DVCF402D Cozy Direct Vent Counterflow Wall Furnaces

Specifications

• Model Numbers (Natural Gas): DVCF402D / DVCF602D
• Model Numbers (Propane Gas): DVCF401D / DVCF601D
• BTU Output: 40,000 – 60,000 BTU/hr

Product Usage Instructions

Installation

1. Carefully read the owner’s manual before installing the Cozy Wall Furnace.
2. Ensure proper ventilation and compliance with local codes for aftermarket manufactured home installations.
3. Do not install in trailers or recreational vehicles.

Warnings

1. Do not store or use flammable vapors near the appliance.
2. Follow installation, adjustment, and maintenance instructions to prevent injury or property damage.

Warranty Information

This wall furnace comes with a limited one-year warranty for defective parts and a limited extended warranty for the combustion chamber.

Self-installation is prohibited and can invalidate the warranty.

FAQs

• Q: Can this wall heater be installed in a mobile home?
  • A: This direct-vent furnace is approved for aftermarket manufactured home installations but not for trailers or recreational vehicles.
• Q: What should I do if I detect a gas leak?
  • A: If you detect a gas leak, immediately contact a qualified installer, service agency, or the gas supplier for assistance.
• Q: How often should I have the wall heater serviced?
  • A: Regular servicing by a qualified installer or service agency is recommended to ensure safe and efficient operation of the wall heater.

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OWNER’S MANUAL

VISITEZ NOTRE SITE WEB POUR LA VERSION FRANÇAISE DE CE MANUEL

INSTALLATION INSTRUCTIONS VISITE NUESTRA PÁGINA WEB PARA LA VERSIÓN EN ESPAÑOL DE ESTE MANUAL www.cozyheaters.com/product-literature/

COUNTERFLOW
DIRECT VENT GAS WALL HEATER
MODEL NUMBERS: (natural gas) DVCF402D / DVCF602D
MODEL NUMBERS: (propane gas) DVCF401D / DVCF601D
SAVE THIS MANUAL FOR FUTURE REFERENCE.
READ THIS OWNER’S MANUAL CAREFULLY BEFORE YOU INSTALL YOUR NEW COZY WALL FURNACE.
DISCONTINUED MODELS: DVCF403C / DVCF553C

WARNING: This direct-vent furnace is approved for aftermarket manufactured home installations (once the manufactured home is sold, installed and stationary) unless prohibited by local codes. Not for manufactured home manufacturer (factory) installation. Do not install any of these furnaces (natural or propane gas) in trailers or recreational vehicles.
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
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or for additional information consult a qualified installer or, service agency.

40,000 – 60,000 BTU/hr.
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: · Open all windows. · Do not try to light any appliance. · Do not touch any electrical switch; do not use any phone or cell phone in your building. · Extinguish any open flame. · 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 the gas supplier.

250 West Laurel Street, Colton CA 92324 · cozyheaters.com · 1-888-444-1212

WARRANTY

The manufacturer, Williams Furnace Co., warrants this 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 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 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 limitation 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, misuses 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 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. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

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.)

2 COUNTERFLOW DIRECT VENT GAS WALL HEATER

SAFETY RULES

WARNING: Read these rules and the instructions carefully. Failure to follow these rules and instructions could cause a malfunction of the furnace. This could result in death, serious bodily injury and/or property damage.
INSTALLATION MUST CONFORM TO LOCAL CODES. IN THE ABSENCE OF LOCAL CODES, INSTALLATION MUST CONFORM TO THE NATIONAL FUEL GAS CODE, ANSI Z223.1. THE APPLIANCE, WHEN INSTALLED MUST BE ELECTRICALLY CONNECTED AND GROUNDED IN ACCORDANCE WITH LOCAL CODES OR, IN THE ABSENCE OF LOCAL CODES, WITH THE CURRENT NATIONAL ELECTRICAL CODE ANSI/NFPA NO. 70.
IN CANADA:
1. Installation must conform to local codes or, in the absence of local codes, the current CAN/CGA B149 installation code.
2. The appliance, when installed, must be electrically connected and grounded in accordance with local codes or, in the absence of local codes, with the current CSA C22.1 Canadian Electrical code.
3. Reference is made in this manual regarding gas type as propane gas Be advised that propane gas is not available in Canada, refer to propane gas.
1. Use only manufacturer’s replacement parts. Use of any other parts could cause injury or death.
2. DO NOT install the furnace in an alcove.
3. DO NOT install this furnace where it could be isolated by closing doors to the heated space.
4. DO NOT install this furnace in a travel trailer or recreational vehicle.
5. MAINTAIN all clearances specified in section “Locating Wall Furnace and Thermostat” and “Vent Installation.”
6. BE SURE this furnace is for type of gas to be used. Check the rating plate by the gas valve in the lower cabinet. Do not change it to use other gases without the proper manufacturer’s Gas Conversion Kit.
7. For natural gas, the minimum inlet gas supply pressure for the purpose of input adjustment is 5″ water column. The maximum inlet gas supply pressure is 7″ water column. For propane gas, the minimum inlet gas supply pressure for the purpose of input adjustment is 11″ water column. The maximum inlet gas supply pressure is 13″ water column.
8. Any safety screen, guard or parts removed for servicing this appliance must be replaced prior to operating the appliance to avoid property damage, bodily injury or death.
9. Install the furnace vent directly to the outdoors so that harmful combustible flue gases will not collect inside
4 COUNTERFLOW DIRECT VENT GAS WALL HEATER

the building. Follow the venting instructions for your type of installation exactly. Use only the type and size of vent pipe and fittings specified.
10. BE SURE to provide for adequate combustion and ventilation air. The flow of this air to the furnace must not be blocked.
11. NEVER vent flue gases into another room, a fireplace or any space inside a building. This could cause property damage, bodily injury or death.
12. Never test for gas teaks with an open flame. Use a soap solution to check all gas connections. This will avoid the possibility of fire or explosion.
13. ALLOW the furnace to cool before servicing. Always shut off electricity and gas to furnace when working on it. This will prevent any electrical shocks or burns.
14. DUE TO HIGH TEMPERATURES, locate the furnace out of traffic and away from furniture and draperies.
15. ALERT children and adults to the hazards of high surface temperatures and warn them to keep away to avoid burns or clothing ignition.
16. CAREFULLY supervise young children when they are in the same room with the furnace.
17. DO NOT place clothing or other flammable material on or near furnace.
18. 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. More frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments, burners and circulating air passages be kept clean.
19. BEFORE INSTALLING: To avoid electrical shock, tum off electrical circuits that pass through the wall where you are going to install the furnace.
20. BE AWARE of good safety practices by wearing personal protective equipment such as gloves and safety glasses to avoid being injured by sharp metal edges in or around furnace and while cutting or drilling holes in wood and/or sheet metal.
21. CAUTION: Label all wires prior to disconnection when servicing controls.
WARNING: Do not use this furnace if any part has been under water. Immediately call a certified service technician to inspect the furnace and to replace any part of the control system and any gas control which has been under water.
WARNING: Do not install any of these furnaces (natural or propane gas) in mobile homes, trucks or

INTRODUCTION

BASIC DESCRIPTION
The following steps are all needed for proper installation and safe operation of your furnace. If you have any doubts as to any requirements, check with local authorities. Obtain professional help where needed. All of the checks and adjustments in the “Start-Up Procedures” are vital to the proper and safe operation of your furnace. Please read our instructions before you install and use your furnace. This will help you obtain the full value from this furnace. It could also help you avoid needless service costs if the answer to the problem is found within this instruction manual.
Always consult your local heating or plumbing inspector, building department or gas utility company regarding regulations, codes or ordinances which apply to the installation of a counterflow Direct Vented wall furnace.
Check the furnace nameplate, located in the burner compartment, to make sure the furnace is equipped to operate on the type of gas available (either natural or propane gas).

DO NOT convert the furnace from natural gas to propane gas or from propane gas to natural gas without the proper manufacturer’s gas conversion kit.
Your Counterflow Direct Vent Furnace draws air in at the top of the furnace by the fan and discharged through the grille near the floor. It is shipped ready to install on the surface of a wall or recessed into a wall. Combustion air is drawn in from the room where the furnace is located and vented out the top of the furnace through listed vent piping to a roof Direct Vent. Venting material is not supplied with this furnace.
This appliance is equipped with a vent safety shutoff system designed to protect against improper venting of combustion products. Operation of this wall furnace when not connected to a properly installed and maintained venting system or tampering with the vent safety shutoff system can result in carbon monoxide (CO) poisoning and possible death.

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. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

5. 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.

6. 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.

7. Close fireplace dampers.

8. 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.

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.

