Gas-Fired Vented
FLOOR FURNACE
P/N 74521
REV. 08/97
INSTALLATION AND
OPERATING INSTRUCTIONS
R
MODEL NUMBERS
MILLIVOLT CONTROL SYSTEM
NATURAL GAS
90N30A
90N50A
90N65A
90N75A
WARNING: If the information in this manual is not followed
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
- Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
•
•
Do not try to light any appliance.
Do not touch any electrical switch; do not use any phone
inyourbuilding.
•
•
Immediatelycallyourgassupplierfromaneighbor’sphone.
Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire
department.
The coating selected to provide
longer life to the heat exchanger
may smoke slightly upon initial
firing. Please provide adequate
ventilation if this occurs.
- INSTALLATION AND SERVICE MUST BE PERFORMED
BY A 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 person.
THIS UNIT IS NOT APPROVED FOR INSTALLATION IN MOBILE HOMES,
GREENHOUSES, OR ENVIRONMENTS INVOLVING DUSTY, WET, CORROSIVE, OR
EXPLOSIVE CONDITIONS. SUCH CONDITIONS WILL INVALIDATE THE WARRANTY
AND MAY CREATE UNSAFE CONDITIONS.
SAFETY RULES - Continued
2.
FOLLOW ALL APPLICABLE CODES AND ORDINANCES. IF THERE ARE NONE, FOLLOW THE
INSTALLATION STANDARDS, LATEST EDITION OF NFPA54/ANSI.Z223.1. A COPY MAY BE OBTAINED
FROM THE AMERICAN GAS ASSOCIATION, 1515 WILSON BLVD., ARLINGTON, VA. 22209, OR THE
NATIONAL FIRE PROTECTION ASSOCIATION, BATTERYMARCH PARK, QUINCY, MA. 02269.
DO NOT INSTALL THIS FLOOR FURNACE IN A RECREATIONAL VEHICLE, TRAILER OR MOBILE HOME.
DO NOT OPERATE THIS FLOOR FURNACE UNLESS IT IS CONNECTED TO A PROPERLY INSTALLED AND
MAINTAINED VENT SYSTEM. DO NOT EXHAUST FLUE GASES UNDER THE FLOOR FOR ANY REASON.
BE SURE THIS FLOOR FURNACE IS EQUIPPED FOR THE TYPE GAS YOU INTEND TO USE.
LOCATE THE THERMOSTAT IN A ROOM OR SPACE THAT CANNOT BE SEPARATED BY A DOOR OR
OTHER MEANS FROM THE ROOM OR SPACE IN WHICH THE FLOOR FURNACE GRILL IS INSTALLED.
NEVER USE A MATCH, CANDLE, FLAME OR OTHER SOURCE OF IGNITION TO CHECK FOR GAS LEAKS.
USE ONLY SOAPY WATER OR LIQUID DETERGENT.
3.
4.
5.
6.
7.
8.
9.
ADEQUATE AIR FOR COMBUSTION AND VENTING MUST BE PROVIDED.
IF IT IS SUSPECTED THAT RISING WATER OR SEEPAGE MAY ENTER THE FLOOR FURNACE, TURN OFF
THE GAS IMMEDIATELY. DO NOT USE THIS FLOOR FURNACE IF ANY PART HAS BEEN UNDER WATER.
IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FLOOR FURNACE AND TO
REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER
WATER.
10.
11.
HAVE YOUR FLOOR FURNACE AND VENT SYSTEM INSPECTED AT LEAST ANNUALLY BY A QUALIFIED
SERVICETECHNICIAN.
THEGRILLBECOMESHOTWHENTHEFLOORFURNACEISINOPERATION. CHILDRENMUSTBECLOSELY
SUPERVISEDWHENINTHEPRESENCEOFANYHEATINGAPPLIANCE. CONTACTWITHBARESKINMAY
RESULTINSEVEREBURNS. KEEPCHILDRENOFFTHEGRILL.
12.
BEFORECLEANINGORSERVICINGTHEFLOORFURNACE, TURNOFFTHEGASANDALLOWITTOCOOL.
THISWILLPREVENTBURNS.
13.
14.
ALWAYSLEAVETHEGRILLINPLACEEXCEPTWHENCLEANINGORSERVICINGTHEFLOORFURNACE.
NEVER OPERATE THE FLOOR FURNACE WITHOUT THE SIGHT GLASS ASSEMBLY IN PLACE, OR WITH
THEGLASSBROKENORMISSING.
HELPFUL INSTALLATION INFORMATION
Do not attempt to heat through more than one doorway in any direction to adjoining rooms.
Always over-estimate the amount of heat required rather than under-estimate it. Always use the next size floor furnace above
your actual heating requirements.
Seal all cracks around windows, doors, and attic access doors or significant heat loss will occur.
INSTALLATION REQUIREMENTS
Listed below are steps that are part of a floor furnace installation. You must see that each step is followed closely so that the
floor furnace will provide maximum efficiency with safe operation.
YOUMUST:
1. Locate the floor furnace in the best available space for safe and efficient operation.
2. Provide fresh air for combustion and venting.
3. Cut and frame the floor opening so that the floor furnace fits properly.
4. Attach the draft hood and connect the vent pipe in compliance with applicable codes.
5. Connect an adequate gas supply to the floor furnace.
6. Select the best location for the thermostat.
7. Check and adjust the floor furnace for safe and efficient operation.
If you have any doubts about the correct way to install a floor furnace, contact local authorities or agency, or your gas supplier.
If local or state codes require that your floor furnace installation be inspected by local authorities, do so after the floor furnace
is installed and before it is put into service.
