hi-efficient direct
vent wall furnace
INSTALLATION AND
OPERATING INSTRUCTIONS
R
R
P/N 72903
/
December 2003
INSTALLER MUST LEAVE THESE INSTRUCTIONS
WITH THE CONSUMER, HAVE THEM COMPLETE,
AND RETURN THE WARRANTY CARD.
MODEL NUMBERS
NAT. GAS
HEDV403
L.P. GAS
HEDV404
WARNING: If the information in these instructions are
not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
-
-
-
•
•
Do not try to light any appliance.
Do not touch any electrical switch; do not use any
-
phone in your building.
•
•
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the
fire department.
-
INSTALLATION AND SERVICE MUST BE PER-
FORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING: Operation of this furnace without the properly installed, factory furnished vent system and
vent cap could result in Carbon Monoxide (CO) poisoning and possible death. For your safety, this
furnace and the vent system should 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, corro-
sive, or explosive conditions. Such conditions will invalidate the warranty and may create unsafe
conditions.
SAFETY RULES
1.
2.
3.
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.
4.
5.
6.
DO NOT INSTALL THIS FURNACE IN A RECREATIONAL VEHICLE OR TRAILER.
Do not operate wall furnace unless it is connected to the supplied vent system with vent cap in place.
Check the rating label attached to the wall furnace to be sure it is equipped for the type gas you intend to
use.
7.
Never use a match, candle, flame or other source of ignition to check for gas leaks. Use only soapy water
or liquid detergent.
8.
9.
10.
11.
Have your wall furnace and vent system inspected at least annually by a qualified service technician.
Before cleaning or servicing, turn off the gas and allow furnace to cool.
Do not operate wall furnace without all components properly installed (top, front, etc.).
Due to high temperatures, the wall furnace should be located out of traffic and away from furniture and
drapes.
12.
Children and adults should be alerted to the hazard of high surface temperature and should be kept away to
avoid burns or clothing ignition.
13.
14.
15.
Young children should be carefully supervised when they are in the same room with the wall furnace.
Do not place clothing or other flammable material on or near the furnace.
INSTALLATION AND REPAIR SHOULD BE DONE BY A QUALIFIED SERVICE PERSON. THE
WALL FURNACE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY BY A
PROFESSIONAL SERVICE PERSON. More frequent cleaning may be required
due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments,
burner, and circulating air passageways of the furnace be kept clean.
16.
17.
18.
Do not install in a closet, alcove, or small hallway where the furnace could be isolated from the space to
be heated by closing a door.
Do not put anything around the furnace or vent cap that will obstruct the flow of combustion and
ventilation air.
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.
19.
20.
21.
Never operate this furnace without the sight glass in place or with the glass broken or missing.
If it is suspected that rising water may enter the furnace, turn off the gas immediately.
Do not use the 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.
22.
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 or loss of life.
Any safety screen or guard removed for servicing must be replaced prior to operating heater.
This appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance.
23.
24.
Page 3
Vent Terminal
Air Supply Inlet
Area where terminal is not permitted
VENT TERMINAL CLEARANCES
REFERENCE LETTER TO
CANADIAN
INSTALLATIONS¹
12 Inches (30 cm)
DRAWING
A = Clearance above grade,
veranda, porch, deck, or
balcony
B = Clearance to window or door 12 Inches (30 cm)
that may be opened
C = Clearance to permanently
closed window
12 Inches (30 cm)
18 Inches (46 cm)
D = Vertical clearance to
ventilated soffit located above
the terminal within a horizontal
distance of 2 Feet (61 cm) from
the center line of the terminal
E = Clearance to unventilated
soffit
18 Inches (46 cm)
F = Clearance to outside corner
G = Clearance to inside corner
H = Clearance to each side of
center line extended above
meter/ regulator assembly
12 Inches (30 cm)
12 Inches (30 cm)
3 Feet (91 cm) within a hei
15 Feet (4.5m) above the
meter/regulator assembly
I = Clearance to service regulator 3 Feet (91 cm)
vent outlet
J = Clearance to nonmechanical 12 Inches (30 cm)
air supply inlet to building or the
combustion air inlet to any other
appliance
K = Clearance to a mechanical
air supply inlet
6 Feet (1.83 m)
L = Clearance above paved
sidewalk or paved driveway
located on public property
7 Feet (2.13m) A vent shal
not terminate directly abo
a sidewalk or paved drivew
Page 4
CLEARANCES
1.
2.
