Cozy 90N30A GAS FIRED VENTED FLOOR FURNACE Owner’s Manual

OWNER’S MANUAL
INSTALLATION INSTRUCTIONShttps://www.cozyheaters.com/products

GAS-FIRED VENTED FLOOR FURNACE

MODEL NUMBERS (natural gas)
90N30A / 90N50A / 90N65A
MILLIVOLT CONTROL SYSTEM

INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.

**WARNING:** Installation and repair must be done by a qualified service person. The appliance should be inspected before use and at least annually by a professional service person.
– 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, maintenance, service, troubleshooting & repairs must be performed by a qualified service agency. DO NOT attempt any of these procedures if you are not qualified as this could expose you to property damage, personal injury, or loss of life and will invalidate all warranties.
– This unit is for residential use only and 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.

**WARNING:** Operation of this furnace when not connected to a properly installed and maintained venting system can result in Carbon Monoxide (C.O.) poisoning and possible death. For your safety, this furnace and the venting system should be inspected at least annually by a qualified service technician.

WARNING: If the information in these instructions 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 or cell phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
•  If you cannot reach the gas supplier, call the fire department.
  – Installation and service must be performed by a qualified installer, service agency, or gas supplier.

WARNING: This product can expose you to chemicals including epichlorohydrin which is known to the State of California to cause cancer and birth defects and/or other reproductive harm. For information go to www.p65warnings.ca.gov

INSTALLATION RECORD
Model No. ………… Serial No………………………….
Original Purchaser…………..
Address…………………….
City and State ………………………………..Zip………………………
Dealer………………………..
Address…………………………………………
City and State……….. Zip………………
HVAC Installation Date……….. HVAC Installer Name…………………….
HVAC Signature………………………
(Dealer or authorized representative who certifies that this appliance is installed in accordance with Manufacturer’s instructions and local codes.)

WARRANTY

The manufacturer, Williams Comfort Products, warrants this Cozy wall furnace or heater to the original purchaser under the following conditions:
ANY WARRANTY CONSIDERATIONS ARE CONTINGENT ON INSTALLATION BY A QUALIFIED INSTALLER (CONTRACTOR). SELF-INSTALLATION IS  PROHIBITED AND WILL INVALIDATE YOUR WARRANTY.

LIMITED ONE-YEAR WARRANTY

1. Any part thereof which proves to be defective in material or workmanship within one year from the date of original purchase for use will be replaced at the Manufacturer’s option, FOB to its factory.
2. No liability is assumed by the Manufacturer for removal or installation labor costs, nor for freight or delivery charges.

LIMITED EXTENDED WARRANTY

1. In addition to the above limited one-year warranty on the complete unit, any combustion chamber which burns out or rusts under normal installation, use, and service conditions during a period of nine years following the expiration of the one-year warranty period will be exchanged for a like or functionally similar part.
2. No liability is assumed by the Manufacturer for removal or installation labor costs, nor for freight or delivery charges.

LIMITATIONS

1. THIS LIMITED WARRANTY IS THE ONLY  WARRANTY MADE BY THE MANUFACTURER, IMPLIED WARRANTIES OF MERCHANTABILITY OR  FITNESS FOR ANY PARTICULAR PURPOSE ARE LIMITED TO THE SAME ONE-YEAR TERM AS THE EXPRESS WARRANTY. UNDER NO  CIRCUMSTANCES SHALL THE MANUFACTURER BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL, SPECIAL, OR CONTINGENT DAMAGES OR  EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM ANY DEFECT IN THE PRODUCT OR ANY COMPONENT OR FROM THE USE THEREOF. THE REMEDIES SET FORTH HEREIN ARE 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, and some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you.

2. This warranty does not include any charge for labor or installation.

3. This warranty does not extend to painted surfaces or to damage or defects resulting from accident, alteration, misuse or abuse, or improper installation.

4. This warranty does not cover claims which do not involve defective workmanship or materials.

DUTIES OF THE CONSUMER

1. The heating equipment must be installed by a qualified installer and operated in accordance with the installation and homeowner’s instructions furnished with the equipment.
2. Any travel, diagnostic costs, service labor, and labor to repair the defective unit will be the responsibility of the owner.
3.  A bill of sale, canceled check, payment record, or permit should be kept to verify the purchase date to establish the warranty period.
4.  Have the installer enter the requested information in the space below.