Page 3
FLOOR FURNACE LOCATION
Choose a central location such as a hallway but where occupant traffic is minimal and where there is at least 18 inches of
room from two adjoining sides of the grill to the nearest wall so that occupants may pass without stepping on the grill. See
Figure Number 1.
WALL
Bedroom
Bath
Kitchen
Vent Pipe
8”Minimum
Thermostat
Bedroom
18” Minimum
Living Room
FIGURE 2
FIGURE 1
Give consideration to available air for combustion, location in relation to chimney or vent system, thermostat location,
clearance under floor, clearance to combustibles, and heat circulation. Any open foundation is unacceptable as wind can
cause pilot outage and reduced efficiency. Keep furniture, drapes, doors, and other combustible materials at least 12 inches
from the edge of the grill. Never locate the floor furnace closer than 8 inches to a wall and never in a corner. See Figure 2.
Two adjoining sides of the floor furnace must have a minimum clearance of 18”. See Figure 1.
After selecting a location in the home, go beneath the floor and check
the position of the floor furnace in relation to joists, supporting
columns, electric wires, water pipes and walls. There must be a minimum
of 6 inches clearance between the top of the draft hood and floor
joists. There must also be at least 6 inches clearance between the
bottom of the floor furnace and the ground. See Figure 3.
FLOOR
JOIST
FLOOR
JOIST
FLOOR
FURNACE
6” Minimum
Draft
Hood
In order to find the location beneath the floor it may be necessary to
drill a 1/16 inch hole through the floor approximately in the center of
the selected floor furnace location to use as a reference point when
measuring under the floor.
Ground
Level
6” Minimum
FIGURE 3
FRESH AIR FOR COMBUSTION AND VENTING
Adequate air for combustion and venting must be provided. Any reduction in the necessary amount of fresh air
can result in an oxygen starved flame that emits Carbon Monoxide (C.O.) an odorless, colorless gas
that can cause serious injury or death. A ventilated crawl space will usually provide enough fresh air. However, you
must check to see that there is 1 square inch of free area of ventilation opening for each 1,000 BTU’s input of your floor furnace.
EXAMPLE: 50,000 BTU floor furnace ) 1,000 = 50 square inches. If another gas burning appliance such as a water heater is
installed within the same crawl space or basement, add the B.T.U.’s of the other appliance to those of the floor furnace before
calculating the total ventilation needed. EXAMPLE: 50,000 B.T.U. floor furnace plus 40,000 B.T.U. water heater equals 90,000
B.T.U. ) 1,000 = 90 square inches. To compensate for the loss of square inches of ventilation due to the use of louvers, grills,
or screens add approximately 50% to the square inches calculated. Screen all openings with mesh not less than ¼ inch to
prevent animals or insects from entering the crawl space.
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
encountered.
Page 4
CUTTING THE FLOOR OPENING
Consult the specification chart on Page 2 for the correct floor opening size for the floor furnace to be installed. Lay out the
opening size on the floor by using masking tape or cutting a piece of cardboard to the opening size. The opening must be cut
square. If you have determined that there is nothing under the floor to interfere with the installation, you are now ready to cut
the opening. Start by drilling ½ inch holes inside the lines of each corner. Use a keyhole saw or a properly grounded saber saw
to cut along the lines making sure to keep the lines straight and the corners square. If the opening dimensions are not correct,
it may be difficult to fit the floor furnace into the opening. Forcing the floor furnace through the opening may create stresses
that cause the floor furnace to be excessively noisy.
Most installation will require cutting a floor joist. Cut the floor joist
JOIST
so that double headers of the same size lumber can be used to frame
around the floor furnace. Double headers are necessary to maintain
the strength of the floor. See Figure 4.
DOUBLE
HEADER
FLOOR
FURNACE
OPENING
If the clearance between the bottom of the floor furnace and the
ground is not adequate, dig a pit that will provide clearances of at
least 6 inches under the floor furnace, 18 inches on the end where
the gas valve is located and 12 inches on the other three sides.
Slope the sides of the pit to prevent dirt from caving into the pit. See
Figure 5.
FIGURE 4
FLOOR
JOIST
FLOOR
JOIST
FLOOR
FURNACE
6” Minimum
DRAFT
HOOD
18”
Minimum
12”
Minimum
6” Minimum
FIGURE 5
If there is any possibility that water may accumulate in the pit, a drain must be provided. If a drain cannot be provided, fabricate
a waterproof pan of at least 16 ounce per square foot sheet copper or a suitable substitute. Size the pan to provide 6 inches
clearance to the bottom of the floor furnace, 18 inches on the side where the gas valve is located and 6 inches on the other three
sides. The sides of the pan must extend at least 4 inches above the ground. Anchor the pan to prevent it from floating
up against the bottom of the floor furnace when water is present. Failure to do so may result in the pan
rising to seal off air for combustion and venting. If this occurs, carbon monoxide (C.O.) a colorless,
odorless gas that can cause serious injury or death may be formed.
SETTING THE FLOOR FURNACE
Lay aside the grill and package containing the thermostat, wires, etc., grasp two opposite sides of the outer casing and lower the
floor furnace gently through the opening. Support the furnace evenly by the flange at the top of the outer casing. Trim back
carpet, padding, and other types of floor covering so that the entire flange rests directly on the floor. If not evenly supported
on all four sides, stresses may be created that cause excessive expansion and contraction noises as the floor furnace heats and
cools. Anchor the floor furnace in place by driving two galvanized roofing nails through each side of the outer casing into the
double headers approximately 1 inch below the flange. Place the grill into position making sure it lays flat against the outer
casing flange. Leave the grill in place until time to light the furnace to keep occupants from falling into the furnace.
