Empire Products DV-35T-1 User's Manual
Contents
1. EMPIRE Heating Systems Installer Leave this manual with the appli ance Consumer Retain this manual for future refer ence WARNING If the information in these instruc tions are not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flamma ble 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 suppli er 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 INSTALLATION INSTRUCTIONS AND OWNER S MANUAL DIRECT VENT WALL FURNACE MODELS DV 25ST 1 DV 35T 1 Thisappliancemaybeinstalledinanaftermarket permanently located manufactured home USA only or mobile home where not prohibited by state or 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 WARNING If not installed operated and maintained in accordance with the manufacturer s instructions this product could expose you to substances2. 1 1 2 screws 3 Installation is completed Reassembly And Resealing Vent Air Intake System When vent air intake system is removed for service the furnace the fol lowing steps will assure proper reassembly and resealing of the vent air intake assembly 1 Remove old caulking beneath the collar of the outside mounting plate Apply new caulking beneath the collar of the outside mount ing plate Use additional caulking to correct uneven wall surface such as clapboard 2 Insert six inch air tube on outside mounting plate INTO six inch air tube attached to inlet air drop chute Position the outside mounting plate so that the six inch air tube has a slight downward slope to the outside The downward slope is necessary to prevent the entry of rainwater Attach outside mounting plate to exterior wall with four 4 10 x 1 1 2 screws 3 Place four inch flue tube on vent cap OVER four inch flue tube at tached to combustion chamber Attach vent cap to outside mount ing plate with three 3 10 x 1 2 screws 4 Reassembly and resealing vent air intake system is completed Installing a Vent Near a Window Ledge Other Type of Project or on Siding vinyl aluminum etc Direct vent furnaces are designed to be installed on a uniform outside wall When the wind comes from any angle up down or from either side it must hit the vent cap equally over both the air inlet and the flue outlet portions of the vent Any wall projection such as a
3. 178 Gasket Inlet Collar 27 M 151 B Gasket Pilot Burner 6 13106 Inlet Tube inner Welded Assembly 28 DV 994 Pilot Shield 7 13064 Inlet Tube Outer Assembly 29 R 2224 Pilot Burner with Orifice Nat 8 13059 Outlet Tube Outer Assembly 29 R 2223 Pilot Burner with Orifice LP 9 13053 Vent Cap Welded Assembly 30 DV 772 Electrode and Wire Assembly 0 13051 Wall Mounting Bracket Assembly 31 DV 913 Casing Front USA 1 13089 Inlet Air Drop Chute Assembly 31 15700 Casing Front Canada 2 DV 762 amp DV 763 Gasket Air Drop Chute 2 Each Required 32 P 86 43 Main Burner Orifice DV 25T Nat 3 DV 951 Casing Top 32 P 86 54 Main Burner Orifice DV 25T LP 4 DV 901 Heat Shield 32 P 86 38 Main Burner Orifice DV 35T Nat 5 13278 Inner Casing Assembly USA 32 P 86 50 Main Burner Orifice DV 35T LP 5 15701 Inner Casing Assembly Canada 33 P 190 Manifold 6 RH 705 Casing Side 2 Required 34 R 191 Manifold Union Assembly 7 M 176 Gasket Flue Outlet Support 35 R 5600 Gas Valve Nat 7000 MVRLC 8 13094 Combustion Chamber DV 25T 35 R 5601 Gas Valve LP 7000 MVRLC 8 13091 Combustion Chamber DV 35T 36 DV 1003 Valve Bracket 9 M 155 Gasket Lighting Hole 37 DV 764 amp DV 765 Gasket Chamber Support 2 Each Required 20 DV 781 Lighting Hole Cover Assembly with Clear Mica 38 DV 908 Valve Shield 21 DV 064 Cover Plate 39 R 854 Piezo Ignitor 22 DV 988 Burner DV 25T Not Shown R 1081 Pilot Orifice Nat 22 DV 990 Burner DV 35T Not Shown R 1089 Pilot Orifice L
4. 330mm The use of tubes not supplied by the manufacturer results in unsatisfactory performance The vent terminal of a direct vent appliance with an input of 50 000 14 6 KW BTU per hour or less shall be located at least 9 229mm from any opening through which flue gases could enter a building The bottom of the vent terminal and the air intake shall be located at least 12 305mm above grade WARNING The nearest point of the vent cap should be a minimum horizontal distant of six 6 1 83m feet from any pressure regulator In case of regulator malfunction the six 6 1 83m feet distance will reduce the chance of gas entering the vent cap 2222222 ph Figure 3 Location of Furnace Pick a location on an outside wall with a clear space of 28 71 1mm high by 49 124cm wide in the room Locating Wall Opening The furnace is to be located on an outside wall Locate wall studs so that wall opening will be located between wall studs The wall studs can be used for attachment of wall mounting bracket The wall opening required as shown in Figure 3 is a diameter of 7 1 2 inches 191mm A template is provided in furnace carton for positioning furnace on the wall Also refer to Figure 3 for positioning the furnace on wall and for locating gas line connection Figure 4 will position the furnace four inches off the floor If it is desired to position the furnace higher on the wall add t