GENERAL

1. The manufacturer neither assumes nor authorizes any person to assume for it any other obligation or liability in connection with said equipment.
2. Service under this warranty should be obtained by contacting your dealer. Provide the dealer with the model number, serial number, and purchase date verification.
3. If, within a reasonable time after contacting your dealer, satisfactory service has not been received,  contact: Customer Service Department, 250 West Laurel Street, Colton, CA 92324 for assistance.
4. HIS  WARRANTY GIVES YOU SPECIFIC LEGAL  RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS  WHICH VARY FROM STATE TO STATE.

READ CAREFULLY BEFORE INSTALLING UNIT

These installation instructions are a general guide and do not supersede applicable local codes and ordinances. Before planning or making the installation be sure it complies with all phases of the local heating code. (Or, in the absence of local codes, with the latest edition of the National Fuel Gas Code, ANSI.Z223.1, or CAN1-B149).
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 the National Electrical Code
ANSI / NFPA 70, or Canadian Electrical Code CSA-C22.1.
All of the ANSI and NFPA standards referred to in these installation instructions are the ones that were applicable at the time the design of this appliance was certified.

NFPA STANDARDS:
NATIONAL FIRE PROTECTION ASSOCIATION
1Batterymarch Park
Quincy, Massachusetts | USA 02169-7471
ANSI & CANADIAN STANDARDS:
CSA GROUP
178 Rexdale Boulevard,
Toronto, Ontario | Canada M9W 1R3
The design of this appliance was certified to comply with the latest edition of ANSI Z21.86 and CSA 2.32.
The installer must leave these instructions with the consumer, have them complete, and return the warranty card.

WARNING: CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.
2.  Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code, CSA B149.1 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition.
3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so the appliance is operating continuously.
7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CSA B149.1.
9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-fired burning appliance to their previous conditions of use.

INSTALLATIONS IN THE STATE OF MASSACHUSETTS

All installations in the State of Massachusetts must use the following requirements when installing, maintaining or operating direct-vent propane or natural gas-fired space heaters.
For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied:

1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall:
   a. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch services both the appliance and the carbon monoxide detector. b. Have battery backup power;
   c. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and
   d. Have been approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR.

A CARBON MONOXIDE DETECTOR SHALL:

a. Be located in the room that houses the appliance  or equipment;
b. Be either hard-wired or battery powered or both; and
c. Shall comply with NFPA 720 (2005 Edition).
3. A product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.
4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the location of the vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

SPECIFICATIONS AND DIMENSIONS

Your floor furnace and draft hood are packed together in one master carton. The carton containing the floor furnace also contains the thermostat, thermostat wire, insulated staples, furnace key, and lighter rod. The draft hood is packed in its own carton within the master pack and contains screws and rope-like gasket material for attaching and sealing the draft hood to the floor furnace. Check the model numbers on the two cartons to be sure they match.

INTRODUCTION

THIS IS A GAS-FIRED, GRAVITY-VENTED FLOOR FURNACE THAT WILL OPERATE SAFELY AND PROVIDE AN EFFICIENT SOURCE OF HEAT WHEN  INSTALLED, OPERATED, AND MAINTAINED AS RECOMMENDED IN THIS INSTALLATION AND OPERATING INSTRUCTIONS. READ THESE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING, SERVICING, OR USING THE APPLIANCE. IF YOU DO NOT UNDERSTAND ANY PART OF  HOUSE INSTRUCTIONS, CONSULT LOCAL AUTHORITIES, OTHER QUALIFIED INSTALLERS, SERVICE TECHNICIANS, THE GAS SUPPLIER, OR THE  MANUFACTURER.

HELPFUL INSTALLATION INFORMATION 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.

YOU MUST:

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 agencies, 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.

SAFETY

1. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualified installer, service agency or gas supplier to keep the burner and control compartment clean. See installation and operating instructions accompanying the appliance. High surface temperatures keep children, clothing, and furniture away.
2. Follow all applicable codes and ordinances. If there are none, follow the installation standards, the latest edition of NFPA54/ANSI.Z223.1. A copy may be obtained from the National Fire Protection Association, 1 Batterymarch Park; Quincy, MA, 02269.
3. DO NOT install this floor furnace in a recreational vehicle, trailer or mobile home.
4. 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.
5. Be sure this floor furnace is equipped for the type of gas you intend to use.
6. 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.
7. Never use a match, candle, flame or another source of ignition to check for gas leaks. Use only soapy water or liquid detergent.
8. Adequate air for combustion and venting must be provided.
9. 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. Have your floor furnace and vent system inspected before using and at least annually by a qualified service technician.
11. The grill becomes hot when the floor furnace is in operation. Children must be closely supervised when in the presence of any heating appliance. Contact with bare skin may result in severe burns. Keep children off the grill.
12. Before cleaning or servicing the floor furnace, turn off the gas and allow it to cool. This will prevent burns.
13. Always leave the grill in place except when cleaning or servicing the floor furnace.
14. Never operate the floor furnace without the sight glass assembly in place, or with the glass broken or missing.