Page 5
INSTALLING THE DRAFT HOOD
The draft hood must be installed in the same atmospheric pressure zone as
the combustion air inlet. The draft hood is packed in its own carton within
the master pack. Make sure the draft hood received is the correct one for
the floor furnace being installed. Included in the carton are two rope-like
gaskets and 7 sheet metal screws. Begin by pressing the rope-like gasket
material into the groove provided around the two male vent outlets on the
floor furnace. See Figure 6.
GASKET
MATERIAL
Slip the two female couplings in the draft hood over the male outlets
extending through the outer casing, making sure the gaskets remain in
place. Press the draft hood tight against the casing and use the 7 sheet
metal screws to secure it tightly. All 7 screws must be used to prevent
leakage of vent gases. Never install or operate a floor furnace
without a draft hood. To do so could result in serious injury,
property damage or death.
FIGURE 6
CONNECTING THE VENT
Refer to the specifications on Page 2 for the correct vent pipe size. Familiarize yourself with local codes or contact authorities
to determine the approved material and method of installing the vent. NOTE: An 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.
Improper or unsafe venting presents a hazard that may result in property damage, bodily injury or loss
of life. Listed below are some guidelines to observe when installing the vent system.
1. Never reduce the vent pipe to a size smaller than the outlet on the draft hood.
2. Never run pipe more than 15 feet horizontally.
3. 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.
4. Slope horizontal pipe upwards at least ¼ inch per lineal foot.
5. Do not use more than one elbow. An elbow restricts the flow of vent gases by approximately 10%.
6. Use a noncombustible thimble when connecting vent pipe to a masonry chimney.
7. Do not insert vent pipe farther than ¼ inch into the interior of the chimney.
8. Single wall pipe must not be used.
9. Never connect the vent pipe to any chimney or vent system serving a solid fuel-burning appliance.
10. If another appliance is being vented through the vent system with the floor furnace, the vent pipe must be
increased to compensate for the additional load.
11. Never install any kind of damper in the vent system.
12. Do not use transite or any other type of ceramic pipe for venting.
Class “B” double wall pipe is acceptable to most codes, and if installed in accordance with the pipe manufacturers instructions
provides the safest and most efficient vent system. Class “B” pipe has an integral lock for securing sections together. These
locks must be properly fitted together. Fasten pipe to draft hood using at least three self-tapping sheet metal screws at equal
intervals around the circumference of the pipe. Support horizontal pipe at three-foot intervals with metal strapping attached to
joists.
The floor furnace you have selected was carefully designed to operate both safely and efficiently when vented with the proper
size vent listed for each furnace on Page 2 of these instructions. We do not recommend doing so, but if you must vent into a
masonry chimney use the following instructions.
Continued – next page
Page 6
CONNECTING THE VENT - Continued
1/4”
SAFE
FIGURE 7A
UNSAFE
FIGURE 7B
RECOMMENDED
FIGURE 7C
If the floor furnace is vented into a masonry chimney, the chimney must be inspected to determine that it is clear and free of
obstructions and that it is safe for the intended use. The inside of the chimney must be at least 6 inches in diameter or 6 inches
by 6 inches if rectangular. Insert the vent pipe into the chimney through a masonry or noncombustible corrosion-resistant
thimble of the correct diameter. Do not push the pipe farther than ¼ inch into the inside of the chimney. See Figure 7A. Pushing
the pipe farther into the inside of the chimney may cause partial or complete blockage as illustrated in Figure 7B.
Even following these instructions you may still have a venting problem because of the larger area to be heated inside the
chimney. This could cause pilot outage, odors coming from the furnace, or noise due to excessive heat not being vented out of
the combustion chamber. If you experience any of these problems, we recommend running the proper size “B” type vent pipe
down the chimney and connecting to the horizontal run of vent pipe with a 90-degree elbow inside the chimney. See Fig. 7C.
Extend the vent system at least 3 feet above the point where it exits the roof and at least two feet higher than any part of the roof
system within 10 feet. Terminate with a listed or approved cap. See Figure 9.
10’OR
LESS
MORE THAN
10 FEET
10’
RIDGE
CHIMNEYOR
METAL PIPE
3’ MINIMUM
2’ Minimum
RIDGE
2’ Minimum
CHIMNEYOR
METAL PIPE
3’ MINIMUM
FIGURE 9
FIGURE 9
Page 7
If more than one gas appliance is vented through
a common vent system, the vent should be
increased in size to accommodate the increased
load. Consult your local code or the tables in the
latest edition of NFPA54/ANSI.Z223.1 for the
correct size. If no local codes apply, use the
following alternate method for sizing a vent
connected to more than one appliance. The
effective area of the vent must be not less than
the area of the largest vent connection plus 50
percent of the areas of additional draft hood
outlets.
CONNECTING THE VENT - Continued
Typical Installation Using
Class “B” Vent Pipe
1. Adequate clearances around floor furnace.
2. Draft Diverter 6” from combustibles.
3. Adequate clearances around vent pipe.
4. Horizontal vent pipe sloping upward 1/4” per foot.
5. Pipe supported with metal straps.
6. Adequate height of vent system.
7. Listed vent cap.
The homeowner appreciates neatness in
workmanship and the neat installation usually
functions better than the sloppy one. Double
check your work to verify that all clearances around
the floor furnace and vent system are adequate
and that the vent system is installed to code or
pipe manufacturers specifications. See Figure 10.