5. TO ORDER REPAIR PARTS Parts can be ordered only through your service person or dealer For best results the service person or dealer should order parts through the distributor Parts can be shipped directly to the service person dealer All parts listed in the Parts List have a Part Number When ordering parts first obtain the Model Number from the name plate on your equipment Then determine the Part Number not the Index Number and the Description of each part from the following appropriate illustration and list Be sure to give all this information Furnace Model Number Part Description Furnace Serial Number Part Number Type of Gas Propane or Natural Do not order bolts screws washers or nuts They are standard hardware items and can be purchased at any local hardware store Shipments contingent upon strikes fires and all causes beyond our control Empire Comfort Systems Inc Nine Eighteen Freeburg Ave Belleville IL 62222 0529 PARTS LIST PLEASE NOTE When ordering parts it is very important that part number and description of part coincide Index Part Description Index Part Number Description No Number No 1 13057 Outlet Tube Inner Assembly Includes 2 amp 3 23 R 942 Thermopile 2 M 177 Gasket Outer Collar 24 DV 1004 Pilot Tubing 3 13104 Outlet Tube Inner Welded Assembly 25 RH 238 Burner Door 4 13062 Inlet Tube Inner Assembly Includes 5 amp 6 26 DV 778 Gasket Burner Door 5 M
6. follow metal tube from gas control The pilot is L 2 THERMOPILE PILOT behind the pilot access cover BURNER a Turn knob on gas control counterclockwise 4 N to PILOT Pushin control knob all the way and hold in Immediately 11 12 light the pilot with the Piezo Pilot Ignitor or a match Continue to hold the control knob in for about one 1 minute after the pilot is lit Release knob and it will pop back up Pilot should remain lit If it goes out repeat steps 5 through 10 e If knob does not pop up when released stop and immediately call your service technician or gas sup plier If the pilot will not stay lit after several tries turn the gas control knob to OFF and call your service technician or gas supplier Replace pilot access cover Turn gas control knob counterclockwise to ON 13 Replace casing front assembly 14 15 16 Turn on all electric power to the appliance if appli cable Set thermostat to desired setting CAUTION Pilot access cover must be kept tightly closed during operation GE TO TURN OFF GAS TO APPLIANCE p Set the thermostat to lowest setting Turn off all electric power to appliance if service is to be performed if applicable Remove casing front assembly 4 5 Push in gas control knob slightly and turn clock wise to OFF Do not force Replace casing front assembly 13117
7. requires that a flexible appliance connector cannot exceed three feet in length FLEXIBLE GAS LINE CONNECTION GAS SUPPLY NPT NIPPLE ra TEE HANDLE _ _Eo K DO 0 FLARE FITTING FLEX TUBING RIGID GAS LINE CONNECTION CLOSE NIPPLE NPT NIPPLE TEE HANDLE Le D SHUT OFF VALVE NPT UNION FLARE SHUT OFF VALVE NPT GAS SUPPLY Figure 1 Consult the current National Fuel Gas Code ANSI Z223 1 CAN CGA B149 1 or 2 installation code Installing a New Main Gas Cock Each appliance should have its own manual gas cock A manual main gas cock should be located in the vicinity of the unit Where none exists or where its size or location is not adequate contact your local authorized installer for installation or relocation 13117 9 0907 Compounds used on threaded joints of gas piping shall be resistant to the action of liquefied petroleum gases The gas lines must be checked for leaks by the installer This should be done with a soap solution watching for bubbles on all exposed connections and if unexposed a pressure test should be made Never use an exposed flame to check for leaks Appliance must be disconnected from piping at inlet of control valve and pipe capped or plugged for pressure test Never pressure test with appliance connected control valve will sustain damage A gas valve and ground joint union should be install
8. the grounding prong from this plug For an ungrounded receptacle an adapter which has two prongs and a wire for grounding can be purchased plugged into the ungrounded receptacle and its wire connected to the receptacle mounting screws With this wire completing the ground the appliance cord plug can be plugged into the adapter and be electrically grounded CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing WARNING Unplugging of blower accessory will not stop the heater from cycling To shut heater off Turn temperature dial or thermostat to lowest setting Turn knob on gas control to OFF depressing slightly Do not force Page 17 OPTIONAL BLOWER INSTALLATION INSTRUCTIONS continued Cleaning The blower wheel will collect lint and could require cleaning once a year If the air output decreases or the noise level increases it indicates a dirty wheel Complete removal of the wheel and scrubbing it with a brush under flowing water is recommended Oiling The blower motor has an oil hole located on each end of the motor Use 20 motor oil only It is best to oil the motor several times during the heating season using 2 or 3 drops each time If the motor fails to start and hums it could be a tight bearing due to lack of oil This may be corrected by pouring kerosene in the oil holes allowing to
9. 10 x 1 1 2 screws and fasten two 2 additional 10 x 1 1 2 screws through the wall mounting bracket and into the solid wall On sheet rock wall when using wall studs for attachment of wall mounting bracket fasten wall mounting bracket to wall studs with four 4 10 x 1 1 2 screws or four 4 plastic expansion anchors On Sheet Rock Wall Using Plastic Expansion Anchors 1 After locating mounting holes drill four 4 5 16 diameter holes into the wall 2 Insert four 4 plastic expansion anchors provided into the holes 3 Tighten four 4 10 x 1 screws provided into the plastic expansion anchors See Figure 6 13117 9 0907 STEP 2 Figure 6 Attaching Furnace to Wall Mounting Bracket 1 2 3 Remove casing front from furnace Lay furnace face down on a non abrasive work surface Place collar on four inch flue tube against combustion camber back Align clearance holes on collar with screw holes in combustion chamber Attach four inch flue tube against combustion chamber with four 4 10 x 1 2 screws Place collar on six inch air tube against inlet air drop chute Align clearance holes on collar holes with screw holes in inlet air drop chute Attach six inch air tube to inlet air drop chute with eight 8 10 x 1 2 screws When facing the furnace the two 2 clearance holes for attaching the furnace to the wall mounting bracket are located beneath the casing top and above the combustion chamber Insert tub
