FIGURE 6 each other . GAS CONNECTION INSTALLING THE FURNACE Make the gas connection between the manual shut offvalve _ and the furnace gas control valve with approved / 2 " The vent system supplied with this furnace will accommodate walls 3 / 4 " ( when recessed ) up to 12 " thick . Use only the connectors . Compounds used on threaded joints of gas exhaust tube . air intake tube and vent cap supplied with piping shall be approved for use with L . P . gas . The gas heater . Do not attempt to lengthen the exhaust or air intake lines must be checked for leaks by the installer with soapy robes , this could cause an imbalance in the heater resulting water or liquid detergent , never use an open flame . If in poor perforlnance and pilot outage ( See Figure 6 ) . connections are not exposed , a pressure test must be run . Be sure to disconnect the gas supply line from the appliance Measure exact distance " X " between surface on which back valve bet \ _ re pressure testing . The manifold pressure is of cabinet will rest ( inside of recessed cavity or face of wall prc - set at the factory and should be 3.5 " w . c . tbr Natural when freestanding ) and the outside wall surfiace ( see Figure Gas and 10 " w . c . t \ ) r L . R Gas . The minimum inlet fpressureor for Natural Gas is 4.5 " w . c . and 11 " w . c . for L . P . Gas , " 6 ) . purpose of input adjustment " . The maximum inlet pressure should never exceed 7.0 " w . c . on Natural Gas or 14 " w . c . Inlet Air Tube " A " Measuring from gasketed surface , on L . P . Gas . mark and cut pipe same as dimension " X " . Remove any burrs . THERMOSTAT INSTALLATION Vent Exhaust Tube " B " Measuring from gasketed Follow the instructions included with the therlnostat . Select surface , mark and cut pipe 1 - 3 / 4 " _ eater than dimension " X " . Remove any burrs . a location for the therlnostat on an inside wall approximately 5 feet above the floor where it won't be affected by heat or Fasten vent exhaust robe " B " to heat exchanger collar and cold sources such as direct sunlight , televisions , fireplaces , Inlet Air Tube " A " to flange on back of furnace using 16 # hidden hot or cold water pipes , drafts , etc . , and a minimum 3 / 8 screws ( " C " ) provided . Be sure gaskets are in place and of 4 ' tiom the heater . The thermostat must never be placed not damaged . Anytime the vent pipes are removed check in an adjacent room . Connect thermostat wires to thermostat and mount to wall . Run wire to furnace and and replace gaskets ( if necessary ) . Failure to replace missing or damaged gaskets may expose homeowner to life make connections to thermostat wires coming out of top of threatening conditions . furnace . Use insulated staples ( provided ) to secure wire to wall . Secure furnace in place using 2 holes provided in bottom of OPERATION casing . NOTE : Make sure both robes are centered in cut out . Slide the vent cap onto the pipes extending from the back of the furnace . A rotating or twisting motion will ease This unit uses a " step action " valve . When the heater comes this installation . Secure vent cap and vent cap spacer plate on initially , it operates at a lower pressure to insure proper , to wall causing the vent tubes to have a slight downward quiet , iguition . After 20 seconds or less , it automatically pitch . This will prevent water from entering . Anchors ( not steps up to the proper manit \ _ ld pressure with a discernabte provided ) may be required . Caulk around vent cap spacer increase in flame height . plate with caulking provided . NOTE : Some framing may be necessary to provide a flat surface against the vent cap After the heat exchanger has wanned sufficiently , the tan spacer plate and to prevent rain from entering the wall will automatically come on to efficiently transfer the heat opening . into the room . NOTE : All but the 40,000 BTU unit ( which is one - speed ) have an automatic two - speed Pan . Page 7
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LIGHTING INSTRUCTIONS : DVCF403B - H / 404B - H , DVCF653B - H / 654B - H FOR YOUR SAFETY READ BEFORE LIGHTING WARNING : If you do not follow these instructions exactly , a fire or explosion may result I causing property damage , personal injury or loss of life . I A . This appliance has a pilot which must be lighted by • If you cannot reach your gas supplier , call the fire hand . When lighting the pilot , tStlow these instmc - department . tions exactly . BEFORE LIGHTING , smell all around the appliance C . Use only your hand to push in or turn the gas control area for gas . Be sure to smell next to the floor because knob . Never use tools . If the knob will not push in or turn some gas is heavier than air and will settle on the by hand , don't try to repair it , call a qualified selaTice _ ] oor . technician . Force or attempted repair may result in a fire or explosion . WHAT TO DO IF YOU SMELL GAS : D . Do not use this appliance if any part has been under water . Do not try to light any appliance . Ilnmediately call a qualified sel - vice technician to inspect Do not touch any electric switch , do not use any the appliance and to replace any part of the control system phone in your building . and any gas control which has been under water . PNg1211 02 / 05 Ilnmediately call yore gas supplier tiom a neighbor's phone . Follow the gas supplier's instructions . LIGHTING INSTRUCTIONS STOP ! Read the inforlnation on the safety label . 