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1. Children and adults should be alerted to the hazards of high surface temperature 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 Do not place clothing or other flammable material on or near the appliance Precautions should be taken so as not to place furniture drapes or other articles directly in front of grille or lower access door that would obstruct air openings as proper air flow is critical to proper operation of unit Any safety screen guard or casing front removed for servicing an appliance must be replaced prior to operating the appliance Heater must be installed with legs resting on the 2x4 floor sill plate recessed or the factory FSK kit flush mount The header plate shall then be installed at a height 65 3 4 inches above top surface of the plate that the heater legs rest on This provides the listed 2 inch minimum floor clearance If the area where the heater is installed contains carpeting tile etc the listed 2 inch minimum floor clearance must be maintained from the top surface of these materials If the heater is installed DIRECTLY on carpeting tile or any combustible material other than wood flooring the heater shall be installed on a metal or wood panel secured to the floor extending the full width and depth of the heater Installation and repair must be done by a qualified installer or serv
2. FIGURE 10 GAS VALVE BBSK CONTROL r4 Blocked Blue Wire Flue Switch FIGURE 11 GAS VALVE NYLON CLIP A SENSING BULB 10 24X3 8 SCREW FIGURE 12 Page 14 BBSK KIT LIGHTING INSTRUCTIONS 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 has a pilot which must be lighted by hand When lighting the pilot follow these instruc 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 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 settle on the floor 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 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
3. INSTALLATION AND OPERATING INSTRUCTIONS P N 84502 REV 03 19 2013 WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department INSTALLATION AND SERVICE MUST BE PERFORMED BYA QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER WARNING Operation of this furnace when not connected to a properly installed and maintained venting system can result in Carbon Monoxide C O poisoning and possible death For your safety this furnace and the venting system should be inspected at least annually by a qualified service technician This appliance is equipped with a blocked flue switch designed to protect against a blocked flue condition The coating selected to provide longer life to the heat exchanger may smoke slightly upon initial firing Please provide adequate ventilation if this occurs This heater may be installed without recessing into stud space by using optional FSK Free Standing Kit This unit is for residential use only and is not approved for inst
4. s instructions LIGHTING INSTRUCTIONS STOP Read the information on the safety label Turn temperature control knob clockwise sy to LO Open cabinet door Depress and turn gas control knob clockwise Pilot is located on side of burner GAS CONTROL KNOB NOTE Knob cannot be turned from PILOT to Depress gas control knob and hold in Immediately OFF unless knob is pushed in slightly Do not force light the pilot with a match Continue to hold the gas control knob in for about one 1 minute after the pilot is lit Release gas control knob and it will pop back up Pilot should remain lit If pilot goes out repeat steps 4 through 8 If knob does not pop up when released STOP and immediately call your service technician or gas supplier 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 9 Turn gas control knob counterclockwise ON 10 Close the cabinet door 11 Turn temperature control knob to desired setting Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the information on the safety label If you don t smell gas go to the next step Locate the pilot Follow metal pilot tube from gas control Turn gas control knob counterclockwise yN to PILOT yN to TO TURN OFF GAS TO APPLIANCE Push in gas control
5. if it whistles or resonates 3 Remove burr or replace orifice Do not enlarge orifices 4 Excessibe gas input 4 See Flame Too Large above Yellow tip flame 1 Too little primary air 1 Adjust air shutter See Page 12 some yellow tipping 2 Clogged main burner ports 2 Clean main burner ports Do not enlarge ports on L P gas is 3 Clogged draft hood 3 Clean draft hood permissible 4 Linted up air shutter 4 Check for dust or lint at air mixer opening and around the shutter Clean as ne Ar Floating Flame 1 Blocked venting 1 Clean flue passageways to remove blockage 2 Insufficient primary air 2 Adjust air shutter to increase primary air supply See Page 12 Gas Odor 1 Gas leak 1 Shut off gas service immediately Check piping Call gas company See Page 1 2 Chimney or flue obstruction 2 Clean flue 3 Drafts around appliance 3 Eliminate drafts Delayed Ignition 1 Pilot flame too small 1 Check pilot orifice increase pilot gas flow if necessary by adjusting inlet pressure 2 Burner ports clogged near pilot 2 Clean burner ports Do not enlarge ports 3 Low gas pressure 3 Check gas supply pressure 4 Pilot decreases in size when main burners 4 Supply piping is inadequately sized Consult local come on gas utility or competent installer 5 Air shutter open too far 5 Close air shutter to proper setting as outlined in these instructions slight yellow tipping is allowable on L P Gas See