10. 9 0907 PILOT FLAME CHARACTERISTICS The correct flame will be almost horizontal blue and will extend past the thermopile 1 4 6mm The flame will surround the thermopile just below the tip On propane LP gas slight yellow might occur where the pilot flame and burner flame meet Natural gas pilots require adjusting when the inlet pressure is above 5 w c 1 25kPa Turn adjustment screw clockwise to reduce flame Propane LP gas will not require adjusting FLAME MUST EXTEND PAST THE THERMOPILE Figure 11 MAIN BURNER FLAME CHARACTERISTICS There will be a short blue inner flame with a much larger lighter blue secondary flame The burner flame may have a yellow tip when hot See the burner drawing showing the approximate heights of each part of the flame Dust in the combustion air will produce an orange or red flame Do not mistake the orange or red flame for an improper yellow flame After use cleaning may be required for the proper flame BURNER FLAME Figure 12 13117 9 0907 Primary Air Adjustment Figure 13 An air adjustment bolt is located on the chamber support bottom The four inch 102mm clearance between the furnace and the floor allows access to the air adjustment bolt The air adjustment bolt is above the rectangular opening on the inner casing bottom On Propane gas if a whistling noise resonation occurs screw air adjustment bolt into the chamber support in order to
11. DE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 13117 9 0907 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inchinsize GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Pro
12. P Not Shown R 5788 Wall Thermostat Millivolt Not Shown 13271 Wall Thermostat Bracket Not Shown DV 885 Hardware Package USE ONLY MANUFACTURER S REPLACEMENT PARTS USE OF ANY OTHER PARTS COULD CAUSE INJURY OR DEATH 13117 9 0907 Page 15 PARTS VIEW O DV 35T 1 SHOWN Sue sss IN Dem Page 16 13117 9 0907 OPTIONAL BLOWER INSTALLATION INSTRUCTIONS OPTIONAL BLOWER DRB 1 Installing Optional DRB 1 Blower 1 Remove casing from front and heat shield 2 When facing appliance insert blower assembly into the left section of the casing adjacent to the combustion chamber 3 Route cordsetthrough opening in casing in bottom The opening in casing bottom is located beneath gas control 4 Align the two 2 screw holes on the inner side panel and the two 2 screw holes on casing back with the four 4 clearance holes on the blower assembly Attach blower assembly to the casing back and inner side panel with four 4 10 x 1 2 screws provided The blower assembly must be attached first to the casing back and then to the casing side panel 5 Replace heat shield and casing front Attention Wiring harness on blower is factory assembled and installed If wiring harness becomes disassembled use the following steps to reassemble the wiring harness 1 Attach 1 pin terminal from black hot wire smooth insulation on cord set to 1 socket terminal on fan control assembl
13. alve it will result in a hazardous condition Checking Manifold Pressure Both Propane and Natural gas valves have a built in pressure regulator in the gas valve Natural gas models will have a manifold pressure of approximately 4 0 w c 996kPa at the valve outlet with the inlet pressure to the valve from a minimum of 5 0 w c 1 245kPa for the purpose of input adjustment to a maximum of 10 5 w c 2 61kPa Propane gas models will have a manifold pressure approximately 10 0 w c 2 49kPa at the valve outlet with the inlet pressure to the valve from a minimum of 11 0 w c 2 739kPa for the purpose of input adjustment to a maximum of 13 0 w c 3 237kPa A 1 8 3mm N P T plugged tapping accessible for test gauge connection is located on the outlet side of the gas control Page 7 CLEARANCES 1 Inselecting a location for installation it is necessary to provide adequate accessibility clearances for servicing and proper installation 2 Unit is supported by a wall bracket secured to the wall 3 Theminimumclearances from casingto combustible construction is 48 121cm ontop 6 152mm on each side and 4 102mm from the floor or from the top surface of carpeting tile or other floor covering and 0 Omm to rear wall 4 The minimum distance from the center of the vent cap to the nearest outside corner or obstruction is 24 610mm 5 The DV 25 and DV 35 minimum wall depthis 4 1 2 114mm and the maximum is 13