COUNTERFLOW DIRECT VENT GAS WALL HEATER 5

INTRODUCTION
Basic Tools Needed
Hand drill or properly grounded electric drill Expansion bit 1/2″ to 1-5/8″ or 1/2″ and 1-1/2″ blade bits 1/8″ and 3/16″ drill bit (metal) 6 ft. folding rule or tape measure Screwdriver (medium blade)
Screwdriver (Phillips and Flat Head) Pliers (wire cutting) Hammer Stud Locater or small finishing nails Tin Snips 8″ adjustable wrench 12″ adjustable wrench 7/8″ wrench 3/4″ wrench 1″ wrench Gloves and safety glasses
Materials
Pipe and fittings to make connections to furnace (See page 17). Caulking compound(silicone rubber with a temperature rating of 500°F). DO NOT use caulking compound advertised as paintable or for bath tub use as most contain fillers and will not withstand high temperatures. Pipe Joint Compound resistant to propane gases. Electrical wiring supplied as needed, see page 26. Minimum wire size is #14 gauge copper. Trim Accessory 4701 is recommended or 3/4″ quarter round or other wood trim molding approximately 16′ long. Oval Vent Kit 9901 is recommended. Vent Enclosure Kit 9812 or 9824 if furnace is to be surface mounted is recommended. 1 x 1 wood strips if Optional Side Outlet Grille Register 6701 is used.
Helpful Installation Information
The following booklets will help you in making the installation: ANSI/NFPA 70 (1990 or current edition) “National Electrical Code”. In Canada: CSA C22.1 Canadian Electrical Code. American National Standard NFPAS4/ANSI Z223.1 1988 or current edition “National Fuel Gas Code”. Obtained from: American National Standards Institute, Inc., 1430 Broadway, New York, N Y 10018.

In Canada: CAN/CGA B149.
Optional Accessories
DIFFUSER GRILLE KITS 6703 & 6704 6703 let’s you route some heated air in a two-way direction. Kit 6704 for one-way direction.
SIDE OUTLET GRILLE KIT 6702 Allows you to direct heated air from the side of furnace into the same room.
OUTLET GRILLE REGISTER 6701 Let’s you route some heated air into a second room. Mounts on the side wall of second room and must be within 10 inches of wall furnace.
TRIM STRIP KIT 4701 Provides finished edge at sides of wall furnace. Neutral beige enamel painted steel.
THERMOSTAT 78355
Unpacking Your Furnace
The furnace is shipped in two cartons, one containing the furnace, installation instruction booklet and hardware bag and the other containing the vent cap with inlet and vent tubes.
1. Lay the carton horizontally.
2. The bottom front panel can be removed by grasping just below the handle and pulling it outward and then upward. See Figure 1
3. Place these and other parts, as they are removed from furnace, where they cannot be lost or damaged before you need them.
NOTE
Check the burner rating plate, located in burner compartment, to make sure your furnace is equipped to operate on the type of gas available (either natural or propane gas).
4. Remove all literature, wire and metal anchors used for free standing installation.
5. Check the fan blade to be sure it spins freely.
6. Take out the four screws holding fan shroud to the side flanges of cabinet and remove shroud. See Figure 1
NOTE
The fan blade must be removed in order to remove the cardboard shipping brace located under motor.
7. Before removing the fan blade, remember its position by examining the blade nut and the amount of shaft visible. Scribe or mark the motor shaft in order to reinstall the fan blade to its original place on the shaft.
8. Loosen the 1/8″ “Allen head” set screw holding the fan blade to motor shaft and remove the fan. Place the fan blade and fan shroud where they will not be damaged.
9. Remove the cardboard shipping brace located under the motor mounting brackets.
10. Properly dispose of shipping materials.

6 COUNTERFLOW DIRECT VENT GAS WALL HEATER

INSTALLING YOUR FURNACE

FIGURE 1
FAN BLADE TOP FRONT PANEL THUMB SCREW

FAN SHIELD SCREWS

HANDLE BOTTOM FRONT PANEL

CABINET

The following steps are needed for proper installation and safe operation of your furnace. If you have any doubts as to any requirements, always consult your local Heating or Plumbing lnspector, Building Department or Gas Utility Company regarding regulations, codes, or ordinances which apply to the installation of a vented wall furnace. Obtain professional help where needed. The CHECK AND ADJUSTMENTS on page 22 are vital to the proper and safe operation of the furnace. Be sure they are done.
IMPORTANT
For satisfactory and trouble-free operation, be sure to:
1. Locate the furnace properly within the space to be heated.
2. Install the furnace in accordance with local codes or ordinances and instructions provided. In the absence of local codes or ordinances, install the furnace to conform with the current edition of the National Fuel Gas Code, NFPA 54, ANSI Z223.1/Canadian Installation Code, CAN/CGA B149.
3. Maintain minimum clearance: Floor 0 inches or ceiling 4 inches, side wall 4 inches. For exception to minimum side wall clearance, as shown on Page 8, Figure 3.
4.Provide enough combustion and ventilation air.

Locating Your Wall Furnace & Thermostat
Consider the following points before attempting to install the furnace:
1. This is a direct-vent wall furnace. It must be installed on an OUTSIDE WALL for proper venting of flue gases (Figure 2).
a. Ideally, the wall should be on the least windy side of the dwelling, as strong gusts may extinguish the pilot.
b. Furnace may be installed flush against a wall or recessed up to 10″ maximum. Wall thickness from back surface of furnace to outside of wall can be 3/4″ minimum to 9″ maximum. See Page 8, Figure 3
With standard furnace discharge outlet, do not install closer than 4″ to intersecting wall. See Page 8, Figure 4
Studs must be spaced on 16-inch centers or stud space will have to be framed in. See Page 9 and 10, Recessed Mounting.
2. The top of the furnace must be at least 4-inches from the ceiling.
3. Check the clearances needed from the furnace and vent (Page 8, Figure 2 and Page 8, Figure 4). You must place the furnace where you will have no less than the clearances shown. See Page 8-9, Figure 5, 6 & 7
4. When using optional kits 6703 or 6704, maintain the clearances as shown on Page 8-9, Figure 5, 6 & 7
5. When using optional kit 6701, maintain clearance as shown on Page 8, Figure. 4. Use only optional outlet and grille kits available from manufacturer.
6. The outside vent cap must be at least 18-inches away from any window or other building opening (Figure 2).
7. The furnace will not work if anything stops free entry of fresh air into the vent, or free flow of flue gases from it. Be sure the center of the vent cap is at least 18 inches above ground level or shrubs are as shown in Figure 2. Make sure shrubs are kept trimmed. It must also be at least 18 inches from any overhang.
8. Try to place the furnace near the center of the space to be heated for good air circulation. Do not put it behind a door or draperies. Do not put in a closet, alcove, hallway or other confined space.
9. Be sure that gas piping and electrical wiring can be brought to the furnace. See sections on gas piping and electrical wiring for your type of furnace mounting.
10. The bottom of the furnace must rest directly on a wood or concrete floor. If the floor is other than wood or concrete, such as carpet or sheet vinyl flooring, there must be a piece of wood or sheet metal under the furnace that is at least the same size as the bottom of the furnace.
WARNING: If vinyl siding is used on exterior wall surface, heat from the vent cap could cause distortion/ discoloration. Shield to protect the siding. Check with manufacturer for additional options.
COUNTERFLOW DIRECT VENT GAS WALL HEATER 7

INSTALLING YOUR FURNACE

FIGURE 2 – MINIMUM CLEARANCES

RECESSED INSTALLATION CLEARANCE NOTE: A portion of the furnace that is recessed into a wall up to 10″ maximum recess may have (0) zero inch clearance to combustibles. (See Figure 3). All other clearances for the unrecessed portion must be observed. 3/4-inch to 5-inch outer wall will require thin wall collar accessory

FIGURE 3 – RECESSED INSTALLATION CLEARANCE

FIGURE 4

11. Be sure to provide adequate clearance and service access. The front of the furnace must face the open room.
12. Choose a location for the thermostat (optional) about 5-feet above the floor on an inside wall. The thermostat wire supplied with your furnace is 20-feet long, which should be enough to run up through the attic of a single- story home, so the thermostat can be a maximum of 16-feet from the furnace measure in a straight line, or about 8-feet from the furnace if the wire is run under the floor. Use heavier wire size if more than 20-feet of wire is required. The thermostat should be sensing average room temperature.

AVOID THE FOLLOWING:

HOT SPOTS

COLDSPOTS:

Concealed pipes or ducts Concealed pipes or ducts

Fireplaces

Stairwells ­ drafts

Registers

Doors ­ drafts

TV sets

Unheated rooms

Radios

on the other side of the wall

Lamps

DEAD SPOTS

Direct sunlight

Behind doors

Kitchen

Corners and alcoves

13. After picking a location that meets the requirements,

inspect the wall, floor and outside areas. Make sure

there are no pipes, wiring, or anything else that would

interfere with furnace, vent, or thermostat installation.

If required, move them or pick a new location.