FLOOR FURNACE LOCATION

Choose a central location such as a hallway but where occupant traffic is minimal & 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. Figure 1
Give consideration to available air for combustion, location in relation to chimney or vent system, thermostat location, clearance under the floor, clearance to combustibles, and heat circulation. Any open foundation is unacceptable as the wind can cause pilot outages 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. Figure 2
Two adjoining sides of the floor furnace must have a minimum clearance of 18″. 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 of clearance between the bottom of the floor furnace and the ground. Figure 3
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.

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 input of your floor furnace.
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 1/4 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 draft hood as possible to allow a venting action to begin before any restriction is encountered.

EXAMPLE 1
50,000 BTU FLOOR FURNACE + 1,000 = 50 SQUARE INCHES

EXAMPLE 2
If another gas-burning appliance, such as a water heater, is installed within the same crawl space or basement: Add the BTUs of the other appliance to those of the floor furnace before calculating the total ventilation needed.

50,000 BTU 40,000 BTU
FLOOR WATER +
FURNACE  HEATER + 1,000 = 90 SQUARE INCHES

CUTTING THE FLOOR OPENING

Consult the specification chart on page 5 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 1/2-inch holes inside the lines of each comer. Use a keyhole saw or a properly grounded saber saw to cut along the lines making sure to keep the lines straight and the comers 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 installations will require cutting a floor joist
Cut the floor 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 the floor.

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.
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 ounces per square foot sheet copper or a suitable substitute. Size the pan to provide 6 inches of 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 may be formed which can cause serious injury or death.

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 look 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.

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. Figure 6
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.

CONNECTING THE VENT
Refer to the specifications on page 5 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 Today design because of higher efficiency requirements that result in lower stack temperatures.

**WARNING:** 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% of the vertical height of the vent.
4. Slope horizontal pipe upwards at least 1/4 inch per linear 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 the vent pipe farther than 1/4 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 transit 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 manufacturer’s 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 the pipe to the 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 5.

We do not recommend doing so, but if you must vent into a masonry chimney, use the following instructions.

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 masonry or noncombustible corrosion-resistant thimble of the correct diameter. Do not push the pipe farther than 1/4 inch into the inside of the chimney. Figure 7A Pushing the pipe farther into the inside of the chimney may cause a 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 a 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. Figure 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. Figure 8

CONNECTING THE VENT

FIGURE 7C – RECOMMENDED

FIGURE 8

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. The homeowner appreciates neatness in workmanship and a 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. Figure 9

FIGURE 9 – TYPICAL INSTALLATION USING CLASS “B” VENT PIPE

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.

GAS PIPE SIZES – CAPACITY NATURAL GAS *| |
---|---|---
LENGTH OF
PIPE – FEET| INSIDE PIPE DIAMETER|
1/2″| 3/4″| 1″
10| 132,000| 278,000| 520,000| CAPACITY
BTU/hr
INPUT
20| 92,000| 190,000| 350,000
30| 73,000| 152,000| 285,000
40| 63,000| 130,000| 245,000
50| 56,000| 115,000| 215,000
60| 50,000| 105,000| 195,000

• Based on the heating value of 1,000 BTU per cubic foot(specific gravity of 0.6) at 0.5 PSIG and a pressure drop of 0.3 inch water column.

GAS TUBING AND PIPE SIZES – CAPACITY PROPANE GAS *| |
---|---|---
LENGTH
OF PIPE
FEET| COPPER TUBING
OUTSIDE DIAMETER”| STEEL PIPE
INSIDE DIAMETER***|
1/2″| 3/4″| 1/2″| 3/4″| CAPACITY
BTU/hr
INPUT
10| 92,000| 329,000| 275,000| 567,000
20| 62,000| 216,000| 189,000| 393,000
30| 50,000| 181,000| 152,000| 315,000
40| 41,000| 145,000| 129,000| 267,000
SO| 37,000| 131,000| 114,000| 237,000
60| 35,000| 121,000| 103,000| 217,000

• Undiluted Liquefied Petroleum Gas at 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 charts below.