14. artments burners and circulating air passageways of the appliance be kept clean DO NOT put anything around the furnace that will ob struct the flow of combustion and ventilation air DO keep the appliance area clear and free from combus tible material gasoline and other flammable vapors and liquids DO examine venting system periodically and replace damaged parts DO make a periodic visual check of pilot and burner Clean and replace damaged parts CAUTION Pilot hole cover must be kept tightly closed during operation e Installation and repair should be done by a QUALIFIED SERVICE PERSON The appliance should be inspected before use and at least annually by a qualified service person More frequent cleaning may be required due to e 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 and any gas control which has been under water VENT KIT INFORMATION Attention The DV 25T and DV 35T direct vent wall furnaces are provided with vent kit DV4T 59 1 for wall depths of 5 to 9 For wall depths greater than 9 refer to Accessories Page 6 Listed below are the vent kits Attention The minimum wall depth for installation of a DV 25T or DV35T MUST BE 5 If the wall depth is less than 5 you can order DV 822 refer to Accessories Page 6 or refer to Figure 7 and Figure 8 with accompanying text Page 10 T
15. door or win dow casing which disturbs the wind on one side of the air inlet section will result in back pressure on the flue section smothering the flame and eventual pilot outage When the vent cap is to be installed on siding or it appears that a pro jection within 6 of any side of the air inlet section could shield the air inlet section the entire vent should be supported away from the wall at least the distance of the projection 2 x 4 framing whose outside dimensions match the overall dimensions of the mounting plate is rec ommended The 2 x 4 framing protects siding from possible warpage or discoloration All joints can then be sealed and painted The wall depth plus the additional depth of the 2 x 4 framing should not exceed a total depth of 19 for DV 25T and DV 35T See Figure 7 Refer to Vent Kits page 3 Page 10 Vinyl siding vent kit DV 822 is available from Empire Comfort Sys tems Inc The depth is 3 which enables the vent cap to be extended away from siding or projections The wall depth plus the additional 3 depth of the vinyl siding vent cap extension should not exceed a total depth of 19 for DV 25T and DV 35T See Figure 8 Refer to Vent Kits page 3 Warning When vinyl siding vent kit DV 822 or 2 x 4 fram ing is added to an existing installation furnace is installed do not attempt to add sections of pipe to the flue outlet tube or air inlet tube An air tight seal is required for both tubes R
16. duct Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 Acomplete parts list forthe venting system design or venting system e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instruc tions shall remain with the appliance or equipment at the completion of the installation Page 5 INTRODUCTION Introduction Always consult your local Building Department regarding regulations codes or ordinances which apply to the installation of a direct vent wall furnace Instructions to Installer 1 Installer must leave instruction manual with owner after installation 2 Installer must have owner fill out and mail warranty card supplied with furnace 3 Installer should show owner how to start and operate furnace and thermostat Warning Any change to this furnace or its control can be dangerous This is a heating appliance and any panel door or guard removed for servicing an appliance must be replaced prior to operating the appliance Genera
17. e cleaned by forcing water into the ports and the throat of the burner The main burner should be blown dry or heated to remove water from main burner Removing Main Burner Orifice 1 Open the brass union located after the gas valve 2 Loosen valve bracket 3 Remove the 3 8 10mm manifold pipe that is attached to the union elbow until the manifold pipe is free 4 The main burner orifice is at the end of the manifold pipe Removing Pilot Orifice 1 Disconnect the pilot supply line at the pilot burner 2 Remove pilot orifice from pilot burner It may be necessary to tap on pilot burner in order to remove the pilot orifice Cleaning Pilot Orifice After use cleaning of the pilot burner may be required for the proper flame Also cleaning of the pilot burner may be required due to spiders spider webs The pilot orifice can be cleaned with high pressure air or by placing under running water Pilot orifice must be dry before replacement Use a pipe cleaner to clean inside the pilot after the pilot orifice has been removed Cleaning Combustion Chamber When the main burner and vent cap are removed all internal areas of the combustion chamber are accessible for cleaning with a vacuum hose TROUBLESHOOTING 1 Lit match goes out as it enters lighter port a Certain wind conditions will blow out match Ignite match and as it flares thrust match through opening b Open nearby door or window and relight pilot 2 Pilot flam
18. ed in the gas line upstream ofthe gas control to aid in servicing It is required by the National Fuel Gas Code that a drip line be installed near the gas inlet This should consist of a vertical length of pipe tee connected into the gas line that is capped on the bottom in which condensation and foreign particles may collect 1 8 NPT PLUGGED HOLE FOR TEST GAGE GAS SUPPLY PIPING MANUAL SHUT OFF VALVE GROUND JOINT UNION IN GAS SUP REN u ql I INLET 1 8 NPT PLUGGED HOLE FOR TEST GAGE Figure 2 Method of Installing a Tee Fitting Sediment Trap Pressure Testing of the Gas Supply System 1 To check the inlet pressure to the gas valve a 1 8 3mm N PT plugged tapping accessible for test gauge connection must be placed immediately upstream of the gas supply connection to the appliance 2 The appliance and its individual shutoff 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 5 kPa 3 The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 5 kPa Attention If one of the above procedures results in pressures in excess of 1 2 psig 14 w c 3 5 kPa on the appliance gas v