8 COUNTERFLOW DIRECT VENT GAS WALL HEATER

FIGURE 5 FIGURE 6

VENT CAP VENT CAP

FIGURE 7

If the distance from the top of the cutout to the ceiling wall plate is more than 18-inches, it is recommended that it be closed off.
Nail a 2″x 4″ long enough to go between the studs at the top of the opening to close off the stud space.
FIGURE 8 – WALL OPENING FOR RECESSED MOUNT

Recessed Mount Installation
FIND THE STUDS Use a stud locator or small finishing nails. Repeatedly drive and remove a nail into the wall in the area of the stud until you find it. Then find one side. Leave the nail there. Drive another nail just on the other side of the same stud.
Inside edge of the other stud should be about 14½-inches from the one found. Drive finishing nail on inside edge of this stud.
NOTE: If studs are not on 16-inch centers, see section “Close off Stud Space”, below.
CUT WALL OPENING 1. Lay out the required opening to be cut in inside wall
(Figure 8). Mark center of the vent hole on wall. Using a window, door or wall corner for reference, measure to find where vent will be on outside wall. Check to be sure clearances (Page 8, Figure 2, and Figures 4, 5, 6 and 7 on page 9) will be right. 2. Drill a ¼-inch hole through vent hole center to the outside wall to mark vent location. 3. Make the required cutout in inside wall. (Figure 8). 4. Using the hole drilled through to the outside wall as the center, cut a 9¼-inch diameter hole for the vent. It may be better to work from outside, especially when breaking through brick, stone or tile. (See Figure 8). 5. In new stud wall construction, install blocks as shown in Figure 7 and install plaster grounds around inside of wall opening. 6. The vertical height of the opening shown is 3-inches greater than height of furnace to allow space for connection of wiring after furnace is installed.
NOTE: Vertical measurements are from finished floor. (Figure 7)
CLOSE OFF STUD SPACE (If Required) If studs are not on 16-inch centers, cut the hole for the furnace next to an existing stud and frame in the other side using a 2″x 4″ and spacer blocks as required. As shown on Page 9, Figure 9.

DVCF60XD DVCF40XD
FIGURE 9 – CLOSE OFF STUD SPACE
COUNTERFLOW DIRECT VENT GAS WALL HEATER 9

INSTALLING YOUR FURNACE

GAS AND ELECTRICAL SUPPLY OPENINGS Holes must be drilled for the gas line and electrical supply. Holes must be located from each side of furnace as shown in Figure 10.
Decide whether the gas line will come through the floor or wall.
Drill a 1½ -inch hole in wall or floor as needed.
Gas line can be run at this time or done after furnace is mounted, see section GAS SUPPLY AND PIPING, on Page 16.
The electrical supply opening should be at the lower portion of the furnace, to match openings shown in Figure 10. Mark ceiling wall plate and drill holes. If not practical to run wiring from the attic, drill holes through wall stud and run wires up through adjoining stud space from crawl space or basement.
Run the electrical supply with the ground wire and thermostat cable to the openings. Leave enough length to connect in the junction box after the furnace is installed. See section “Electrical Wiring,” on page 15.

FIGURE 10 – GAS AND ELECTRICAL OPENINGS

CAUTION: Do not run wire in any location where it might be damaged. Avoid splicing thermostat wire unless the spliced wires are properly cleaned, soldered, and taped.

OFFSET WALL INSTALLATION To mount the wall furnace on an offset wall, the area behind the furnace must be made flush or flat.
Use lumber (2″x 4″s, 2″x 6″s etc.) to make the surface flush with other portion of wall.
Use sheet rock or paneling etc. to finish area. Follow procedures under Surface Mount Installation.
SURFACE MOUNT INSTALLATION – FIND THE STUDS 1. Find two studs at spot where furnace is to be placed.
Use a stud indicator or small finishing nails. Repeatedly drive and remove a nail into the wall in the area of the stud until you find it. Then find one side. Leave the nail there. Drive another nail just on the other side of the same stud. 2. Inside edge of the other stud should be about 14½-inches from the one found. Drive finishing nail on inside edge of this stud.
CUT VENT OPENINGS 1. Lay out and mark the center of the hole to be cut
through the wall for the vent (Page 9, Figure 8). Using a window, door, or wall corner for reference, measure to find where vent will be on outside wall. Check to be sure clearances are correct. (See Pages 7-9, Figures 2, 4, 5, 6 & 7).
10 COUNTERFLOW DIRECT VENT GAS WALL HEATER

DVCF60XD
DVCF40XD
2. Drill a ¼-inch hole through vent hole center to the outside. Cut the 9¼- inch diameter hole through inside wall. Using the ¼-inch hole as the center, cut a matching hole in outside wall. It may be better to work from the outside, especially when breaking through brick, stone or tile.
GAS AND ELECTRICAL SUPPLY OPENINGS Holes must be drilled for the gas line and electrical supply. Holes must be located from each side of furnace as shown on Page 10, Figure 10.
Drill a 1½-inch hole in floor or wall for gas line.
Gas line can be run at this time or done after furnace is mounted, see section: Gas Supply and Piping, Page 16. Mark ceiling or wall to match wall furnace openings and drill a 1-inch hole for the power supply and a ½-inch hole for the thermostat cable. Run the electrical supply and ground wires to the opening. Leave enough length to connect in the junction box after the furnace is installed. See section “Electrical Wiring,” Page 15.

ROUGH-IN OPTIONAL SIDE OUTLET NO. 6701 Install plaster ground as shown in Figures. 12 & 13. Flanges of plaster ground extend the thickness of normal plaster. If “dry-wall” or other thin material, flanges must be trimmed off flush with wall surface.
Follow measurements given carefully, and note that when a side outlet is used, the furnace casing must be exactly 4 inches from surface of adjacent wall except minimum clearance may be ¾-inch when optional 1-way Diffusing Grille Kit 6704 is used.
FIGURE 11 – WALL OPENING (SURFACE MOUNT)

FIGURE 13 – PLASTER GROUND INSTALLATION

DVCF60XD DVCF40XD
FIGURE 12 – PLASTER GROUND INSTALLATION

MOUNTING OPTIONAL SIDE OUTLET GRILLE KIT NO. 6701 Refer to Figure 14. 1. Before setting furnace into position, cut 5″x 7″ rectan
gular opening in furnace outer casing where marked. See Page 10, Figure 10. 2. Place the outer boot against casing with inner flanges exactly on edges of cut hole, mark screw location, re move boot and drill #33 holes for the sheet metal screws. 3. Remove the knockout plate and knockouts for screws from the inner liner. 4. Secure 1″x 1″ wood strip (not included with this kit) to the wall next to the side outlet as a backup for metal filler strips. 5. Fasten metal filler strips to the side of the furnace casing with the front surface exactly opposite the front of wood backup strip. 6. After the furnace is placed in position, place the outer boot through the plaster ground tight against the furnace casing. Then mark and cut off the outer end flush with the wall surface. 7. Press the inner boot against liner, mark and cut it off flush with the wall surface. Install the outer boot first, then the inner boot, fastening through all holes with the screws provided.
FIGURE 14 – MOUNTING GRILLE KIT 6701

COUNTERFLOW DIRECT VENT GAS WALL HEATER 11

INSTALLING YOUR FURNACE

OPTIONAL 2-WAY DIFFUSING GRILLE KIT NO. 6703 Refer to Figure 15.
CAUTION: For use only in conjunction with a front outlet when the furnace is spaced at least 12-inches from an intersecting wall (see Page 8, Figure 5).
Metal clips on backside of the optional grille snap into the side louvers of the front warm air outlet. Adjust clips with pliers if necessary. Grille may also be attached with sheet metal screws.
1-WAY FRONT DIFFUSING GRILLE KIT NO. 6704 Follow instructions for 2-WAY FRONT DIFFUSING GRILLE 6703 ABOVE, except furnace clearance to an adjacent wall must be ¾-inch minimum.
CAUTION: Use only optional kits available from the manufacturer.
FIGURE 15 – TWO-WAY DIFFUSING GRILLE 6703

through wall until even with thermostat location. 7. Snag thermostat cable through the hole and pull the
cable through the hole in wall so that 6-inches of cable protrudes. 8. Route cable to wall furnace.
MOUNTING THE THERMOSTAT
1. To remove thermostat cover, squeeze both sides and lift. Carefully remove and discard the packing tab protecting the switch contacts. See Fig 17.
2. Connect the thermostat wires to the terminal screws on the thermostat base. Make sure the wiring does not interfere with thermostat operation.
3. Push any excess wire back through the hole in the wall and plug the hole with insulation to prevent drafts from affecting thermostat operation.
4. Being sure to level the thermostat for best appearance, fasten the thermostat base to the wall through the mounting holes with the screws provided.
5. Replace the thermostat cover.
FIGURE 16 – ROUTE THERMOSTAT CABLE

Thermostat Installation

1. Thermostat 78355 or any millivolt thermostat. 2. If an old thermostat is being replaced and is in a
satisfactory location and the wiring appears to be in good condition, use existing wiring. If in doubt, use new wire. 3. If a new location is chosen or if this is a new installation, thermostat cable must first be run to the location selected. All wiring must agree with local codes and ordinances. These instructions cover bringing the wire down from the attic but it can be run from a basement or crawl space using similar methods. 4. Before drilling a hole in the wall at selected location, drive a small finishing nail through the ceiling in the corner of the wall and ceiling above the thermostat location. Pull the nail out and push a small stiff wire through the hole so it can be found in the attic. Drill a ½-inch hole through the ceiling wall plate. 5. Probe for obstructions in the partition. Then drill a ½-inch hole through wall at the selected location for thermostat. 6. From the attic, feed the thermostat cable or a stiff wire
12 COUNTERFLOW DIRECT VENT GAS WALL HEATER

FIGURE 17 – THERMOSTAT

SQUEEZE FIRMLY BOTH SIDES AND LIFT TO REMOVE COVER

Vent Installation
WARNING: DANGER OF PROPERY DAMAGE, BODILY INJURY OR DEATH. Proper vent installation is critical to the safe operation of the furnace. Therefore, carefully read and follow all the instructions given in this section.
The following instructions are for either surface or recess mounted wall furnace.
USE ONLY THE VENT ASSEMBLY SUPPLIED.
IMPORTANT: All joints in the inlet and vent tubes and all gaskets must be tight. Installation in any other manner voids the C.S.A. design certification and will affect the warranty.
Refer to Page 14, Figure 19 for the name and location of the vent parts.
DETERMINE PROPER LENGTHS
IMPORTANT: To prevent harmful flue gases from entering the house, make sure NOT to trim air or vent tubes shorter than specified below.