3.
4.
As you face the heater, the clearance to a side wall on the right side is 0” (Fig. 1), and the left side is 1”
(Fig. 2).
The minimum clearance from the top of the heater to the ceiling or any projecting overhang is 10”.
(See Figure 3).
The minimum clearance from the bottom of the heater to the floor, or the top surface of carpeting, tile, etc.
is 0”. (See Figure 4).
When the furnace is installed directly on carpeting, tile or other combustible material other than wood
flooring, the furnace shall be installed on a metal or wood panel extending the full width and depth of the
furnace.
5.
6.
The minimum clearance from the edge of the vent cap to any overhanging obstruction, perpendicular side
wall, or corner of building is 12”. (See Figure 5).
Vent cap must be located at least 9” from any opening that would allow combustion products to enter the
building, windows, doors, etc., and 12” above the ground or shrubbery (See Figure 5). Do not install vent
cap in a window well. Provisions must be made to prevent snow accumulation from infringing on vent cap
clearances.
Ceiling or Overhang
1” (2.54 cm)
10” (25.4 cm)
FIGURE 2
FIGURE 1
FIGURE 3
FIGURE 5
Page 5
CLEARANCES
7.
RESIDENTIAL GARAGE INSTALLATION: Gas utilization equipment in residential garages
shall be installed so that all burners and burner ignition devices are located not less than 18 inches
(46 cm) above the floor. You must build a platform 18” above floor, the full width and depth of
the heater, including the rear trim kit. HEATER IS NOT DESIGNED TO HANG ON WALL.
Unit should be located or protected so it is not subject to damage by a moving vehicle. Use care
in selecting a good location whith in the grage. DO NOT locate the appliance 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 flam-
mable vapors to be stored or used in the same area as the heater.
LOCATION
1.
2.
The wall furnace must be installed on an outside wall, unless optional Kit No. HEVK-5 is used.
For most efficient performance, locate furnace as centrally as possible in the area to be heated and
where occupants may move about freely without coming into contact with the cabinet, and within
reach of a 115V wall outlet.
3.
If the furnace is installed in a basement, a 12” clearance must be maintained between ground level
and the bottom of the vent cap. Do not install furnace where vent cap will terminate in a window
well or any other opening below ground level. Do not allow snow accumulation to build up
within 12” of the vent cap.
OPTIONAL KITS
1.
HEVK-5 - To extend vent 5 foot from heater. This will allow vent cap to be installed above grade
from basement or to an outside wall. A total of 3 kits with 2 additional elbows may be used.
rade
tion
Page 6
INSTALLATION
Failure to follow these instructions carefully could result in poor performance, property damage, personal injury, or
death.
STEP 1. LOCATE VENT OPENING (Requires 3-1/2” diameter wall opening)
a)
Select area on wall where heater will be installed. Using template (packed with heater) mark shaded area
where hole can be cut and to locate the wall brackets.
b)
c)
d)
e)
Locate studs on each side of this area.
Mark location for 3-1/2” diameter hole between studs. Hole should be offset to miss studs. (See Figure 6).
Check outside wall at this location for proper clearances around vent cap.
Cut vent openings into both the inside and outside walls, being sure to maintain level across both openings.
Template
Shaded
Area
Wall
Studs
16” O.C.
FIGURE 6
1/8” N.P.T. Plugged Hole
for Pressure Gauge
Gas
Valve
Manual Shut
Off Valve
Ground Joint
Union
Gas Supply
Inlet
3” (76mm) Min.
FIGURE 7
STEP 2. ROUGH-IN GAS SUPPLY (See Figure 7)
a)
Install a 1/2” gas supply line. The gas line will enter the heater from the 5” spacing between the heater
back and the wall.
b)
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. The furnace and its individual shut off valve must be disconnected from the gas
supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig
(3.5Pa). The furnace must be isolated from the gas supply piping system by closing its individual manual
shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than 1/2 psig (3.5Pa).
Page 7
INSTALLATION - CONTINUED
STEP 3 INSTALLING VENT SYSTEM 5” - 32” WALL THICKNESS (12.7 cm - 81.3 cm)
a)
Use only factory supplied parts. Do not attempt to modify in any way. To do so could cause a system
imbalance resulting in poor performance and/or unsafe operating conditions.
b)
Slide collection box pipes through cutout and secure collection box to inside wall. Anchors (not supplied)
may be required. (See Figure 8).
c)
d)
From outside house, mark collection box pipes and cut off 1/2” beyond outside wall.