6. Figure 10 Secure P N 40225 switch bracket to the BBSK control switch using two 2 6x 4 screws provided See Figure 10 Place BBSK control switch inside front panel align engagement holes with clearance holes in P N 40230 heat shield and the 4 drilled holes in the front panel Attach using two 2 8x 2 screws provided Make sure heat shield is between the BBSK control switch and the heat exchanger Connect each end of the black wires to the two outside terminals on the BBSK control switch route wires down the inside of the front panel See Figure 11 Straighten the bulb capillary tube using extreme care not to bend or damage the tube route the tube down the inside of the front panel Install the front panel onto the wall furnace Insert the control knob onto the control rod See Figure 10 Open the front panel door Connect one black wire to the stripped end of the blue blocked flue switch wire Connect the other black wire to the TH TP terminal on the gas valve See Figure 11 NOTE If you are replacing an existing wall thermostat you must first disconnect the thermostat wires from the gas valve Secure the sensing bulb to the bottom of the gas valve using the nylon clamp and blunt screw provided See Figure 12 Close the front panel door Follow the lighting instructions to place the heater in operation Page 13 BBSK INSTALLATION INSTRUCTIONS SIDE VIEWS FRONT PANEL FRONT f PANELSIDE 6X1 4 2
7. Page 12 6 Drafts around appliance 6 Eliminate drafts 7 Bad venting 7 See Venting 2 Defective gas valve 2 Replace gas valve water vapor Burner won t 1 Defective or sticking automatic valve 1 Clean or replace valve turn off 2 Excessive gas pressure The supply gas 2 To correct this situation contact the utility pressure must not exceed 1 2 psi or 14 supplying the gas water column Incorrect gas input Gas input not checked 1 Re check gas input 2 Clogged orifice 2 Check orifice for clogging If clogged clean out the hole carefully with a smooth wood toothpick Do not in any way enlarge or distort it Not enough heat Appliance undersized 1 This is especially true when a dwelling or room is enlarged Have the heat loss calculated and compare to the appliance output 70 of input Your gas company or installer can supply you with this information If appliance is undersized replace with correct size unit Temperature dial set too low Bulb Raise setting of Temperature Dial See type valves Lighting and Shutting Down Instructions Incorrect supply pressure Check supply pressure as outlined above Too much heat Temperature dial set too high Lower setting of temperature dial See Lighting and Shutting Down Instructions Combination control valve sticks open Replace combination control valve Page 20 TROUBLE SHOOTING CHART AUTOMATIC PILOT amp VALVE Burner won
8. THE GENERATOR BURNER FLAME ADJUSTMENT STAINLESS STEEL BURNER 1 FLAME TOO SOFT Yellow 2 FLAME TOO HARD Deep Blue 3 NORMAL FLAMES Flame Open air shutters until Coloration Closing air shutters yellow tipping disappears to a point where yellow tipping begins re open slightly to eliminate yellow tipping Air shutter adjustment is now correct NOTE Itis advised that the burner flames be checked at least twice during the heating season for any changes in burner characteristics Vacuum burner compartment at start of heating season or as often as needed Page 12 STEP 3 STEP 4 STEP 6 SIEP7 STEP 8 STEP 10 STEP 11 STEP 12 STEP 13 STEP 14 STEP 15 BBSK INSTALLATION INSTRUCTIONS Select left or right side of front panel for most convenient location of the temperature control knob Remember to choose the side that allows adequate clearance for accessibility to adjust the control knob On selected side locate three 3 vertical dimples beginning approximately 20 12 above bottom of the front panel See Figure 9 On Gravity Wall Furnaces manufactured prior to November 2005 without bracket hole dimples in the left and right side you may use the gravity BBSK bracket as a template to locate holes Measure 20 1 2 up on the preferred side to locate lowest hole Using these three 3 dimples as locator drill three 14 holes Remove the BBSK control switch from the packing set See
9. be done by a qualified flame should surround at least the top 3 8 of the powerpile service person The appliance should be inspected before pilot generator or thermocouple see below The pilot is use and at least annually by a professional service person unregulated so it will be operating at inlet line pressure Max More frequent cleaning may be required due to excessive 7 w c for natural gas and 11 w c for propane To decrease lint from carpeting bedding material etc It is the pilot flame turn the screw clockwise approximately seven imperative that control compartments burners pilot to nine full turns to bottom of pilot light channel until you burners circulating air passageways and venting systems produce sufficient flame at the minimum noise level of the appliance be kept clean 2 If the appliance has been equipped with the optional PILOT FLAME ADJUSTMENT WFFS l C fan kit assembly the bearings of the motor should be oiled everv six months with approximatelv 2 drops of S A E 20 oil 3 8TO 1 2 INCH j The appliance area must be kept clear and free of any combustible materials gasoline and other flammable vapors and liquids A It is essential that the flow of combustion and ventilation air not be obstructed 5 Periodic examination of the entire ventilation system as a routine part of the safety performance check is recommended on an annual basis PILOT FLAME SHOULD ENVELOP 3 8 TO 1 2 INCH OF THE TIP OF
