Cowon Systems D2 MP3 Player User Manual
Contents
1. Aq possed q oq 1noxoo ouo 51 Inoy ouo jnoxoo 08 51 220 JNS c JT c 49156 0 UMPI pue jurod yey 4015 sdojs Jo Aue ur uonoung eui e sr oou JT ALON umg 9 IOUING Ser I0JIUSI 0 Soso p yms ounssoJdd lt c m Q 10 SJL 3e1souriau L 1 op s dw ye Joye jnox2o T ON ON 1010 A 101U9A ses suodo pezi amp 1ougq 50501 YAMS Joonpuy yeay 10 105000 ser uonusy xiedg 5 jq 0 jejsouou yeISOULIOYL 91940 SunvoH 8 jjo 1oonpur SOSO D Kq pueig onuoo ser J nd 1504 99S 0c 098 ST NOLLVYAdO AO HONANOAS VENT RISER KIT VRK5 10 NOTE This kit has been designed and certified for use with a Cozy gas baseboard heater only Use only factory supplied kit and components WARNING DO NOTINSTALL IN WINDOW WELL OR BELOW GRADE WHERE WATER MAY ACCUMULATE MUST TOUCH THE GROUND STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 Install Cozy gas baseboard heater per installation instructions Check that the air intake pipe exten2. 2 Combination control valve stuck open 2 Replace combination control valve Main burner goes out 1 Defective flame sensor 1 Check voltage and replace if low during normal operation 2 Input too high 2 Check input rate 3 Cover around pilot lighter hole not air 3 Tighten screws securing sight glass tight Check and replace gasket if needed 4 Vent tubes not properly installed or 4 Follow instructions Check both sealed exhaust and air intake tubes and vent cap Be sure all gaskets are in place and properly sealed Use only tubes and vent cap supplied Do not alter vent tubes or cap Check wall thickness and tube lengths 5 Limit switch opens 5 Check rate remove any obstructions to circulating air 6 Exhaust or air intake tubes blocked 6 Remove obstruction Check for snow Page 21 TROUBLE SHOOTING CONTROL BOARD TO IMPROVE DIAGNOSING AND SERVICING THIS CONTROL MODULE IS EQUIPPED WITH A SELF DIAGNOSING RED INDICATOR LIGHT TO INDICATE STAND BY MODE AND PROPER OPERATION THIS LIGHT WILL REMAIN OFF IF THERE SHOULD BE A MALFUNCTION THE LIGHT WILL FLASH A VARYING NUMBER OF TRIES WITH A PAUSE BETWEEN EACH SERIES OF FLASHES THE NUMBER OF FLASHES WILL INDICATE WHICH CIRCUIT TO CHECK OF REASON FOR FLASHES INDICATION POSSIBLE CAUSES CORRECTIVEACTION 1 Air flow fault a Pressure switch tubing disconnected a Connect or replace tubing or damaged b Pressure switch tubing to wrong b Correct tubing connection
3. 24 V Thermostat Gas Baseboard Gas Baseboard T4 Gas Baseboard When wiring more than one baseboard heater to a single thermostat the baseboard heaters must be wired in PARALLEL When wiring more than one baseboard heater to a single 24 VAC thermostat the baseboard heaters must be hard wired in parallel Do not use cord sets Do not cross thermostat connections between heaters Purple thermostat connection from first heater to purple thermostat on second and third heater Do the same with white thermostat connection FIGURE 10 e The anticipator setting on the thermostat should be equivalent to the current draw of the total number of valves being controlled NUMBER OF BASEBOARD HEATERS ANTICIPATOR SETTING 1 2 2 AMP 3 3 AMP STEP 7 COMPLETING INSTALLATION a Connect gas supply line to flex gas line shut off valve from heater b Turn gas supply on Check connections with soapy solution Plug power cord into grounded 115 V outlet or turn power on if hard wired d Replace cabinet cover and secure with three screws at bottom Heater is now installed follow lighting instructions to put heater in operation During initial warm up the heater may smoke slightly Provide adequate ventilation should this occur Page 10 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage pers
4. Remove pipe plug from wall sleeve Apply petroleum jelly or equivalent lubricant around the outside of the O ring Insert the air intake tube through the PVC wall sleeve until back of heater is against the wall Secure heater to wall CONT D ILLUSTRATIONS NEXT PAGE Page 19 VENT WEATHER SEAL KIT Cont d Can of Glue PVC Wall Sleeve PVC Pull Strap 2 A ra Weather Seal Apply Lubricant Wall Thickness 8 1 4 PVC Wall Sleeve 7 8 Longer Than Wall Thickness PVC Pull Strap FIGURE 2 Inside Wall Insert Pull PVC Straps To Pull Tight FIGURE 3 PVC Pull Strap PVC Wall 44 Sleeve IS Screws not supplied FIGURE 4 Back Of Gas Baseboard O Ring placed 2 from edge of 2 air intake tube FIGURE 5 Page 20 TROUBLE SHOOTING CHART Flame too large 1 Defective operator section of valve 1 Replace valve 2 Burner orifice too large 2 Check with local gas company for proper orifice size and replace 3 If installed above 2 000 ft 3 See burne orifice section Page 12 Yellow burner flame 1 Clogged burner ports 1 Remove burners and check for obstructions in throats ports and orifices Clean but do not enlarge ports or orifices 2 Obstruction around vent cap 2 Make sure area around vent cap is clear be sure vent system is sealed 1 Gas leak 1 S
