Louisville Tin and Stove DVCF403B-R User's Manual
Contents
1. Replace cabinet door Page 8 Do not force LIGHTING INSTRUCTIONS DVCF407B DVCF408B DVCF557B DVCF558B FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device which e If you cannot reach your gas supplier call the fire automatically lights the pilot Do not try to light the department pilot by hand BEFORE LIGHTING smell all around the appliance area C Use only your hand to push in or slide the gas control for gas Be sure to smell next to the floor because some lever Never use tools If the lever will not push in or gas is heavier than air and will setting on the floor slide by hand don t try to repair it call a qualified service technician Force or attempted repair may result WHAT TO DO IF YOU SMELL GAS in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under Do not touch any electric switch do not use any phone water Immediately call a qualified service technician in your building to inspect the appliance and to replace any part of the Immediately call your gas supplier from a neighbor s control system and any gas control which has been phone Follow the gas supplier s instructions under water LIGHTING INSTRUCTIONS STOP Read the information on the safety label 82. tions exactly BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to push in or slide the gas control lever Never use tools If the lever will not push in or slide 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 LIGHTING INSTRUCTIONS STOP Read the information on the safety label Set thermostat to lowest setting Turn off all electric power to the appliance Remove cabinet door Push in gas control lever slightly and slide right to OFF Max High Pressure Ge gt Gas Control Lever NOTE Knob can not be moved to OFF unless it is pushed in slightly Do not force Step Pressure Regulator Wait five 5 minutes to clear out any gas Then smell for gas incl
3. Manifold Burner Orifice Natural Gas Burner Orifice L P Gas Fan Motor Fan Blade Rubber Grommet Limit Switch 60T11 L220F Limit Switch 60T11 L180F Fan Switch 60T12 120 15 Deg F Speed Switch 60T13 F160 30 Aux Limit Switch 60T15 L350 Thermostat 24 Volt Transformer Transformer Plate Terminal Board Pilot 0 140 512 Natural Gas Pilot 0 140 502 L P Gas Cozy Handle Thermostat Wire Thermocouple Q309A1954 Insulated Staples Pilot 3S 24F Natural Gas Pilot 3S 24F L P Gas Wiring Harness Flame Sensor S 1 CONTINUED r Contractor we only sell parts through our wholesalers but the prices listed above are for your conve ience For prompt parts service contact the wholesaler from which you purchased your Cozy heater NOTE Parts amp schematic drawings on current models are shown at www cozyheaters com MARCH 2005 Page 19 weu Le MODEL NUMBER L P parroescnipion he PART DESCRIPTION NO N Power Cord Sight Glass Assembly Sight Glass Cover Sight Glass Gasket Burner Box Gasket Slip Joint Assembly w Gaskets Slip Joint Gasket Slip Joint Ring Gasket Slip Jt Ring Gsk 2 pc Graphite Flue Outlet Pipe Gasket Air Intake Pipe Gasket Heat Exchanger Cover Plate Heat Exchanger Cover Plate Gasket Burner Box Inlet Gasket Exhaust Pipe Gasket Manifold Gasket Piezo Igniter Igniter Wire 0 028 508 Spark Igniter SP715 Natural Gas Spark Igniter SP845 L P Gas Heat Exchanger Kit Vent Cap Assembly Complete
4. Thermostat not set high enough to call 2 Set thermostat to higher temperature for heat 3 Clogged burner orifice 3 Clean burner orifice do not enlarge 4 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 1 Defective or damaged thermostat wire 1 Can be checked by removing wire from valve terminal or thermostat If valve goes off 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 1 Gas input not checked 1 Re check gas input 2 Clogged orifice 2 Clean orifice with a smooth wood toothpick do not enlarge Not enough heat 1 Furnace undersized 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 Thermostat set too low 2 Raise temperature setting Incorrect supply pressure 3 Check supply pressure Too much heat Thermostat set too high 1 Lower temperature setting Combination control valve stuck open 2 Replace combination control valve Pilot and main burner Weak thermocouple 1 Check millivoltage and replace if low go out during normal