10. connections 6 Check the connection on both the switch and the gas valve Tighten if necessary on the vent safety wiring harness DO NOT BYPASS THE BLOCKED FLUE SWITCH To do so could expose the consumer to property damage personal injury or possible death Page 21 Prices and specifications subject GRAVITY WALL FURNACE to change without notice All LIST PRICES MARCH 2013 prices are F O B factory SINGLE WALLFURNACE DUAL WALLFURNACE Model Numbers Model Numbers Nat LP aa Nat LP W255F W256F a W505F W506F W355F W356F ror S ORA R A o WFF81 C FAN KIT Used on Single and Dual Wall models es ae BURNER ASSEMBLY DUAL WALL FURNACE REAR REGISTER KIT Used NOTICE When ordering any component in the Burner Assembly on Single Wall models only Page 22 specify either Honeywell or Robertshaw components REV 06 2006 HOW TO PROPERLY ORDER PARTS In addition to part description and part information can be found on the rating plate that is attached to heater FRONT PANEL DOOR amp BODY ASSEMBLY FOR MODELS PART DESCRIPTION Front Panel Assemblv REF NO Lower Door Handle Assemblv Body Assembly Draft Diverter Assembly Draft Diverter Assembly Heat Exchanger Upper Shield Header Assembly Lower Front Shield Gasket Flue Pipe Blocked Flue Sw 350 Deg Wiring Harness Wall Ae e m OAN e 47 BURNER ASSY PARTS FOR MODELS REF Bur
11. knob slightly and turn clockwise poy to OFF Do not force Close cabinet door Turn temperature control knob clockwise p to l LO Open cabinet door 4 Page 15 P N 91288 09 05 MODEL WEFF81 C OPTIONAL FAN KIT INSTALLATION INSTRUCTIONS NOTE This fan kit is to be installed after installation of wall furnace and with the wall furnace front panel in place STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 Bracket Wall Mountin Bracket This appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the latest edition of the National Electric Code ANSI NFPA No 70 In Canada see the current Canadian Electrical Code CSA C22 1 Set fan kit on top of the wall furnace front panel Using the back top edge of the fan kit cabinet as a guide mark a horizontal line across the wall Mark a small vertical line which aligns with the slot located toward the rear of the fan kit casing Using the four one inch screws provided secure the wall mounting bracket to wall 1 8 below the horizontal line Fan attachment bracket must be up and threaded nut sert aligned with the small vertical line Note Anchors not provided may be required Remove junction box and connect 115v power supply in accordance with the wiring diagram Replace junction box Set fan kit on top of wall furnace front panel Slot should align with the nut sert Secure fan kit to wall
12. mounting bracket with thumb screw provided Threaded Nut Sert 8 A i ee it ta i kr i ai One Inch Screw 4 Junction Box Fan Kit ae I FE om at pel oe gA A 5 z Wall Furnace Front Panel B g g om mil pel rs FE ETETETT JAN WARE ES AVE TEAL A AT ET A EVEN Page 16 WFFS81 C WIRING SCHEMATIC L1 Black 115 VAC GREEN GROUND WIRE 115 VAC 60 HZ Less than 12 Amps If any of the original wire as supplied with this appliance must be replaced it must be replaced with type thermoplastic 105 degree C wire or its equivalent Page 17 40542 A REAR REGISTER KIT Optional Accessory INSTALLATION INSTRUCTIONS FOR GRAVITY VENTED WALL FURNACES STEP 1 Cut hole within stud space behind heater in the back wall 8 1 4 high by 12 5 8 wide The lower edge of the hole to be 45 3 4 above the floor plate or 47 from the floor with standard 2 x4 7 floor base as shown in Figure 13 STEP 2 Install plaster ground frame for rear register in hole and nail frame to stud as shown in Figure 14 STEP 3 REAR REGISTER INSTALLATION Cut and remove embossed plates in inner and outer casing Follow instructions for installation of regular furnace STEP 4 After furnace is installed attach rear register grille as shown in Figures 16 amp 17 by insertion over plaster ground and attach with sheet metal screws provided STEP 5 Damper as shown in Figure 17 can be adjusted from full
13. one square inch per 1 000 btu per hour of the total input rating of all gas appliances in the confined space but not less than 100 square inches One of the openings shall be within 12 inches of the ceiling and one within 12 inches of the floor See Figure A If the home is of unusually tight construction new and remodeled homes free air must be supplied through opening s to the outdoors This can be accomplished by providing 2 permanent openings one commencing within 12 inches of the ceiling and one within 12 inches of the floor These openings shall communicate directly with the outdoors or spaces that communicate freely with the outdoors such as a ventilated attic and crawl space through galvanized or equivalent corrosion resistant ducts Exception unobstructed stud and joist spaces are acceptable ducts provided that not more than one fire block is removed Special provisions must be taken to insure that these stud and joist spaces cannot be blocked with insulation or other objects Each of these openings using vertical ducts shall have a minimum free area of one square inch per 4 000 btu hr of total input rating of all gas appliances See Figure B and C If horizontal ducts are used the minimum free area shall be one square inch per 2 000 btu hr of total input rating of all gas appliances Fresh make up air can also be provided through a duct to one permanent opening commencing within 12 inches of the ceiling The minimum free area of this ope