5. connections c Wire disconnected or damaged c Replace or connect wire d Obstruction in vent pipe d Remove obstructions e Defective draft inducer e Replace draft inducer Flame a Defective gas valve a Replace gas valve for heat b Defective control module b Replace control module c Defective thermostat wire c Check and replace thermostat wire Ignition Lock Out Defective ignitor a Replace ignitor 3 Attempts b Ignitor cable disconnected b Connect ignition cable Heater is in one no gas to burner hour lockout mode c Manual gas control in OFF c Turn manual gas control to ON This one hour position position lockout can be by 4 Loose or damaged wire to gas d Connect or replace wire to gas valve passed by resetting valve the thermostat MAINTENANCE INSTRUCTIONS SERVICE RECORD For correct and safe operation keep heater and heater area clean DATE DATE DATE At regular intervals turn control valve to OFF let heater cool and clean inside control and heat exchanger compartments To clean outside cover use a damp cloth do not use any kind of solvent of cleaning fluid as they may leave a residue that could burn or give off odors when heater is turned on Have heater including vent system checked cleaned and or repaired by a qualified service person prior to use each year Follow a regular service and maintenance schedule for safe and efficient opera
6. be inspected at least annually by a qualified service person May be installed in an aftermarket permanently located manufactured home mobile home where not prohibited by local codes See owner s manual for details This appliance is not convertible for use with other gases unless a certified kit is used This unit is not approved for installation in greenhouses or environments involving dusty wet corrosive or explosive conditions Such conditions will invalidate the warranty and may create unsafe conditions NOTE Obstruction in the vent exhaust tube or air intake tube due to insects small animals debris etc will prevent the heater from operating but DOES NOT constitute a warranty issue The State of Massachusetts requires that installation and service of gas appliance be performed by a plumber or gas fitter licensed in the Commonwealth of Massachusetts CONTENTS IntrOGdHe ofi oio eters renes 2 Wiring Diagram rrr 14 Specifications and Dimensions 2 Removing Main 13 Safety Rules scenes 3 Proper Burner Flame 13 Clearances cec BOE 4 5 Sequence of 15 5 Optional 16 20 Installation i eoe rede edere don 6 10 Trouble Shoott g 21 22 Lighting Instructions ess 11 Parts Drawing ove re
7. remove power cord from junction box and discard Install electrical wiring into junction box through appropriate knockout Secure with strain relief fitting supplied d Connect wires to factory installed wires in junction box Secure with wire nuts provided Secure ground wire under screw holding junction box to heater back See Figure 9 f Replace and secure junction box cover CAUTION all wires prior to disconnection when servicing controls Wiring errors could cause improper or dangerous operation Verify proper operation after servicing STEP 6 THERMOSTAT CONNECTION a This heater is designed to operate on a 24 V thermostat supplied Do not connect to existing line voltage thermostat b Connect thermostat wire to purple and white wire in control compartment labeled thermostat wire Secure connection with wire nuts CONTROLLING MORE THAN ONE HEATER WITH A SINGLE THERMOSTAT Up to a maximum of three baseboard heaters may be controlled by a single thermostat provided heaters are in the same room with the wall thermostat d If more than one baseboard heater is being controlled from a single thermostat the 115 V supply must be supplied from the same circuit When wiring more than one baseboard heater to a single 24 V thermostat the baseboard heaters must be hard wired in parallel Do not use individual cord sets See Figure 10 Cont d next page Page 9 INSTALLATION
8. use a match candle flame or other source of ignition to check for gas leaks Use only soapy water or liquid detergent Have your baseboard heater and vent system inspected at least annually by a qualified service technician Before cleaning or servicing turn off the gas and allow heater to cool Do not operate baseboard heater without all components properly installed Due to high temperatures the baseboard heater should be located out of traffic and away from furniture and drapes Children and adults should be alerted to the hazard of high surface temperature and should be kept away to avoid burns or clothing ignition Young children should be carefully supervised when they are in the same room with the baseboard heater Do not place clothing or other flammable material on or near the heater INSTALLATION AND REPAIR SHOULD BE DONE BY A QUALIFIED SERVICE PERSON THE BASEBOARD HEATER SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNU ALLY BY A PROFESSIONAL SERVICE PERSON More frequent cleaning may be required due to excessive lint from carpeting bedding material etc It is imperative that control compartments burner and circulating air passageways of the heater be kept clean Do not install in a closet alcove or small hallway where the heater could be isolated from the space to be heated by closing a door Do not put anything around the heater or vent that will obstruct the flow of combustion and ventilation air The flow of ventilatio