19. efer to Vent Kits page 3 to order tubes APPLY CAULKING OUTSIDE MOUNTING PLATE Figure 7 APPLY CAULKING 2X4 FRAMING OUTSIDE MOUNTING P Figure 8 VENT CAP EXTENSION 13117 9 0907 THERMOSTAT LOCATION Millivolt wall thermostats are specially designed for use on self generating systems They should never be used on line or low voltage A C circuits IF BRACKET IS INSTALLED AFTER UNIT IS IN PLACE DRILL HOLE INTO CASING SIDE AND ATTACH HERE THERMOSTAT WITH BRACKET USE THIS EXISTING SCREW TO MOUNT BRACKET IF INSTALLING BEFORE UNIT IS AGAINST THE WALL PARTIAL VIEW OF LEFT REAR CORNER Figure 9 Interior Wall The thermostat can also be installed on an inside wall away from the furnace but in the same room It is important to use wire of a gauge proper for the length of the wire RECOMMENDED WIRE GAUGES Maximum Length Wire Gauge l to 10 18 10 to 25 16 25 to 35 14 Proper operation depends on a good pilot flame The flame must cover the top of the thermopile Cleaning of the pilot orifice and burner may be required due to spiders System Check Figure 10 A millivolt meter is required to check the system Millivolt readings should be e Across the terminals 400 450 millivolts with thermostat OFF e Across the thermopile terminals 150 250 millivolts with thermostat ON Across the thermostat wires at the millivolts with ther
20. es but goes out when knob is released a See Lighting Instructions Relight Pilot b Relight the pilot and hold knob down longer and harder Close lighter hole cover just after igniting Check for a good pilot flame c Defective thermopile or defective magnet in safety section of valve Replace 3 Yellow pilot flame a Obstruction at pilot orifice b Clean pilot orifice Page 14 4 Pilot and main burner go out during normal operation Check millivolts Check for proper size of pilot flame Check for defective or weak thermopile Check input reduce as needed Cover on pilot lighter hole must be air tight Check for tight fit of air and flue tubes at both ends of vent assembly No obstruction around vent that would prevent the wind from hitting all of the vent equally Bonocop 5 Thermostat does not turn the main burner on a Check wiring b Check all millivolt readings c Check for spider in main burner orifice 6 Yellow main burner flame soot on the vent cap a See Page 13 Primary Air Adjustment b Remove main burner to check for obstructions in throat and ports c Install new main burner orifice and pilot orifice Refer to Parts List page 15 7 On Propane gas if a whistling noise resonation occurs a See Page 13 Primary Air Adjustment b Reduce manifold pressure c Size main burner orifice with a drill bit For DV 25 use 54 drill bit For DV 35 use 50 drill bit 13117 9 0907 HOW
21. es through wall opening as you hang the furnace on the wall mounting bracket by aligning two 2 tabs on the wall mounting bracket with two 2 slots located on inner casing top Attention You must support the weight of the furnace until the fur nace is attached to the wall mounting bracket Attach furnace to wall mounting bracket with two 2 10 x 1 2 screws Attention You will need a 5 16 socket with a 10 12 extension to attach furnace to wall mounting bracket The inner casing bottom is to be fastened to the wall On solid wall fasten inner casing bottom with two 2 10 x 1 1 2 screws On sheet rock wall fasten inner casing bottom with two 2 plastic ex pansion anchors Page 9 Installing Vent Assembly Attention Do not attempt to cut vent tubes When you order appropriate vent kit for measured wall depth the vent tubes will fit together 1 Place provided caulking beneath the collar of the outside mounting plate Use additional caulking to correct uneven wall surface such as clapboard 2 Insert six inch air tube on outside mounting plate INTO six inch air tube attached to inlet air drop chute Place four inch flue tube on vent cap OVER four inch flue tube attached to combustion cham ber Position the outside mounting plate so that six inch air tube has a slight downward slope to the outside The downward slope is necessary to prevent the entry of rainwater Attach outside mounting plate to exterior wall with four 4 10 x
22. he difference to the A B and C dimensions Note The vent opening is not in the center of the furnace Page 8 WALL MOUNTING Pb 14 Il 2 x 4 STUDS BRACKET 1 i 16 ON CENTER I I i SR besas 7 1 2 DIA WALL OPENING 1 17 11716 4 21 172 je 15 172 37 GAS INLET TO VALVE Figure 4 13117 9 0907 INSTALLATION INSTRUCTIONS continued DV 25 SHOWN UNIT IS SUPPORTED BY WALL BRACKET x OUTSIDE WALL ae MIN WALL DV 25 DV 35 MOUNTING PLATE CAULK UNDER FLANGE VENT CAP AVA OUTLET TUBE OUTER INLET TUBE OUTER OUTLET TUBE INNER STEN INLET TUBE INNER UNIT FASTENED TO WALL WITH 2 SCREWS 7772 Ir Installing Wall Mounting Bracket Locate and cut wall opening If there is insulation above the wall open ing air inlet tube a barrier should be installed above the wall opening air inlet tube to prevent insulation from coming in contact with the air inlet tube The barrier must not penetrate into the 7 1 2 diameter wall opening Place the flat surface of the wall mounting bracket toward the wall Insert half round flange of wall mounting bracket into and at the top of the wall opening Level the wall mounting bracket in the wall opening GAS INLET TO REAR OF CASING Figure 5 On solid wall when using wall studs for attachment of wall mounting bracket fasten wall mounting bracket to wall studs with two 2