14. second and subsequent ceiling levels See Figure D Firestop spacers supplied by manufacturer of B W gas vent Installation of B W gas vent for each subsequent ceiling or floor level of multi story buildings Plate cut away to provide passage of B W gas vent Nail firestop spacer securely FIGURE D VENT INSTALLATION LISTED 2 FT MIN ai TE a FLASHING Te OVAL TO EE r ROUND ADAPTER CEILING PLATE SPACERS LISTED BW VENT PIPE BASE PLATE CEILING PLATE SPACER LANCES HEADER PLATE 2X4 WALL STUDS FIGURE 2 VENT INSTALLATION FIGURE4 Front Panel FIGURE 5C INSTALLATION STEP 6 To place furnace into position grasp furnace and lift so furnace flue vent and header plate vent opening engage Do not use burner or gas control to lift heater Lift furnace upward and swing bottom into wall opening until legs rest on floor plate and are flush to finished wall For proper combustion level heater front to back and side to side Nail legs to studs DO NOT BEND LEGS as this will put the entire unit into a bind and cause expansion noises See Figure 3 STEP 7 A drip leg and a manual valve equipped with a 1 8 N P T plugged tapping accessible for test gauge connection should be installed immediately upstream of the gas supply connection to the appliance Some codes and ordinances require that the manual valve be located outside the appliance STEP 8 Make gas con
15. t Pilot flame too large or too small Re adjust pilot flame using adjustment on turn on combination control valve Dirt in pilot orifice Clean pilot orifice with air or solvent do not ream Defective automatic pilot section in Replace entire combination control valve combination control valve Defective pilot generator Replace pilot generator Defective combination control valve Replace valve Manual reset blocked flue switch Reset switch see Page 6 and blocked flue tripped section below TROUBLE SHOOTING CHART BLOCKED FLUE SWITCH For QUALIFIED SERVICE TECHNICIAN 1 Blockage in Check vent pipe for blockage such as bird nest wasp nest twigs leaves etc vent pipe Check inside the bottom of the vent pipe to make sure the top of the draft diverter did not rip the inner liner causing it to block part of the vent opening Check that no insulation from the header plate got caught on top of the draft diverter when the heater was inserted into the wall Check that the vent cap is properly installed not shoved too far down on the vent pipe 2 Burner is Check the manifold pressure overfiring Check the rate NOTE This appliance was orificed for elevations up to 2 000 feet When installed at higher elevations refer to orifice chart in controls section of instructions for proper orifice size and re orifice accordingly 3 Improper vent Correct vent system system A Vent too short A The vent sho
16. 000 feet the BTU input must be reduced 4 per 1 000 feet See the following orifice chart for the proper orifice for a specific elevation A blank orifice is shipped in the high altitude kit with each heater This orifice s will have to be drilled to correct size by a qualified installer service technician or the gas supplier NATURALGAS Model 0 to No 2 000 4 000 6 000 6 000 8 000 8 000 10 000 W255F 43 W355F 36 ORDER KIT 49820 45 1 HIGH ALTITUDE KIT W505F 43 AA 45 47 48 ORDER KIT 49850 2287 2 HIGH ALTITUDE KIT L P GAS Model 0 to No 2 000 2 000 4 000 4 000 6 000 6 000 8 000 8 000 10 000 W256F 145mm 54 W356F 52 d ORDER KIT 49820 45 1 HIGH ALTITUDE KIT W506F 1 45mm 54 54 99 55 ORDER KIT 449850 2287 2 HIGH ALTITUDE KIT COMBUSTION AND VENTILATION AIR When installed this gas appliance must be provided with fresh air for combustion ventilation and dilution of hot flue gases The minimum required volume of the area where the appliance is installed should be 50 cubic feet per 1 000 btu hr If installed in an area of the home that is considered an unconfined space the natural infiltration of air around windows and doors will be adequate If the area is considered a confined space less than 50 cubic feet per 1 000 btu fresh air can be supplied by providing two permanent openings into adjoining rooms Each opening shall have a minimum free area of
17. CTIONS THOROUGHLY BEFORE INSTALLING SERVICING OR USING THE APPLIANCE IF YOU DO NOT UNDERSTAND ANY PART OF THESE INSTRUCTIONS CONSULT LOCAL AUTHORITIES OTHER QUALIFIED INSTALLERS SERVICE TECHNICIAN THE GAS SUPPLIER OR THE MANUFACTURER SPECIFICATIONS Your vented wall furnace comes packed in a single carton For wall thermostat models that includes the thermostat thermostat wire and insulated staples Before installing the wall furnace check the rating plate to verify that the Model Number is correct and that the wall furnace is equipped for the type gas you intend to use Model Type Type BTU Hr Vent Gas Shpg REAR REG KIT FAN KIT No Control Gas Input Size Inlet FINISHED DIMENSIONS Wt Model Weight Model Wt SINGLE WALL FURNACE Wall Stat 4 16 1 2 Wx68 Hx6 1 2 D 40542 WFF81 10 Ibs Wall Stat P 4 4 16 1 2 Wx68 Hx6 1 2 D 40542 WFF81 10 Ibs Wall Stat 16 1 2 Wx68 Hx6 1 2 D 40542 WFF81 10 Ibs Wall Stat T j 16 1 2 Wx68 Hx6 1 2 D 40542 WEF81 10 Ibs DUAL WALL FURNACE Wall Stat j 16 1 27Wx68 Hx6 1 27D Wall Stat P ki 16 1 2 Wx68 Hx6 1 2 D Page 2 A B D clearance from cabinet to combustible construction Side Wall 1 SAFETY RULES The wall furnace should be located near the center of the house for best heat distribution Due to high temperatures the appliance should be located out of traffic and away from furniture and draperies
18. Floor Furnace Cozy Gas Fired Wall Furnace Cozy Gas Fired Vented Console Heater Cozy Gas Fired Direct Vent Heater Cozy Gas Fired Counterflow Furnace Cozy Gas Fired Counterflow Direct Vent Furnace Cozy Gas Fired Mobile Home Direct Vent Furnace Cozy Gas Fired Hi Efficient Direct Vent Wall Furnace Cozy Gas Fired Direct Vent Baseboard Heater Cozy Fan Type Direct Vent Through The Wall Gas Heater Cozy Blue Flame Vent Free Heater Cozy Infra Red Vent Free Heater LOUISVILLE TIN amp STOVE COMPANY 737 S 13 STREET LOUISVILLE KY 40210 TAA AAAAAAAAAAAAAAAAAAAAAS Warranty Period Heat Exchanger Tubes Burners 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years warat AAAAAAAAAAAAAAAAA A w A Y A Yy A v A v 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years N A N A 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years N A AAAA y A Yy SAATATAA