• 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.

Refer to Figure 10 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 Propane 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 over-tighten as damage to the valve can occur.

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.

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.
   ADDITIONAL PROPANE GAS REQUIREMENTS

8. Have all connections made at the storage tank by a licensed Propane Gas installer?

9. Have Propane 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 1/2 PSIG the floor furnace must be isolated from the gas supply piping system by closing the manual gas shutoff valve on the floor furnace. If the test pressure exceeds 1/2 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. Overfrring 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 METHODS 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 operations. Verify proper operation after servicing.

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. 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 tum it to the off position. Reconnect the pilot supply tubing and check for leaks with soap and water or liquid detergent.

WARNING: When purging gas piping, the area around the floor furnace must be well ventilated to allow any gas to dissipate. Liquid Petroleum (Propane) 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.

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: Figure 12
STEP 1 Connect black limit switch wire to black thermostat wire using a wire nut. (Nut not furnished).
STEP 2 Connect white thermostat wire to the terminal on gas valve marked “TH TP”.
STEP 3 Connect white limit switch wire to the terminal on gas valve marked “TH”.
STEP 4 Connect the thermostat wires to the thermostat following the instructions provided by the thermostat manufacturer.

WARNING:
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

FOR YOUR SAFETY READ BEFORE LIGHTING

A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions 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.

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.

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 tum 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.

LIGHTING INSTRUCTIONS

1. STOP! Read the information on the safety label.

2. Set the thermostat to the lowest setting.

3. Remove the floor grille.

4. Place the furnace key on the control rod, push down slightly and turn clockwise  to “ALL OFF.”
   NOTE:
   The control rod cannot be turned from “PILOT” to “ALL OFF” unless the control rod is pushed down slightly.

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.

8. Tum the control rod counterclockwise until the pointer is on “PILOT.”

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 the pilot is lit, or use the lighter rod with a match. Continue to hold the control rod down for about one (1) minute after the pilot is lit. If it goes out, repeats steps 4 through 10.
    • If the control rod does not pop up when released, STOP & 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 the “BURNER” position. Remove the furnace key and replace the floor grille.

12. Set the thermostat to the desired temperature.

TURNING 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 tum clockwise to “ALL OFF.” Do not force.
4. Replace floor grille.

ADJUSTING THE BURNER

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, tum the floor furnace off immediately and refer to the installation instructions or local code for proper installation procedure.

ADJUSTING THE PILOT FLAME
Refer to Figure 13 for the correct size pilot flame. If adjustment is necessary, refer to Figure 11 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 tum clockwise to decrease the flame or counterclockwise to increase the flame. 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″ Propane Gas, a pilot adjustment must be made.
BURNER ORIFICE
This appliance is equipped only for altitudes 0- 2,000 feet. If installed above 2,000 feet, the BTU input must be reduced by 4% per 1,000 feet. Orifice change must be completed by a qualified installer or service technician. See the following orifice chart for the proper orifice for a specific elevation.

NATURAL GAS (SPECIFIC ELEVATIONS)

MODEL NO.| 0 – 2,000′| 2,001 – 4,000′| 4,001 – 6,000| 6,001 – ! 8,001 – 8,000 10,000
90N30A| 38| 41| 42| 43| 44
90N50A| 30| 31| 31| 32| 35
90N65A| 26| 28| 29| 30| 30
ORDER KIT #49800 44-1 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. Figure 15

Now open the shutter slightly beyond the point that the yellow disappears and the flame bums blue. Figure 16 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.

FIGURE 14

FIGURE 15

FIGURE 16

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  OUR 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:

MINIMUM INLET PRESSURE
Natural Gas . . . . . . . . . . . . . . . . . . . . . . 4.5 Inches Water Column
Propane Gas . . . . . . . . . . . . . . . . . . . . 11.0 Inches Water Column

MAXIMUM INLET PRESSURE
Natural Gas . . . . . . . . . . . . . . . . . . . . . . 7.0 Inches Water Column
Propane Gas . . . . . . . . . . . . . . . . . . . . 14.0 Inches Water Column
(If the inlet pressure is found to exceed 14.0 inches of 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).

MANIFOLD PRESSURE
Natural Gas . . . . . . . . . . . . . . . . . . . . . . 3.5 Inches Water Column
Propane Gas . . . . . . . . . . . . . . . . . . . 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 Figure 17-A & tum 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 in this setting during mild weather.