Slide vent cap pipes onto collection box pipes and push in until flange is flush against house. Secure vent
cap assembly to outside wall with a slight downward slope. This will prevent water from entering and
allow and condensation to drain. Caulk around the edges of the vent cap mounting plate. NOTE: It may
be necessary to build a metal or wood frame to provide a flat surface for the mounting plate to be flush
against or to attain the 5” minimum wall thickness.
Vent Cap
Assembly
BRACKETS
Collection Box
Assembly
Vent Cap
Mounting
Plate
FIGURE 9
Page 8
STEP 4. INSTALLING HEATER
a)
b)
c)
d)
e)
Screw wall brackets to wall. Location marked with template. (See Step 1a)
Screw trim kit brackets to back of heater. (See Figure 9).
Slide heater to within approximately 5” from wall.
Attach air intake hose to collector box outlet and burner box inlet with clamps provided. (See Figure 10).
Attach vent exhaust tube to exhaust pipe on collector box and draft inducer outlet on back of heater.
Secure with clamps provided. (See Figure 10).
f)
GAS CONNECTION. Make gas connection between manual shut off valve and furnace valve with
approved connectors. Compounds used on threaded joints of gas piping shall be approved for use with
L.P. gas. The gas lines must be checked for leaks by the installer with soapy water or liquid detergent,
never an open flame. If connections are not exposed, a pressure test must be run. Be sure to disconnect
the gas supply line from the appliance valve before pressure testing. The manifold pressure is pre-set at
the factory and should be 3.5” w.c. for Natural Gas and 10” w.c. for L.P. gas. The minimum inlet
pressure for Natural Gas is 4.5” w.c. and 11” w.c. for L.P. Gas, “for purpose of input adjustment”. The
maximum inlet pressure should never exceed 7.0” w.c. on Natural Gas or 14” w.c. on L.P. Gas.
STEP 5. INSTALLING REAR TRIM KIT
a)
b)
c)
d)
Secure right and left trim kit sides to the wall and trim kit brackets with eight #8 screws provided. See
figure 11. The back of the heater should now be spaced 5” from the wall.
Remove the temperature sensing unit from the back of the heater. Save the nylon attachment clip and the
#8 screw.
Slide the temperature sensing unit through the 1/2” bushing located on the right trim kit side. Viewed from
the front of the heater.
Secure the temperature sensing unit to the outside of the right trim kit side using the nylon clip and #8
screw saved from step B. Engagement hole provided.
e)
f)
g)
Secure trim kit top panel to trim kit sides with four #8 screws provided.
Plug power supply cord into a 115V grounded electrical outlet.
Turn the manual gas supply valve to the “on” position.
HEATER IS NOW INSTALLED, FOLLOW LIGHTING INSTRUCTIONS.
Trim Kit Top
Trim Kit
Right Side
Trim Kit
Left Side
1/2” Bushing
Trim Kit
Bracket (4)
FIGURE 11
Page 9
FOR YOUR SAFETY READ BEFORE OPERATING
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.
B.
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.
• If you cannot reach your gas supplier, call
the fire department.
C.
D.
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.
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.
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
1.
2.
3.
4.
STOP! Read the safety information above on
5.
6.
Remove front panel.
this label.
Pull the gas control lever DOWN clockwise 6
to “OFF”. Do not force.
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 safety
information above on this label. If you don’t
smell gas, go to the next step.
Set the thermostat to lowest setting.
Turn off all electric power to the appliance.
This appliance does not have a pilot. It is
equipped with an ignition device which auto-
matically lights the burner. Do not try to
light the burner by hand.
7.
8.
Push gas control lever UP counterclockwise 7
to “ON”.
9.
10.
11.
12.
Replace front panel.
Turn on all electric power to the appliance.
Set thermostat to desired setting.
If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance”
and call your service technician or gas supplier.
Gas control
knob shown
in “OFF”
Gas
Inlet
position
TO TURN OFF GAS TO APPLIANCE
1.
2.
Set the thermostat to lowest setting.
4.
Pull the gas control lever DOWN clockwise 6
to “OFF”. Do not force.
Replace front panel.
Turn off all electric power to the appliance
if service is to be performed.
Remove front panel.
5.
3.
Page 10
PROPER BURNER FLAME
Primary Flame
Burner
The burner flame may be observed by raising the sight
glass cover. 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.