9. END USE THE CUT OFF SECTION FROM THE AIR INTAKE TUBE AS A GUIDE Do not cut to less than 7 1 2 FIGURE 5 9 1 1 2 BASEBOARD 1 HEATER EXHAUST NS TUBE AIR INTAKE TUBE EXTERIOR WALL HEATER MUST BELEVEL USETHE MOUNTING HOLES PROVIDED IN THECASING BACK MOUNT BASEBOARD TO WALL ATLEAST ONEMOUNTING HOLE MUST ALIGN WITH A WALL STUD FIGURE 6 BASEBOARD HEATER FIGURE 7 Black wire to L2 on control module Wire Nuts Green Wire i Black wire to L1 Ground Wire on control Black Wire PUE Electric White Wire Connection Electric Connection Junction Box Cover Electric Power Supply FIGURE 9 Page 8 FIGURE 8 INSTALLATION Cont d STEP 4 INSTALLING THE BASEBOARD HEATER a Use only factory supplied parts Do not modify in any way b Using a measuring tape measure the thickness of the wall See Figure 5 Using a tube cutter cut the air intake pipe 1 5 3 8 cm longer than the wall thickness less than 5 1 2 Measuring from the threaded end cut the vent exhaust pipe 3 0 7 62 cm longer than the wall thickness no less than 7 5 19 05 cm After cutting check the inside of both pipes for burrs Both pipes must be smooth and clean without any reduction to the inside diameter NOTE Correct pipe length is critical to proper operation d Attach vent exhaust tube to heater
10. LE NOTE 3 DIA HOLE REQUIRED FOR WEATHER SEAL KIT 11 3 8 gt T A Fr 2 INSTALLATION Cont d STEP 2 ROUGHINGAS SUPPLY See Figure 3 a Select the bottom rear or right side to bring the factory supplied flexible gas line assembly out of the heater b The valve must be connected only by means of a pipe union of the ground joint type Mr Installer hold gas valve when connecting gas supply line Install at least a 3 8 gas line Contact local gas supplier if any questions d Install a drip leg in gas supply line immediately upstream from the gas connection to heater see local codes and provide a 1 8 N P T plugged tapping accessible for test gauge connection and a individual manual shut off valve accessible within room where heater is installed The heater and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of psig 3 5Pa The heater must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than psig 3 5Pa e Test all connections for leaks using a soapy solution NEVER USE AN OPEN FLAME TO TEST FOR LEAKS f The maximum inlet gas supply pressure for natural and L P Propane gas is V2 p s i or 14 w c The minimum inlet as supply p
11. SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance CRITICAL SAFETY POINTS TO REMEMBER e Your gas has been odorized so that you can smell it Always smell around for gas before lighting your appliance e Sniff for L P gas at floor level LP gas is heavier than air and may temporarily exist at floor level e If you smell gas do not attempt to light the pilot Do not cause a spark by turning on or off electrical switches or appliances or by using the phone Turn off the gas to the appliances and call your gas supplier from another location e If your gas control has gotten wet as the result of flooding or other wetting it must be replaced immediately by a trained gas service technician Water can lead to damage of the internal safety mechanism in the gas control and can create a hazardous condition Page 25 VAAL AAAAAAAAAAAAAA A AAAAAA VV VV AY AAA VAAAAAAAAAAAAAAAAAAAAAAAA 5 WAY ARIS AN The Louisville Tin
12. Y NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Product Cozy Gas Fired Floor Furnace Cozy Gas Fired Wall Furnace Cozy Gas Fired Vented Console Heater Cozy Gas Fired Direct Vent Heater Cozy Gas Fired Counterflow Furnace TABLE A Warranty for gas appliance heat exchangers only 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 Warranty Period 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years 10 Years LOUISVILLE TIN AND STOVE COMPANY P O Box 2767 Louisville Kentucky 40201 2767 v AAAA v VAV AAA AA AAAAA A AAAA
13. amp Stove Co warrants to the original user the accompanying product for the period specified herein provided said product is installed operated maintained serviced and used according to the instructions and specifications accompanying the product AS OUTLINED IN OUR INSTRUCTIONS ANY WARRANTY CONSIDERATIONS ARE CONTINGENT ON INSTALLATION BY A QUALIFIED INSTALLER CONTRACTOR SELF INSTALLATION IS NOT RECOMMENDED AND MY INVALIDATE YOUR WARRANTY If within a period of one year from the date of installation of the product any part supplied by the manufacturer proves to be defective due to workmanship or material it will replace such part provided parts have not been subjected to misuse alteration neglect or accidents The term of the warranty for the heat exchanger 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 us
14. by screwing threaded end into inducer outlet See Figure 5 Attach air intake pipe to back of heater using six 8 screws provided See Figure 6 f Slide the indoor intake gasket over the air intake pipe and against the back of the heater g Place the vent tubes into center of the hole cut through wall and slide the entire heater towards the wall feeding the 115 V line and thermostat wires through the appropriate holes in the rear bottom or right side of the heater h Level and secure heater to wall with screws not provided through mounting holes in back of heater Anchors not provided may be required See Figure 7 NOTE Mounting the heater on a wall that is not plumb or over tightening mounting screws may cause undue stress which may result in excessive noise during warm up and cool down i From outside the house slide weather seal over air intake pipe and against outside wall See Figure 8 STEP 5 ELECTRICAL CONNECTIONS If this heater is replacing a 220 volt electric baseboard heater the circuit must be converted to 115 volt by a licensed electrician This appliance must only be connected to a properly grounded 115 V electrical circuit DO NOT CONNECT TO 220 VOLT SUPPLY CIRCUIT USING FACTORY INSTALLED POWER CORD a Unwrap power cord and plug directly into nearest 115 volt electrical outlet Do not use extension cord HARD WIRING HEATER a Remove junction box cover See Figure 9 b Disconnect factory wired power cord