23. hough you may not continue to smell gas do not turn on the gas again Do not re enter the building vehicle trailer or area Finally let the service man and firefighters check for escaped gas Have them air out the area before you return Properly trained LP Gas service people should repair the leak then check and relight the gas appliance for you NO ODOR DETECTED ODOR FADE Some people cannot smell well Some people cannot smell the odor of the chemical put into the gas You must find out if you can smell the odorant in propane Smoking can decrease your ability to smell Being around an odor for a time can affect your sensitivity or ability to detect that odor Sometimes other odors in the area mask the gas odor People may not smell the gas odor or their minds are on something else Thinking about smelling a gas odor can make it easier to smell The odorant in LP gas is colorless and it can fade under some circumstances For example if there is an underground leak the movement of the gas through soil can filter the odorant Odorants in LP Gas also are subject to oxidation This fading can occur if there is rust inside the storage tank or in iron gas pipes The odorant in escaped gas can adsorb or absorb onto or into walls masonry and other materials and fabrics in a room That will take some of the odorant out of the gas reducing its odor intensity LP Gas may stratify in a closed area and the odor intensity could vary at d
24. ifferent levels Since it is heavier than air there may be more odor at lower levels Always be sensitive to the slightest gas odor If you detect any odor treat it as a serious leak Immediately go into action as instructed earlier SOME POINTS TO REMEMBER Learn to recognize the odor of LP gas Your local LP Gas Dealer can give you a Scratch and Sniff pamphlet Use it to find out what the propane odor smells like If you suspect that your LP Gas has a weak or abnormal odor call your LP Gas Dealer Ifyouare not qualified do not light pilot lights perform service or make adjustments to appliances on the LP Gas system If you are qualified consciously think about the odor of LP Gas prior to and while lighting pilot lights or performing service or making adjustments Sometimes a basement or a closed up house has a musty smell that can cover up the LP Gas odor Do not try to light pilot lights perform service or make adjustments in an area where the conditions are such that you may not detect the odor if there has been a leak of LP Gas Odor fade due to oxidation by rust or adsorption on walls of new cylinders and tanks is possible Therefore people should be particularly alert and careful when new tanks or cylinders are placed in service Odor fade can occur in new tanks or reinstalled old tanks if they are filled and allowed to set too Page 4 long before refilling Cylinders and tanks which have been out of service for a
25. in fuel or from fuel combustion which can cause death or serious illness Page 1 TABLE OF CONTENTS SECTION Important Safety Information Vent Kit Information Safety Information for Users of LP Gas Requirements for Massachusetts Introduction Specifications Gas Supply Clearances Installation Instructions Thermostat Location Lighting Instructions Pilot Flame Characteristics Main Burner Flame Characteristics Maintenance Troubleshooting How to Order Repair Parts Parts List Parts View Optional Blower Installation Instructions Service Notes Page 2 13117 9 0907 IMPORTANT SAFETY INFORMATION THIS IS A HEATING APPLIANCE DO NOT OPERATE THIS APPLIANCE WITHOUT FRONT PANEL INSTALLED Dueto high temperatures the appliance should be located out of traffic and away from furniture and draperies Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing ignition Young children should be carefully supervised when they are in the same room as the appliance Clothing or other flammable material should notbe placed on or near the appliance Any safety screen or guard removed for servicing an appliance must be replaced prior to operating the ap pliance Keep burner and control compartment clean Vent cap hot while furnace is in operation excessive lint from carpeting bedding materials etc It is imperative that control comp
26. l Information This furnace is design certified in accordance withAmerican National Standard CSA Standard Z21 86 and CSA 2 32 by the Canadian Standard Association as a Gravity Direct Vent Wall Furnace to be installed on an outside wall according to these instructions Any alteration of the original design installed other than as shown in these instructions or use with a type of gas not shown on the rating plate is the responsibility of the person and company making the change Important All correspondence should refer to complete Model No Serial No and type of gas Notice During initial firing of this unit its paint will bake out and smoke will occur To prevent triggering of smoke alarms ventilate the room in which the unit is installed Installation in Residential Garages Gas utilization equipment in residential garages shall be installed so that all burners and burner ignition devices are located not less than 18 457mm above the floor Such equipment shall be located or protected so it is not subject to physical damage by a moving vehicle Qualified Installing Agency Installation and replacement of gas piping gas utilization equipment or accessories and repair and servicing of equipment shall be performed only by a qualified agency The term qualified agency means any individual firm corporation or company which either in person or through a representative is engaged in and is responsible for a the installation o