19. ING TO VENTILATED ATTIC HOLES CONNECTING TO VENTILATED CRAWL SPACE BASED ON 4 000 BTU OF TOTAL INPUT RATING OF ALL GAS APPLIANCES THE HEATER ONLY REQUIRES A MINIMUM FREE AREA OF SQUARE SQUARE BIU IN IN 25 000 6 25 ki 785 35 000 8 9 1 76 50 000 12 50 E 3 14 VENTING This appliance must be properly connected to a venting system Consult local ordinances governing venting Install only UL listed type BW 4 oval gas vent When the vent enters the attic a listed type B 1 round flue pipe may be used See Figure 2 Page 7 Vent pipe must connect to the wall furnace header plate with a B vent base plate and terminate with a cap at a point at least 12 foot above the bottom of the wall furnace two feet above any obstacle within a 10 foot radius and at least 3 foot above the roof Provisions must be made for adequate combustion and ventilation air This appliance is equipped with a manual reset blocked flue switch designed to protect against a blocked flue condition which would cause combustion products to spill back into the living quarters NOTE A partially blocked inadequate or disconnected vent system may not activate the switch Discoloration of the grille is an indication of a bad vent If this occurs the vent can be checked by a qualified serviceman using a draft gauge After 15 minutes the gauge should read between 02 up to 04 inches w c Vent must be checked at the beginning of each heating s
20. LIST 22 l Damper 3 00 2 40 15 00 cel E7 e b c b c FILA FH 23 24 25 26 21 Damper Spring Frame Assembly Register Chain Bell Pull Register Assembly Installation Manual FSK A FREE STANDING KIT W25 W35 only Floor Plate Assembly X Right Side Assembly Upper Left Side Upper Right Side Upper Front Left Side Assembly 40220 N A N A PILOTS ORIFICES Ref No 38 Ref 32 PART LIST PART LIS T 84128 12 00 Q350A 1545 Nat 846391 4 20 84128 12 00 Q350A 1545 Nat 846421 4 20 841281 12 00 Q350A 1545 Nat 95274 4 20 ATTN CONTRACTORS AND SERVICE TECHNICIANS 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 40025 Includes Lower Door 40032 and Handle Assembly 40033 TWO REQUIRED Page 23 MARCH 2013 REVISED 06 2006 mA y A y A V A V A V VAAAAA AAAA y NNA y A NANANA Z y A y A NAANA Z NAA SA A A AAAA A AA A WA AZZ 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 accordin
21. NN Cap Internal Manifold light the pilot with a match Continue to hold the Pressure Regulator gas control knob in for about one 1 minute after NOTE Knob cannot be turned from PILOT to OFF unless the pilot is lit Release gas control knob and it will knob is pushed in slightly Do not force pop back up Pilot should remain lit If pilot goes 5 Wait five 5 minutes to clear out anv gas Then out repeat steps 4 through 8 smell for gas including near the floor If vou smell e If knob does not pop up when released STOP and gas STOP Follow B in the information on the immediately call your service technician or gas supplier safety label If you don t smell gas go to the next e Ifthe pilot will not stay lit after several tries turn the gas step control knob to OFF and call your service technician 6 Locate the pilot Follow metal pilot tube from gas or gas supplier control 9 Turn gas control knob counterclockwise JEN to ra Turn gas control knob counterclockwise MEN to ON l PILOT 10 Close the cabinet door 11 Set thermostat to desired setting TO TURN OFF GAS TO APPLIANCE Set the thermostat to it s lowest setting 3 Push in gas control knob slightiv and turn clockwise Open cabinet door f to OFF Do not force Close cabinet door Page 11 PILOT ADJUSTMENT MAINTENANCE INSTRUCTIONS Locate the pilot adjustment screw on the valve The pilot L Installation and repair should
22. allation in mobile homes greenhouses or environments involving dusty wet corrosive or explosive conditions Such conditions will invalidate the warranty and may create unsafe conditions THIS UNIT IS NOT TO BE INSTALLED IN MOBILE HOMES Installation maintenance service troubleshooting and repairs must be performed by a qualified service agency MR MRS HOMEOWNER DO NOT attempt any of these procedures yourself as this could expose you to property damage personal injury or loss of life and will invalidate all warranties CONTENTS PGE OCG CO soccer cs ccgeensusenegeenstesyeeeate 2 Lighting Instructions eeeseseeseeesseeessseesssesseressressse 11 SpecificatlONS ss seneeenenenzzznnznnnenenznnnaz 2 Pilot Adjustment ss sseesnenzznnnnzznnaznnnzznnnennnnzzana 12 Safety RUES i a 3 Burner Flame Adjustment se sesseeneznnnzzznnnenzznni 12 i ta 3 Maintenance Instructions ss ss seeeesssenzennnnnzzznnznna 12 CONOIS sanoceesestens sen aa iaaea 3 BBSK Kit Instructions ss eneennenezznnnnnzzznnezenzznna 13 15 Combustion amp Ventilation Air L Mas WFFSI Fan Instructions nn ennnnnznnnnenn 16 17 A L O E E E 6 7 40542 Rear Register Kit Instrucitons en 18 19 Rough In Instructions nn f Trouble Shooting Chart ise lsiera tjeda 20 21 is ta Ott 9 Pars a a 22 Wiring Iasttru ttonS isss i e iienineinetzzikaiezzniien 10 l Cee Oe eee E eee een ee 22 The State of Massachusetts req