15. catches release COZY Gas Baseboard Heater Manual gas shut off valve must have cut off above floor Mounting Plate Mounting plate catches 4 1 4 Above floor Floor Mounting Holes 4 FIGURE 1 COZY Ga Baseboard Heater Manual gas shut off valve must have cut off above floor Wrapper FIGURE 2 Page 18 VENT WEATHER SEAL KIT VWSK5 10 NOTE This kit has been designed and certified for use with a Cozy gas baseboard heater only Use only factory supplied kit and components See Figure 1 for parts list of Vent Weather Seal Kit STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 STEP 11 STEP 12 STEP 13 STEP 14 STEP 15 Change the location for the vent by following Figure 1 in the installation and operating instructions provided with the Cozy gas baseboard heater Drill a three 3 inch diameter hole through the wall of the chosen location Measure the wall thickness Using a two 2 inch tube cutter cut the PVC wall sleeve seven eights 7 8 inch longer than the measured wall thickness See Figure 2 Clean the PVC sleeve and apply PVC cement provided on opposite sides of sleeve Place straps on cement leaving eight 8 inches past sleeve end Wait ten 10 minutes for cement to dry before proceeding to Step 6 See Figure 2 Apply petroleum jelly or an equivalent lubricant to the
16. chp DIRECT VENT GAS def A HEATER INSTALLATION AND OPERATING INSTRUCTIONS P N 64900 September 2004 MODEL NUMBERS INSTALLER MUST LEAVE THESE INSTRUCTIONS NAT GAS L P GAS WITH THE CONSUMER HAVE THEM COMPLETE BBT53 BBT54 AND RETURN THE WARRANTY CARD BBT103 BBT104 WARNING Ifthe information in these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or loss of life gt 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 This appliance must be connected to an electrical ground SOOM a Do not try to light any appliance Do not touch any electrical switch do not use any WARNING phone in your building CONNECT TO 115V ELECTRICAL Immediately call your gas supplier from a neighbor s SG CONN GT TO 220V phone Follow the gas supplier s instructions POWER SUPPLY If you cannot reach your gas supplier call the fire department U S PATENT 5253635 INSTALLATION AND SERVICE MUST BE PER FORMED BY A QUALIFIED INSTALLER CANADIAN PATENT SERVICE AGENCY OR THE GAS SUPPLIER 2066870 MADE IN U S A WARNING Operation of this furnace without the properly installed factory furnished vent system could result in Carbon Monoxide CO poisoning and possible death For your safety this furnace and the vent system should
17. clockwise to OFF Do not force Wait five 5 minutes to clear out any gas If you smell gas STOP Follow B in safety information on this label If you don t smell gas go to next step Turn gas control knob counterclockwise to ON Turn on all electric power to the appliance Set thermostat to desired setting If the appliance does not operate follow instructions To Turn Off Gas To Appliance and call your service technician gas supplier Gas control knob shown in OFF position TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Turn gas control knob clockwise to OFF Do not force Page 11 P N 91428 03 04 GAS CONVERSION The gas control valve supplied on this heater is field convertible CAUTION A qualified installer or service agency must perform any conversion of this gas control valve CONVERSION INSTRUCTIONS 1 Remove the converting seal cap See Figure A WARNING Do not remove or tamper with any other valve components 2 Remove the black rubber gasket from the down side of the converting seal cap and reinstall gasket on opposite side of converting seal cap Gasket must be on down valve side of converting seal cap See Figure A Invert the converting seal cap and reinstall 4 Insure that the desired gas LP for liquefied petroleum or NAT for natural gas symbo
18. ds 1 1 2 past the outside wall and the vent exhaust tube extends 2 1 2 past outside wall See Figure 1 Place the mounting plate over the air intake tube and slide back flush against wall Mark the location of the six mounting holes on wall See Figure 2 Drill the six mounting holes Depending on wall material install anchors not provided if needed Secure mounting plate to wall with screws not provided Place the vent riser kit over the vent exhaust tube slide back into position and secure to mounting plate with screws provided See Figure 3 AIR INTAKE FIGURE 1 Page 16 MOUNTING VENT EXHAUST TUBE FIGURE 2 INSTALLED FIGURE 3 SIDE VALVE CONCEALER KIT SVCK5 10 NOTE This kit has been designed and certified for use with a Cozy gas baseboard heater only Use only factory supplied kit and components STEP 1 With the offset up and out from the wall place the mounting bracket flush to the right side of the heater cabinet Align the top of the mounting plate with the top of heater cabinet Mark the location of the mounting holes See Figure 1 STEP 2 Drill holes where marked Depending on wall material install wall anchors nor provided if needed STEP 3 Secure mounting plate to wall with screws not provided STEP 4 Attach the cover to the mounting plate by placing the cover top edge over the offset on the mounting plate Push the cover in toward wall unti