5. 3 35 440 144 Lbs Page 2 99 E En 10 11 12 13 14 15 16 17 18 19 SAFETY RULES 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 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 NFPA70 In Canada see the current CSA C22 2 Canadian Electrical Code available from International Approval Services 178 Rexdale Boulevard Etobicoke Ontario Canada M9W IR3 Do not install this furnace in a recreational vehicle or trailer 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 Never use a match candle flame or other source of ignition to check for gas leaks Use only soapy water or liquid detergent Before cleaning or servicing turn off the gas and allow furnace to cool Do not operate furnace without grilles and front panel in pla
6. 4 5m above the meter assembly 3 Feet 91 cm J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance K Clearance to a mechanical air supply inlet L Clearance above paved sidewalk or paved driveway located on public property 12 Inches 80 cm 6 Feet 1 83 m 7 Feet 2 13m A vent shall not t directly above a sidewalk or por driveway that is located betwee single family dwellings and serve dwellings M Clearance under veranda porch deck or balcony 12 Inches 80 cm permitted onh veranda porch deck or balcon open on a minimum of two side tin accordance with the current CSA B149 1 Natural Gas and Prop Page 4 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 SIDEWALL 6 The minimum clearance from any overhanging projection is 24 4 Minimum to top of vent cap See Figure
7. Cord a E Povver Cord Green Black Green Black Terminal Board Motor Black Terminal Board Motor Black Ground oreen Go Transformer Black Ground Gren Transformer Black Green Power Cord White Green Power Cord White P N91123 P N 91122 DVCF557B 558B 653B 654B DVCF403B 404B 407B 408B 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 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 MAINTENANCE INSTRUCTION For proper and safe operation keep furnace and furnace area clean At regular intervals turn control valve off let cool and clean inside control compartment To clean cabinet use only a damp cloth Do not use any kind of solvent 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 bearings 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 safe and efficient operation FIGURE 10 Examine the venting system as a routine part of the safety performance check
8. Input too high 2 Check input rate operation Cover around pilot lighter hole not 3 Tighten wing nuts securing cover and sight glass air tight Check and replace gasket if needed Vent tubes not properly installed or 4 Follow instructions Check both exhaust and air sealed 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 Page 16 TROUBLE SHOOTING CHART Continued SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Burner won t turn on Gas valve not turned on Turn gas valve to on position No voltage to valve Check for 24 Volts to valve from transformer Defective thermostat Check wall thermostat No 115 V Line voltage Provide line voltage Gas valve defective Replace gas valve Manual reset switch not engaged Depress red button on switch STANDING PILOT Air in line Bleed line Defective thermocouple Replace thermocouple Pilot won t light or Pilot flame too low Adjust pilot flame stay lit Manual reset switch not engaged Depress red button on switch LI D PILOT Sparker won t work Check wire connections provide adequate ground Pilot won t light Sparker won t light pilot a Pilot flame too small b Turn valve to on position c Check for pilot restriction Manual reset switch not engaged Depress red button on switch SERVICE RECORD SE
9. Set the thermostat to it s lovvest setting Turn off all electric povver to the appliance Maximum High This appliance is equipped with an ignition device which Pressure Regulator Gas Control automatically lights the pilot Do not try to light the Lever pilot by hand Remove cabinet door Slide gas control lever left to ON Push in gas control lever slightly and slide right gt to OFF Maximum High Pressure Regulator Gas Control Outlet Manifold Ke Tap NOTE Lever can not be moved to Step Pressure Regulator OFF unless it is pushed in slightly Do not force D Replace cabinet door Turn on all electric power to the appliance Set thermostat to desired setting e If the appliance will not operate follow the Step Pressure Regulator instructions TO TURN OFF GAS TO Wait five 5 minutes to clear out any gas Then small APPLIANCE and call your service technician or for gas including near the floor If you smell gas STOP gas supplier 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 Turn thermostat to it s lowest setting Turn off all electric power to the appliance if service is to be performed Remove cabinet door Push in gas control lever slightly and slide gt to OFF Do not force Replace cabinet door Outlet Manifold Pressure Ta Page 9 PILOT ADJUSTMENT Locate t