ATTACHING TUBE TO FURNACE The smaller diameter vent tube (Page 14, Figure 19 “B”) must be installed first. The easiest way to install the vent tubes and get the gaskets positioned properly is to have the furnace lying front down on a flat surface.
IMPORTANT: To prevent harmful flue gases from entering the house, make sure NOT to trim air or vent tubes shorter than specified below.
1. Attach vent tube (Page 14, Figure 19 “B”) and gasket to the back of the furnace heat exchanger with (8) #8 x -inch sheet metal screws provided.
2. Attach air tube (Page 14, Figure 19 “A”) and gasket to the back of the furnace casting with (8) #8 x -inch sheet metal screws provided.
FIGURE 18 – WALL THICKNESS

SURFACE MOUNT

WALL WITH SIDING

Air inlet air tube A’ and vent tubeB’ are supplied in lengths to handle wall thickness up to 8½-inches.
To find the correct vent and air tube length, measure exact distance X’ between surface on which back of cabinet will rest (inside of recessed cavity or face of wall when freestanding and the outside wall surface). See Page 13, Figure 18 & Page 15, Figure 19. Inlet air tubeA’ Add -inch to dimension X’. Mark on tube starting from end with collar and holes. Cut off evenly. File off any burrs resulting. Vent tubeB’ – Add 2-inches to dimension `X’. Mark on tube starting from end with collar and holes. Cut off evenly. File off any burrs resulting.
CUT ONLY THE PLAIN END (WITHOUT THE FLANGE) OF THE TUBES. MAKE A SQUARE CUT TO THE EXACT LENGTH.
HELPFUL CUTTING HINT To make a straight cut, measure from the end and mark tube in several places. Align a piece of tape with the marks and wrap it around the tube. Use the edge of the tape as a guide to help keep the cut straight.

RECESSE MOUNT
BRICK VENEER
WALL
NOTE: Each tube must overlap the collars of the vent cap a minimum of 1¼- inches, which is obtained when tubes are cut correctly as previously described.

COUNTERFLOW DIRECT VENT GAS WALL HEATER 13

INSTALLING YOUR FURNACE

FIGURE 19 – VENT INSTALLATION

furnace), push it into place until the stops are contacted. If the stops prevent the mounting plate from reaching the wall, refer back to “DETERMINE PROPER LENGTHS” Page 13.
NOTE: The smaller tube in the vent cap must slide over the vent “B”.
5. Fasten the vent cap mounting plate to the wall with (4) 1½-inch wood screws “D” provided.
6. On masonry construction, drill into the wall and use plugs or anchors. Additional sealant (silicone) may be required if the mounting surface is uneven.
FIGURE 20 – FURNACE TRIM STRIPS

TOP VIEW OF FURNACE

DVCF60XD

DVCF40XD

TRIM STRIPS (2)

Trim
To conceal the space between the furnace and wall, use 4701 Trip Strip Package (not furnished with furnace), ¾-inch round or other wood trim.
TRIM COVER Place the trim cover on top of the furnace. See Page 14, Figure 20. Drill through the top casing flange and fasten each side with a sheet metal screw. This plate covers the space between the top of the furnace and wall opening after electrical connections are made.
MOUNT FURNACE THROUGH WALL Mount the furnace through the wall using surface or recessed mounting instructions. See Pages 11 – 15. Refer to Figure 19 for the following steps. 1. Check to see that the air tube protrudes through wall
7/8-inch min. to 1-inch max. for proper seal in vent cap. 2. Check to see that the vent tube protrudes past the air
tube 1/8 inch min. to ¼- inch max. for proper seal in vent cap. 3. Apply a single strip of mastic (“E” provided in the vent cap carton) continuously around the outer edge of the vent cap mounting plate. 4. Holding the vent cap in an upright position (embossed “top” on the mounting plate towards the top of the
14 COUNTERFLOW DIRECT VENT GAS WALL HEATER

TWO STRIPS ON EACH SIDE
Mounting Your Furnace
To obtain adequate clearance for fastening the furnace or to install gas supply fittings, it may be necessary to remove the burner and control assembly as follows:
CAUTION: Be careful not to damage burner pan gasket when removing burner and control assembly.
1. Lay the furnace on its back for the following steps. Remove burner compartment door by pulling the door top out and up.

MODELS: DVCF40XD, DVCF60XD
a. Remove the manual spark igniter and bracket by removing the (2) screws and disconnecting the wire at the back of the igniter.
b. Disconnect the two (2) slip-on connectors (24 volt wires) from the gas valve.
c. Remove the (3) screws A’ holding burner pan to the upper heating element support (Page 15, Figure 22). Rotate the burner toward the front until the (3) pinsB’ disengage from the upper heating element support slots.
d. Remove the burner and control assembly from furnace.
NOTE: Attach vent tubes BEFORE mounting the furnace. See Pages 13 & 14
2. If furnace is recessed in the wall, clear the recess of all debris. 3. Be sure the gas is shut off at the meter. 4. Before placing the furnace in position, remove the gas
piping stub if necessary to locate the furnace. 5. After installing the vent tubes, carefully move the
furnace into position, being sure not to bend the vent tubes.
FASTEN FURNACE BOTTOM (SURFACE AND RECESSED MOUNT)
NOTE: Fasteners are not furnished because of different requirements of various types of wall construction.
Fasten the furnace to the floor through the holes provided in the furnace bottom. If you have concrete flooring, use an alternate fastening method. See Page 15, Figure 21
If the burner and control assembly were removed, replace them by reversing steps 1a through 1d.

FIGURE 21 – FURNACE MOUNTING FIGURE 22 – BURNER PAN

IMPORTANT: When replacing the burner and control assembly, be sure that pins “B” all enter the slots in the upper heating element support. To prevent damage to wiring, be careful not to pinch them between furnace components and route them away from the burner pan surface.

FIGURE 23 – IGNITION CONTROL

FASTEN FURNACE TOP (SURFACE MOUNTING) Fasten the furnace top to wall using two (2) metal anchors (packed in plastic bag with thermostat) by placing them over the back flange of the furnace top and screwing them to the wall. Refer to Figure 21.
FASTEN FURNACE TOP (RECESSED MOUNTING) Fasten the furnace top by drilling two (2) holes through the side flanges of the furnace top and securing it with two (2) screws or nails into the wall studs. Refer to Figure 21.

CAUTION: Be careful not to damage furnace components or wiring when drilling holes.

COUNTERFLOW DIRECT VENT GAS WALL HEATER 15

INSTALLING YOUR FURNACE

Gas Supply and Piping
Gas control valve, within the furnace, is shipped with a seal over the gas inlet tapping. Do not remove seal until ready to connect piping.

FIGURE 24 – LEFT SIDE GAS INLET

WARNING: Danger of property damage, bodily injury or death. Make sure the furnace is equipped to operate on the type of gas available. Models designated as natural gas are to be used with natural gas only. Furnace designated for use with liquefied petroleum propane gas rate orifices sized for commercially pure propane gas. They cannot be used with butane or a mixture of butane and propane.

GAS SUPPLY For Natural gas, the minimum inlet gas supply pressure for the purpose of input adjustment is 5″ water column. The Maximum inlet gas supply pressure is 7″ water column.
For propane gas, the minimum inlet gas supply pressure for the purpose of input adjustment is 11″ water column. The maximum inlet gas supply pressure is 13″ water column.
Gas pressure and input to the burners must not exceed the rated input and pressure shown on the rating plate. On Natural Gas the manifold pressure should be 4 inches water column. The manifold pressure should be 10.5 inches water column for propaned gas. See page 19 for operation above 2,000 feet altitude. Orifice change may be required to suit gas supplied. Check with your local gas supplier.
ORIFICE SIZES Furnace Technical Information, page 23, shows the correct orifice sizes for the different input ratings when using Natural or propane gas.
GAS PIPING The gas supply line must be of adequate size to handle the BTU/hr. requirements and length of the run for the unit being installed.
Determine the minimum pipe size from Page 16, Figure 24, basing the length of the run from the gas meter or source to the unit.
All piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.1), whichever applies. In Canada: Follow CAN 1(B149 Installation Code.
Refer to Page 15, Figure 21, for the general layout at the unit. It shows the basic fittings needed.