19. ee Page 1 Delayed Ignition 1 Low gas pressure 1 Check gas supply pressure 2 Igniter not properly located 2 Check ignitor location and correct if necessary Failure to ignite 1 Main gas off 1 Open all manual gas valves 2 Thermostat not set high enough to call 2 Set thermostat to higher temperature for heat 3 Clogged burner orifice 3 Clean burner orifice do not enlarge 4 Incorrect wiring 4 Check wiring diagram 5 Defective valve 5 Replace valve 6 No power to unit 7 Minis power 7 Defective pressure switch Burner won t turn off 1 Defective or damaged thermostat wire be checked by ae wire from or thermostat control board terminal If burner goes off replace thermostat 2 Thermostat location 2 Re locate thermostat out of drafts hot or cold spots 3 Defective or sticking valve 3 Replace valve 4 Excessive gas pressure 4 Contact utility supplying gas 5 Defective or damaged thermostat 5 Replace thermostat 1 Re check gas input 2 Clean orifices with a smooth wood toothpick do not enlarge Not enough heat 1 Furnace undersized 1 This is especially true when a dwelling or room is enlarged Have the heat loss calculated and compare to furnace output Your gas company can supply you with this information If furnace is undersized replace with correct size unit or add up to two more heaters 2 Temperature dial set too low 2 Raise temperature 3 Inco 1 3
20. er and the manufacturer will not be liable for any expenses incurred by the user in remedying any defect in the product Service under this warranty is the responsibility of the installer In the event service under this warranty is needed the user of the product shall request such service directly from the installer If the user is unable to locate the 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 DAMANGES 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 APLY TO YOU SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATIONS OR EXCLUSIONS MA
21. imit Switch Wire 26 White Limit Switch Wire 46 White Limit Switch Wire 17 White Heat Exchanger Clamp Burner Box Air Drop Sight Glass Burner Access Plate Sight Glass Gasket Burner Access Plate Gasket Burner Support Bracket Burner Burner Orifice Natural Gas Burner Orifice L P Gas Manifold Gas Valve Natural Gas Gas Vlave L P Gas Draft Inducer Draft Inducer Gasket Draft Inducer Mounting Plate Draft Inducer Outlet Gasket Pressure Switch Junction Box Cover Junction Box Control Module 174 30 174 30 Thermostat Wire Lead 6 Purple 1 10 1 10 Pos Gas Valve 8 Red 1 60 1 60 Neg Gas Valve 7 Dark Blue Pressure Switch 8 1 2 White Pressure Switch 11 Black Power Cord Connector 5 1 2 Black Ground 9 Green Power Cord Thermostat Wire Thermostat Air Box Gasket Vent Exhaust Tube Air Intake Tube Assembly Air Intake Tube Gasket Indoor Intake Gasket Weather Seal 64405 10 70 Flex Gas Line Shut off Valve Assembly 64072 24 60 USES 2 gt 2 oF 21125 64200 N A yoo aja a uJ 1 2 E E Sa Oo OR gt gt gt Mr Contractor we only sell parts through our wholesalers but the prices listed above for your convenience For prompt parts service contact the wholesaler from which you purchased your Cozy heater NOTE Parts prices amp schematic drawings on current m
22. l catch snaps into place See Figure 2 STEP 5 For access to the manual gas shut off valve locate finger handle at the bottom of the cover Pull out until snap catch releases then lift cover up to remove from mounting plate See Figure 2 COZY Gas Baseboard Heater Offset must be out from wall Mounting Holes 4 Mounting Plate Manual gas shut off valve eO oy COZY Baseboard Heater Cover Gas Cabinet catch Manual gas shut off valve Fuse handle FIGURE 2 Page 17 BOTTOM VALVE CONCEALER KIT BVCK5 10 NOTE This kit has been designed and certified for use with a Cozy gas baseboard heater only Use only factory supplied kit and components STEP 1 Place the mounting plate against the wall and flush with the bottom of the gas baseboard heater The mounting plate must cover the manual gas shut off valve See Figure 1 Mark the location of the mounting holes STEP 2 Drill holes where marked Depending on wall material install anchors not provided if needed STEP 3 Secure mounting plate to wall with screws not provided STEP 4 Attach the cover to the mounting plate by lining up the two catches inside the cover with catches on mounting plate Push cover toward wall until catches snap into place See Figure 2 STEP 5 For access to the manual gas shut off valve grasp the cover on both sides and pull out until the snap
23. l is visible after reassembly of cap See Figure A 5 Remove the burner orifice and replace with burner orifice of correct size for your type of gas and elevation See orifice chart in these instructions 6 Check for gas leaks 7 Using amanometer check for correct manifold pressure 3 5 w c for natural gas and 10 0 w c for L P ai NAT on top for Natural Gas pr LP on top for LP Gas BT Converting Seal Cap Mx Gasket 5p Maxitrol Gas Valve FIGURE A Page 12 PROPER BURNER FLAME The burner flame may be observed through the sight glass located in the burner box cover See Figure 11 A proper flame will have a dark blue inner mantle with a lighter blue outer mantle that extends from the burner into the heat exchanger tube see Figure 12 There is no primary air adjustment on the burner and proper flame is assured since the correct manifold pressure and orificing has been done at the factory for elevations up to 2 000 feet TO REMOVE MAIN BURNER FOR INSPECTION AND CLEANING Turn off all electrical supply to heater Turn off gas supply Remove cabinet cover Remove burner box cover See Figure 13 Remove two 2 screws holding burner to burner bracket See Figure 13 Burner can now be slid forward off orifice lift up slide back and out of burner box g Clean or replace as needed h Reinstall by reversing Steps f through mh BURNER ORIFICE This heater is