10. installer the user should write directly to the manufacturer and the name of an alternative service source will be supplied The product safety registration card packed inside the appliance must be completed and returned to the factory THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED WHETHER WRITTEN OR ORAL ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE IS EXPRESSLY LIMITED TO THE DURATION OF THE MANUFACTURER S EXPRESS WRITTEN WARRANTY UNDER NO CIRCUMSTANCES SHALL THE MANUFACTURER BE LIABLE FOR ANY SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES OR EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM ANY COMPONENT OR FROM THE USE THEREOF THE REMEDIES SET FORTH HEREIN SHALL BE THE EXCLUSIVE REMEDIES AVAILABLE TO THE USER AND ARE IN LIEU OF ALL OTHER REMEDIES SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE TABLE A Warranty for gas appliance heat exchangers only Product Warranty Period Cozy Gas Fired Floor Furnace Cozy Gas Fired Wall Furnace Cozy Gas Fired Vented Console Heater Cozy Gas Fired Direct Vent Heater 1
11. 0 Years 10 Years 10 Years 10 Years AAAA y ANAAAANANAAA PA AAAAAA VATA 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 10 Years 10 Years 10 Years 10 Years LOUISVILLE TIN AND STOVE COMPANY P O Box 2767 Louisville Kentucky 40201 2767 TATATATA ATAATA TA Ga
12. 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 D FLOOR 0 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 FIGURE 2 DVCF403B 404B 407B AND 408B FIGURE 2B DVCF557B 558B 653B AND 654B Page 5 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 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 4 Donot install the furnace in a closet alcove or small hallway where the furnace could be isolated from the spa
13. 40 000 BTU and 68 1 2 for 55 000 and 62 500 BTU models Be sure both cutouts are level with each other INSTALLING THE FURNACE The vent system supplied with this furnace will accommodate walls 34 when recessed up to 12 thick Use only the exhaust tube air intake tube and vent cap supplied with heater Do not attempt to lengthen the exhaust or air intake tubes this could cause an imbalance in the heater resulting in poor performance and pilot outage See Figure 6 Measure exact distance X between surface on which back of cabinet will rest inside of recessed cavity or face of wall when freestanding and the outside wall surface see Figure 6 Inlet Air Tube A Measuring from gasketed surface mark and cut pipe same as dimension X Remove any burrs Vent Exhaust Tube B Measuring from gasketed surface mark and cut pipe 1 3 4 greater than dimension X Remove any burrs Fasten vent exhaust tube B to heat exchanger collar and Inlet Air Tube A to flange on back of furnace using 16 3 8 screws C provided Be sure gaskets are in place and not damaged Anytime the vent pipes are removed check and replace gaskets if necessary Failure to replace missing or damaged gaskets may expose homeowner to life threatening conditions Secure furnace in place using 2 holes provided in bottom of casing NOTE Make sure both tubes are centered in cut out Slide the vent cap
14. D INSTALLER CONTRACTOR SELF INSTALLATION IS NOT RECOMMENDED AND MAY 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 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 under this warranty is needed the user of the product shall request such service directly from the installer If the user is unable to locate the
15. DIRECT VENT COUNTERFLOW WALL FURNACE INSTALLATION AND OPERATING INSTRUCTIONS Ne P N 72900 REV 12 03 EATIFIED i B 24 VOLT SYSTEM WITH LOW BTU PILOT 24 VOLT SYSTEM W INTERMITTENT IGNITION IID MODEL NUMBERS NAT GAS 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 Donot 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 could result in Carbon Monoxide CO poisoning and possible death For your safety this furnace and the vent system should b