FIGURE 10
GAS SUPPLY AND PIPING
The gas piping system must meet the requirements of local codes or the specifications of the servicing gas supplier. It must
have adequate capacity to supply the floor furnace and any other appliance within the home with enough gas to maintain the
full rated capacities without excessive pressure drop when all appliances are operating at full rate.
GASTUBINGANDPIPESIZES-CAPACITY -
*L.P. GAS
GAS PIPE SIZES - CAPACITY - *NATURAL GAS
Length of
Pipe/Tubing
**Copper Tubing **Steel Pipe
Outside Diameter Inside Diameter
Length of
Pipe - Feet
INSIDE PIPE DIAMETER
1/2” 3/4” 1”
Feet
10
20
30
40
50
60
1/2”
3/4”
1/2”
3/4”
10
20
30
40
50
60
132,000 278,000 520,000
92,000 329,000 275,000 567,000
92,000 190,000 350,000 Capacity
73,000 152,000 285,000 B.T.U.
63,000 130,000 245,000 Per Hour
56,000 115,000 215,000 Input
50,000 105,000 195,000
62,000 216,000 189,000 393,000 Capacity
50,000 181,000 152,000 315,000 B.T.U.
41,000 145,000 129,000 267,000 Per Hour
37,000 131,000 114,000 237,000 Input
35,000 121,000 103,000 217,000
*Based on heating value of 1,000 btu per cubic foot (specific gravity
of 0.6) @ 0.5 PSIG and a pressure drop of 0.3 inch water column.
*Undiluted Liquefied Petroleum Gas @ 11 inches water column inlet
pressure. Based on a pressure drop of 0.5 inches water column.
**Copper tubing must comply with limitations of NATIONAL FUEL
GAS CODE reference 2.6.3 metallic tubing.
***Steel pipe should be of at least standard weight (Schedule 40).
Support the piping or tubing at regular intervals with
metal pipe strapping. See chart below.
Nominal Steel
Pipe Size
Spacing of
Supports
Nominal size of
tubing O.D.
Spacing of
Supports
1/2”
3/4” or 1”
6’
8’
1/2”
5/8” or 3/4”
4’
6’
Where local conditions include earthquake, tornado, unstable ground or flood hazards, give special consideration to
increased strength and flexibility of piping supports and connections. Consult local authorities for recommendations.
All unused openings in the piping system must be securely closed gas-tight.
Page 8
CONNECTING THE GAS PIPING
Refer to Figure 11 for the basic fittings you will need
at the furnace.
1. Use black iron or steel pipe and fittings or other
pipe and fittings that are approved by local codes.
2. Use pipe joint compound that is resistant to the
action of Liquefied Petroleum (L.P.) Gas or to any
other chemical constituents of the gases to be
conducted through the piping only on male
threads.
3. Use two wrenches when making the connection
to the valve to keep from bending the mounting
bracket or manifold pipe. Do not overtighten as
damage to the valve can occur.
GAS VALVE
TEE
1/8” N.P.T. PLUG
GROUND
JOINT UNION
4. Provide a 1/8” nominal pipe thread (NPT) plugged
tapping for test gauge connection immediately
upstream of the gas supply connection to the
floor furnace.
MANUAL VALVE
SUPPLY
5. Provide a sediment trap at least 6 inches long to
trap dirt and moisture. Provide space to permit
cleaning or emptying.
6. Use a ground joint union.
7. Install an approved manual shut-off valve.
FIGURE 11
ADDITIONAL L.P. GAS REQUIREMENTS
8.
9.
Have all connections made at the storage tank by a licensed L.P. Gas installer.
Have L.P. Installer check all lines, piping, and connections from the storage tank to the floor furnace when the floor
furnace is connected to the storage tank.
10.
The regulator on the storage tank should be set at 11 inches water column.
CHECKING THE GAS PIPING
All joints must be tested for leaks by applying pressure to the piping system. If the test pressure is equal to or less than ½
PSIG the floor furnace must be isolated from the gas supply piping system by closing the manual gas shut-off valve on the
floor furnace. If the test pressure exceeds ½ PSIG, the floor furnace and its manual gas shut-off valve must be disconnected
from the gas piping system before testing. Failure to do so may result in damage to the pressure regulator
in the gas valve resulting in overfiring. Overfiring can result in combustion chamber failure, property
damage, bodily injury or death.
Use a mixture of soap and water or liquid detergent to check each joint. Leaks will be indicated by bubbles forming. Correct
even the smallest leak at once. Since some soaps may cause corrosion, or stress cracking, rinse the gas piping exterior with
water after testing to remove the soap.
WARNING
Never use a match, candle, open flame or other method which could provide a source of ignition to
test for leaks. To do so may result in property damage, bodily injury or death.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.
Page 9
CHECKING THE GAS PIPING - CONTINUED
Limit Switch Wires
When you have determined that there are no leaks in the gas
piping system you may purge the system of air. Disconnect the
pilot supply tubing from the right side of the valve. See Figure
12.
Turn the knob on the gas valve to the pilot position. Press the
knob down and hold until you smell gas at the pilot supply
opening. Release the knob and turn it to the off position.
Reconnect the pilot supply tubing and check for leaks with soap
and water or liquid detergent.
Pilot
Adjustment
Pilot Supply
Tubing
WARNING
When purging gas piping, the area around the floor furnace must
be well ventilated to allow any gas to dissipate. Liquid Petroleum
(L.P.) Gas is heavier than air and may puddle in low places under
the floor. Check thoroughly to determine that no gas is present
before lighting the floor furnace. Failure to do so could result in
property damage, bodily injury or death.