24. m 4icm 10cm BBT104 9 000 BTU 72 5 375 9 375 3 8 L P 16 4 2 61 KW 183cm 13 65cm 23 8cm 4icm 10cm Page 2 SAFETY RULES The Direct Vent Gas Baseboard Heater and its components meet all applicable safety standards when installed as directed in this manual For safe installation and operation of your Direct Vent Gas Baseboard Heater read all these instructions before you begin Failure to follow them exactly will void your warranty and may present a fire hazard 1 2 h 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Improper installation adjustment alteration service or maintenance can cause property damage bodily injury or death Use in other than a residential application may result in unsatisfactory performance and may void the warranty Follow all applicable codes and ordinances If there are none follow the latest edition of National Fuel Gas Code ANSI Z223 1 A copy may be obtained from the CSA International or the National Fire Protec tion Association Batterymarch Park Quincy MA 02269 In Canada use latest edition of CAN1 B149 installation code DO NOT INSTALL THIS FURNACE IN RECREATIONAL VEHICLE Do not operate baseboard heater unless it is connected to the factory supplied vent system Check the rating label attached to the baseboard heater to be sure it is equipped for the type gas you intend to use Never
25. n air through the upper and lower louvers must not be obstructed The appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the latest edition of National Electrical Code ANSI NFPA 70 In Canada use CSA C22 1 Never operate this heater without the burner sight glass in place or with the glass broken or missing If it is suspected that rising water may enter the heater turn off the gas immediately Do not use the heater if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water It is necessary to replace damaged gaskets or sealing material within the vent or air intake system Failure to do so may result in property damage personal injury loss of life or unsatisfactory performance The cabinet cover removed for servicing must be replaced prior to operating heater This heater must not be connected to a chimney flue Page 3 CLEARANCES CLEARANCES TO COMBUSTIBLES If the heater is installed directly COMBUSTIBLE CLEARANCE on carpeting tile or other com 0 Inches 0 cm bustible material other than Right Side 0 Inches 0 cm Left Side O Inches wood flooring the heater shall 0 Inches 0 cm be installed on a metal or wood 16 Inches 41 cm panel extending the full width 36 Inche
26. ns and modifications the following kits are available from your local dealer To ensure safe efficient operation of your Direct Vent Gas Baseboard be sure to use only authorized kits Table 1 Special adaptation and modification kits available for use with the Direct Vent Baseboard Heaters MODEL DESCRIPTION CONTENTS VWSKS 10 Vent Weather Seal Kit 2 diameter PVC pipe external wall seal O ring 2 PVC straps PVC glue instructions VRK5 10 Vent Riser Kit Wall mount plate 21 1 2 stainless steel vent riser instructions SVCK5 10 Side Valve Concealer Kit 4 cabinet extension wall plate screws instructions BVCK5 10 Bottom Valve Concealer Kit 4 cover wall plate screws instructions INSTALLATION WARNING Failure to follow these instructions carefully could result in poor performance property damage personal injury or loss of life STEP 1 LOCATE VENT OPENING Requires a 2 1 2 hole when not using vent weather seal kit a Select area on wall where heater will be installed b Check outside vent termination for proper clearances See Figure 1 Locate studs behind heater location d Using template supplied mark location for 2 1 2 hole between studs See Figure 2 e Cut vent openings through both the inside and outside walls being sure to maintain level across both openings VENT HOLE LOCATION FOR THE AIR INTAKE AND EXHAUST TUBES FOR STANDARD INSTALLATION 2 1 2 DIA HO
27. nstallation codes NOTE H Not to be installed above a meter regulator assembly local codes or regulations may require different within 3 feet 90 cm horizontally from the center line clearances of the regulator I Clearance to service regulator vent outlet 6 feet 1 8 m minimum Page 4 CLEARANCES CONT D RESIDENTIAL GARAGE INSTALLATION Gas utilization equipment in residential garages shall be in stalled so that all burners and burner ignition devices are located not less than 18 inches 46 cm above the floor Unit should be located or protected so it is not subject to damage by a moving vehicle Use care in selecting a good location within the garage DO NOT locate the heater where heated air will be directed onto a nearby parked vehicle Paint may discolor or rubber may harden and crack DO NOT allow open or closed containers of paint gasoline or other liquids having flammable vapors to be stored or used in the same area as the heater poste QUO LOCATION This heater must be installed on an outside wall For efficient performance locate heater as centrally as possible in the area to be heated Check outside wall where vent will exit for proper clearances See Figure 1 compliance with local codes and clearances above grade Also consider exterior appearance walkways plantings etc Check that a gas supply line is accessible Check that a 115 V power supply circuit is accessible Do not use 220 volt cur