16. RVICE RECORD Page 17 DIRECT VENT COUNTERFLOW WALL FURNACE MODELS DVCF403B R DVCF404B R DVCF407B R DVCF408B R DVCF557B R DVCF558B R DVCF653B R DVCF654B R 5 SPARK IGNITER LI D Prices and specifications subject to change without notice All prices are F O B factory BURNER ASSEMBLY DVCF40B R DVCF55B R DVCF65B R SERIES 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 amp schematic drawings on current models are shown at www cozyheaters com Page 18 HOW TO PROPERLY ORDER PARTS In addition to part description and part number please give model number serial number and type of gas used MODEL NUMBER P DVCF404B R DVCF408B R DVCF558B R DVCF654B R PART DESCRIPTION NO NO PRICE NO PRICE NO PRICE NO PRICE Casing Side Right la Casing Side Left 1b Center Front Panel Assembly 1c Top Assembl 1d Upper Back Assembly Lower Back Assembly Bottom Assembly Casing Mounting Brackets Liner Assembly Fan Shroud Assembly Top Louver Bottom Louver Assembl Upper Front Shield Switch Box Switch Box Cover Lower Front Shield Motor Mounting Bracket Burner Pilot Bracket Valve 7200ER Natural Gas 137 90 137 90 Valve 7200ER L P Gas 137 90 137 90 Valve 7200IPER Natural Gas 129 00 129 00 Valve 7200IPER L P Gas 129 00 129 00
17. Vent Cap Spacer Plate Assembly Vent Cap Mounting Kit Air Intake Pipe Assembly Vent Exhaust Pipe Assembly Elbow 3 8x90 Degree Air Drop Assembl Burner Box Bottom Assembly Burner Access Door Burner Access Gasket 90 Deg Pilot Fitting Pilot Tube Bracket Vent Terminal Shield Pilot Tubing w Fittings Pilot Tube Gasket HOW TO PROPERLY ORDER PARTS In addition to part description and part number please give model number serial number and type of gas used A 31 32 33 34 50 N A 61 N A 36 37 52 38 39 40 55 41 42 43 43 44 45 DVCF403B R DVCF404B R PART NO LIST PART PRICE NO DVCF407B R DVCF408B R LIST PRICE DVCF557B R DVCF558B R DVCF653B R DVCF654B R PART LIST PART LIST NO PRICE NO PRICE 104 50 143 30 274 60 127 90 14 50 10 70 285 60 127 90 14 50 10 70 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 amp schematic drawings on current models are shown at www cozyheaters com Page 20 MARCH 2005 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 inform
18. ation 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 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 IF YOU SMELL GAS DON T LIGHT IT IF YOU CAN T LIGHT IT DON T FIGHT IT MAG Se American Gas Association gama THIS IS NOT AN ADVERTISEMENT WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer servic
19. ce Due to high temperatures locate furnace 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 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 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 burners and circulating air passageways of the furnace be kept clean Do not put anything around the furnace or vent cap that will obstruct the flow of combustion and ventilation air When installing the furnace allow adequate accessibility clearances for servicing and proper operation See Figure 1 Page 5 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 Do not use this heater if any part has been under water Immediately call a qualified service technician to inspect the heater and to replace any part of the control system which has been under water For your safety
20. ce See Figure 4 I 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 5kPa 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 Va psig 3 5kPa FIGURE 5 Page 6 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 for heater between studs on the interior wall and cut out the floor plate between 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 BTU model is 78 518 for the 55 000 and 62 500 models the cut out height is 87 5116 NOTE This dimension may be increased to allow more room for installation and making the wiring connection then refinished Next cut out a 9 1 4 opening in exterior wall for the vent tubes to pass through The center of opening for the 40 000 BTU furnace is 59 the center for opening for 55 000 and 62 500 BTU furnaces is 68 1 2 See Figure 5 on Page 6 If the heater is to be surfaced mounted cut out 9 1 4 opening through the interior and exterior wall The center of cut out will be 59 for
21. ce to be heated by closing a door FIGURE 3 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 terminate in a window well or any other opening below Gas ground level Supply Line INSTALLATION d d Cut OFF 1 8 N P T ELECTRICAL ROUGH IN Valve Pressure Tap For convenience this furnace is equipped with a three prong 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 Amps see Page 2 Specifications and Dimensions ROUGH IN GAS SUPPLY Install a 1 2 inch diameter gas supply line The gas line can enter the cabinet through the right side or bottom See Figure 3 The gas line must have an individual manual shut off valve Also you must install a drip leg and provide a 1 8 N P T plugged tapping accessible for test gauge connection pvckio 159 immediately upstream of the gas supply connection to the DVCF55 65 68 1 2 furna