Pressure Tap
FIGURE 12
THERMOSTAT INSTALLATION
Follow the instructions included with the thermostat. Locate the thermostat approximately five feet above the floor. 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 pipe, drafts, etc. The thermostat must never be installed in an adjoining room where a door
can be closed between the thermostat and floor furnace. This floor furnace is equipped with a self-generating control system.
Never connect to a 24-volt transformer or to the household electric system. Do not use more thermostat wire than is included
with the floor furnace.
WIRE AS INDICATED: (See Figure 13)
Step 1. Connect black limit switch wire to black thermostat wire using wire nut. (Nut not furnished).
Step 2. Connect white thermostat wire to terminal on gas valve marked “TH PP”.
Step 3. Connect white limit switch wire to terminal on gas valve marked “TH”.
Step 4. Connect the thermostat wires to the thermostat following the instructions provided by the thermostat manufacturer.
Limit
Switches
POWERPILE
GENERATOR
Thermo-
stat
Red
TERMINALBLOCK
ON GAS VALVE
TH TP
TP
TH
Terminal Block
FIGURE 13
Page 10
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.
A. This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these instruc-
tions exactly.
B. BEFORE LIGHTING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the
floor.
department.
C. 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.
D. 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.
WHATTODOIFYOUSMELLGAS:
•
•
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
LIGHTING INSTRUCTIONS
1. STOP! Read the information on the safety label.
2. Set thermostat to lowest setting.
3. Remove the floor grille.
Pilot
Burner
Pilot is located
on the side of
and toward
control end
of burner
4. Place the furnace key on the control rod, push down
slightly and turn clockwise
to “ALL OFF”.
NOTE: Control
rod cannot be
turned from
“PILOT” to “ALL
OFF” unless the
control rod is
pusheddown
slightly.
BURNER
Control
Rod
9. Locate the red piezo igniter button beside the control rod.
10. Press down on the control rod with the furnace key.
Immediately begin a series of pushing and releasing the
red piezo igniter while observing the pilot through the sight
glass opening, continue to spark until pilot is lit or use the
lighter rod with match. Continue to hold the control rod
down for about one (1) minute after the pilot is lit. If it goes
out, repeat steps 4 through 10.
ALL OFF
5. 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.
6. Remove the sight glass assembly from the opening
on top of the heat exchanger.
7. Locate the pilot burner looking down through the
sight glass opening.
•
If control rod 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 control
rod to “OFF” and call your service technician or gas
supplier.
•
11. Replace the sight glass assembly and turn the control rod
counterclockwise to “BURNER” position. Remove
furnace key and replace the floor grille.
12. Set thermostat to desired temperature.
8. Turn the control rod counterclockwise
the pointer is on “PILOT”.
until
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to it’s lowest setting.
2. Allow floor grille to cool, then remove.
3. Place furnace key on control rod, push slightly and
turn clockwise
to “ALL OFF”. Do not force.
4. Replace floor grille.
Page 11
VENT SYSTEM
After the floor furnace has been burning for five minutes, hold a match or candle under the draft hood at the air intake area. If
the vent system is working properly, the flame will be pulled into the air inlet of the draft hood. If the vent system is not working
properly, turn the floor furnace off immediately and refer to the installation instructions or local code for proper installation
procedure.
ADJUSTING THE PILOT FLAME
PILOT FLAME ADJUSTMENT
Pilot flame should envelop 3/8 to
1/2 inch of the tip of the generator.
RefertoFigure17forthecorrectsizepilotflame. Ifadjustmentisnecessary,
refer to Figure 12 for the location of the pilot adjustment screw. Using a
standard screwdriver, remove the pilot adjustment screw cover. Insert a
small screwdriver into the pilot adjustment screw and turn clockwise
decrease the flame or counterclockwise to increase the flame.
to
3/8 to
1/2”
If the flame is too low, the safety pilot may cause all of the gas to be cut
off. NOTE: The gas supply to the pilot is unregulated. When line pressure
exceeds 7” Natural Gas, or 11” L.P. Gas, a pilot adjustment must be
made.
BURNER ORIFICE
This appliance is orificed at the factory for elevations up to 2,000 feet. If
installed above 2,000 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.
FIGURE 17
L.P. GAS
NATURAL GAS
SPECIFICELEVATIONS
SPECIFICELEVATIONS
Model No.
0 to 2,000 - 4,000 - 6,000 - 8,000–
2,000’ 4,000’ 6,000’ 8,000’ 10,000’
Model No.
0 to 2,000 - 4,000 - 6,000 - 8,000 –
2,000’ 4,000’ 6,000’ 8,000’ 10,000’
90P30A
90P50A
90P65A
1/16 53
53
49
45
54
50
47
54
51
48
90N30A
90N50A
90N65A
38
30
26
41
31
28
42
31
29
43
32
30
44
35
30
47
43
49
44
ORDER KIT #49800 44-1 HIGH ALTITUDE KIT
ORDER KIT #49800 44-1 HIGH ALTITUDE KIT
90P75A
51
52
52
53
54
90N75A
33
36
37
38
41
ORDER KIT #49850 2287-2 HIGH ALTITUDE KIT
ORDER KIT #49850 2287-2 HIGH ALTITUDE KIT
ADJUSTING THE BURNER
After the floor furnace has been burning 15 minutes, remove the bottom pan from the outer casing exposing the complete
burner assembly. Loosen the screw at the bottom side of the sliding air shutter. Slide the air shutter closed until yellow tips
start to appear at the top of the flame. See Figure 19. (75,000 BTU floor furnace has two burners, both of which may need
adjustment). Now open the shutter slightly beyond the point that the yellow disappears and the flame burns blue. (See
Figure 20). Airborne dust particles may cause flashes or streaks of yellow flame as they are drawn into the flame but will
have no effect on the efficiency of the floor furnace. If you are satisfied that the burner is properly adjusted, tighten the set
screw to lock the shutter in position. Replace the bottom pan. Check air shutter setting at least twice each season to assure
that changing conditions are not causing yellow tipping.