27. mostat ON e Across the thermostat wires at the thermostat less than 5 millivolts with thermostat ON Strong winds dirty pilot and low pres sure will reduce readings thermopile valve less than 30 Piezo Pilot Ignitor Instructions Depressing the button completely causes a spark to occur at the pilot This is a substitute for a match which requires opening the pilot hole cover 13117 9 0907 To light the pilot it is important that the electrode be 1 8 3mm from the thermopile The spark must occur at the point the burner flame hits the thermopile The end of the electrode will be red hot with the pilot on On a new installation with air in the gas line it is suggested that a match be used The match will light the pilot faster than the piezo under this condition TO THERMOSTAT TO THERMOPILE Figure 10 Page 11 LIGHTING INSTRUCTIONS Gu FOR YOUR SAFETY READ BEFORE LIGHTING HSE WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance has a pilot which must be lighted by hand When lighting the pilot follow these instructions exactly BEFORELIGHTING smellallaround theappliance 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 electrical switch do not use an
28. nclude the three 3 additional inches for TOTAL wall depth when ordering a vent kit 11 1 2 292mm 1 2 13mm 11 1 2 292mm 1 2 13mm Page 6 13117 9 0907 GAS SUPPLY Locating Gas Supply The gas line can enter the unit either through the floor or outside wall The gas line opening should be made at this time Location of the opening will be determined by the position of floor joists and the valve and union used for servicing Recommended Gas Pipe Diameter Pipe Length Schedule 40 Pipe Tubing Type L Out Inside Diameter side Diameter Bar er ue fer 0 10 Feet 1 2 3 8 1 2 3 8 0 3 Meters 12 7mm 9 5mm 12 7mm 9 5mm 10 40 Feet 1 2 1 2 5 8 1 2 4 12 Meters 12 7mm 12 7mm 15 9mm 12 7mm 40 100 Feet 1 2 1 2 3 4 1 2 13 30 Meters 12 7mm 12 7mm 19mm 12 7mm 100 150 Feet 3 4 1 2 7 8 3 4 31 46 Meters 19mm 12 7mm 22 2mm 19mm Note Never use plastic pipe Check to confirm whether your local codes allow copper tubing or galvanized Note Since some municipalities have additional local codes it is always best to consult your local authority and installation code The use of the following gas connectors is recommended ANSZ21 24 Appliance Connectors of Corrugated Metal Tubing and Fittings ANS Z21 45 Assembled Flexible Appliance Connectors of Other Than All Metal Construction The above connectors may be used if acceptable by the authority having jurisdiction The state of Massachusetts
29. o decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETEC TORS Atthe time ofinstallation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a Inthe event thatthe side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b Inthe event that the requirements of this subdivision can not be met at the time of completion of installa tion the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXI
30. r replacement of gas piping or b the connection installation repair or servicing of equipment who is experienced in such work familiar with all precautions required and has complied with all the requirements of the authority having jurisdiction State of Massachusetts The installation must be made by a licensed plumber or gas fitter in the Commonwealth of Massachusetts The installation must conform with local codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 NFPA 54 Natural Gas and Propane Installation Code CSA B149 1 Available from the American National Standards Institute Inc 11 West 42nd St New York NY 10036 High Altitudes For altitudes elevations above 2 000 feet 610m input ratings should be reduced at the rate of 4 percent for each 1 000 305m feetabove sea level Canadian High Altitudes for locations having an elevation above mean sea level between 2 000 feet 610m and 4 500 feet 1370m the manifold pressure is to be decreased from 4 0 w c 996kPa to 3 2 w c 796kPa for Natural Gas and from 10 0 w c 2 49kPa to 8 0 w c 1 992kPa for Propane Gas SPECIFICATIONS Model DV 25T DV 35T Input BTU HR KW H 25 000 7 3 35 000 10 3 Height 27 3 4 705mm 27 3 4 705mm Width 37 940mm 37 940mm Depth Gas Inlet Pipe Vent Kit 12 to 19 wall depth DV4T 1219 1 DV4T 1219 1 Vinyl siding vent kit DV 822 adds 3 to wall depth You must i
31. reduce the amount of primary air If the whistling noise resonation is not eliminated when the air adjustment bolt is screwed into the chamber support this may indicate the air adjustment bolt is misaligned Grasp air adjustment bolt and pivot push air adjustment bolt away from yourself Observe the main burner flame as you push air adjustment bolt and when the main burner flame begins to develop a yellow flame you should stop pushing on the air adjustment bolt Screw air adjustment bolt out of the chamber support until the yellow flame on the main burner is eliminated The air adjustment bolt should now be properly aligned The reduction in primary air will soften the main burner flame and will eliminate the whistling noise resonation On Propane or Natural gas if a yellow flame occurs screw air adjustment bolt out of the chamber support but do not completely remove air adjustment bolt from chamber support The repositioning of the air adjustment bolt will increase the amount of primary air The increase in primary air will sharpen the main burner flame and will eliminate the yellow flame Figure 13 Page 13 MAINTENANCE Removing Main Burner 1 Disconnect the thermopile and pilot supply line at the pilot burner 2 Remove the burner compartment cover 3 Remove orifice shield 4 Remove bolt on each side of burner and lift out Cleaning Main Burner The main burner may b