22. cluded with the thermostat Select a location for the thermostat on an inside wall approximately 5 feet above the floor where it won t be affected by heat or cold sources such as direct sunlight televisions fireplaces hidden hot or cold water pipes drafts etc and a minimum of 4 from the heater The thermostat must never be placed in an adjacent room Connect thermostat wires to thermostat and mount to wall Run wire to furnace and make connections to thermostat wires coming out of top of furnace Use insulated staples provided to secure wire to wall OPERATION This unit uses a step action valve When the heater comes on initially it operates at a lower pressure to insure proper quiet ignition After 20 seconds or less it automatically steps up to the proper manifold pressure with a discernable increase in flame height After the heat exchanger has warmed sufficiently the fan will automatically come on to efficiently transfer the heat into the room NOTE All but the 40 000 BTU unit which is one speed have an automatic two speed fan LIGHTING INSTRUCTIONS DVCF403B DVCF404B DVCF653B DVCF654B FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life Outlet Manifold Pressure Tap This appliance has a pilot which must be lighted by hand When lighting the pilot follow these instruc
23. e 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 CRITICAL SAFETY POINTS TO REMEMBER e Your gas has been odorized so that you can smell it Always smell around for gas before lighting your appliance e Sniff for L P gas at floor level LP gas is heavier than air and may temporarily exist at floor level eGo e 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 e If your E 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 VVVVAI AVAV VV VAAAAAAAAAA RKRNKNNKN AAAAAA INN SINNNNNNNNNNNNN NNN NNN NNN NN VAAAAAAAAAAAAAAAAAAAAAAAA 5 LIMITED WARRANTY The Louisville Tin amp 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 QUALIFIE
24. e inspected at least annually by a qualified service person 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 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 Interes ar ad ep 2 Removing Burner aaa nana anen eneve 10 Specifications and Dimensions 2 Proper Burner Flame 10 Safety RULGSiaicsucasvsvrbessnrsnednmaetaroreras 3 Optional Side Discharge Kit 14 EE ee 4 5 Terminal Block Wings 13 Ett EEN 6 Manual RES t rvi viset 13 e EE 6 Maintenance Instructions aaa aaa esence 13 Operation sp ei erorien ni egen E 7 Trouble eege vi nente En 16 17 Lighting Instructions es 8 9 Parts Drawing seed E AAR ie die 18 Pilot Adjustment 2 deeie deed Ee 10 Parts LIS vecse Davis kunece kushte 19 20 Warranty ons sncavesus vesht aa 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 a
25. gency 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 Type Type Btu Hr Gas Blower Control Gas Input Inlet Finished Dimensions Speed Amps 24 VOLT SYSTEM WITH LOW BTU STANDING PILOT DVCF403B R 24 Volt Nat 40 000 Va 14 5 16 Wx78 5 8 Hx11 3 4 D 1 1 95 320 128 Lbs DVCF404B R 24Volt LP 40 000 Va 14 5 16 Wx78 5 8 Hx11 3 4 D 1 1 95 320 128 Lbs DVCF653B R 24 Volt Nat 62 500 Va 14 5 16 Wx87 5 16 Hx11 3 4 D 2 3 05 440 142 Lbs DVCF654B R 24 Volt LP 62 500 Va 14 5 16 Wx87 5 16 Hx11 3 4 D 2 3 05 440 142 Lbs 24 VOLT SYSTEM WITH INTERMITTENT IGNITION LLD DVCF407B R 24 Volt Nat 14 5 16 Wx78 5 8 Hx11 3 4 D 1 22 320 130 Lbs DVCF408B R 24Volt LP p 14 5 16 Wx78 5 8 Hx11 3 4 D 1 2 25 320 130 Lbs DVCF557B R 24 Volt Nat R S 14 5 16 Wx87 5 16 Hx11 3 4 D 2 3 3 440 144 Lbs DVCF558B R 24Volt LP R 14 5 16 Wx87 5 16 Hx11 3 4 D 2