Secondary Flame
Heat Exchanger Tube
TO REMOVE MAIN BURNER FOR INSPEC-
TION AND CLEANING
FIGURE 12
NOTE: THE FURNACE AND ALL COMPO-
NENTS MUST BE INSPECTED AT LEAST
ANNUALLY BY A QUALIFIED SERVICE PER-
SON. THIS SHOULD INCLUDE THE
BURNER, HEAT EXCHANGER, AND VENT
SYSTEM. BE SURE THAT THE FLOW OF
COMBUSTION AND VENTILATION AIR ARE
NOT OBSTRUCTED AND THAT ALL HOSES
ARE UNDAMAGED, AND ALL CLAMPS ARE
SECURELY TIGHTENTED.
1.
2.
3.
4.
5.
6.
Turn off all electrical supply to heater.
Turn off gas supply.
Remove front panel.
Unplug wire to ignitor and sensor. (See Fig. 13.)
Disconnect vacuum hose from burner box.
Remove screws holding burner box top to burner
box. (See Figure 13.)
Remove burner plate and burner box top. Take
care not to contact, or strain ignitor in any way
as it is extremely fragile. (See Figure 13.)
Remove 2 nuts holding burner bracket. (See
Figure 13).
7.
8.
9.
Slide burners toward heat exchanger and lift up
from rear and back. (See Figure 13).
Clean or replace as needed.
Valve
10.
11.
Burner
Box
Reinstall by reversing Steps 9 - 1.
Top
Burner
Burner
BURNER ORIFICE
Mani-
fold
Box
Plate
Sensor
This appliance is 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.
Nut
Burner Bracket
Ignitor
Vacuum
Hose
SPECIFIC ELEVATIONS
FIGURE 13
MODEL
NO.
0 to
2,000’
4,000’
4,000’
6,000’
6,000’
8,000’
8,000’ -
10,000’
2,000’
NATURAL GAS
HEDV403
HEDV404
45
55
47
48
49
56
50
57
L.P. GAS
55
56
NOTE: If this heater is installed above an elevation of 8,000 feet, the factory installed pressure switch may not
function properly. If you experience a problem with the pressure switch, contact a qualified service agency to
replace the factory installed pressure switch with a high altitude pressure switch P/N 72521. To order see your
local Cozy dealer or contact the factory.
Page 11
WIRING
WARNING
This appliance is equipped with a three prong grounding
plug. For your protection against shock hazard, this ap-
pliance should be plugged directly into a properly grounded
three-prong receptacle. Do not cut or remove the ground-
ing prong from this plug.
THIS IS A GAS-FIRED APPLIANCE. KEEP THE
AREA CLEAR OF GASOLINE AND OTHER FLAM-
MABLE VAPORS AND LIQUIDS. ALL COMBUS-
TIBLE MATERIAL MUST BE KEPT CLEAR OF THIS
AREA TO AVOID FIRE OR EXPLOSION.
NOTE: If any of the original wire supplied with this ap-
pliance has to be replaced, it must be replaced with type
105EC 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.
Pressure
Switch
Gas Valve
Circulating
Blower
Black
Black
XFMR
Draft
Inducer
Circulating
Blower
L 1
Yellow
Yellow
EAC/LSPD
White
Red
Heat
Hum
M 1
Black
White
W
Ignitor
M 2
C
R
Y
Thermostat
Flame
Yellow
Sensor
Yellow
Neutrals
115 VAC
Draft
Inducer
White
Transformer
Primary
White
24 VAC
Black
White
Green
Transformer
Flame
Sensor
Secondary
24 VAC
Brown
White
Black
3 Amp
Fuse
High
Limit
Thermostat
Limit
Switch
Pressure
Switch
Gas
Valve
MODEL HEDV 403, 404
Page 12
SEQUENCE OF OPERATION - HEDV403/4
@t=0
THERMOSTAT
CALLS FOR
HEAT
@t=X
Thermostat
is satisfied
t=20 sec.
t=10 sec.
t=15 sec.
t=50 sec.
t=X+15 sec.
t=x sec.
t=X+120 sec.
Power to
Combust.
Fan
Gas
Flow
IGNITION
PROVED?
Blower
On
Blower
Off
Fan
Proved
Power to
Ignitor
Burners
Off
YES
YES
Combust.
Fan Off
NO
NO
NO
Three
Attempts
Made?
10 SEC
PURGE
YES
10 SEC
PURGE
Three
Attempts
Made?
NO
YES
STEP #
STEP #
1)
2)
3)
4)
5)
6)
7)
8)
Thermostat calls for heat.