32. s Pink eme ie 13106 a owemu nes ne no Co Deer Que um ns C Tee uen om mon 13117 9 0907 Page 3 SAFETY INFORMATION FOR USERS OF LP GAS Propane LP Gas is a flammable gas which can cause fires and explosions In its natural state propane is odorless and colorless You may not know all the following safety precau tions which can protect both you and your family from an accident Read them carefully now then review them point by point with the members of your household Someday when there may not bea minute to lose everyone s safety will depend on knowing exactly what to do If after reading the following information you feel you still need more information please contact your gas supplier LP GAS WARNING ODOR If a gas leak happens you should be able to smell the gas because of the odorant put in the LP Gas That s your signal to go into immediate action Do not operate electric switches light matches use your phone Do not do anything that could ignite the gas Get everyone out of the building vehicle trailer or area Do that IMMEDIATELY Close all gas tank or cylinder supply valves LP Gas is heavier than air and may settle in low areas such as basements When you have reason to suspect a gas leak keep out of basements and other low areas Stay out until firefighters declare them to be safe e Use your neighbor s phone and call a trained LP Gas service person and the fire department Even t
33. stand for a few hours and then oiling properly PARTS LIST Index Part Description No No 1 R 2090 Motor 2 632016 Motor Cushion 3 RH 036 Motor Support 4 642030 Blower Wheel 5 RH 710 Blower Housing Assembly 6 9120106 Fan Control Switch 7 872087 Heyco Bushing 8 DV 806 Switch Box 9 DV 807 Switch Box Cover 10 R 2091 Wire Assembly 19 483mm 11 8720161 Heyco Bushing 12 R 2099 Cord Set 72 1 83m Page 18 FAN CONTROL SWITCH ES INSULATION NSULATION BLACK HOT SMOOTH es BLACK NEUTRAL RIBBED IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS UNIT MUST BE REPLACED IT MUST BE REPLACED WITH 125 C 2 64 INSULATION WIRE OR ITS EQUIVALENT WHITE BLACK BLACK BLACK MOTOR eg A FAN CONTROL m SWITCH am un gt Bee ee 5 GREEN GROUND WIRE 5 lt L lt J faa am NEUTRAL SPT 2 CORD HOT 13117 9 0907 SERVICE NOTES 13117 9 0907 Page 19 Empire Comfort Systems Inc 918 Freeburg Ave Belleville IL 62220 PH 618 233 7420 or 800 851 3153 info empirecomfort com Empire Comfort Systems www empirecomfort com Page 20 13117 9 0907
34. time may develop internal rust which will cause odor fade If such conditions are suspected to exist a periodic sniff test of the gas is advisable If you have any question about the gas odor call your LP gas dealer A periodic sniff test of the LP gas is a good safety measure under any condition If at any time you do not smell the LP Gas odorant and you think you should assume you have a leak Then take the same immediate action recommended above for the occasion when you do detect the odorized LP Gas If you experience a complete gas out the container is under no vapor pressure turn the tank valve off immediately If the container valve is left on the container may draw in some air through openings such as pilot light orifices If this occurs some new internal rusting could occur If the valve is left open then treat the container as a new tank Always be sure your container is under vapor pressure by turning it off at the container before it goes completely empty or having it refilled before it is completely empty 13117 9 0907 REQUIREMENTS FOR MASSACHUSETTS For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area ofthe venting including but not limited t
35. y 2 Attach 1 pin terminal from black neutral wire ribbed insulation on cord set to 1 socket terminal from white neutral wire on motor 3 Attach 1 pin terminal on fan control assembly to 1 socket terminal from black hot wire on motor 4 Attach green ground wire beneath one of the 10 x 1 2 13mm screws on the blower housing D U COMBUSTION CHAMBER BLOWER ASSEMBLY SWITCH BOX 13117 9 0907 Fan Control The automatic fan control is located in the switch box The switch box is attached to the front of the blower assembly The switch box is adjacent to the combustion chamber The fan control is a non adjustable automatic type The fan control will require between 5 and 10 minutes of main burner operation before the fan control closes and activates the blower The blower will continue to run between 5 and 10 minutes after the main burner shuts off before the fan control opens and deactivates the blower Wiring The appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or Canadian Electrical Code CSA C22 1 ifan external electrical source is utilized This appliance is equipped with a three prong grounding plug for your protection against shock hazard and should be plugged directly into a properly grounded three prong receptacle Do not cut or remove
36. y phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions C e If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water eee LIGHTING INSTRUCTIONS STOP Read the safety information above Set the thermostat to lowest setting Turn off all electric power to the appliance if appli cable Remove casing front assembly Push in gas control knob slightly and turn clockwise AT to OFF GAS CONTROL KNOB S NOTE Knob cannot be turned from PILOT to OFF unless knob is pushed in slightly Do not force Wait ten 10 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Remove the pilot access cover located on the combustion chamber 8 Find pilot
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