2 . Set thermostat to lowest setting . 3 . Turn off all electric power to the appliance . 4 . Remove lower front panel . 5 . Push in gas control knob slightly and turn ctcoclcvvise € " N to " OFF " . , u4 Gas Control Knob NOTE : Knob 10 . Push in pilot control knob and hold in . Ilrnnediately begiE can not be a series of pushing and releasing the red piezo ignitoi turned ti'om button , while observing the pilot through the sight glass " PILOT " to Continue to spark until pilot is lit . Continue to hold the " OFF " unless pilot control knob in for about one ( 1 ) minute after the pilot is lit . Release the pilot control knob and it wilt poF knob is pushed in slightly . Do back up . Pilot should remain lit . If pilot goes out , repeal J not % rce . steps 4 thin 9 . Pilot Control Knob , , If knob does not pop up when released , STOP and immediately call your service technician or gas supplier . 6 . Wait five ( 5 ) minutes to clear out any gas . Then smell for • If the pilot will not stay lit after several tries , turn the gas gas , including near the floor . If you smell gas , STOP ! control knob to " OFF " and call your service technician oi Follow " B " in the intbnnation on the safety label . If you gas supplier . don't smell gas , go to the next step . 11 . Close sight glass cover . 7 . Open sight glass cover . 12 . Turn gas control knob countercloclcvvise _ to " ON " . 8 . Locate red piezo iNlitor button on side of gas control . 13 . Replace lower tiont panel . Locate pilot behind sight glass . ( Follow metal pilot tube 14 . Turn on all electric to the appliance . fioln gas control ) . 15 . Set thermostat to desired setting . 9 . Turn gas control knob countercloclcvvise N " " N to " PILOT " . PN91211 02 / 05 TO TURN OFF GAS TO APPLIANCE Turn thermostat to it's lowest setting . 2 . Turn off all electric power to the appliance if service is to be performed . 3 . Remove lower front panel . 4 . Push in gas control knob slightly and mm clockwise _ to " OFF " . Do not % rce . PN91211 02 / 05 5 . Replace lower front panel . Page 8
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LIGHTING INSTRUCTIONS : DVCF407B - H / 408B - H _ DVCF557B - H / 558B - H FOR YOUR SAFETY READ BEFORE LIGHTING WARNING : If you do not follow these instructions exactly , a fire or explosion may result causing property damage , personal in , iur , v or loss of life . A . This appliance is equipped with an ignition device which • If you cannot reach your gas supplier , call the tire automatically lights the pilot . Do not try to light the department . pilot by hand . B . BEFORE OPERATING , smell all around the appliance area C . Use only your hand to push in or turn the gas control for gas . Be sure to smell next to the floor because some knob . Never use tools . If the knob wilt not push in or gas is heavier than air and will settle on the floor . turn by hand , don't try to repair it , call a qualified service technician . Force or attempted repair may result in a fire WHAT TO DO IF YOU SMELL GAS : or explosion . Do not try to light any appliance . D . Do not use this appliance if any part has been Do not touch any electric switch : do not use any phone water . Ilnmediately call a qualified service in your building . hmnediately call your gas supplier from a neighbor's under water . phone . Follow the gas supplier's instructions . LIGHTING INSTRUCTIONS 1 . STOP ! Read the information on the safety label . 8 . Turn gas control knob counterctoclcvvise _ to " ON " 2 Set thermostat to lowest setting . 3 Turn off all electric power to the appliance . Gas Control This appliance is equipped with an iNlition device which Knob automatically lights the pilot . Do not try to light the pilot by hand . Remove lower front panel . Push in gas control knob slightly and turn cloclcvvise to " OFF " . Gas Control Knob NOTE : Knob can not be I turned to " OFF " unless knob is pushed 9 . Replace lower front panel . in slightly . Do 10 . Turn on all electric power to the appliance . not force . 11 . Set thermostat to desired setting . 12 . If the appliance will not operate , follow the instructions " TO TURN OFF GAS TO APPLIANCE " and call your sela : ice technician or gas supplier . Wait five ( 5 ) minutes to clear out aW gas . Then smell l \ _ r PN91214 02 / 05 gas , including near the floor . If you smell gas , STOP ! Follow " B " in the information on the safety label . If you don't smell gas , go to the next step . TO TURN OFF GAS TO APPLIANCE 1 . Turn thermostat to it's lowest setting . 2 . Turn off all electric power to the appliance if service is to be pert \ tuned . 3 . Remove lower front panel . 4 . Push in gas control knob slightly and turn clockwise _ to " OFF " . Do not t \ ) rce . PN91214 02 / 05 5 . Replace lower tiont panel . Page 9