Manifold Tube
Sliding Air Shutter
YELLOW
BLUE
BURNER
CORRECT FLAME ADJUSTMENT
IMPROPER FLAME ADJUSTMENT
Set Screw
FIGURE 18
FIGURE 19
FIGURE 20
Page 12
ADJUSTING THE BURNER – Continued
If difficulty in adjusting the burner is experienced, it may be the result of incorrect gas supply pressure or manifold pressure.
Pressure can only be checked and adjusted by a trained service technician using instruments designed for that purpose.
WARNING: Do not attempt to change pressure settings without proper training and instruments.
To do so may cause your floor furnace to malfunction resulting in property damage, bodily injury, or
death.
The following information is provided for use by a trained service technician with measuring instruments.
MinimumInletPressure, NaturalGas…………………………………………………….
Minimum Inlet Pressure, Liquefied Petroleum (L.P.) Gas………………………………..
4.5 Inches Water Column
11.0 Inches Water Column
MaximumInletPressureforNaturalGas…………………………………………………
Maximum Inlet Pressure, Liquefied Petroleum (L.P.) Gas……………………………….
7.0 Inches Water Column
14.0 Inches Water Column
(If the inlet pressure is found to exceed 14.0 inches water column, check the performance of the control valve thoroughly as
damage may have occurred. If manifold pressure cannot be adjusted, replace the control valve).
ManifoldPressure, NaturalGas…………………………………………………………..
Manifold Pressure, Liquefied Petroleum (L.P.) Gas……………………………………..
3.5 Inches Water Column
10.0 Inches Water Column
OPTIONAL OPERATION
Your floor furnace has been designed to meet all safety requirements of the American National Standards Institute and
government regulations by offering two modes of operation.
OPTION 1. Place the furnace key on the damper control
rod (See Figure 21) and turn counterclockwise
until the warning flag is concealed and the damper is
open. Your floor furnace will now cycle on and off
maintaining a moderate grill temperature and an even
room temperature. Your floor furnace will function best
on this setting during mild weather.
OPTION 2. Turn the furnace key clockwise
until the
warning flag reading “WARNING – GRILL IS HOT – Keep off –
can cause burns” is visible and the damper is closed. The limit
control will now cease to function and the floor furnace will now
put out the maximum amount of heat until the room temperature
reaches the thermostat setting. Use this option only in extremely
cold weather. If furnace continues to cycle on limits, assure that
damper door is 100% closed by adjusting damper door pin if
necessary.
OPTION 1
In mild weather,
operate furnace
with damper open.
Furnace will cycle
on and off main-
OPTION 2
In extremely cold
weather, close damper
(which exposes warning
plate). Furnace will then
put out maximum
Damper
Open
taining a moderate
grill temperature
Damper
Closed
amount of heat until
room temperature
and an even room
temperature.
reaches setting on wall
thermostat.
FIGURE 21
WARNING
FIGURE 22
FLOOR FURNACE GRILLS BECOME
HOT WHEN FURNACE IS IN
LIMIT SWITCH
TEMPERATURE SETTINGS
90{N,P}30A……………………..
90{N,P}50A……………………..
90{N,P}65A……………………..
90{N,P}75A……………………..
OPERATION. CONTACT OF BARE
SKIN WITH GRILL MAY RESULT IN
SEVERE BURNS. KEEP CHILDREN
OFF, PROVIDE FENCE OR REGISTER
GUARD FOR THEIR PROTECTION.
140N
160N
180N
170N
Page 13
MAINTENANCE INSTRUCTIONS
WARNING
Do not use any kind of solvent or cleaning
fluid to clean your floor furnace. It may leave
a residue or invisible coating that will burn
or smell when you turn your floor furnace on.
Use only a damp cloth.
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper and
dangerous operation.
For proper operation, Floor Furnace must be kept clean. At
regular intervals turn control valve to off, let cool, remove register
and clean dust and foreign material from jacket with vacuum
cleaner.
Repair service must be performed by qualified
persons. The floor furnace must be inspected
before initial use. An annual cleaning of floor
furnace and safety performance check should be
made by a qualified service person. More
frequent cleaning may be required when exposed
to the excessive lint conditions due to carpeting
and bedding material, etc. It is imperative that
the control compartment, burners, and circulating
air passageways of the floor furnace be kept clean.
Any safety screen or guard removed for servicing
the floor furnace must be replaced prior to
operating heater.
Have the Floor Furnace checked by a qualified service technician
for venting system, pilot, and burner operation prior to its use
each year.
Follow a regular service and maintenance schedule for safe
and efficient operation.
Keep flammable materials away from floor furnace area.
Be sure not to obstruct combustion and ventilation air.
TO CLEAN BURNER
1. Remove bottom pan from outer casing.
2. Remove 2 screws from burner support bracket.
3. Remove 2 screws from pilot bracket allowing burner to
slide off of manifold and out of floor furnace.
4. Examine the burner. If any distortion is noticed, replace
burner.
Examine the entire venting system as a routine part of
the safety performance check on an annual basis.
5. Clean burner ports by inserting a toothpick in ports to
remove any debris that might have accumulated.
6. Inspect burner for spider webs or dust buildup during the
off-season. If necessary, wash out with garden hose.