FIGURE 25 ­ PROPER PIPING PRACTICE
2 THREADS EXPOSED

PROPER PIPE THREADING

SEALANT THIN ENOUGH TO SHOW
THREADS

DAMAGED THREADS

SEALANT PAST TIP

INCORRECT THREADING

SEALANT OVER THREADED TOO THICK

16 COUNTERFLOW DIRECT VENT GAS WALL HEATER

The following rules apply: 1. Use new, properly reamed pipe free from metal chips
and debris such as steel or black iron pipe. Use fittings approved by local codes. 2. Do not thread pipe too far. Valve distortion or mal function may result from excess pipe within control. Apply moderate amount of good quality dope to pipe only, leaving 2 end threads bare. If propane gas installation, use compound resistant to action of liquefied petroleum gases. 3. Use ground joint unions. 4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. Drip leg must be a minimum of 3 inches long. 5. Install a manual shut-off valve. 6. Provide a 1/8″ NPT test gauge connection immediately before the gas supply connection to the furnace.
GAS CONNECTION If installation is for propane gas, have propane gas installer use two-stage regulation and make all connections from storage tank to furnace. Use two pipe wrenches when making the connection to the valve to prevent turning or damage to gas valve.
Connections between the manual shutoff valve and burner control assembly can be made with an A.G.A. / C.G.A. design certified flexible connector if allowed by local codes. Drip leg and ground joint unions are still required.
Tighten all joints securely.
CHECKING THE GAS PIPING Test all piping for leaks. When checking gas piping to the furnace with gas pressure less than 1/2 PSI, shut off manual gas valve to the furnace. If gas piping is to be checked with the pressure at or above 1/2 PSI, the furnace and manual shut off valve must be disconnected during testing. (SEE WARNING.) Apply soap solution to each joint. Bubbles forming indicate a leak. Correct even the slightest leak at once.

FIGURE 26 – GAS PIPE SIZES

PIPE CAPACITY – BTU/hr. WITH FITTINGS

LENGTH OF PIPE
FEET

NATURAL GAS PIPE CAPACITY BTU/hr.

PIPE SIZE (INCLUDES FITTINGS)

1/2″

3/4″

1″

20

92,000

40

63,000

60

50,000

190,000 130,000 105,000

350,000 245,000 195,000

LENGTH OF PIPE
FEET

PROPANE PIPE CAPACITY BTU/hr.

PIPE SIZE (INCLUDES FITTINGS)

1/2″

3/4″

1″

20

189,000

40

129,000

60

103,000

393,000 267,000 217,000

732,000 504,000 409,000

Electrical Wiring
WARNING: Danger of property damage, bodily injury or death. Turn off electric power at the fuse box or service panel before making any electrical connections. Insulate where necessary. All line voltage and ground connections must be completed before electrical power is restored.
All electrical work must conform to your local codes and ordinances or in their absence, with National Electrical Code, ANSI/NFPA 70. If you are not familiar with wiring codes, in general, have a competent electrician do this job. In Canada: Follow C22.1, Canadian Electrical Code.

WARNING: Danger of property damage, bodily injury or loss of life. Never use a match or open flame to test for leaks. Never exceed specified pressures for testing. High pressures may damage the gas valve and cause over-firing which may result in heat exchanger failure. Liquid petroleum (propane gas) is heavier than air and it will settle in any low area, including open depressions and it will remain there unless area is ventilated. Never attempt startup of unit before thoroughly ventilating area.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
CAUTION: Do not connect 115V service line to the gas control valve or wall thermostat.
ELECTRICAL CONNECTION Refer to paragraph covering GAS AND ELECTRICAL SUPPLY OPENINGS, Page 10. Follow Wiring Diagrams, Pages 26.
If you have any doubt regarding the electrical hookup, or compliance with code or ordinance, consult your electrical inspector or a licensed electrician.
COUNTERFLOW DIRECT VENT GAS WALL HEATER 17

INSTALLING YOUR FURNACE

HELPFUL HINT After wire nuts are screwed to wires, a small strip of electrical tape can be applied over wire nut at its base and onto wires to make a very solid connection.

GROUNDING The appliance when installed must be electrically grounded in accordance with local codes and ordinances or in their absence, with National Electrical Code (ANSI/ NFPA 70) or Canadian Electrical Code (CSA C22.1) if an external electrical source is utilized. This appliance is equipped with three- prong (grounding) plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug. A ground lug is installed for the ground connection. Use a copper conductor (#AWG) from the unit to a grounded connection in the electric service panel or a properly driven and electrically grounded ground rod.

ELECTRICAL POWER SUPPLY Remove three-prong (grounding) service cord from the envelope parts package to be installed in the furnace. Remove 7/8 inch diameter (22mm) knockout at the left or right bottom side panel to route the three-prong service cord to an electrical outlet. 1. Insert the nylon cap attached to the end of the three-
prong service cord thru the 7/8-inch diameter knockout into the burner control assembly area and insert it into the nylon plug attached to the outer casing bottom. If desired, you may route the thermostat wire alongside of the service cord and thru the same opening or choose another entry into the burner control assembly area. 2. Attach 7/8-inch diameter strain relief around the threeprong service cord and thermostat wire (if thermostat wire is routed thru the knockout). Insert the 7/8-inch strain relief into the 7/8-inch hole in the side panel of furnace.

REPLACEMENT PART LISTING:

DESCRIPTION Service cord

PART NUMBER P323335

top of furnace, using two wire nuts provided. See Wiring Diagrams on Pages 26. Refer to Page 12, Figure 16 also.
Replace the fan to the original position on the motor shaft, and tighten securely. Replace the fan shroud, making sure it is centered vertically on the fan.
Tighten the screws securely.
Replace the top front panel and secure with thumbscrew.
COMPLETE WIRING DIAGRAMS ON PAGES 26.

WARNING: Do not insert the three-prong (grounding) service cord inside the burner control assembly area more than 10 inches (245mm). This could cause damage to the electrical cord resulting in electrical shock hazard and/or fire.

A branch circuit including this furnace must not exceed 15 Amperes. Run a separate 115V, 60Hz. 15 Ampere circuit from a separate circuit breaker or fuse in your service panel.
WALL THERMOSTAT WIRING Run thermostat wire to the furnace. Connect thermostat to the two wires marked “Thermostat” extending from
18 COUNTERFLOW DIRECT VENT GAS WALL HEATER

START UP PROCEDURE

Start the furnace using the procedures in the section “OPERATING YOUR FURNACE”.

WARNING: Danger of bodily injury or death. Liquefied petroleum gas (L.P. Gas) is heavier than air and it will settle in any low area, including open depressions and it will remain there unless the area is ventilated. Never attempt to start-up the unit before thoroughly ventilating area.

Check the furnace operation as outlined in the following instructions. If any sparking, odors or unusual noises are encountered, shut off electric power immediately. Recheck for wiring errors or obstructions in or near fan motor.

CHECK GAS INPUT AND PRESSURES For furnaces located at elevations between sea level and 2,000 feet, the measured input must not be greater than the input shown on the rating plate of the furnace. For elevations above 2,000 feet, the measured input must not exceed the input on the rating plate reduced by 4 percent for each 1,000 feet that the furnace is above sea level.

The gas supply pressure and manifold pressure with the burners operating is specified on the rating plate.

TYPE OF GAS

MANIFOLD PRESSURE, IN. W.C.

NATURAL

4.0

PROPANE

10.0

Rated input will be obtained on a heating value of 2,500 BTU/hr. for propane at 10-inches manifold pressure with factory-sized orifices. If L.P. Gas having a different heating value is supplied, orifices must be changed by a qualified service technician before the furnace is operated.

CHECK THERMOSTAT Check thermostat operation. When set above room temperature shown on the thermostat, the main burner should light. Make certain the thermostat turns off the furnace when the room temperature reaches the selected setting and starts the furnace when room temperature falls a few degrees.

ADJUST PILOT BURNER PiIot fIame should surround 5/8-inch to 1/2-inch of the thermocouple tip. To adjust, remove the cap from the pilot adjustment screw on gas valve. Turn screw counterclockwise to increase the flame, clockwise to decrease. Replace cap. Refer to Page 23, Figure 30.