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PILOT ADJUSTMENT TO REMOVE MAIN BURNER FOR INSPECTION AND CLEANING Locate the pilot adjustment screw on the valve . The 1 . Turn thermostat to lowest setting and allow furnace to cool . pilot flame should surround at least the top 3 / 8 " of the 2 . Turn off " all electric power to furnace . powerpile ( pilot generator ) or flame sensor ( see Figure 3 . Remove lower mille . 7 ) . The pilot is unregulated so it will be operating at 4 . Disconnect gas supply to valve . inlet line pressure ( Max . 7 " w . c . for Natural Gas and 5 . Disconnect wires from gas vane . 11 " w . c . tbr Propane ) . To decrease the pilot flame , 6 . Remove 15 screws holding burner door to burner box . Pull turn the screw clockwise _ ( approximately six full door fbrward to remove complete burner , gas valve assembly . turns to bottom ofpitot light channel ) until you produce 7 . After inspecting and cleaning , place burner assembly back sufficient flame at the minilnum noise level . into burner box and tighten 15 screws . NOTE : Be sure door gasket is not damaged and will effect a proper seal or pilot outage will occur . 8 . Connect wires back to valve . PILOT FLAME ADJUSTMENT : Pilotflame 9 . Connect gas supply back to valve . should envelop 3 / 8 to 1 / 2 inch of the tip of sensor . 10 . Turn on electric to furnace . 11 . Follow lighting instructions , and replace lower _ ille . It is recommended that the furnace and all components be inspected . _ 3 / 8 " to 1 / 2 " at least annually by a qualified service person . This should include the burner , pilot , heat exchanger , and vent system . Be sure that the flow of combustion and ventilation air is not obstructed . IMPORTANT : Keep burner and control compartment clean . Vacuum control compartment at the start of the heating season and as often as needed . PROPER BURNER FLAME FIGURE 7A FIGURE 7B The burner flame may be observed by raising the sight glass cover . A proper flame will have a dark blue inner mantle that sits right STANDING PILOT I . I . D . PILOT on top of the burners with a lighter blue outer mantle rising above the burner ( See Figure 8 ) . There may be some yellow where the pilot flame and burner flame meet . There is no primary air adjustment on the burner , and proper flame is assured since the correct manifold pressure and orificing has been done at the factory . NOTE : It is advised that the burner flames be checked at least twice during the heating season for any changes in burner flame characteristics . The appliance area must be kept clear and tree from combustible materials , gasoline , and other flammable vapors and liquids . This heater comes fioln the factory with the proper Pilot Adj . Screw Pilot Adj . Screw burner orifice for elevations up to 2,000 feet . Heaters installed above 2,000 feet must be derated 4 % for every 1,000 feet . For the proper orifice size , find the Model Nmnber and elevation on the HONEYWELL HONEYWELL orifice chart . Replace burner orifice . VR8200H SERIES VR8204H SERIES NATURAL GAS FIGURE 7C FIGURE 7D STANDING PILOT I . I . D . PILOT MODEL 0 to 2,000 - 4,000 - 6,000 - 8.000 NI _ 4FIER 2 000 ' 4 000 ' 6 000 ' 8 000 ' I0 000 ' DVCF403B 32 34 35 36 40 DVCF407B 32 34 35 36 40 [ - 1 / 01 DVCF557B 3.6m 29 30 30 31 3 / 4 DVCF653B 25 27 28 29 30 ORDERKIT # 498402287 - 1HIGHALTITUDEKIT L . P . GAS MODEL 0 to 2.000 - 4.000 - 6.000 - 8.000 iXXEVIBER 2 _ 000 ' 4000 ' 6000 ' 8000 ' 10 _ 000 ' FIGURE 8 DVCF404B 49 50 51 52 52 DVCF408B 49 50 51 52 52 DVCF558B 44 45 47 48 49 DVCF654B 2.3n _ n 44 45 47 48 ] ORDER KIT # 49840 2287 - 1 HIGH ALTITUDE KIT Page 10
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DVCF403B / 404B - H STANDING PILOT DVCF653B / 654B - H THERMOSTAT POWER CORD BLACK 7RANSFORNEER BLACK BLUE SPILL LIMIT FAN SWITCH S \ VIT ( H DVCF403 / 404B - H PICTORIAL SCHEMATIC PICTORIAL SCHEMATIC MODEL NO . AMPS MODEL NO . AMP S DVCF653 - B - H 3.05 DVCF403B - H 1.95 DVCF654 - B - H 3.05 GAS \ A _ E DVCF404B - H 1.95 FAN SWITCH FAN SWITCH LIMIT SWITCH LIMIT SWITCH TRANNFUR _ ER DVCF653B - H DVCF403B - H DVCF654B - H DVCF404B - H LADDER LADDER SCHEMATIC SCHEMATIC [ AUXILIARY AUXILIARY LIMIT LIMIT Page 11
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DVCF407B - H , DVCF408B - H I . I . D . DVCF557B - H , DVCF558B - H DVCF557 / 558B - H THERMOSTAT THERMOSTAT POWER DVCF407 / 408B - H PICTORIAL CORD PICTORIAL POWER SCHEMATIC SCHEMATIC CORD MOTOR i BLACK BLACK SPILL BROWN SPILL MODEL NO . AMPS MODELNO . AMPS J LJ DVCF407B - H 2.2 DVCF557B - H 3.3 DVCF408B - H 2.25 DVCF558B - H 3.35 SELECTOR FAN SWITCH SWITCH FAN SWITCH LIMIT SWITCH TCH TRANSFORMER TRANSFORMER THERMOSTAT DVCFSS7B - H DVCFSS8B - H DVCF408B - H LADDER , LADDER , , 41 SCHEMATIC SCHEMATIC AUXILIARY LIMIT AUXILIARY LIMIT Page 12