28. ntre 23 Gas 1 12 Parts ERR RE ARIES TUR 24 Burner Once sez iue eere tes 13 26 INTRODUCTION THIS IS A GAS FIRED DRAFT INDUCED POWER DEPENDENT DIRECT VENT WALL FURNACE THAT WILL OPERATE SAFELY AND PROVIDE AN EFFICIENT SOURCE OF HEAT WHEN INSTALLED OPERATED AND MAINTAINED AS RECOMMENDED IN THESE INSTALLATION AND OPERATING INSTRUCTIONS READ THESE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING SERVICING OR USING THE APPLIANCE IF YOU DO NOT UNDERSTAND ANY PART OF THESE INSTRUCTIONS CONSULT LOCAL AUTHORITIES OTHER QUALIFIED INSTALLERS SERVICE AGENCIES THE GAS SUPPLIER OR THE MANUFACTURER SPECIFICATIONS AND DIMENSIONS Your Direct Vent Wall Furnace is shipped complete in one carton This carton contains the furnace vent exhaust tube air inlet tube template with rough in dimensions installation and operating instructions power cord consult electrical codes ball valve w flex connector and wall thermostat MODEL INPUT GAS TYPE MAX WALL MIN WALL NO BTU HR WIDTH DEPTH HEIGHT CONN GAS Thickness Thickness BBT53 5 000 BTU 48 5375 9 375 3 8 NAT 16 4 1 45 KW 122cm 13 65cm 23 8cm 4icm 10cm BBT54 5 000 BTU 48 5 375 9 375 3 8 L P 16 4 1 45 KW 122cm 13 65cm 23 8cm 4icm 10cm BBT103 9 000 BTU 72 5 375 9 375 3 8 NAT 16 4 2 61 KW 183cm 13 65cm 23 8c
29. odels are shown at www cozyheaters com Page 24 MARCH 2005 IMPORTANT SAFETY BULLETIN ON YOUR GAS CONTROL AND PILOT LIGHT SYSTEM FOR HEATING EQUIPMENT WHAT YOU DON T KNOW CAN HURT YOU Your pilot light system has been designed for safe and reliable operation Although safety mechanisms are built in the potential for hazard exists This information is intended to help you avoid these hazards YOUR GAS CONTROL AND PILOT LIGHT SYSTEM Your gas control and pilot light system has a safety device whose purpose is to shut off the gas supply to the appliance if the pilot light goes out If you have trouble lighting the pilot or keeping it lit it may mean that this safety device is warning you that there is a problem with your system Inspection and repairs or replacement must be made by a trained gas service technician TAMPERING IS DANGEROUS The pilot safety system may also not work if you do not follow the lighting instructions carefully or if you tamper with the gas control that you use to light the pilot Tampering with the gas control particularly with tools can damage the safety mechanism in the control and can allow gas to leak This can result in a fire or explosion causing property damage personal injury or death IF YOU SMELL GAS DON T LIGHT IT IF YOU CAN T LIGHT IT DON T FIGHT IT AGA Gas Association gama THIS IS NOT AN ADVERTISEMENT WHAT DO IF YOU
30. onal injury or loss of life This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions 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 OPERATING INSTRUCTIONS STOP Read safety information on this label Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn gas control knob
31. orificed at the factory for elevations up to 2 000 ft If installed above 2 000 ft the BTU input must be reduced 4 per 1 000 ft See the following orifice chart for the proper orifice for a specific elevation SPECIFIC ELEVATIONS 0 to 2 000 2 000 4 000 4 000 6 000 6 000 8 000 8 000 NATURAL GAS 56 57 57 1 45mm 54 54 ORDER KIT 49800 44 1 HIGH ALTITUDE KIT FOR NAT OR L P GAS Page 13 FIGURE 11 COMBUSTION TUBE 4 i Plate t gt v Bracket A Cw Sight Sight Glass Glass Gasket FIGURE 13 WIRING If any of the original wire supplied with heater has to be replaced it must be replaced with type 105 Degree C wire or its equivalent CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing WIRING DIAGRAM 53 amp BBT54 BBTS3 T5 4 GAS VALVE PICTORIAL IGNITOR DRAFT INDUCER PRESSURE SWITCH 115 VAC IGNITION MODULE 24 VAC LIMIT SWITCH ELECTRIC POWER SUPPLY THERMOSTAT BBT103 BBT103 BBT104 BBT104 0 PICTORIAL LADDER Do ELECTRIC LIMIT SWITCH POWER THERMOSTAT SUPPLY THERMOSTAT Page 14 NI MON SI sun 6 S9SO 9 SLO 8 poysnes 0 0 4 Iamod Sundnuojut JO
32. outside of the weather seal The lubricant will make it easier to push the weather seal through the wall See Figure 2 From inside hold the wall sleeve with the PVC straps lined up horizontally Push the PVC pipe and weather seal slowly through the wall until the weather seal is completely outside the wall See Figure 3 Pull the PVC straps toward you to pull the weather seal firmly against the outside wall See Figure 3 Being careful to keep the PVC straps lined up horizontally and pulled tight to maintain the outside seal bend the straps away from sleeve and secure to wall Depending on type of wall anchors not provided may be required See Figure 4 First put blue pipe plug in PVC pipe to prevent insulation from getting inside Insert nozzle from a tube of foam insulation between the wall and the wall sleeve Starting at the weather seal slowly inject the foam working towards the inside wall CAUTION Read the manufacturers instructions on the can of foam for special instructions and warnings Wait fifteen 15 minutes for foam to dry cut away any excess from around sleeve on inside wall If Cozy gas baseboard heater will be installed at a later date leave the pipe plug in the wall sleeve to seal the vent hole Install the Cozy gas baseboard heater per the installation instructions provided with heater Slide the O ring over the air intake tube to a position approximately two 2 inches from the end of the tube See Figure 5