23. eason The switch when activated on a bulb control burner will extinguish the pilot flame on a thermostat controlled burner the thermostat circuit will be broken turning off the main burner flame Before the heater can be relit the reset button must be activated See Figure B for location of the manual reset blocked flue switch To reset the switch insert a slender rigid object 1 e screwdriver through the front panel louvers and push the reset button down See Figure B 1 However you may have to remove the front panel then reset the switch and reinstall the front panel to relight heater If homeowner experiences this problem the vent system must be checked and corrected NOTE A pre existing vent that has worked for years may not be adequate for todays design because of higher efficiency requirements that result in lower stack temperatures See Possible Causes and Corrective Action on Page 16 All type B vents shall extend in a generally vertical direction with offsets not exceeding 45 degrees except that a vent system having not more than one 60 degree offset may be allowed Any angle greater than 45 degrees from the vertical is considered horizontal The total horizontal run of a vent plus the horizontal vent connector shall be not greater than 75 percent of the vertical height of the vent Any offsets used should be as far above the drafthood as possible to allow a venting action to begin before any restriction is enco
24. f 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 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 Product Cozy Gas Fired
25. g to the instructions and specifications accompanying the product AS OUTLINED IN OUR INSTRUCTIONS ANY WARRANTY CONSIDERATIONS ARE CONTINGENT ON INSTALLATION BY A QUALIFIED INSTALLER CONTRACTOR SELF INSTALLATION IS PROHIBITED AND WILL INVALIDATE YOUR WARRANTY If within a period of one year from the date of installation of the product any part supplied by the manufacturer proves to be defective due to workmanship or material it will replace such part provided parts have not been subjected to misuse alteration neglect or accidents The term of the warranty for the heat exchanger and burners is covered in Table A below Any claim not made within ten 10 days after the expiration of the warranty period shall be deemed waived by the user The manufacturer shall have no liability or be required to perform any obligation under this warranty unless when requested the user returns at the user s expense the component or product claimed defective to the manufacturer for inspection to enable the manufacturer to determine if the claimed defect is covered by this warranty No charges for freight labor or other expenses incurred in the repair removal or replacement of any product or component claimed to be defective will be paid by the manufacturer to the user and the manufacturer will not be liable for any expenses incurred by the user in remedying any defect in the product Service under this warranty is the responsibility o
26. he required fire stop Square up and nail the header in place with the top front of header located 65 3 4 above floor plate See arrow on right side of header and Figure 1 5A and 5B on Page 7 STEP 3 Rough in 2 gas supply on center line of left stud either 4 above top of floor plate or 4 to right of left stud through floor plate See Figure 1 located on Page 7 Page 7 ROUGH IN INSTRUCTIONS FIGURE 1 ROUGH IN DIMENSIONS 65 3 4 This measurement must be taken from top of floor plate NOTE For proper combustion make sure units are level front to back and side to side Dry Wall B W Type Vent Front Panel Plaster Ground i GF AW SE SE EE NT MET A NOTE Front Panel must be in front of plaster ground channel Do not hang it over front of plaster ground FIGURE 5A DRY WALL Plaster B W Type Vent Front Panel Plaster Ground NOTE Front Panel must be in front of plaster ground channel Do not hang it over front of plaster ground FIGURE 5B PLASTER WALL Page 8 STEP 4 Remove double ceiling plate between studs Install one ceiling plate spacer across the cut out in ceiling plate Install vent pipe into position be sure to lock bottom of vent pipe into the base plate Nail second ceiling plate spacer in place See Figure C Page 6 STEP 5 If the vent continues through additional stories within the 2x4 stud space then fire stop spacers must be installed at the
27. ice technician The wall furnace must be inspected before use and at least annually by a qualified service technician CLEARANCES As viewed from front of heater the minimum Floor 2 Ceiling 11 In selecting a location for installation it is necessary to provide adeguat accessibility clearances for servicing and proper operation This appliance must not be connected to a chimney flue that serves to vent a solid fuel burning wood or coal appliance or a multi vent system Page 3 CONTROLS All controls are preassembled at the factory The normal manifold pressure should be 3 5 w c on Natural Gas and 10 w c on L P Gas The maximum inlet pressure in the gas supply pipe should never exceed 14 w c on L P Gas or 7 0 w c on Natural Gas 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 12 psig 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 The minimum inlet pressure in the gas supply pipe should be 5 0 w c on Natural Gas or 11 w c on L P Gas for purpose of input adjustment The appliance is orificed at the factory for elevations up to 2 000 feet If installed above 2