IN MILD WEATHER, OPERATE THE FURNACE WITH THE DAMPER OPEN.
The furnace will cycle on and off maintaining a moderate grill temperature and an even room temperature.

OPTION 2
Tum 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 Figure 17-B. 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 the furnace continues to cycle on limits, assure that the damper door is 100% closed by adjusting the damper door pin if necessary.

FIGURE 17-B

IN EXTREMELY COLD WEATHER, A CLOSE DAMPER
(Which Exposes the Warning Plate). The furnace will then put out the maximum amount of heat until the room temperature reaches the setting on the wall thermostat.

LIMIT SWITCH TEMPERATURE SETTINGS
90N30A
90N50A
90N65A

**WARNING:** Floor furnace grills become hot when the furnace is in operation. Contact of bare skin with a grill may result in severe burns. Keep children off, and provide a fence or register guard for their protection.

MAINTENANCE

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operations.
For proper operation, the Floor Furnace must be kept clean. At regular intervals tum the control valve off, let cool, remove the register, and clean dust and foreign material from jacket with a vacuum cleaner.
Has the Floor Furnace been checked by a qualified service technician for a 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 the floor furnace area.
Be sure not to obstruct combustion and ventilation air.

TO CLEAN BURNER

1. Remove the bottom pan from the outer casing.
2. Remove 2 screws from the burner support bracket.
3. Remove 2 screws from the pilot bracket allowing the burner to slide off of the manifold and out of the floor furnace.
4. Examine the burner. If any distortion is noticed, replace the burner.
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 a garden hose.
7. Re-install and adjust the burner.

**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.

Repair service must be performed by a qualified service technician. The floor furnace must be inspected before initial use. Annual cleaning of floor furnace and safety performance check should be made by a qualified service technician. More frequent cleaning may be required when exposed to 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 the heater.
Examine the entire venting system as a routine part of the safety performance check on an annual basis.

**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.

GAS FLOOR FURNACE PARTS LIST

NATURAL GAS PART NUMBERS

90N30A| 90N50A| 90N65A
REF.
NO.| REPLACEMENT PART DESCRIPTION| 90N30A| 9ONSOA| 90N65A
---|---|---|---|---
1| Liner, complete assembly| 23001| 23980| 24380
2| Limit control 607 11| 74306| 74307| 74308*
3| Heat exchanger with gasket| 23074| 24099| 24499
4| Grille, floor| 23145| 24175| 24475
5| Casing, complete assembly| 23040| 24002| 24402
6| Sight glass assembly gasket not included| 23150| 23150| 23150
7| Valve rod| 24035| 24035| 24035
8| Draft hood assembly with gasket| 23200-K| 24075-K| 24477-K
9| Washer, valve rod| 24044| 24044| 24044
10| Key, furnace Instruction Plate, lighting| P322445| P322445| P322445
11| Instruction plate, lighting| 91256| 91256| 91256
12| Valve rod indicator plate| 24045| 24045| 24045
13| Thermostat, Millivolt| 74592| 74592| 74592
14| Electrode| 74350| 74350| 74350
15| Igniter wire| 74351| 74351| 74351
16| Piezo igniter| 80016| 80016| 80016
17| Disappearing Bushing – 1/4 x 3/8| 74414| 74414| 74414
17 / 18| Disappearing Bushing – 1/4 x 3/8
Valve, VS821A1061 – (Natural w/ 74414 bushing)| 74315| 74315| 74315
19| Burner support, front| 24036| 24036| 24036
20| Manifold| 74416| 74416| 74416
21| Burner orifice natural gas/propane gas| 74390| 74406| 74407
22| Burner with pilot bracket plus air adjust| 74401| 74401| 74402
| Pilot burner with orifice Q350A/271 natural| 74410| 74410| 74410
23| Pilot burner with orifice Q350A/271 natural
Pilot burner with orifice Q350A/589 propane| 74415| 74415| 74415
24| Mounting screws, pilot (2)| 50107| 50107| 50107
25| Pilot generator Q313A/014 V. 23″| 70098| 70098| 70098
26| Pilot tubing with fittings| 74452| 74452| 74452
N/A| Gasket, heat exchanger| 74530| 74530| 74532
N/A| Draft hood gasket with screws| 23225| 24077| 24077
N/A| Wire, thermostat 20′| 49925| 49925| 49925
N/A| Staples, thermostat wire| 74209| 74209| 74209
N/A| Propane conversion kit| 49200| 49210| 49220
N/A| Burner support, rear| 24430| 24430| 24430
N/A| Warning flag| 24068| 24068| 24068
N/A| Wiring harness| 74320| 74321| 74322
N/A| Bottom burner cover| 24039| 24039| 24431

PART DRAWINGS

ATTENTION: Contractors and qualified service technicians: We only sell parts through our wholesalers. For prompt parts service, contact the wholesaler from which you purchased your Cozy heater.