Combustion fan turns on.
Pressure switch closes.
Power to Ignitor.
Ignitor warm up period.
Gas flow to burner.
Burner ignition proven.
Circulating blower on.
NOTE: If there is a mal-
function in any of the
above steps, the sequence
will stop at that point and
8) Continued...
return to Step 2. If after 3 attempts
malfunction still occurs, furnace will
go into lockout mode for one hour.
This one hour mode can be bypassed
by resetting thermostat.
9)
Thermostat satisfied.
10) Gas valve closes.
11) Combustion fan off.
12) Blower off.
HEATER NOW IN STAND-BY MODE.
Page 13
HEVK-5
5’ VENT EXHAUST KIT
INSTALLATION INSTRUCTIONS
WARNING: Use only Louisville Tin & Stove Company factory supplied parts and kits. Failure to do so could result in
loss of life, personal injury, property damage, or unsatisfactory performance.
CONTENTS OF KIT
1 only P/N 72532 2”x3” Steel Coupling
1 only P/N 72575 2”x5’ Black Flocked Tube
1 only P/N 72612 2”x6’ Black Flex Tubing
2 only P/N 41515 Support Brackets
1 only P/N 41520 Center Bracket
8 only P/N 72593 2” Hose Clamps
1 only P/N 72578 2”x3” Black Silicone
Wrapped Coupling
STEP 1 - LOCATE VENT OPENING
a)
b)
c)
d)
e)
Select location on outside wall that vent will exit through.
Check outside for proper clearances around vent cap. See installation instructions.
Mark and cut 3-1/2” hole through both inside and outside walls, being sure to maintain level across both openings.
Measure wall thickness. Mark and cut off both intake and exhaust pipes to 1/2” beyond outside wall.
Secure collection box to wall. Wall anchors, not provided, may be required.
STEP 2 - INSTALL HEATER
a)
b)
c)
Select location on wall where heater will be installed.
Using wall template supplied with heater, mark location for trim kit wall brackets.
Attach brackets to wall (wall anchors, not provided may be required) and back of heater. Using screws provided on
back of heater.
d)
e)
f)
Slide heater into position and secure brackets togehter. This should position back of heater 5” off wall.
Select direction vent will exit trim kit, left, right, or straight up.
Before installing trim kit remove knockout on this side.
STEP 3 - INSTALL VENT
a)
b)
c)
Remove and discard P/N 72611 2”x24” black flex tubing from air inlet. (Save hose clamp).
Attach P/N 72612 2”x6’ black flex tubing to air inlet. Secure with P/N 72593 2” hose clamp.
Slide P/N 72575 2”x5’ flocked tube through trim kit opening (knockout) and attach to P/N 72610 orange silicone
90E elbow supplied with heater. Secure with 2” hose clamp.
d)
Attach P/N 41515 support brackets to wall. Wall anchors, not provided, may be required. Postion support brackets
within 8” from side of trim kit and end of pipe. Secure flex tubing and flocked tube to brackets using 2” hose
clamps.
e)
Attach P/N 41520 center bracket 2-1/2’ from pipe end and insert flex tube through bracket. This will prevent the
flex tube from touching the black flocked exhaust tube.
f)
Connect flex air intake tube and flocked exhaust tube to collection box.
Complete gas connection and attach trim kit to brackets.
g)
h)
Follow lighting instructions.
SPECIAL NOTES
a)
You may use up to three HEVK-5 Kits for a total of 15’ vent extension with two additional elbows. DO NOT
EXTEND VENT BEYOND 15’ OR USE MORE THAN THREE TOTAL ELBOWS (one elbow is attached to
heater outlet).
b)
c)
To connect two vent kits together use P/N 72532 2”x3” steel coupling. Secure with 2” hose clamps.
If you are using one, two, or three kits, after installation is complete you will discard 2 P/N 72593 hose clamps and
one P/N 72532 steel coupling.
d)
e)
If you need to make a 90E offset you will need to order P/N HEEL-1 90E Elbow Kit. Two offsets require two kits.
If complete vent extension is horizontal, pipes may be sloped down slightly to allow any condensate to
drain through the exhaust pipe to the outside. DO NOT ALLOW TO DRAIN ONTO WALKWAY. If any part of
vent extension is vertical or local codes do not allow draining of condensate to outside you must add P/N HECK-1
Condensate Kit.
f)
For cosmetic purposes, the addition of the HEVK-5 Kit can be enclosed by adding a HEVE-5 Vent Enclosure Kit.