7. Re-install and adjust burner.
WARNING
This is a gas-fired floor furnace. Keep the
area clear of gasoline and other flammable
vapor and liquids. All combustible material
must be kept clear of this area to avoid fire
or explosion.
SERVICE RECORD
SERVICE RECORD
SERVICE RECORD
SERVICE RECORD
Page 14
TROUBLE SHOOTING CHART - MAIN BURNER
SYMPTOM
POSSIBLE CAUSES
CORRECTIVE ACTION
Flame too large
1. Defective operator section of gas valve.
2. Burner orifice too large.
1. Replace complete valve.
2. Check with local gas company for
proper orifice size and replace.
3. If installed above 2,000 ft.
Too much primary air.
1. Too much primary air.
2. Noisy pilot.
3. Refer to Burner Orifice Section, Pg. 12.
Adjust air shutter. See Page 12.
1. Adjust air shutter. See Page 12.
2. Reduce pilot gas with adjusting screw marked
pilot on combination gas control valve. See
Page 12.
Flame pops back
Noisy Flame
3. Burr in orifice (if it whistles or
resonates).
3. Remove burr or replace orifice. (Do not
enlarge orifices).
4. Excessive gas input.
1. Too little primary air.
2. Clogged main burner ports.
3. Clogged draft hood.
4. Linted up air shutter.
4. See “Flame Too Large” above.
1. Adjust air shutter. See page 12.
2. Clean main burner ports. (Do not enlarge ports).
3. Clean draft hood.
4. Check for dust or lint at air mixer opening and
around the shutter.
Yellow tip flame (some
yellow tipping on L.P.
gas is permissible)
Floating flame
Gas odor
1. Blocked venting.
1. Clean flue passage ways to remove blockage.
2. Adjust air shutter to increase primary air supply.
1. Clean chimney or vent - replace if necessary.
2. Eliminate drafts.
2. Insufficient primary air.
1. Chimney or vent obstruction.
2. Drafts around appliance.
3. Gas leak.
3. See Page 1.
Delayed ignition
1. Pilot flame too small.
1. Check pilot orifice, close, increase pilot gas flow if
necessary by adjusting at combination control valve.
See Page 12.
2. Burner ports clogged near pilot.
3. Low gas pressure.
2. Clean burner ports (Do not enlarge ports).
3. Check gas supply pressure.
4. Pilot decreases in size when main burners
come on.
5. Air shutter open too far.
4. Supply piping is inadequately sized. Consult local
gas utility or competent installer.
5. Close air shutter to proper setting as outlined in
these instructions (slight yellow tipping is
allowable on L.P. gas).
6. Drafts around appliance.
7. Bad venting.
6. Eliminate drafts.
7. See “Venting”.
Failure to ignite
1. Main gas off.
2. Defective gas valve.
1. Open all manual gas valves.
2. Replace gas valve.
Condensation of water vapor 1. Improper venting.
1. See “Venting.
Burner won’t turn off
Incorrect gas input
Not enough heat
1. Defective or sticking automatic valve.
1. Clean or replace valve.
2. To correct this situation contact the utility
supplying the gas.
2. Excessive gas pressure (The supply gas
pressure must not exceed 1/2 psi or 14”
water column).
1. Gas input not checked.
2. Clogged orifice.
1. Recheck gas input.
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.
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.
2. Setting of thermostat. See “Lighting and Shutting Down
Instructions”.
1. Appliance undersized
2. Thermostat set too low.
3. Incorrect supply pressure.
1. Thermostat set too high.
3. Check supply pressure as outlined above.
1. Lower setting of temp. dial. See “Lighting and Shutting
Down Instructions”.
Too much heat
2. Combination control valve sticks open.
2. Replace combination control valve.
TROUBLE SHOOTING CHART - AUTOMATIC PILOT & VALVE
Burner won’t turn on
1. Pilot flame too large or too small.
1. Readjust pilot flame using adjustment screw marked
“Pilot” on combination control valve. See Page 10.
2. Clean pilot orifice with air or solvent, do not ream.
3. Replace entire combination control valve.
2. Dirt in pilot orifice.
3. Defective automatic pilot section in
combination control valve.
4. Defective Thermocouple.
4. Replace thermocouple.
5. Replace valve.
5. Defective combination control valve.
Page 15
MODELSINCLUDED:
90N30A NAT.
GAS FLOOR FURNACELIST PRICES
90N50A NAT.
90N65A NAT.
Prices and specifications subject to change
witout notice. All prices
90N75A NAT.
are F.O.B. factory. Specify model number
when ordering parts.
3
42
1
4
10
2
11
14
13
12
18
26
17
16
15
44
22
45
41
43
36
40
28
38
39
29
39
36
37 38
32
33
32
41
33
27
31
31
34
40
34
BURNER ASSEMBLY FOR:
90N30A 90N50A 90N65A
BURNERASSEMBLYFOR:
90N75A
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 & schematic drawings on current models are
MARCH 2005
Page 16
HOW TO 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 that is attached to heater.
MODEL NUMBER
NAT.
REF.
NO.
1
90N30A
90N50A
90N65A
90N75A
PART
LIST
PART
LIST
PART
LIST
PART
LIST
PRICE
$370.40
$7.20
PART DESCRIPTION
Heat Exchanger w/Gasket
Gasket, Heat Exchanger
Liner, Complete Assembly
Grille, Floor
NO.
PRICE
NO.
PRICE
NO.
PRICE
NO.