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CAUTION : Label all wires prior to disconnection when servicing controls . Wiring errors can cause improper and dangerous operation . Verify proper operation after servicing . TERMINAL BLOCK WIRING DIAGRAM _ Fml / Limit Switch ( Brown ) F Fan / Limit Switch ( Brown ) Selector Switch - 1 / r - Power Cord ( Black ) | FP ° wer Cord ( Black ) / IF Transt ` onner ( Black ) ( Red ) [ / [ F Transf ° nner ( Black ) / 11 LhNt Lh _ t Motor _ _ _ JL [ ] JL . _ _ - Switch _ - _ 1 _ - _ 1 [ _ - ] ] , , - - - - - Swit ch u u ( Blue ) ( Red ) ( Blue ) 0 MOTOR ( White ) O O MOTOR ( Wlfite ) O _ ' Fan _ ' Selector Power Cord _ _ _ _ _ j = _ If = = = ll r - - 31 _ _ _ _ Switch ' m ' _ = : _ r " _ - - - _ " _ - - - - Switch ( Green ) _ - _ l F [ L - ] I1F u ( Black ) - - / / - - ( Black ) Power ( Green ) C _ _ O . . r + d _ . , Terminal t ; oard Tenninat Board _ 1 | | l L Motor ( Black ) Ground ( Gree _ } otor - Ground ( Gree _ / totor _ l [ LTransi ` onner ( Black ) ( Green ) Power Cord ( White ) ( Green ) L _ _ _ Power Cord ( White ) P / N91122 P / N91123 DVCF557 , 558 , 653,654B - H DVCF403 , 404 , 407 , 408B - H MANUAL RESET SWITCH For your safety this furnace is equipped with a manual reset limit switch . In case of failure by the primary limit switch , this switch wilt shut the valve do , am completely before unsafe temperatures are reached . After a cool down period , switch must be manually reset . If outages persist , call a qualified service person . MAINTENANCE INSTRUCTION For proper and sate operation , keep furnace and furnace area clean . At regmlar intervals turn control valve oft ; let cool and clean inside control compartment . To clean cabinet , use only a damp cloth . OILTUBE / Do not use any kind of sotvent or cleaning fluid that could leave a residue or invisible coating that would burn or give off fumes when furnace is turned on . Have the furnace checked , cleaned , and repaired by a qualified service person for vent system , pilot and burner operation prior . ¢ to use each year . The beatings of the fan motor should be oiled every twelve ( 12 ) months with S . A . E . 20 oil . ( See Figure 10 ) . Follow a regular service and maintenance schedule for sate and efficient operation . FIGURE 10 Examine the venting system as a routine part of the safety performance check on an annual basis . WARNING : This is a gas - fired appliance . Keep the area clear of gasoline and other flamlnaabte vapors and liquids . All combustible material must be kept clear of this area to avoid fire or explosion . I Page 13
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OPTIONAL SIDE DISCHARGE KITS ROUGH - INS FOR SIDE DISCHARGE SIDE DISCHARGE ON CASING Install plaster mounds as shown in Figure 9 . NOTE : When 1 . Use Optional Kit No . 306SR - A . 2 . Cut out and remove embossed area on casing side . side discharge Kit No . 30SRB is being used , furnace should be 3 . Remove talockout from inner liner . set exactly 4 " fiom side wall . 4 . Place 1 - 1 / 2 " boot from kit through opening , matching flanges of boot to knockout on inner liner . 5 . Mark screw holes and remove boot . 6 . Drill holes with a 1 / 8 " drill . 7 . Attach inner boot with screws provided . 8 . Place grille into position , drill holes into casing , and attach with screws provided . 14 - 3 / 8 " SIDE FIGURE 9 KIT NO . 306SR SIDE REGISTER - FLUSH SIDE DISCHARGE ( With Extension Boot ) NOTE : Maximum boot length is 10 inches . 1 . Use Optional Kit No . 30SRB - A . 2 . Cut opening in drywall as shown in Fig . 9 . 3 . Position plaster ground as shown in Figure 9 . ( Optional ) . 4 . Cut out and remove embossed section on casing side . 5 . Remove kalockout on inner liner . 6 . Put heater into position . 7 . Place inner boot into position , mark and cut boot flush with watt . Place outer boot into position , mark and cut boot flush with wall . KIT NO . 30SRB 8 . Place boot trim into position , slide inner boot through SIDE REGISTER W / BOOT wall fiom adjacent room and attach to inner liner . Slide outer boot through wall from adjacent room and attach to casing side . 9 . Place grill in position and secure to wall . Page 14