To completely enclose the HEVK-5 Kit one HEVE-5 will be needed for each HEVK-5 used.
P/N 72612
2”x6’ Black
Flex Tubing
P/N 72532
Use only if connecting
flex tubing of 2 or
more ktis
P/N 72578 2”x3”
P/N 41515
Black Silicone
Support
Wrapped Coupling
Brackets (2)
P/N 41520
Center Bracket
P/N 72575 2”x5’
Black Flocked Tube
P/N 72593
2” Hose Clamps
Page 14
HEVE-5
HECK-1
VENT ENCLOSURE KIT
INSTALLATION INSTRUCTIONS
CONDENSATE KIT
INSTRUCTIONS
STEP 1)Position end of Part No. 41610 enclosure body to
heater trim kit where pipes exit trim kit, centering
pipes inside body and attach to wall. Wall anchors,
not provided, may be required. Collector box may
be behind HEVE-5 Kit.
STEP 1)Attach condensate trap to back of heater using 2 #8
screws provided, as shown below. End of trap
should extend through back of heater and into
bottom of condensate pan.
STEP 2)Remove and discard cap from bottom of draft
inducer drain tube.
STEP 2)Cut to fit enclosure panel 1” beyond end of vent
run. Insert Part No. 41620 End Cap and attach
using three #8 screws provided.
STEP 3)Connect 1/4” plastic line from draft inducer drain
tube to condensate trap. Secure with 2 1/4” hose
clamps, provided.
SPECIAL INSTRUCTIONS
STEP 3)If more than one HEVE-5 Kit is used, attach Part
No. 72604 Trim Kit where ends meet.
STEP 4)Fill condensate pan with water.
STEP 4)If making a 90E turn, measure 1” beyond outside
turn and cut off enclosure panel. Notch panel on
surface of direction turn is being made to allow
pipes to pass through into next HEVE-5 Kit.
Attach second panel to wall and attach Part No.
72604 Trim Kit where two bodies meet. Install
WARNING:
Keep condensate pan filled with water.
The water provides a seal to prevent combustion products
from being pushed through the drain into the house.
BACK OF HEATER
end cap Part No. 41620.
Exhaust
Drain Tube
From Draft
1/4” Clear Tubing
Inducer
Condensate
Trap
Condensate trap empties through back
of heater into a condensate pan below
heat exchanger.
HEEL-1
90E ELBOW KIT
Contains 1 only P/N 72613 90/ Elbow 2”
Page 15
MAINTENANCE INSTRUCTIONS
For proper and safe operation keep furnace and furnace area clean. At regular intervals turn control valve to off, let
cool and clean inside control and heat exchanger compartment. To clean front panel use only a damp cloth, do not
use any kind of solvent or cleaning fluid that could leave a residue to burn or give off fumes when furnace is turned
on.
Remove the blower filter from back of heater and clean as needed. Filter can be cleaned with garden hose, in bathtub,
sink, etc. Use only water or air to clean. DO NOT USE ANY CLEANING SOLUTION AS THEY COULD BE
FLAMMABLE AND COULD CAUSE ODORS. Dry thoroughly and re-install. Do not operate heater without filter
in place.
Have the furnace checked, cleaned, and repaired by a qualified service person. Check venting system, and burner
operation prior to use each year.
Follow a regular service and maintenance schedule for safe and efficient operation.
Do not obstruct combustion and ventilation air. Examine the venting system as a routine part of the safety perfor-
mance check on an annual basis.
If the heat exchanger is removed, check the heat exchanger intake gasket and draft inducer gasket and replace if there
is any sign of damage. Be sure all gaskets are in place when the heat exchanger is replaced.
Failure to replace any gasket that has been damaged may result in property damage, personal injury or loss of life.
Oil the bearings of the fan motor every 6 months with S.A.E. 20 oil.
SERVICE RECORD
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Page 16
TROUBLE SHOOTING CHART
SYMPTOM
Flame too large
POSSIBLE CAUSES
1. Defective operator section of valve.
2. Burner orifice too large.
CORRECTIVE ACTION
1. Replace valve.
2. Check with local gas company for proper
orifice - size and replace.
3. If installed above 2,000 ft.
1. Clogged burner ports.
3. See burner orifice section, Page 11.
Yellow burner flame
1. Remove burners and check for obstruc-
tions in throats, ports, and orifices. Clean -
but do not enlarge ports or orifices.