33. rent Installation must provide clearance for servicing heater If heater is installed in a basement a 12 30 cm clearance must be maintained between ground level and the vent intake pipe Do not install heater where the vent will terminate in a window well or any opening below ground level Do not allow snow accumulation to build up within 12 30 cm of the vent air intake pipe Clearances must be maintained providing adequate air circulation around the heater A minimum of 16 inches 41 cm must be maintained from the front of the heater to furniture doors etc Up to three baseboard heaters may be controlled by one thermostat provided all three heaters are in the same room with the thermostat THERMOSTAT LOCATION Locate thermostat on an inside wall about 5 feet off the floor and 6 feet from the baseboard heater accessible to wiring service and adjustment in a frequently used room such as a living room rec room etc Do notlocate thermostat in unusual heating conditions such as in sunlight close to lamps TV sets radiators registers or other heat producing appliances Do not locate thermostat in unusual cooling conditions such as on an outside wall or one separating an unheated room or in drafts from stairwells doors windows etc Do not locate thermostat where air circulation is poor such as in a corner alcove over furniture or the wall behind an open door Page 5 OPTIONAL KITS For special installation applicatio
34. ressure for the purpose of adjustment is 4 5 w c for natural gas and 11 0 w c for L P Propane gas STEP 3 PREPARING TO INSTALL THE YOUSHOULD HAVE BASEBOARD HEATER e 1 Baseboard Heater 2 1 Exhaust Tube e 1 Intake Tube Open the carton and carefully remove the Direct 1 4 10 Stainless steel flexible Vent Baseboard Heater connector with a manual shut off valve b Remove the cover of the baseboard heater s e Template to locate venting and cabinet by removing the screws at the bottom mounting positions in package with front of the cover See Figure 4 manual Make sure that all of the components illustrated e 1 Vent Sealing Gasket have been included e Manual Weather Seal Wallthermostat w wire amp staples Ie 482 5M BTU 72 9M BTU BASEBOARD CABINET 2 FROM END OF CABINET FLEX LINEBALL VALVE MUST BE FLOOR E 5 ABOVEFLOOR MANUAL SHUT OFF VALVE WITH 1 8 NPT PLUGGED TAPPING 1 GAS SUPPLY DRIPLEG H 1 2 BLACK IRON PIPE FIGURE 4 COMPONENTS OF THE DIRECT VENT GAS BASEBOARD HEATER Fam Flex Line Ball Valve Screws a 48 BBT53 amp BBT54 Cover 72 BBT103 amp BBT104 FIGURE 4 Page 7 CUT THE AIR INTAKE 1 1 2 LONGER THAN THE WALL THICKNESS Do not cut to less than 5 12 Wall Thickness W CUT THE EXHAUST TUBE FROM THE UNTHREADED END
35. s 91 cm and depth of the heater 4 Inches 10 cm 2 5 Inches 6 35 cm OUTSIDE LOCATION FOR VENT OUTLET TERMINAL A Clearance above grade veranda porch deck or balcony J Clearance to non mechanical air supply inlet to building 12 inches 30cm minimum or the combustion air inlet to any other appliance 12 B Clearance to window or door that may be opened inches 30 cm minimum 6 inches 15 cm minimum Clearance to a mechanical air supply inlet 6 feet C Clearance to permanently closed window minimum 12 1 8 m minimum inches 30 cm recommended to prevent condensation f Clearance above paved side walk or a paved driveway on window located on public property 7 feet 2 1 m minimum D Vertical clearance to ventilated soffit located above the M Clearance under a veranda porch deck or balcony terminal within a horizontal distance of 2 feet 60 cm 12 inches 30 cm minimumz from the center line of the terminal 18 inches 46 cm minimum E Clearance to unventilated soffit 12 inches 30 cm T A vent shall not terminate directly above a sidewalk or minimum paved driveway which is located between two single Clearance to outside corner 12 inches 30 cm family dwellings and serves both dwellings minimum t Only permitted if veranda porch deck or balcony is G Clearance to inside corner 24 inches 60 cm fully open on a minimum of 2 sides beneath the floor minimum Asspecified in CGA B149 i
36. tion Do not obstruct combustion ventilation or circulating air If any components are removed make sure all gaskets are reinstalled andare in good condition If any sign of damage replace gasket as this is a sealed system and must be air tight for proper operation DO NOT operate heater with any gasket missing or damaged Failure to replace a missing or damaged gasket may result in property damage personal injury or loss of life Page 22 DIRECT VENT GAS MODEL NUMBERS BASEBOARD HEATER BBT53 BBT103 NAT GAS Prices and specifications subject BBT54 BBT104 L P GAS to change without notice All prices are F O B factory Mr Contractor we only sell parts through our wholesalers but the prices listed are for your convenience For prompt parts service contact the wholesaler from which you purchased your Cozy heater NOTE Parts prices amp schematic drawings on current models are shown at www cozyheaters com Page 23 HOW PROPERLY ORDER PARTS In addition to part description and part number please give model number serial number and type of gas used This information can be found on the rating plate located inside the cabinet cover MODEL NUMBER PART LIST PART Cap Left 21045 10 60 21045 End Cap Right Cabinet Base Cabinet Cover Heat Exchanger Heat Exchanger Gasket Igniter Igniter Cable Limit Switch Limit Switch Bracket Limit Switch Wire 27 White L
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