CHECK THE MANIFOLD GAS PRESSURE A tapped opening is provided in the gas valve to facilitate measuring the manifold gas pressure. A “U Tube” manometer having a scale range from 0 to 12-inches of water should be used for this measurement. The manifold pressure must be measured with the burner and pilot operating. Any major changes in flow must be made by

changing the size of the burner orifice.
Check with your local gas supplier for proper orifice sizing.
CHECK THE GAS INPUT (NATURAL GAS ONLY)
WARNING: Natural gas heating value (Btu per cubic foot) can vary significantly. Therefore, it is the installer’s responsibility to see that Btu/hr. input to the furnace is adjusted properly. Failure to do so could cause combustion chamber failure, asphyxiation, fire or explosion resulting in damage, bodily injury or death. Refer to the National Fuel Gas Code (NFPA 54) to be sure the furnace is burning fuel at the proper rate.
Under firing could cause inadequate heat, excessive condensation or ignition problems. Over firing could cause sooting, flame impingement or overheating of the heat exchanger.
Before starting natural gas input check, obtain heating value of gas (BTU per cubic foot) at standard conditions from your local supplier. This factor is used in “Check the Gas Input” section and procedure.
To measure the input, using the gas meter, proceed as follows: 1. Turn off gas supply to all other appliances except
the furnace. 2. With the furnace operating, time the smallest dial on
the meter for one complete revolution. If this is a 2-cubic-foot dial, divide the seconds by 2. If it is a 1-cubic-foot dial, use the time in seconds as is. This gives the seconds per cubic foot of gas being delivered to the furnace. 3. Assuming natural gas with a heating value of 1,000 BTUper cubic foot and 34-seconds per cubic foot used as determined by step (2), then:
Seconds per hour = 3,600 Input = 1,000 x 3,600 / 34 = 106,000 Btu/hr. This measured input must not be greater than the input indicated on the nameplate of the furnace. 4. Relight all other appliances turned off in Step 1 above. Be sure all pilots are operating.
FIGURE 27 – THERMOSTAT
INDICATOR LOWEST SETTIG
COUNTERFLOW DIRECT VENT GAS WALL HEATER 19

OPERATING YOUR FURNACE

WARNING: Danger of bodily injury or death. Liquefied petroleum L.P. Gas is heavier than air and it will settle in any low area, including open depressions and it will remain there unless the area is ventilated.
NOTE: For models equipped with Cozy gas valve P322041 or P322042 refer to this pages 20-21 for “SAFETY & LIGHTING INSTRUCTION” and “TURN GAS OFF TO APPLIANCE.”
For models equipped with Cozy gas valve P321704 or P321705 refer to this page and Page 23 for “SAFETY & LIGHTING INSTRUCTIONS” and “TURN GAS OFF TO APPLIANCE.”
These furnaces are equipped with a manually operated Piezo spark igniter device to ignite the pilot gas. Follow the steps under “Lighting Instructions” (see Page 21) and use the manual spark igniter to light the pilot in Step 10. Press spark igniter button vigorously and repeatedly.
On new installations, the gas lines will be filled with air and it may take several minutes to establish the pilot flame.
Keep all access doors and panels in place except for inspection and maintenance.
WARNING: The surface of the furnace is hot during operation. Keep children, clothing, furniture, and flammable material away from it. Do not store or use gasoline or other flammable liquids or vapors near the furnace.
SAFETY CONTROLS These furnace are protected against unsafe operation by four automatic safety controls: (1) A safety pilot acts to shut OFF the gas valve in case of pilot failure; (2) A redundant gas valve; (3) A limit switch shuts down the main burner to prevent overheating the furnace cabinet; this limit switch wilt reset when furnace cools; and (4) A thermal overload protects the motor against burnout caused by current surges or if anything should block the flow of air through the furnace. This switch will reset itself when the motor cools down and it cannot be adjusted.
WARNING: Danger of bodily injury or death. Do not operate the furnace with a broken or missing pilot observation door.

FOR MODELS EQUIPPED WITH COZY GAS VALVE P321704 OR P321705. Models are equipped with a two-rate control valve. The rate knob on the gas valve is marked “LO” and “HI.” Turn the rate knob to the “LO” position and the room thermostat will operate the main burner at about 70% of maximum capacity. Turn the rate knob to the “HI” position only when a fast heat-up is desired during extremely cold weather. High operation develops maximum capacity of the furnace.
A TWO-SPEED FAN IS USED WITH MODELS DVCF60XD.
Blower will operate at low speed then shift to high speed as the furnace heats up.
WARNING: Danger of property damage. Bodily injury or death. If the furnace overheats or fails to shut off, turn off the manual gas valve to the furnace before turning off the electric power.
For your SAFETY, read before lighting
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these Instructions exactly.
B. BEFORE LIGHTING smell 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 or strike a match. · 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 turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

20 COUNTERFLOW DIRECT VENT GAS WALL HEATER

NOTE: FOR ADDITIONAL INFORMATION REFER TO THE INSTALLATION AND OPERATION INSTRUCTION MANUAL SUPPLIED WITH THIS APPLIANCE OR CONTACT THE MANUFACTURER IDENTIFYING THE PRODUCT BY ITS MODEL NUMBER LOCATED ON THE RATING PLATE, FOUND NEAR THE GAS VALVE.
Lighting Instructions
1. STOP! Read the safety information above. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. Remove control access panel. 5. Turn the gas control knob clockwise to “OFF”.

6. Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor. If you then smell gas, stop! Follow “B” In the safety information above. If you don’t smell gas, go to the next step.
7. Loosen wing nut and open pilot observation door (If equipped).
8. To find the pilot, follow the metal tube from the gas control valve. The pilot is mounted on the side of the burner.
9. Turn knob on gas control counterclockwise to “PILOT.”
10. Push in the red reset button all the way and hold in. Immediately light the pilot. Continue to hold the red reset button in for about (1) minute after the pilot is lit. Release button and it will pop back up. Pilot should remain lit. If it goes out, repeat steps 5 through 10.
· If button does not pop up when released, stop and immediately call your service technician or gas supplier.
· If the pilot will not stay lit after several tries, turn the gas control knob to “OFF” and call your service technician or gas supplier.
11. Close the pilot observation door and tighten wing nut (if equipped).
12. Turn gas control knob counterclockwise to “ON”. The knob can be turned to “ON” only if red reset button is up.
13. Replace the control access panel. 14. Turn on all electric power to the appliance. 15. Set thermostat to the desired setting.

To Turn OFF GAS to appliance
1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance if service is
to be performed (if applicable). 3. Remove the control access panel. 4. Push in the gas control knob slightly and turn it
clockwise to “OFF”. Do not force. 5. Replace the control access panel.
IMPORTANT: KEEP BURNER AND CONTROL COMPARTMENT CLEAN.
WARNING: DUE TO HIGH SURFACE TEMPERATURES – KEEP CHILDREN, CLOTHING, FURNITURE OR ANY COMBUSTIBLE MATERIAL AWAY FROM THE FURNACE.

COUNTERFLOW DIRECT VENT GAS WALL HEATER 21

CARING FOR YOUR FURNACE

How To Care For Your Furnace
WARNING: Danger of bodily injury or death. Turn off electric power supply at the disconnect switch, fuse box or service panel before removing any doors or access or service panels from the unit.
CABINET FINISH Clean the cabinet with damp rag. Never use abrasive cleaners. Cabinets are finished in heat resistant powder coated finish DO NOT refinish with wall paint.
COMBUSTION AND VENTILATION AIR he combustion and ventilation air supply must not be blocked.
Do not put anything in or on the furnace cabinet.
For better circulation and more effective heating, do not place obstructive furniture closer than four feet to the front of the cabinet or two feet to either side of the cabinet.

ADJUST PILOT BURNER (Page 23 Figure 30) 1. Remove screw cover over pilot adjusting screw. 2. Insert small screwdriver, adjust flame as needed.
Turn screw counterclockwise to increase flame, clockwise to decrease. 3. Turn thermostat to highest setting. Main burners should light quickly and smoothly. Turn thermostat to lowest setting. Main burners should go out. Pilot should remain lit.
BURNER FLAME Start the furnace and let it operate about 10 minutes then look at the burner flame. Flames should be soft and blue, see Figure 30. If flames appear abnormal, contact the gas company or a qualified service technician immediately.
VENTING SYSTEM Make sure that no parts of the vent air system are blocked or rusted. Clean or replace before using furnace.
FIGURE 29 – MAIN BURNER FLAME PATTERN

FURNACE AREA Keep the area near the furnace clear and free from combustible materials, gasoline, and other flammable liquids and vapors.

ANNUAL UPKEEP NEEDED It is recommended that a qualified service technician perform these checks at the beginning of each heating season.

CLEANING AND OILING Shut off electricity, and then remove cabinet door and front panel. Clean any lint or dirt from fan blades, fan motor, and exposed air passages. Use a brush.

Put 5 drops of SAE 20 oil in each of the two cups or oil tubes on the fan motor, See Figure 36, below.

FIGURE 28 – MOTOR OIL HOLES

PILOT BURNER Light pilot using instructions in OPERATING YOUR FURNACE (on pages 21). Leave thermostat at lowest setting.
Pilot flame should surround 3/8 to 1/2 inch of the thermocouple tip. Refer to Figure 30, Page 23. If flame needs adjusting, do it as follows:
22 COUNTERFLOW DIRECT VENT GAS WALL HEATER

BURNER CLEANING Check burner. If cleaning is required, contact a qualified service technician to clean and service burner.