2. Make sure area around vent cap is clear, be
sure vent system is sealed.
2. Obstruction around vent cap.
Gas odor
1. Gas leak.
1. See Page 1.
Delayed Ignition
1. Low gas pressure.
2. Igniter not peroperly located.
1. Check gas supply pressure.
2. Check ignitor location and correct if
necessary.
Failure to ignite
1. Main gas off.
1. Open all manual gas valves.
2. Set temperature dial or thermostat to
higher temperature.
3. Clean burner orifices (do not enlarge).
4. Check wiring diagram.
2. Temperature dial or thermostat not set high
enough to call for heat.
3. Clogged burner orifice.
4. Incorrect wiring.
5. Defective valve.
5. Replace valve.
6. No power to unit.
6. Plug in power supply cord. Check 115 V.
wall outlet.
Burner won’t
turn off
1. Defective or damaged thermostat wire,
or thermostat.
1. Can be checked by removing wire from con-
trol board terminal. If burner goes off, replace
thermostat.
2. Thermostat sensor location on back of heater.
2.Thermostat sensor attached to back of heater
to re-locate out of drafts, hot, or cold spots.
3. Defective or sticking valve.
4. Excessive gas pressure.
5. Defective or damaged sensor.
1. Gas input not checked.
2. Clogged orifices.
3. Replace valve.
4. Contact utility supplying gas.
5. Replace thermostat.
1. Re-check gas input.
2. Clean orifices with a smooth wood toothpick,
do not enlarge.
Incorrect gas
input
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.
2. Temperature dial set too low.
3. Incorrect supply pressure.
2. Raise temperature setting.
3. Check supply pressure.
Too much heat
1. Temperature dial set too high.
2. Combination control valve stuck open.
1. Lower temperature setting.
2. Replace combination control valve.
Main burner
goes out
1. Defective flame sensor.
2. Input too high.
1. Check voltage and replace if low.
2. Check input rate.
during normal
operation
3. Cover around pilot lighter hole not air
tight.
4. Vent tubes not properly installed or
sealed.
3. Tighten wing nuts securing cover and sight
glass. Check and replace gasket if needed.
4. Follow instructions. Check both 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.
5. Limit switch opens.
5. Clean air filter.
6. Exhaust or Air Intake tubes blocked.
6. Remove obstruction. Check for snow
accumulation around vent cap.
Page 17
TROUBLE SHOOTING CONTROL BOARD
To improve diagnosing and servicing, this control board is equipped with a self diagnosing
green status light (see wiring diagram). To indicate stand by mode and proper operation
this light will remain on. If there should be a malfunction, the light will flash a varying
number of times with a pause between each series of flashes. The number of flashes will
indicate the circuit to check.
# of
Reason for Indication
Possible Causes
Corrective Action
Flashes
1
Failed ignition attempts
Hot Surface Ignitor:
Hot Surface Ignitor:
(3 times)
a) Broken
a) Replace
This puts heater into one hour
lockout mode. This one hour
lockout can be bypassed by
resetting the thermostat.
b) Loose or damaged wire.
b) Connect or replace wire
No Gas to Burner:
No Gas to Burner:
a) Turn to “ON”
b) Open gas supply valve.
c) Connect or replace wire.
d) Replace or clean sensor.
a) Valve in “OFF” position.
b) Gas supply turned OFF.
c) Loose or damaged wire to valve.
d) Defective or dirty flame sensor.
2
3
Pressure switch stuck closed
Pressure switch failed to close
Defective switch.
Replace switch.
a) Vacuum hose disconnected or damged.
b) Defective switch.
a) Reconnect or replace vacuum hose.
b) Replace switch.
c) Wire disconnected or damaged.
d) Obstruction in vent pipe.
c) Connect or replace wire.
d) Remove obstruction.
4
5
Limit switch circuit open
a) Defective limit switch.
b) Disconnected or damaged wire.
a) Replace limit switch.
b) Replace or connect wire.
Gas valve energized with no
call for heat
a) Defective gas valve.
b) Sensor defective.
a) Replace gas valve.
b) Replace sensor.
c) Short in sensor wire.
c) Replace sensor wire.
6
Polarity reversal
a) Hot and neutral electrical supply
wire reversed in junction box.
a) Unplug supply cord from wall
socket. Open junction box and
switch the hot and neutral wires.
very
rapid
Page 18
MODEL NUMBERS
HEDV403 - NAT. GAS
HEDV404 - L.P. GAS
HI-EFFICIENT DIRECT VENT
WALL FURNACE
Prices and specifications subject
to change without notice.