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14 - PEK KIT INSTRUCTIONS ( 14 ' PLUG EXTENSION KIT ) FOR NON - RECESSED INSTALLATIONS ONLY UNITS WITH TERMINAL BOARD 90 De _ ee Outside - - ' + STEP # Corner 1 . Turn heater off following Section 3 in " Lighting Instructions " and allow to cool . © 2 . Turn offall electricity to heater . 3 . Remove top louver assembly , tan shroud and fan blade . 3 FT . SECTION 4 . Loosen two screws on romex connector . 5 . Remove junction box cover plate . © 6 . Disconnect three power cord terminals and pull power cord out of top of heater . 7 . Insert power cord provided in kit through romex connector and plug onto terminal board following wiring diagram found in lighting and operating instructions . 8 . Tighten two screws on romex connector . 9 . Replace junction box cover plate . 3 FT . 10 . Replace fan blade , fan shroud and top louver SECTION assembly . 11 . Snap 90 degree outside corner ( Ref . 1 ) onto 3 ® foot section ( Ref . 2 ) plastic raceway . Insert power cord and remove blue backing from adhesive strip on raceway and apply to side of heater . 12 . Insert power cord into second 3 - foot section of raceway ( Ref . 3 ) and remove blue backing and apply to side of heater , butting up against bottom of other section . 13 . Cut 14 - inch long bottom section to required length ( see chart ) , insert power cord , remove backing and apply to side of heater . 14 . Plug power cord into wall receptacle . 15 . Light the heater following lighting instructions . LENGTH OF BOTTOM SECTION ( REF . 4 ) MODEL NO . PLASTIC RACEWAY DVCF40 5 - 5 / 16 Inches DVCF55 14 Inches DVCF65 14 Inches NOTE : Above lengths terminate approximately 2 inches above floor . Page 15
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TROUBLE SHOOTING CHART SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION i . Flame too large Defective operator section of valve , i . Replace valve . 2 . Burner orifice too large . 2 . Check with local gas company for proper orifice size and replace . 3 . If installed above 2,000 feet . 3 . See orifice chart , page 10 . Yellow burner flame i . Remove main burner and check for obstructions in Clogged burner ports . 1 . throat , ports , and orifices . Clean - but do not enlarge ports or orifices . Obstructions around vent cap . 2 . Make sure area around vent cap is clear , be sure vent system is sealed . Gas Odor Gas leak . i . See Page 1 . 1 . Pilot flame too small . I . Delayed Ignition Adjust pilot flame . 2 . Burner ports clogged at pilot . 2 . Clean burner ports ( do not enlarge ) . 3 . Low gas pressure . 3 . Check gas supply pressure . 4 . Pilot decreases in size when main 4 . Supply piping is too small . Consult local gas burners come on . company or competent installer . Failure to ignite Main gas off . i . Open all manual gas valves . Thermostat not set high enough to call 2 . Set thermostat to higher temperature . for heat . Clogged burner orifice . 3 . Clean burner orifice ( do not enlarge ) . Thermostat wired wrong or defective . 4 . Check wiring , jump across thermostat terminals at valve , if valve open , re - check wires , replace thermostat . Burner won't turn off Defective or damaged thermostat wire , 1 . Can be checked by removing wire from valve temlinal . or themmstat . If valve goes of'f , replace wire or thermostat . 2 . Thermostat location . 2 . Follow instructions , check location . 3 . Defective or sticking valve . 3 . Replace valve . 4 . Excessive gas pressure . 4 . Contact utility supplying gas . Incorrect gas input I . Gas input not checked . i . Re - check gas input . 2 . Clogged orifice . 2 . Clean orifice with a smooth wood toothpick , do not enlarge . i . Furnace undersized . Not enough heat I . 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 . Thermostat set too low . 2 . Raise temperature setting . 3 . Incorrect supply pressure . 3 . Check supply pressure . Too nmch heat i . Thermostat set too high . I . Lower temperature setting . 2 . Combination control valve stuck open . 2 . Replace combination control valve . Pilot and main burner 1 . Weak thennocouple . 1 . Check millivoltage and replace if low . go out during normal 2 . Input too high . 2 . Check input rate . operation 3 . Cover around pilot lighter hole not 3 . Tighten wing nuts securing cover and sight glass . air tight . Check and replace gasket if needed . 4 . Follow instructions . Check both exhaust and air 4 . Vent robes not properly installed or sealed . intake robes , 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 . Page 16
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TROUBLE SHOOTING CHART - Continued SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Burner won't tuna on 1 . Gas valve not turned on . i . Turn gas valve to " on " position . 2 . Check for 24 Volts to valve from transformer . 2 . No voltage to valve . 3 . Defective thermostat . 3 . Check wall thermostat . 4 . No 115 W . Line voltage . 4 . Provide line voltage . 5 . Gas valve defective . 5 . Replace gas valve . 6 . Manual reset switch not engaged . 6 . Depress red button on switch . i . Air in line . 1 . Bleed line . ( STANDING PILOT ) 2 . Defective thermoeouple 2 . Replace thermocouple . 3 . Pilot flame too low . Pilot won't light , or 3 . Adjust pilot flame . stay lit 4 . Manual reset switch not engaged . 4 . Depress red button on switch . ( Ll . D . PILOT ) i . Sparker won't work . 1 . Check wire connections , provide adequate ground . Pilot won't light 2 . Sparker won't light pilot . 2 . { a } Pilot flame too small . { b } Turn valve to " on " position . { c } Check for pilot restriction . 3 . Manual reset switch not engaged . 3 . Depress red button on switch . SERVICE RECORD SERVICE RECORD Page 17