FIGURE 30 – PILOT FLAME & SPARK GAP

WARNING: Danger of bodily injury or death. Make sure electric power and gas supply are off before removing panels or doors, etc.

CLEANING BURNER COMPARTMENT Because cold air is attracted to the flame during furnace operation, a build up of lint from bedding and dust, etc., in the burner area will occur each heating season. It is necessary to clean this area regularly. Use a vacuum cleaner with a narrow attachment to reach small areas. Be careful in and around the pilot. A change in its adjustment could be made if struck during cleaning.

PROPANE GAS
FLAME

WARNING: A BUILDUP OF ANY DUST, LINT OR FOREIGN MATERIAL IN THE PRIMARY AIR OPENING OF THE BURNER CAN INTERFERE WITH THE PROPER AIR GAS MIXTURE AND GAN RESULT IN A YELLOW FLAME WHICH CAN PRODUCE CARBON MONOXIDE AND SOOT. THIS CONDITION, IF ALLOWED TO DEVELOP, CAN LEAD TO BODILY INJURY INCLUDING DEATH. IT IS IMPERATIVE THAT THE BURNER(S) BE KEPT GLEAN.

Disconnect the gas line inside the cabinet.
Remove three screws from the front of the combustion chamber bottom panel and drop the assembly down. Clean inside the combustion chamber and the burner with a shop type vacuum cleaner.
To remove burners remove screw from the end of the burner and slide the burner out of its bracket (it may be necessary to slightly spring the bracket).
Inspect the Burner Box gasket. Replace if damaged.
Replace burner assembly and control assembly by reversing the above procedures.
Check the spark gap. It must be carefully adjusted to specifications, as illustrated (Figure 30), for the ignition device to function properly.

MODEL 7728 7732

GAS CONVERSION KITS NATURAL GAS TO PROPANE GAS
DESCRIPTION DVCF40XD DVCF60XD

FURNACE TECHNICAL INFORMATION

MODEL NUMBER

GAS TPE

INPUT** RATING BTU/hr.

DVCF402D NATURAL 40,000

DVCF401D PROPANE 40,000

DVCF602D NATURAL 60,000

DVCF601D PROPANE 60,000

MAIN BURNER ORIFICE

DRILL #32 #48 #38 N/A

DEC. .1160 .0760 .1010 .0640

QTY. 1 1 2 2

The efficiency rating of these appliances is a product of a thermal efficiency rating system determined under continuous operating conditions and was determined independently of any installed system.
For elevations above 2,000 feet reduce ratings 4% for each 1,000 feet above sea level.
BTU/hr. = British Thermal Units per hour.

MODEL 7729 7733

GAS CONVERSION KITS PROPANE NATURAL GAS
DESCRIPTION DVCF40XD DVCF60XD

COUNTERFLOW DIRECT VENT GAS WALL HEATER 23

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 back-up 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 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”.

24 COUNTERFLOW DIRECT VENT GAS WALL HEATER

HARDWIRE ACCESSORY 9940

Installation Instructions:
DVCF401D/ DVCF402D/ DVCF601D/ DVCF602D
WARNING: Danger of bodily injury. Turn off electric power supply at disconnect switch, fuse box or service panel before working on the furnace.
SUMMARY: This accessory converts Cozy Counterflow furnaces using the electric service cord provided, to a hardwired, permanent electrical connection. If this furnace is equipped or has been previously installed and operated using the service power cord, disconnect the

cord at the receptacle connector located at the base of the furnace and remove the cord completely from the furnace.
Following the wiring diagram below, make all the necessary wiring connections from an outside electrical source. All electrical work must conform to your local codes and ordinances or in their absence, with National Electrical Code, ANSI/NFPA 70 or in Canada, Canadian Electrical Code C22.1. If you are not familiar with wiring codes in general, have a competent electrician do this job. Be sure this accessory is of the type and design required for use with your furnace.
The DVCF40XD model series with a single speed motor is shown in the wiring diagram below. The required field wiring connections are applicable to all models listed above. For internal wiring connections to your model, refer to the wiring diagram attached to the furnace.

COUNTERFLOW DIRECT VENT GAS WALL HEATER 25

WIRING DIAGRAMS

MODELS – DVCF402D/ DVC401D

MODELS – DVCF602D/DVCF601D

26 COUNTERFLOW DIRECT VENT GAS WALL HEATER

FURNACE ASSEMBLY REPLACEMENT PARTS DVCF40XD MODELS

REF. NO.
1 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
Not Shown
Not Shown

NATURAL DVCF402D

MODEL NUMBERS

PROPANE DVCF401D

REPLACEMENT PART DESCRIPTION

DVCF402D

DVCF401D

Outer Casing with Air Pan Heating Element Element Tube Inner Liner Deflector Baffle Handle Fan Shroud Top Front Panel Center Front Panel Bottom Front Panel Element Face Cover Limit Switch Fan Switch Motor Motor Support (2 Req.) Transformer Internal Wires (except for 4007332 / 4007331) Vibration Isolator (4 Req.) Fan Blade Switch Box Switch Box Cover Observation Door Assembly Element Face Gasket Air Pan Tunnel Gasket Seal Gasket KIT Venting Kit KIT Side Outlet Kit KIT Side Casing Grille KIT Diffusing Grille – Two-Way KIT Diffusing Grille – One-Way Gasket, Burner Pan (2 Req.) Knob

11C42-2 11C67 11C37 11B46 11C63 11B86 11B102 11C62 11B117 11A103 P200300 P200200 P151101 7B46 P024200 11A152 P022800 P200600 11B05 11C68 12B40 P200900 P151900 P103100 9802 6701 6702 6703 6704 P321020 P332606

11C42-2 11C67 11C37 11B46 11C63 11B86 11B102 11C62 11B117 11A103 P200300 P200200 P151101 7B46 P024200 11A152 P022800 P200600 11B05 11C68 12B40 P200900 P151900 P103100 9802 6701 6702 6703 6704 P321020 P332606

Thermostat

78355

78355

COUNTERFLOW DIRECT VENT GAS WALL HEATER 27

EXPLODED VIEW & REPLACEMENT PARTS

25

15

17

16

14

18

6

13

3
1

22 10

24
4

7

2

19 11

23 12 20

8
21
5

9 29
28

26 27

28 COUNTERFLOW DIRECT VENT GAS WALL HEATER

CONTROL ASSEMBLY REPLACEMENT PARTS DVCF40XD MODELS

REF. NO.
1 2 3 4 5 6
7
8 9 10 11 12 13
NOT SHOWN

NATURAL DVCF402D

MODEL NUMBERS

REPLACEMENT PART DESCRIPTION

Manifold Manifold Gasket Orifice Fitting, Specify Model & Gas 50mm Burner Burner Pan Gas Valve Pilot, Natural Pilot, Propane Thermocouple Pilot Tube Gasket Pilot Tube Seal Gasket – 44 inch Piezo Gas Lighter Manifold Adapter Ignition Control Wires

PROPANE DVCF401D
DVCF402D
P323653 P151700 P090532 P323648 11B133 P323209 P323418
­­­ P254000 P151800
11A41 P101600 P285500 P321888
­­­

DVCF401D
P323653 P151700 P090548 P323648 11B133 P322042
­­­ P323419 P254000 P151800
11A41 P101600
­­­ P321887 31B036

3
1
2
5 14
6

4
8 7 11
9 10

13 12

COUNTERFLOW DIRECT VENT GAS WALL HEATER 29

FURNACE ASSEMBLY REPLACEMENT PARTS DVCF60XD MODELS

REF. NO.
1 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

NATURAL DVCF602D

MODEL NUMBERS

REPLACEMENT PART DESCRIPTION

Outer Casing with Air Pan Air Pan Tunnel Gasket Inner Liner Heating Element Observation Door Assembly Burner Pan Gasket (2 Req.) Bottom Front Panel Center Front Panel Bottom Air Deflector Center Air Deflector Selector Switch Fan Switch Switch Box Cover Switch Box Seal Gasket Element Baffle Limit Switch Top Air Deflector Top Front Panel Fan Shroud Element Face Gasket Fan Blade Motor Motor Support (2 Req.) Vibration Isolator (4 Req.) Transformer Internal Wires Element Tube KIT Venting Kit KIT Side Outlet Kit KIT Side Casing Grille

PROPANE DVCF601D
DVCF602D
11C42-1 P151900 11B120
11C66 12B40 P321020 11B103 11C59 11B123 11B119 P200400 P200200 11C68 11B05 P103100 11B116 P321942 11B119 11B102 11B86 P304000 P200600 P321601 7B46 P022800 P024200 6007732 11C37 9809 6701 6702

DVCF601D
11C42-1 P151900 11B120
11C66 12B40 P321020 11B103 11C59 11B123 11B119 P200400 P200200 11C68 11B05 P103100 11B116 P321942 11B119 11B102 11B86 P304000 P200600 P321601 7B46 P022800 P024200 6007731 11C37 9809 6701 6702