28. nal injury or loss of life This appliance has a pilot which must be lighted e If you cannot reach your gas supplier call the fire by hand When lighting the pilot follow these in department structions exactly BEFORE LIGHTING smell all around the Use only your hand to push in or turn the gas control appliance area for gas Be sure to smell next to the knob Never use tools If the knob will not push in floor because some gas is heavier than air and will or turn by hand don t try to repair it call a qualified settle on the floor service technician Force or attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been under Do not try to light any appliance water Immediately call a qualified service technician Do not touch any electric switch do not use any phone to inspect the appliance and to replace any part of the in your building control system and any gas control which has been Immediately call your gas supplier from a neighbor s under water phone Follow the gas supplier s instructions LIGHTING INSTRUCTIONS 1 STOPI Read the information on the safetv label pA Set thermostat to it s lowest setting Pilot is 3 Open cabinet door occi 4 Depress and turn gas control knob clockwises 7 d to OFF eee of burner Gas Control Knob QEA 5 F Manifold LA d Pressure Tap 8 Push gas control knob and hold in Immediatel Pilot Adjustment 8 M TE
29. nection using connector the same size as gas connection of furnace CHECK ALL CONNECTIONS FOR GAS LEAKS WITH LEAK DETECTOR SOLUTION DO NOT USE OPEN FLAME STEP 9 For wall thermostat units see Wiring section for thermostat connections Make sure all connections are correct and connector stems are not touching STEP 10 To fasten front panel to furnace be sure exposed portion of header is free of debris Place outer panel over furnace with top of panel about one inch above header and centered in opening Keep front panel flush to finished wall and slide down until rear flange of top outer panel 1s wedged tight against the front of the plaster ground channel and flush with wall CAUTION Do not hang front panel behind over front lip the plaster ground channel as this could result in excessive noise Open bottom door of front panel and place sheet metal screw into locking latch Secure top of front panel to header plate with screw provided This will hold front panel securely to wall See Figures 5A 5B See Page 8 and 5C Page 9 Page 9 CAUTION Label all wires prior to disconnection when Thermostat servicing controls Wiring errors can cause improper Manual and dangerous operation Verify proper operation Reset after servicing Blocked Flue Switch WIRING INSTRUCTIONS GRAVITY WALL FURNACE THERMOSTAT MODELS NAT LP W255F W256F W355F W356F W505F WS506F Gas Valve WARNING Failure to locate the thermostat properl
30. ner Support Assy 28 Burner Steel 29 Burner Steel WITH Carry Over Tapping 29A Burner Restrictor Plate N A for W506F Orifice Coupling 30 Elbow 3 8 90 Degree 31 Manifold 33 Pipe Nipple N A Pilot Tubing w Fittings 44 Air Shutter 35 36 38 Pilot Generator 23 39 Thermostat 40 Wire Thermostat 41 Carry Over Shield 43 Installation Instructions N A Lighting Instr Wall N A GAS VALVES Ref No 36 PART DESCRIP TION 6003 Natural Gas Dexen Valve 6003 L P Gas Dexen Valve 6003 Natural Gas Dexen Valve 6003 L P Gas Dexen Valve 6003 Natural Gas Dexen Valve 6003 L P Gas Dexen Valve LST 163 00 12 40 5 70 203 00 5 70 203 00 48 00 N A 163 80 3 80 84631 84124 84123 2 20 PART L N PRICE 5 80 2 50 SEE ORIFICES SEE VALVES SEE PILOTS W255 W256F IST O N A N A 84070 50 70 N A N A N A N A PART LIST MODEL NO PRICE NO 84085 166 60 W255F 84085 166 60 W355F 84085 166 60 W505F 177 20 W25F W35F W50F number please give model number serial number and tvpe of gas used This WFFES81 C FAN KIT Fits all Models REF PART LIST Fan Cabinet 13 43 10 Junction Box 8 80 Motor Mounting Brk 5 30 Motor 72 50 Fan Blade Heyco Strain Relief Fan Switch Wiring Diagram label LIST A Fan Housing Fan Switch Wire Wall Mtg Bracket Installation Manual 40542 A REAR REGISTER KIT REF PART
31. ning shall be one square inch per 3 000 btu hr of the total input rating of all gas appliances but not less than the sum of the areas of all vent connectors in the space See Figure D When calculating the amount of fresh air needed you must include make up air requirements for the operation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces Additional information can be found in the latest edition of ANSI Z223 1 National Fuel Gas Code Page 4 COMBUSTION AND VENTILATION AIR ALL COMBUSTION AIR FROM ADJACENT INDOOR SPACES THROUGH INDOOR COMBUSTION AIR OPENINGS UL Listed Vent Cap UL Eee Gas Vent Opening Opening FIGUREA ALL COMBUSTION AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACEAND OUTLET AIR TO VENTILATED ATTIC UL Listed Vent Cap UL Listed Gas Vent di Ventilation Louvers I each end of attic AUT Outlet Air Inlet Air Ventilation louvers for unheated crawl space FIGURE B ALL COMBUSTION AIR FROM OUTDOORS THROUGH VENTILATED ATTIC UL Listed Vent Cap UL Listed Gas Vent Ventilation Louvers each end of attic Outlet Air Inlet Air Duct Ends 1 ft 300mm above floor FIGUREC ALL COMBUSTION AIR FROM OUTDOORS THROUGH SINGLE COMBUSTION AIR OPENING UL Listed Vent Cap UL Listed Gas Vent Opening Alternate Opening Location FIGURE D Page 5 USING ADJACENT STUD SPACE FOR ALL COMBUSTION AIR FROM OUTSIDE HOLES CONNECT
32. open for maximum heat to fully closed PLASTER PLASTER OPENING 7 8 FROM EACH PLASTER ROUGH IN DIMENSIONS FOR REAR REGISTER PLACING FRAME FOR REAR REGISTER FIGURE 13 FIGURE 14 40542 A REAR REGISTER KIT 40542 REAR REGISTER KIT W25 35 Series only Ref Part Part Description No No Damper 40375 Damper Spring 40377 Frame Assembly 40365 Register Chain 40379 Bell Pull 85003 Register Assembly 40355 Installation Instructions 84504 Form 84504 Page 18 REV 07 98 40542 A REAR REGISTER KIT Continued INSTALLATION INSTRUCTIONS FOR GRAVITY VENTED WALL FURNACES Form 84504 REV 07 98 Plaster Ground Frame Closed Position FIGURE 15 Casing Opening Retainer Screw Holes Register Grille Plaster Ground Frame Page 19 Damper gh Open Position Casing Finished Wall 2 x4 Upright FIGURE 17 Finished Heater Wall Casing FIGURE 16 TROUBLE SHOOTING CHART for qualified service technician MAIN BURNER POSSIBLE CAUSES CORRECTIVE ACTION Flame too large 1 Defective operator section of gas valve 1 Replace complete valve 2 Burner orifice too large 2 Check with local gas company for proper orifice size and replace 3 If installed above 2 000 ft 3 Refer to orifice chart Page 3 Noisy Flame 1 Too much primary air 1 Adjust air shutter See Page 12 2 Noisy pilot 2 Reduce pilot gas with adjusting screw on combination gas control valve 3 Burr in orifice