TROUBLESHOOTING YOUR FURNACE

MAIN BURNER – for qualified service technicians

2. Burner orifice too large.
3. If installed above 2,000 ft.| 1. Replace the complete valve.
2. Check with the local gas company for proper orifice size
and replace.
3. See burner orifice section, Page 15
Flame Pops Back| 1. Too much primary air.| 1. Adjust the air shutter. Page 15
Noisy Flame| 1. Too much primary air.
2. Noisy pilot.
3. Bun in orifice (if it whistles or resonates).
4. Excessive gas input.| 1. Adjust the air shutter. Page 15
2. Reduce pilot gas by adjusting the screw-marked pilot on
a combination gas control valve. Page 15
3. Remove the bun or replace the orifice. (Do not enlarge orifices).
4. See the “Flame Too Large” section above.
Yellow Tip Flame (Some yellow tipping on propane gas is permissible)| 1. Too little primary air.
2. Clogged main burner ports.
3. Clogged draft hood.
4. Linted up air shutter.| 1. Adjust air shutter. Page 15
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.
Floating Flame| 1. Blocked venting.
2. Insufficient primary air.| 1. Clean flue passageways to remove the blockage.
2. Adjust air shutter to increase the primary air supply.
Gas Odor| 1. Chimney or vent obstruction.
2. Drafts around the appliance.
3. Gas leak.| 1. Clean chimney or vent – replace if necessary.
2. Eliminate drafts.
3. Page 1
Delayed Ignition| 1. Pilot flame too small.
2. Burner ports clogged near the pilot.
3. Low gas pressure.
4. Pilot decreases in size when main burners come on.
5. Air shutter opens too far.
6. Drafts around the appliance.
7. Bad venting.| 1. Check the pilot orifice, close, and increase the pilot gas flow if necessary by adjusting the combination control valve. Page 15
2. Clean burner ports (Do not enlarge parts).
3. Check gas supply pressure.
4. Supply piping is inadequately sized. Consult a local gas utility
or competent installer.
5. Close the air shutter to the proper setting as outlined in these instructions (slight yellow tipping is allowable on propane gas).
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 Tum Off| 1. Defective or sticking automatic valve.
2. Excessive gas pressure (The supply gas pressure must not exceed 1/2 psi or 14” water column).| 1. Clean or replace valve.
2. To connect this situation contact the utility supplying the gas.
Incorrect Gas Input| 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).
Not Enough Heat| 1. Appliance undersized
2. Thermostat set too low.
3. Incorrect supply pressure.| 1. This is especially true when a dwelling or room is enlarged.
Have the heat loss calculated and compared to the
appliance output (70% of input). Your gas company or
installer can supply you with this information. If the appliance is
undersized, replace with correct size unit.
2. Setting of the thermostat. See “Lighting and Shutting Down
Instructions.”
3. Check supply pressure as outlined above.
Too Much Heat| 1. Thermostat set too high.
2. Combination control valve
sticks open.| 1. Lower the setting of a temperature dial. See “Lighting and Shutting Down Instructions”.
2. Replace the combination control valve.
AUTOMATIC PILOT & VALVE
Burner Won’t Tum On| 1. Pilot flame too large or too small.
2. Dirt in the pilot orifice.
3. Defective automatic pilot section
in the combination control valve.
4. Defective Thermocouple.| 1. Readjust pilot flame using adjustment screw marked “Pilot”
on the combination control valve. Page 12
2. Clean pilot orifice with air or solvent, do not remain.
3. Replace the entire combination control valve.
4. Replace thermocouple.

www.cozyheaters.com | 888-444-1212 | 250 West Laurel Street, Colton CA 92324 USA
Subject to change without notice | © 2022

References

• Home - Cozy Heating Systems LLC
• Home - Cozy Heating Systems LLC
• Register Your Furnace Product - Williams Comfort Products
• p65warnings.ca.gov
• Products - Cozy Heating Systems LLC

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