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DIRECT VENT COUNTERFLOW WALL FURNACE MODELS : DVCF403B - H , DVCF404B - H DVCF407B - H , DVCF408B - H DVCF557B - H , DVCF558B - H DVCF653B - H , DVCF654B - H - - . @ J @ - @ VENT AS SEMLBY oO Mr . Contractor , we only sell parts through our wholesalers , but the prices listed are for your convenience . Forpromptparts service , contact the wholesaler from which you pur - chased your Cozy heater . NOTE : Parts & I . I . D . CONTROL MODULE schematic drawings on current models are HONEYWELL shown at www . cozyheaters . com THERMOSTAT BUrStER AS SEMBLY DVCF40B - H , DVCF55B - H , DVCF65B - H SERIES I USE ONLY FACTORY SUPPLIED PARTS I i Prices and specifications subject to change without notice . All prices are F . O . B . factory . MARCH 2005 Page 18 REV . 03 / 05
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HOW TO PROPERLY ORDER PARTS In addition to part description and part nmnber , please give model nmnber , serial nmnber , and type of gas used . NAT , DVCF403B - H DVCF407B - H DVCFS57B - H DVCF653B - H MODEL NUMBER L , P . DVCF404B - H DVCF408B - H DVCFS58B - H DVCF654B - H REE PART LIST PART LIST PART LIST PART LIST PART DESCRIPTION NO . NO . PRICE NO . PRICE NO . PRICE NO . PRICE Casing Side , Right la 34065 $ 56.10 34065 $ 56.10 34560 $ 61.30 34560 $ 61.30 Casing Side , Left lb 34055 $ 56 . ! 0 34055 $ 56 . ! 0 34550 $ 61.30 34550 $ 61.30 Center Front Panel Assembly 1 c 34104 $ 27.80 34104 $ 27.80 30534 $ 28.80 30534 $ 28.80 Top Assembly ld 34050 $ 10.60 34050 $ 10.60 34050 $ 10.60 34050 $ ! 0.60 Upper Back Assembly le 34080 $ 42.80 34080 $ 42.80 34080 $ 42.80 34080 $ 42.80 Lower Back Assembly If 34090 $ 36.60 34090 $ 36.60 34575 $ 40.40 34575 $ 40.40 Bottom Assembly lg 34070 $ ! 6.10 34070 $ 16.10 34070 $ 16.10 34070 $ 16.10 Casing Mounting Brackets NIA * 30260 $ ! . 20 * 30260 $ 1.20 * 30260 $ 1.20 * 30260 $ 1.20 Liner Assembly 2 34115 $ 81.30 34115 $ 81.30 34600 $ 87.60 34600 $ 87.60 Fan Shroud Assembly 3 34140 $ 23.80 34140 $ 23.80 34140 $ 23.80 34140 $ 23.80 Top Louver 4 34100 $ 16.30 34100 $ 16.30 34590 $ 17.70 34590 $ 17.70 Bottom Louver Assembly 6 30100 $ 31.60 30100 $ 3 ! . 60 30100 $ 31.60 30100 $ 31.60 Upper Front Shield 7 30250 $ 3.50 30250 $ 3.50 30250 $ 3.50 30250 $ 3.50 Switch Box 8 30252 $ 7.10 30252 $ 7.10 30450 $ 7.20 30450 $ 7.20 Switch Box Cover 9 30253 $ 2.80 30253 $ 2.80 30253 $ 2.80 30253 $ 2.80 Lower Front Shield ! 0 30256 $ 5.10 30256 $ 5.10 30256 $ 5.10 30256 $ 5.10 Motor Mounting Bracket 11 * 34088 $ 3.60 * 34088 $ 3.60 * 34579 $ 2.10 * 34579 $ 2.10 Burner 12 72107 $ 38.20 72107 $ 38.20 72107 $ 38.20 72107 $ 38.20 Pilot Bracket 53 34440 $ 4.00 34440 $ 4.00 34440 $ 4.00 34440 $ 4.00 Valve , VR8200H - 1004 , Natural Gas 13 78090 $ 125.00 N / A N / A N / A N / A 78090 $ 125.00 Valve , VR8200H - 1137 , L . P . Gas 13 78091 $ 129.20 N / A N / A N / A NIA 78091 $ 129.20 Valve , VR8204H - 1006 , Natural Gas 13b N / A NIA 78092 $ ! 22.90 78092 $ 122.90 N / A N / A Valve , VR8204H - 1014 , L . P . Gas 13b NIA N / A 78093 $ 122.90 78093 $ 122.90 N / A N / A Manifold 14 72103 $ 19.10 72103 $ ! 9.10 72103 $ 19.10 72103 $ 19.10 Burner Orifice , Natural Gas 15 72147 $ 3.40 72147 $ 3.40 72140 $ 3.40 72142 $ 3.40 Burner Orifice , L . R Gas 15 72149 $ 3.40 72149 $ 3.40 72141 $ 3.40 72143 $ 3.40 Fan Motor ! 6 72108 $ 73.90 72108 $ 73.90 72110 $ 83.90 72110 $ 83.90 Fan Blade 17 78101 $ 24.20 78101 $ 24.20 78101 $ 24.20 78101 $ 24.20 Rubber Grommet 18 78010 $ 3.00 78010 $ 3.00 78010 $ 3.00 78010 $ 3.00 Limit Switch 60T11 - L220F 19 N / A N / A NIA NIA 72160 $ 5.90 72160 $ 5.90 Limit Switch 60T11 - L180F 19 78065 $ 5.90 78065 $ 5.90 N / A N / A N / A N / A Fan Switch 60T12 - 120 - 15 Deg . F 20 78067 $ 6.10 78067 $ 6.10 78067 $ 6.10 78067 $ 6.10 Speed Switch 60T13 - F160 - 30 21 NIA NIA N / A N / A 78066 $ 8.90 78066 $ 8.90 Aux . Limit Switch 60T15 - L350 22 78086 $ 9.30 78086 $ 9.30 78086 $ 9.30 78086 $ 9.30 Thermostat 24 Volt 23 78355 $ 20.00 78355 $ 20.00 78355 $ 20.00 78355 $ 20.00 Transformer 24 78069 $ 23.50 78069 $ 23.50 78069 $ 23.50 78069 $ 23.50 Transformer Plate N / A 34089 $ 3.80 34089 $ 3.80 34089 $ 3.80 34089 $ 3.80 Terminal Board 35 78300 $ 5.00 78300 $ 5.00 78300 $ 5.00 78300 $ 5.00 Pilot 0.140.512 , Natural Gas 25 72020 $ 22.70 NtA N / A N / A N / A 72020 $ 22.70 Pilot 0.140.502 , L . P . Gas 25 72021 $ 22.70 N / A N / A NiA N / A 72021 $ 22.70 Cozy Handle 26 84003 $ 2.30 84003 $ 2.30 84003 $ 2.30 84003 $ 2.30 Thermostat Wire 27 74518 $ 1.30 74516 $ 1.30 74518 $ 1.30 74518 $ 1.30 Thermocouple Q309A1954 28 78095 $ 11.40 N / A NiA N / A N / A 78095 $ 11.40 Insulated Staples 29 74209 $ 1.20 74209 $ 1.20 74209 $ 1.20 74209 $ 1.20 Pilot Assembly Electronic , Natural Gas 25b N / A NiA 78098 $ 29.80 78098 $ 29.80 N / A N / A Pilot Assembly Electronic , L . P . Gas 25b N / A NiA 78099 $ 29.80 78099 $ 29.80 N / A N / A Wiring Harness 30 72251 $ 18.80 72251 $ 18.80 72250 $ 21.10 72250 $ 21.10 Flame Ignitor Assembly Honeywell 28b N / A NiA 78096 $ 29.80 78096 $ 29.80 N / A N / A - CONTINUED - Mr . Contractor , we only sell parts through our wholesalers , but the prices listed above are for your conve - nience . 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 . MARCH 2005 Page 19 REV . 03 / 05