30 COUNTERFLOW DIRECT VENT GAS WALL HEATER

REF. NO.
32
Not Shown
Not Shown

REPLACEMENT PARTS DESCRIPTION KIT Diffusing Grille – Two-Way KIT Diffusing Grille – One-Way Knob Thermostat

DVCF602D 6703 6704
P332606 78355

DVCF601D 6703 6704
P332606 78355
29

26

28

25

27

23

22

24

1

20 21
16 18
19
17 14
13 11 12

15
4

3
2

8

5

10

9

7

6

30 31

32

COUNTERFLOW DIRECT VENT GAS WALL HEATER 31

CONTROL ASSEMBLY REPLACEMENT PARTS DVCF60XD MODELS

REF. NO.
1 2 3 4 5 6 7
8
9 10 11 12 13 14

NATURAL DVCF602D

MODEL NUMBERS

REPLACEMENT PARTS DESCRIPTION

Manifold Manifold Gasket Orifice Fitting, Specify Model & Gas (2) 50 mm Burner (With pilot bracket) 50 mm Burner (Without pilot bracket) Burner Pan Gas Valve Pilot, Natural Pilot, Propane Thermocouple Pilot Tube Gasket Pilot Tube Seal Gasket – 44 inch Piezo Gas Lighter Manifold Adapter

PROPANE DVCF601D
DVCF602D
P323654 P151700 P090538 P323648 P32649 11B156 P323209 P323418
­ P254000 P151800
11A41 P101600 P285500 P321888

DVCF601D
P323654 P151700 P332621 P323948 P323649 11B156 P322042
­ P323419 P254000 P151800
11A41 P101600 P285500 P321888

32 COUNTERFLOW DIRECT VENT GAS WALL HEATER

EXPLODED VIEW & REPLACEMENT PARTS

1

3

3

5
2

4
9 8

6
12
14

10

7

11

13

COUNTERFLOW DIRECT VENT GAS WALL HEATER 33

TROUBLESHOOTING YOUR FURNACE

ISSUE 1. Pilot will not stay lit
after following lighting instructions.
2. Main burner will not come ON – pilot burning and thermostat set for heat.

POSSIBLE CAUSE(S) A. Thermocouple producing
insufficient millivolts.
B. Loose or dirty thermocouple connection at gas valve.
C. Thermocouple defective.
D. Thermomagnet pilot safety defective
A. Gas valve not turned ON after lighting the pilot.
B. Electric power to furnace turned OFF.
C. Low voltage transformer or limit switch defective.
D. Wall thermostat defective.
E. Burner orifice plugged. F. Gas valve defective.

CORRECTIVE ACTION
Check pilot flame ­ it must impinge on the thermocouple. The pilot flame may be low or blowing (high) causing pilot to drop out. The pilot orifice or aerating hole may be plugged (check for spiders, webs or other organic material). Be sure the thermocouple is fully inserted in its bracket. Clean and/or tighten the thermocouple fitting at the connection to the valve.
Check thermocouple with millivolt meter ­ it should generate approximately 30 millivolts when not connected to a load. When connected to a load, it should generate approximately 14 millivolts. If below 7 millivolts, replace. Replace gas valve after above is checked out.
Turn gas valve knob to the “ON” position – if no main gas flow, proceed to Step. “B”.
Check for line voltage at furnace – if okay and no main gas flow, proceed to Step “C”. Check for 24 volts at the low voltage terminals of the transformer. If no voltage, turn OFF electric power to furnace. Remove one wire from the limit switch and check for continuity across both terminals. No continuity ­ replace the limit switch. With a good limit switch back in the circuit and the electric power turned ON – if no voltage, replace transformer. NOTE: Before replacing the transformer or limit switch, check wiring for loose connections or broken wires and repair as needed. If voltage is present at transformer, proceed to Step “D”. With thermostat set for heat (contacts closed) check for voltage at the terminals on gas valve. If no voltage is present replace defective thermostat. NOTE: Before replacing thermostat, be sure to check the wiring from the furnace to thermostat for loose connections or broken wires and replace as needed. If voltage is present at the terminals on gas valve and still no gas flow to main burners, proceed to Step “E”. Clean or replace the orifice – if okay and still no gas flow to main burners, proceed to Step “F”. Replace defective gas valve.

3. Burner comes “ON” but goes OFF before blower turns ON.

A. Defective wiring.

B. Defective limit switch. C. Defective motor (2-speed).

D. Defective motor (1-speed). E. Detective fan switch.

Turn OFF electric power to the furnace. Remove the top front panel, fan shroud and blower wheel. Refer to Wiring Diagram and check all wiring inside the junction box. Remove center front panel and check all wiring inside switch box containing fan, limit and selector switches. Correct if necessary. If correct, proceed to Step “B”. NOTE: Selector switch used only on Models DVCF60XD.
If the burner goes OFF in less than five minutes from room temperature start, check the limit control switch. If detective, replace. NOTE: Blower should turn “ON” within three minutes after burner is “ON” from a room temperature start. If not, proceed to Step “C”.
Jumper across the fan switch, turn electric power ON, the motor should rotate. If a 2-speed motor is used – jumper from “brown” terminal on the fan switch to

2 (red) terminal on the selector switch, motor should rotate on “LOW” speed.

Jumper from same “brown” terminal on the fan switch to #3 (black) terminal on the selector switch, motor should rotate on “HIGH” speed. Replace motor if defective.
Jumper across the fan switch, turn electric power ON, motor should rotate. Replace motor if detective.
If, after checking the above possibilities, problem still exists, replace the fan switch.

4. Burner comes “ON”, blower comes “ON”, but cycles “ON” and “OFF” while burner remains “ON”.

A. Furnace not operating at full rate.

34 COUNTERFLOW DIRECT VENT GAS WALL HEATER

Check for low gas pressure at gas valve – should be 4″ W.C. for Natural Gas, 11″ W.C. for L.P. Gas. Check burner orifice.
Check for high gas pressure at the gas valve – correct if necessary. See correct

ISSUE
5. Burner comes “ON”, blower comes “ON”, but burner cycles “OFF” and “ON” with blower “ON”.

POSSIBLE CAUSE(S)
A. Furnace operating over-rate. B. Line voltage too low. C. Recirculation.

CORRECTIVE ACTION
pressure above. Check line voltage to motor, if below 115 volts the motor will run too slow. Heated air discharging against an object causing recirculation, such as a hall installation or a large piece of furniture within 4′ of discharge.

6. Furnace operates but turns “OFF” before room temperature is attained.
7. Furnace operates but will bnot shut “OFF” when room temperature is attained.

A. Thermostat location. B. Defective thermostat.

Check location of the thermostat. It should not be in the path of warm air discharge from the furnace, near a lamp, or above a TV set or stereo.
Check the thermostat calibration or replace.

A. Thermostat wiring defective. B. Thermostat location.

Check the thermostat wiring from furnace to the thermostat – may be shorted together by a nail or staple.
Check thermostat location – if on an outside wall or there is a hole in wall behind the thermostat causing cold air to contact the thermostat, relocate the thermostat.

8. Abnormal operation.
9. Burner comes “ON” but goes “OFF” after operating for no apparent reason.

A. Blower noise.
B. Expansion noise ticking.
C. Selector switch defective (2-speed).
A. Vent tube and air inlet tube improperly installed.

Check the motor mounts – they may be loose. Fan blade could be out of balance. Set screw may be loose on the motor shaft. Blower may be rubbing on the fan shroud. Motor may need oiling. Correct as needed.
Check installation – casing may be twisted or not level when installed. Expansion slip joint may be binding; check by removing vent cap assembly from outside wall.
During normal furnace operation the motor will be on “LOW” speed when operating on minimum input capacity and on “HIGH” speed when operating at maximum input capacity. If there is no change in motor speed, replace the selector switch.
Check the vent tube and air inlet tube. Follow the installation instructions. Be sure joints are tight and both tubes are in place. Use only the vent tubes furnished. Do not extend tubes beyond their original length.

HINTS AND INFORMATION

If your furnace fails to work correctly, you may avoid the inconvenience and cost of a service call by checking the troubleshooting section on page 34-35 before you call for service.
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
DO NOT store or use gasoline or other flammable vapors and liquids in the vicinity or this or any other appliance.
HOW TO ORDER REPAIR PARTS When ordering repair parts, always give the following Information: 1. MODEL NUMBER 2. MFG. DATE CODE 3. PART NUMBER 4. PART DESCRIPTION

All parts listed herein may be ordered from your equipment supplier. The Model Number of your Cozy wall furnace will be found on the nameplate near gas valve, inside control compartment. WHAT TO DO IF YOU SMELL GAS · Open all of the windows. · Do not try to light any appliance. · Do not touch any electrical switch. · Do not use any phone or cell phone in your building. · Extinguish any open flame. · Immediately call your gas supplier from a neighbor’s
phone. 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.
COUNTERFLOW DIRECT VENT GAS WALL HEATER 35

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

P323925_RV 04/22

References

• p65warnings.ca.gov

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