All prices are F.O.B. factory.
51
46
44
45
6
36
37
39
34
52
35
48
43
33
38
5
41
7
4
40
42
32
28
31
47
27
26
3
24
23
29
50
25
22
21
30
2
53
49
20
8
9
1
14
10
12
19
13
15 16
54
18
11
5
17
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 shown at www.cozyheaters.com.
Page 19
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
HEDV403
HEDV404
REF.
LIST
LIST
PART DESCRIPTION
Bottom Louver Panel
Center Front Panel
Upper Front Panel
Left Side Panel Insulation
Cabinet Side Panel
Circulating Blower Assembly
Limit Switch
Front Heat Shield Assy.
Heat Exchanger Assembly
Cabinet Base Assembly
Leg Leveler (4 per unit)
Draft Inducer Gasket
Draft Inducer Assembly
Sight Glass Frame
Sight Glass
Flame Sensor
Sight Glass Gasket
Ignitor
Burner Orifice (2 per unit)
Manifold
Burner Box
Burner Box Top Gasket
Burner Box Top
Gas Valve
Gas Valve Bracket
Burner Box Mounting Gasket
Transformer
NO.
1
PART NO.
72690
41080
72691
72665
41085
72500
80091
41165
72530
41100
80009
72602
72505
41215
70150
72570
72600
72550
72156
72640
41185
72606
41210
72540
41220
72605
78069
72510
72685
72520
41120
72523
72633
72611
72593
41300
72608
41230
72607
72587
72610
41275
41270
41050
41262
41255
41260
72615
72533
72534
72692
72693
41217
41212
PRICE
$37.50
$36.60
$37.50
$1.90
$23.00
$229.30
$9.30
$26.00
$126.80
$60.00
$1.50
$11.70
$135.70
$1.60
$1.20
$10.60
$2.10
$21.10
$3.40
$18.80
$30.90
$5.90
PART NO.
PRICE
$37.50
$36.60
$37.50
$1.90
$23.00
$229.30
$9.30
$26.00
$126.80
$60.00
$1.50
$11.70
$135.70
$1.60
$1.20
$10.60
$2.10
$21.10
$3.40
$18.80
$30.90
$5.90
72690
41080
72691
72665
41085
72500
80091
41165
72530
41100
80009
72602
72505
41215
70150
72570
72600
72550
72139
72640
41185
72606
41210
72541
41220
72605
78069
72510
72685
72520
41120
72523
72633
72611
72593
41300
72608
41230
72607
72587
72610
41275
41270
41050
41262
41255
41260
72615
72533
72534
72692
72693
41217
41212
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
$5.00
$77.30
$5.00
$5.00
$77.30
$5.00
$5.90
$5.90
$23.50
$116.90
$18.80
$28.10
$48.50
$72.70
$4.40
$9.80
$1.70
$60.20
$1.90
$239.30
$1.20
$23.50
$116.90
$18.80
$28.10
$48.50
$72.70
$4.40
$9.80
$1.70
$60.20
$1.90
$239.30
$1.20
Control Board
Wiring Harness
Pressure Switch
Casing Back Assy.
Thermostat
Control Knob
Fresh Air Intake Hose
2" Hose Clamp (4 per unit)
Vent Cap Assembly
Vent Cap Gasket
Collector Box Assembly
Collector Box Gasket
Collector Box Cap
Exhaust Tube
Trim Kit Bracket (4 per unit)
Wall Mounting Bracket (4 per unit)
Casing Top Assy.
Trim Kit Left Side Panel
Trim Kit Top
$1.50
$173.10
$7.50
$1.50
$173.10
$7.50
$2.00
$2.00
$105.30
$22.70
$27.10
$22.70
$25.80
$9.20
$105.30
$22.70
$27.10
$22.70
$25.80
$9.20
Trim Kit Right Side Panel
Air Filter
Burner (2 per unit)
Burner Mounting Bracket
End Cap, Left Side
End Cap, Right Side
Wire Bracket, HEDV
Ignitor Bracket, HEDV
$5.90
$5.90
$16.40
$16.40
$2.60
$16.40
$16.40
$2.60
$2.50
$2.50
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 20
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 . . .
Your gas control and pilot light system has a safety
•
•
Do not try to light any appliance.
Do not touch any electrical switch; do not use any
phone in your building.
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.
•
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.
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
Page 21
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