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HOW TO PROPERLY ORDER PARTS In addition to part description and part nmnber , please give model nulnber , serial nmnber , and type of gas used . NAT . DVCF403B - H DVCF407B - H DVCFSS7B - H DVCF653B - H MODEL NUMBER L . P , DVCF404B - H DVCF408B - H DVCFSS8B - H DVCF654B - H REF . PART LIST PART LIST PART LIST PART LIST PART DESCRIPTION NO . NO . PRICE NO . PRICE NO . PRICE NO . PRICE Power Cord N / A 78213 $ 4.70 78213 $ 4.70 78213 $ 4.70 78213 $ 4.70 Sight Glass Assembly 31 43252 $ 6.50 43252 $ 6.50 43252 $ 6.50 43252 $ 6.50 Sight Glass Cover 32 43258 $ 1.50 43258 $ 1.50 43258 $ 1.50 43258 $ 1.50 Si , qht Glass Gasket 33 72067 $ 1.50 72067 $ 1.50 72067 $ 1.50 72067 $ 1.50 Burner Box Gasket 34 72059 $ 5.90 72059 $ 5.90 72059 $ 5.90 72059 $ 5.90 Slip Joint Assembly w / Gaskets 50 34220 $ 27.20 34220 $ 27.20 34220 $ 27.20 34220 $ 27.20 Slip Joint Gasket N / A 72057 $ 4.70 72057 $ 4.70 72057 $ 4.70 72057 $ 4.70 Slip Joint Ring Gasket 61 72056 $ 2.30 72056 $ 2.30 72056 $ 2.30 72056 $ 2.30 Slip Jt . Ring Gsk . ( 2 pc . Graphite ) N / A 72058 $ 4.70 72058 $ 4.70 72058 $ 4.70 72058 $ 4.70 Flue Outlet Pipe Gasket 36 72055 $ 1.90 72055 $ 1.90 72055 $ 1.90 72055 $ 1.90 Air Intake Pipe Gasket 37 72054 $ 3.80 72054 $ 3.80 72054 $ 3.80 72054 $ 3.80 Heat Exchan , qer Cover Plate 52 34195 $ 3.60 34195 $ 3.60 34195 $ 3.60 34195 $ 3.60 Heat Exchanger Cover Plate Gasket 38 72053 $ 1.60 72053 $ 1.60 72053 $ 1.60 72053 $ 1.60 Burner Box Inlet Gasket 39 72052 $ 7.00 72052 $ 7.00 72052 $ 7.00 72052 $ 7.00 Exhaust Pipe Gasket 40 72051 $ 2.30 72051 $ 2.30 72051 $ 2.30 72051 $ 2.30 Manifold Gasket 55 72068 $ 1.50 72068 $ 1.50 72068 $ 1.50 72068 $ 1.50 Piezo Igniter 41 70050 $ 5.60 N / A N / A NIA N / A 70050 $ 5.60 Igniter Wire 0.028.508 42 72022 $ 4.70 N / A NIA N / A N / A 72022 $ 4.70 Ignition Control Box S8600B , Honeywell 43 N / A NIA 78097 $ 128.00 78097 $ 128.00 NIA N / A Heat Exchanger Kit 44 34805 $ 272.40 34805 $ 272.40 34810 $ 274.60 34825 $ 285.60 Vent Cap Assembly Complete 45 34250 $ 127.90 34250 $ 127.90 34250 $ 127.90 34250 $ 127.90 Vent Cap Spacer Plate Assembly 46 34273 $ 14.50 34273 $ 14.50 34273 $ 14.50 34273 $ 14.50 Vent Cap Mounting Kit 47 34330 $ 10.70 34330 $ 10.70 34330 $ 10.70 34330 $ 10.70 Air Intake Pipe Assembly 48 34280 $ 28.40 34280 $ 28.40 34280 $ 28.40 34280 $ 28.40 Vent Exhaust Pipe Assembly 49 34290 $ 22.20 34290 $ 22.20 34290 $ 22.20 34290 $ 22.20 Elbow 3t8x90 Degree NIA 84501 $ 2.10 84501 $ 2.10 84501 $ 2.10 84501 $ 2 . ! 0 Air Drop Assembly 51 34201 $ 124.60 34201 $ 124.60 34630 $ I40 . 10 34630 $ 140.10 Burner Box Bottom Assembly 58 34400 $ 50.90 34400 $ 50.90 34400 $ 50.90 34400 $ 50.90 Burner Access Door 56 34425 $ 1 ! . 00 34425 $ 11.00 34425 $ 11.00 34425 $ 11.00 Burner Access Gasket 57 72065 $ 8.20 72065 $ 8.20 72065 $ 8.20 72065 $ 8.20 90 Deg . Pilot Fitting N / A N / A NIA 70352 $ 16.70 70352 $ 10.70 N / A NIA Pilot Tube Bracket 60 34475 $ 2.00 34475 $ 2.00 34475 $ 2.00 34475 $ 2.00 Vent Terminal Shield NIA 34950 $ 60.80 34950 $ 60.80 34950 $ 60.80 34950 $ 60.80 Pilot Tubing w / Fittings NIA 78452 $ 5.40 78452 $ 5.40 78452 $ 5.40 78452 $ 5.40 Pilot Tube Gasket 59 72063 $ ! . 20 72063 $ ! . 20 72063 $ 1.20 72063 $ 1.20 Lighting Instructions DVCF NIA 91260 N / C 91261 N / C 91261 NIC 91260 N ! C Mr . Contractor , we only sell parts through our wholesalers , but the prices listed above are for your convenience . For prompt parts service , contact the wholesaler from which you purchased your Cozy heater . NOTE : Parts & schematic drawings on current models are shown at www . cozyheaters . com . MARCH 2005 REV . 03 / 05 Page 20
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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 sate and reliable operation . Although safety mechanisms are built - in , the potential for hazard exists . This information is intended to help you avoid these hazards . WHAT TO DO IF YOU SMELL GAS . . . YOUR GAS CONTROL AND PILOT LIGHT • Do not try to light any appliance . SYSTEM • Do not touch any electrical switch ; do Your gas control and pilot light system has a safety not use any phone in your building . • Immediately call your gas supplier from device whose purpose is to shut - offthe gas supply a neighbor's phone . Follow the gas to the appliance if the pilot light goes out . If you supplier's instructions . have trouble lighting the pilot or keeping it lit , it • If you cannot reach your gas supplier , call the fire department . may mean that this safety device is warning you that there is a problem with your system . Installation and service must be performed Inspection and repairs or replacement must be by a qualified installer , service agency or the made by a trained gas service technician . gas supplier . Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance . CRITICAL SAFETY POINTS TO REMEMBER . . . TAMPERING IS DANGEROUS • Your gas has been odorized so that you can smell it . Always smell around for The pilot safety system may also not work if you gas before lighting your appliance . do not follow the lighting instructions carefully or • Sn ! fffor L . E . gas at floor level . LP - gas is heavier than air and may temporarily if you tamper with the gas control that you use to exist at floor level . 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 . IF YOU SMELL GAS , DON'T LIGHT 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 YOU CAN'T LIGHT IT , DON'T FIGHT IT ! 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 Association gama mechanism in the gas control and can create a hazardous condition . THIS IS NOT AN ADVERTISEMENT
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LIMITED WARRANTY Service under this warranty is the responsibility of The Louisville Tin & Stove Co . wan'ants to the installer . In the event service under this warranty is needed , the original user the accompanying product for the period the user of the product shall request such service directly from specified herein , provided said product is installed , the installer . If the user is unable to locate the installer , the operated , maintained , serviced , and used according to user should write directly to the manufacturer , and the name the instructions and specifications accompanying the of an alternative service source will be supplied . product . AS OUTLINED IN OIR INSTRUCTIONS , ANY WARRANTY CONSIDERATIONS ARE The product safety registration card ( packed inside CONTINGENT ON INSTALLATION BY A the appliance ) must be completed and returned to the factory . THIS WARRANTY IS EXPRESSLY IN LIEU OF QI ALIFIED INSTALLER ( CONTRACTOR ) . ANY OTHER WARRANTIES , EXPRESS OR IMPLIED SELF - INSTALLATION IS NOT RECOMMENDED ( WHETHER WRITTEN OR ORAL ) . ANY IMPLIED AND MAY INVALIDATE YOIR _ ARRANTY . WARRANTY OF MERCHANTABILITY OR OF FITNESS If within a period of one year from the date of FOR A PARTICULAR PURPOSE IS EXPRESSLY LIMITED installation of the product , any part supplied by the TO THE DURATION OF THE MANUFACTURER'S manufacturer proves to be detective due to workmanship EXPRESS , WRITTEN WARRANTY . or material , it will replace such part , provided parts have UNDER NO CIRCUMSTANCES SHALL THE not been subjected to misuse , alteration , neglect , or MANUFACTURER BE LIABLE FOR ANY SPECIAL , accidents . The term of the warranty for the heat INDIRECT OR CONSEQUENTIAL DAMAGES OR exchanger is covered in Table A below . Any claim not EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM made within ten ( 10 ) days after the expiration of the ANY COMPONENT OR FROM THE USE THEREOF . THE warranty period shall be deemed waived by the user . REMEDIES SET FORTH HEREIN SHALL BE THE The manufacturer shall have no liability or be EXCLUSIVE REMEDIES AVAILABLE TO THE USER AND required to perform any obligation under this warl " anty ARE IN LIEU OF ALL OTHER REMEDIES . unless , when requested , the user returns , at the user's SOME STATES DO NOT ALLOW LIMITATIONS expense , the component or product claimed defective , ON HOW LONG AN IMPLIED WARRANTY LASTS , SO to the manufacturer for inspection , to enable the THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU . manufacturer to determine if the claimed defect is SOME STATES DO NOT ALLOW THE covered by this warranty . EXCLUSION OR LIMITATION OF INCIDENTAL OR No charges for freight , labor or other CONSEQUENTIAL DAMAGES , SO THE ABOVE expenses incurred in the repair , removal , or LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO replacement of any product or component claimed to YOU . be defective , will be paid by the manufacturer to the THIS WARRANTY GIVES YOU SPECIFIC LEGAL user , and the manufacturer will not be liable for any RIGHTS , AND YOU MAY ALSO HAVE OTHER RIGHTS , expenses incun'ed , by the user , in remedying any WHICH VARY , FROM STATE TO STATE . defect in the product . TABLE A Warranty for gas appliance heat exchangers only . Product Wananty Period 10 Years Cozy Gas Fired Floor Furnace 10 Years Cozy Gas Fired Wall Furnace 10 Years Cozy Gas Fired Vented Console Heater 10 Years Cozy Gas Fired Direct Vent Heater 10 Years Cozy Gas Fired Counterflow Furnace If . 10 Years Cozy Gas Fired Counterflow Direct Vent Furnace 10 Years Cozy Gas Fired Direct Vent Baseboard Heater 10Years Cozy Gas Fired Hi - Efficient Direct Vent Wall Furnace LOUISVILLE TIN AND STOVE COMPANY P . O . Box 2767 Louisville , Kentucky 40201 - 2767
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