26. he pilot adjustment screw on the valve The pilot flame should surround at least the top 3 8 of the powerpile pilot generator or flame sensor see Figure 7 The pilot is unregulated so it will be operating at inlet line pressure Max 7 w c for Natural Gas and 11 w c for Propane To decrease the pilot flame turn the screw clockwise SM approximately six full turns to bottom of pilot light channel until you produce sufficient flame at the minimum noise level PILOT FLAME ADJUSTMENT Pilot flame should envelop 3 8 to 1 2 inch of the tip of sensor ae to 1 2 FIGURE7A FIGURE 7B STANDING PILOT LI D PILOT Pilot e Screw Pilot Adj Screw ROBERTSHAW ROBERTSHAW 7200ER SO4 7200IPER SO4 FIGURE7C FIGURE 7D STANDING PILOT LI D PILOT TO REMOVE MAIN BURNER FOR INSPECTION AND CLEANING Turn thermostat to lowest setting and allow furnace to cool Turn off all electric power to furnace Remove lower grille Disconnect gas supply to valve Disconnect wires from gas valve Remove 15 screws holding burner door to burner box Pull door forward to remove complete burner gas valve assembly After inspecting and cleaning place burner assembly back 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 9 Connect gas supply back to valve 10 Turn on electric to furnace 11 Follow lighting in
27. lue backing from adhesive strip on raceway and apply to side of heater 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 Cut 14 inch long bottom section to required length see chart insert power cord remove backing and apply to side of heater Plug power cord into wall receptacle Light the heater following lighting instructions TROUBLE SHOOTING CHART SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Flame too large 1 Defective operator section of valve 1 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 1 Clogged burner ports 1 Remove main burner and check for obstructions in throat ports and orifices Clean but do not enlarge ports or orifices 2 Obstructions around vent cap 2 Make sure area around vent cap is clear be sure vent system is sealed 1 Gas leak 1 See Page 1 Delayed Ignition 1 Pilot flame too small 1 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 1 Main gas off 1 Open all manual gas valves 2
28. on an annual basis WARNING This is a gas fired appliance Keep the area clear of gasoline and other flammaable vapors and liquids All combustible material must be kept clear of this area to avoid fire or explosion Page 13 OPTIONAL SIDE DISCHARGE KITS SIDE DISCHARGE ON CASING ROUGH INS FOR SIDE DISCHARGE Use Optional Kit No 306SR A Install plaster grounds as shown in Figure 9 NOTE When Cut out and remove embossed area on casing side side discharge Kit No 30SRB is being used furnace should be Remove knockout from inner liner set exactly 4 from side wall Place 1 1 2 boot from kit through opening matching flanges of boot to knockout on inner liner Mark screw holes and remove boot Drill holes with a 1 8 drill Attach inner boot with screws provided Place grille into position drill holes into casing and attach with screws provided ERSE QO SIN AA 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 Cutout and remove embossed section on casing side 5 Remove knockout on inner liner 6 Put heater into position 7 Place inner boot into position mark and cut boot flush with wall Place outer boot into position mark and cut boot flush with wall 8 Place boot trim into po
29. onto the pipes extending from the back of the furnace A rotating or twisting motion will ease this installation Secure vent cap and vent cap spacer plate to wall causing the vent tubes to have a slight downward pitch This will prevent water from entering Anchors not provided may be required Caulk around vent cap spacer plate with caulking provided NOTE Some framing may be necessary to provide a flat surface against the vent cap spacer plate and to prevent rain from entering the wall opening Page 7 Vent Cap Spacer Plate FIGURE 6 GAS CONNECTION Make the gas connection between the manual shut off valve and the furnace gas control valve with approved 1 2 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 use 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 THERMOSTAT INSTALLATION Follow the instructions in
30. sition slide inner boot through wall from adjacent room and attach to inner liner SIDE REGISTER W BOOT Slide outer boot through wall from adjacent room and attach to casing side 9 Place grill in position and secure to wall KIT NO 30SRB Page 14 14 PEK KIT INSTRUCTIONS 14 PLUG EXTENSION KIT FOR NON RECESSED INSTALLATIONS ONLY 90 Degree UNITS WITH TERMINAL BOARD Outside STEP Corner 1 2 3 3 FT SECTION 4 o KA 7 3FT 10 SECTION 12 13 BOTTOM SECTION 4 14 15 LENGTH OF BOTTOM SECTION REF 4 PLASTIC RACEWAY 5 5 16 Inches 14 Inches 14 Inches NOTE Above lengths terminate approximately 2 inches above floor Page 15 Turn heater off following Section 3 in Lighting Instructions and allow to cool Turn off all electricity to heater Remove top louver assembly fan shroud and fan blade Loosen two screws on romex connector Remove junction box cover plate Disconnect three power cord terminals and pull power cord out of top of heater Insert power cord provided in kit through romex connector and plug onto terminal board following wiring diagram found in lighting and operating instructions Tighten two screws on romex connector Replace junction box cover plate Replace fan blade fan shroud and top louver assembly Snap 90 degree outside corner Ref 1 onto 3 foot section Ref 2 plastic raceway Insert power cord and remove b