23074
74530
23001
23145
23040
24048
74510
24035
24044
74205
91256
24045
23200
23225
74592
74518
74209
74315
74414
49200
N/A
$206.20
24099
74530
23980
24175
24002
24048
74510
24035
24044
74205
91256
24045
24075
24077
74592
74518
74209
74315
74414
49210
N/A
$291.10
24499
74532
24380
24475
24402
24048
74510
24035
24044
74205
91256
24045
24477
24077
74592
74518
74209
74315
74414
49220
N/A
$331.90
24699
74535
24580
24675
24602
24048
74510
24642
24044
74205
91256
24045
24676
24077
74592
74518
74209
74315
74414
49330
74403
74404
N/A
N/A
2
$4.20
$167.60
$142.30
$159.90
$14.10
$2.10
$3.70
$1.20
$1.20
$4.50
$1.90
$74.40
$3.70
$20.00
$1.30
$1.20
$164.30
$2.00
$22.70
N/A
$4.20
$148.90
$180.80
$183.00
$14.10
$2.10
$3.70
$1.20
$1.20
$4.50
$1.90
$81.10
$4.80
$20.00
$1.30
$1.20
$164.30
$2.00
$22.70
N/A
$5.90
$161.00
$230.50
$210.60
$14.10
$2.10
$202.90
$270.20
$227.10
$14.10
$2.10
3
Casing, Complete Assembly
Vision Cap, Complete Assy.
Lighter Rod
4
10
11
12
13
14
16
17
18
19
22
23
24
26
37
N/A
27
28
29
31
32
32
33
34
36
N/A
38
39
39
41
42
N/A
43
44
45
N/A
Valve Rod
$3.70
$3.80
Washer, Valve Rod
$1.20
$1.20
Key, Furnace
$1.20
$1.20
Instruction Plate, Lighting
Valve Rod Indicator Plate
Drafthood Assembly w/Gasket
Drafthood Gasket w/Screws
Thermostat, Millivolt
Wire, Thermostat 20'
Staples, Thermostat Wire
Valve, VS821A1061 Nat. Gas M.V.
Disappearing Bushing 1/4x3/8
L.P. Conversion Kit
$4.50
$4.50
$1.90
$1.90
$83.80
$4.80
$88.50
$4.80
$20.00
$1.30
$20.00
$1.30
$1.20
$1.20
$164.30
$2.00
$164.30
$2.00
$22.70
N/A
$22.70
$23.80
$21.80
N/A
Left Burner w/Pilot Bracket 75
Right Burner 75
N/A
N/A
N/A
N/A
N/A
N/A
Burner w/Pilot Brkt. & Air Adj.
Pilot Generator, Q313A1014 M.V.
Pilot Burner w/Orifice Q350A1271 N.
Pilot Burner w/Orifice Q350A1589 LP
Mounting Screws, Pilot (2)
Pilot Tubing w/Fittings
Burner Support, Front
Burner Support, Rear
Manifold
74401
70098
74410
74415
50107
74452
24036
24038
74416
74390
74609
24068
*74306
74320
70050
74351
74350
24039
$22.30
$32.30
$9.80
$9.80
$1.20
$7.00
$5.10
$2.60
$6.70
$3.40
$3.40
$9.80
74401
70098
74410
74415
50107
74452
24036
24038
74416
74406
74606
24068
$22.30
$32.30
$9.80
$9.80
$1.20
$7.00
$5.10
$2.60
$6.70
$3.40
$3.40
$9.80
74402
70098
74410
74415
50107
74452
24036
24430
74416
74407
74607
24068
$24.40
$32.30
$9.80
70098
74410
74415
50107
74452
24036
24627
74412
$32.30
$9.80
$9.80
$9.80
$1.20
$1.20
$7.00
$7.00
$5.10
$5.10
$2.90
$3.40
$6.70
$24.00
$3.40
Burner Orifice, Natural Gas
Burner Orifice, L.P. Gas
Warning Flag
$3.40 *74408
$3.40 *74608
$3.40
$9.80
24068
$9.80
Limit Control 60T11
Wiring Harness
$9.30 *74307
$9.30 *74308
$9.30 *74309
$9.30
$8.40
$5.60
$5.10
$3.70
$8.20
74321
70050
74351
74350
24039
$8.70
$5.60
$5.10
$3.70
$8.20
74322
70050
74351
74350
24431
$9.50
$5.60
$5.10
$3.70
$10.40
74323
70050
74351
74350
24628
$10.00
$5.60
Piezo Ignitor
Ignitor Wire
$5.10
Electrode
$3.70
Bottom Burner Cover
$11.70
Prices and specifications subject
to change without notice. All
prices are F.O.B. factory.
P/N 74521
*2 Required
Mr. Contractor, we only sell parts through our
wholesalers, but the prices listed above are for your
convenience. For prompt parts service, contact the
wholesaler from which you purchased your Cozy
heater. NOTE: Parts & schematic drawings on
MARCH 2005
Page 17
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
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.
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.
•
•
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.
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.
CRITICAL SAFETY POINTS TO REMEMBER . . .
•
Your gas has been odorized so that you can smell
it. Always smell around for gas before lighting
your appliance.
•
Sniff for L.P.-gas at floor level. LP-gas is heavier
than air and may temporarily exist at floor level.
IF YOU SMELL GAS, DON’T LIGHT IT
•
•
If you smell gas, do not attempt to light the pilot.
Do not cause a spark by turning on or off
electrical switches or appliances or by using the
phone. Turn off the gas to the appliances and call
your gas supplier from another location.
If 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.
IF YOU CAN’T LIGHT IT,
DON’T FIGHT IT!
THIS IS NOT AN ADVERTISEMENT
|