33. uires that installation and service of a gas appliance be performed by a plumber or gas fitter licensed in the Commonwealth of Massachusetts READ CAREFULLY BEFORE INSTALLING UNIT This appliance must be installed in accordance with local codes if any if not follow the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CSA B149 1 This 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 if an external electrical source is utilized The ANSI standards are available from the American Gas Association 1515 Wilson Blvd Arlington Virginia 22209 The NFPA standards are available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 Canadian standards are available from International Approval Services 178 Rexdale Blvd Etobicoke Ontario Canada MOW 1R3 NOTE If optional rear register kit is to be used see supplemental installation instructions No 84504 and section marked Special Instructions for Rear Register Kit Application prior to installation of Rough In INTRODUCTION THIS IS AGAS FIRED GRAVITY VENTED WALL FURNACE THAT WILL OPERATE SAFELY AND PROVIDE AN EFFICIENT SOURCE OF HEAT WHEN INSTALLED OPERATED AND MAINTAINED AS RECOMMENDED IN THESE INSTALLATION AND OPERATING INSTRUCTIONS READ THESE INSTRU
34. uld terminate a minimum of 12 feet above the floor See Figure 2 Also the top of the vent must be at least 2 foot above any obstacle within a 10 foot radius including the roof See Figure A B Restriction in All type B vents shall extend in a generally vertical direction with offsets not exceeding 45 vent system degrees except that a vent system having not more than one 60 degree offset may be allowed caused by offsets Any angle greater than 45 degrees from the vertical is considered horizontal The total horizontal run of a vent plus the horizontal vent connector shall be not greater than 75 percent of the vertical height of the vent Any offsets used should be as far above the drafthood as possible to allow a venting action to begin before any restriction is encountered C Incorrect vent pipe C Use listed BW type vent pipe Do not use tansite or any other type of ceramic pipe for venting Do not use single wall pipe When venting into a masonry chimney the chimney must be properly lined and sized for this gas furnace The use of type B or flexible chimney liner is recommended 4 Incorrect header 4 The header plate must be 65 3 4 above the floor plate See rough in instructions plate location 5 Vent pipe not down 5 Use a base plate obtained from the vent pipe manufacturer on top of our header plate on the header plate This will lock the vent pipe down and prevent the draft diverter from shoving it up securel 6 Loose
35. untered Page 6 WARNING Do not bypass the blocked flue switch To do so could expose the consumer to property damage personal injury or possible death More than 10 eight above an roof surface FIGUREA horizontally Man Reset Blocked Flue Switch Draft Diverter Relief Opening Combus tion Chamber To heater gas control valve o _ _ Manual cut off valve LL l R 1 8 NPT Pressure Tap Drip GAS SUPPLY ROUGH IN INSTRUCTIONS NOTE Maximum wall thickness for a dual wall W505 W506 installation is 5 3 8 STEP 1 Attach the base plate purchased with the vent pipe to the header plate using two No 8 sheet metal screws through the pre punched holes The heater may not vent properly without a base plate to anchor and seal the vent system See Figure C or for first floor of multi Ceiling plate spacers to story buildings center B W gas vent in stud space nail securely at both ends Plate cut away for ful width of stud space to provide ventilation Studs on 16 inch centers Sheet metal screw base plate to header Use manufacturer s method of fastening pipe to base plate Header plate of vented wall furnace also acts as firestop FIGURE C STEP 2 Cut out an opening between the studs of 14 3 8 x 66 1 2 above the floor plate Embed the rear flange of the channel on top of header into either the drywall or the plastered wall This provides part of t
36. y or to wire the furnace correctly may result in continuous operation control damage or failure to operate This can cause property damage personal injury or loss of life Follow the instructions included with the thermostat Locate the thermostat approximately five 5 feet above the floor and four feet 4 from appliance Always mount the thermostat on an inside wall 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 The thermostat must never be installed in an adjoining room where a door can be closed between the thermostat and wall furnace This wall furnace 1s equipped with a self generating control system Never connect to a 24 volt transformer or to the household electrical system Do not use more thermostat wire than is included with the wall furnace Do not run thermostat wire in same stud space with vent Conceal wire inside wall or secure to wall with insulated staples that are included FIGURE 8 VOUR FURNACE IS SHIPPED WITH A WALL THERMOSTAT Figure 8 YOU MAY CONVERT CONTROL TO BUILT IN BULB CONTROL WITH THE OPTIONAL BBSK KIT SEE PAGE 13 14 and 15 FOR INSTALLATION INSTRUCTIONS Page 10 LIGHTING INSTRUCTIONS MODELS W255F W256F W355F W356F W505E W506F FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage perso

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