31. structions and replace lower grille OE ie It is recommended that the furnace and all components be inspected 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 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 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 free from combustible materials gasoline and other flammable vapors and liquids This heater comes from the factory with the proper burner orifice for elevations up to 2 000 feet Heaters installed above 2 000 feet must be derated 4 for every 1 000 feet For the proper orifice size find the Model Number and elevation on the orifice chart Replace b
32. 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 Side discharge kit boots must not exceed 10 inches 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 MI Vent Terminal Air Supply Inlet Area where terminal is not permitted VENT TERMINAL CLEARANCES REFERENCE LETTER TO DRAWING A Clearance above grade veranda porch deck or balcon B Clearance to window or door that may be opened CANADIAN INSTALLAT 12 Inches 30 cm 12 Inches 30 cm 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 80 cm 18 Inches 46 cm E Clearance to unventilated soffit 24 Inches 61 cm F Clearance to outside corner 12 Inches 80 cm G Clearance to inside corner 12 Inches 30 cm H Clearance to each side of center line extended above meter regulator assembi Clearance to service regulator vent outlet 3 Feet 91 cm within a height 15 Feet
33. uding 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 Open sight glass cover Locate red piezo ignitor button on side of gas control Locate pilot behind sight glass Follow metal pilot tube from gas control Slide gas control lever left to Set and hold Immediately begin a series of pushing and releasing the red piezo ignitor button while observing the pilot through the sight glass Continue to spark until pilot is lit Continue to hold the gas control lever to Set for about one 1 minute after the pilot is lit Release the gas control lever and it will return to Pilot Pilot should remain lit If pilot goes out repeat steps 5 thru 9 If gas control lever does not return to Pilot when released STOP and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries slide the gas control lever to OFF and call your service technician or gas supplier Close sight glass cover Slide gas control lever right gt to ON Replace cabinet Turn on all electric to the appliance Set thermostat to desired setting TO TURN OFF GAS TO APPLIANCE Turn thermostat to it s lowest setting Turn off all electric power to the appliance if service is to be performed Remove cabinet door Push in gas control lever slightly and slide right gt to OFF
34. urner orifice NATURAL GAS 2 000 4 000 6 000 8 000 DVCF403B DVCF404B STANDING PILOT DVCF653B DVCF654B THERMOSTAT LIMIT FAN LIMIT SWITCH SWITCH SWITCH SW BLACK SWITCH AUXILIARY a DVCF403 DVCF404 DVCF653 DVCF654 wt PICTORIAL SCHEMATIC PICTORIAL SCHEMATIC MODEL NO AMPS MODEL NO AMPS DVCF403 1 95 DVCF653 3 05 DVCF404 1 95 DVCF654 3 05 SELECTOR o FAN SWITCH swITCH Q O LIMIT SWITCH 115 V A C TRANSFORMER THERMOSTAT AC THERMOSTAT 24 V A C DVCF403 DVCF653 DVCF404 DVCF654 LADDER LADDER SCHEMATIC SCHEMATIC AUXILIARY AUXILIARY LIMIT LIMIT DVCF407 DVCF408 DVCF557 DVCF558 PICTORIAL PICTORIAL SCHEMATIC SCHEMATIC LIMITSWITCH FAN CZ SWITCH licks SWITCH MODEL NO MODEL NO AMPS DVCF407 DVCF557 3 3 DVCF408 DVCF558 3 35 SELECTOR Se SWITCH FAN SWITCH SWITCH LI LI LIMIT SWITCH LIMIT SWITCH TRANSFORMER TRANSFORMER THERMOSTAT DVCF407 DVCF557 DVCF408 DVCF558 LADDER LADDER SCHEMATIC SCHEMATIC SP715 NAT OR SP735 L P Page 12 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 Fan Limit Switch Brown Fan Limit Switch Brown Selector Switch Power Cord Black Power Cord Black Red Transformer Black Transformer Black Motor of Jo bf Je bff Sten O VV otor witc Red Blue MOTOR White Power
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