COZY Furnace Wall Manual L0805260

User Manual: COZY COZY Furnace Wall Manual COZY Furnace Wall Owner's Manual, COZY Furnace Wall installation guides

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INSTALLATION AND

OPERATING INSTRUCTIONS

P/N 78111

REV. 05/03

MODEL NUMBERS

_.4VOLT SYSTEM NATURAL GAS CF353C-R CF503C-R CF653C-R

vVITH LOW-BTU

_ILOT L.P. GAS CF354C-R CF504R CF654C-R

_.4VOLT SYSTEM NATURAL GAS

_ITH INTERMITTENT

IGNITION (I.I.D.) L.P. GAS

CF357C-R

CF358C-R

CF557C-R

CF558C-R

This appliance is equipped

with a blocked flue switch

designed to protect against

improper venting of

combustion products.

THIS UNIT IS NOT TO

I WARNING: If the information in this manual is not followed exactly, a I

fire or explosion may result causing property damage, personal injury or I

loss of life.

Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in

your building. \

)_ Immediately call your gas supplier from a neighbor's phone.

Follow the gas supplier's instructions.

)_ If you cannot reach your gas supplier, call the fire department.

INSTALLATION AND SERVICE MUST BE PERFORMED

BY A QUALIFIED INSTALLER, SERVICE AGENCY OR BE INSTALLED IN

THE GAS SUPPLIER. MOBILE HOMES.

WARNING: Operation of this furnace when not connected to a properly installed and main-

tained 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 quali-

fied service person.

The coating selected to provide longer life to the heat exchanger may smoke slightly upon initial firing Please

)rovide adequate ventilation if this occurs.

This unit is not approved for installation in mobile homes, greenhouses, or environments involving dusK, wet, corrosive,

or explosive conditions. Such conditions _411invalidate the warran D"and may create unsafe conditions.

CONTENTS

Contents.............................................................. 2

Introduction ................................................. 2

Specifications ............................................... 2

Safety Rules ................................................ 3

Helpful Installation hR'onnation ............................... 3

Connecting the Vent............................................. 3,4

Combustion and Ventilation Air...................................... 5

Furnace Location................................................ 6

Rough-In Instructions ......................................... 6,7

Installation......................................................... 8

Controls............................................................. 9

Pilot Flmne Adjustment......................................... 9

Lighting & Re-Lighting Instructions .................... 10,11

Operation......................................................... 12

TerminalBlock Wiring Diammn ............................. 13

MmmalReset................................................... 13

Maintenance Instructions .................................. 13

WS-illgDiagrmn................................................. 14,15

Side & Rear Discharge Kits ................................. 16,17

Trouble Shooting Chart..................................... 18,19

Repair Parts (break down) .................................. 20-24

RepairPartsList............................................... 21-25

Whrranty......................................................... 27

IINSTALLER MUST LEAVE THESE INSTRUCTIONS WITH THE CONSUMER, HAVE THEM I

COMPLETE, AND RETURN THE WARRANTY CARD. I

INTRODUCTION

THIS IS A GAS-FIRED, GRAVITY VENTED WALL FURNACE THAT WILL OPERATE SAFELY AND PROVIDE AN

EFFICIENT SOURCE OF HEAT WHEN INSTALLED, OPERATED AND MAINTAINED AS RECOMMENDED IN THESE

INSTALLATION AND OPERATING INSTRUCTIONS. READ THESE INSTRUCTIONS THOROUGHLY BEFORE

INSTALLING, SERVICING, OR USING THE APPLIANCE. IF YOU DO NOT UNDERSTAND ANY PART OF THESE

INSTRUCTIONS CONSULT LOCAL AUTHORITIES, OTHER QUALIFIED INSTALLERS, SERVICE AGENCIES, THE

GAS SUPPLIER, OR THE MANUFACTURER.

COUNTERFLOW WALL FURNACE SPECIFICATIONS

Your counterflow wall furnace is packed in a single carton that also includes thermostat, thermostat wire, and insulated staples.

The thermostat, wire, and staples are packed in the burner compartment and are accessible by removing the burner access door.

While the burner access door is open, check the rating plate to verify that the model number is correct and that the wall furnace

is equipped t\_rthe type gas you intend to use.

Vent Approx.

Model Type Type BTUAtR. Size Gas Blower Shipping

Number Control Gas Innut (OvaB Inlet Finished Dimensions Speed Amos CFM Weight

MODELS WITH LOW-BTU STANDING PILOT

CF353C 24Volt Nat. 35,000 4" ½" 14-5/16"Wx10¼"Dx78-5/8"H 1 1.95 320 95 Lbs.

CF354C 24Volt L.R 35,000 4" ½" 14-5/16"Wx10¼"Dx78-5/8"H 1 1.95 320 95 Lbs.

CF503C 24Volt Nat. 50,000 4" ½" 14-5/16"Wx10¼"Dx81-5/16"H 2 2.25 440 104Lbs.

CF504C 24Volt L.R 50,000 4" ½" 14-5/16"Wx10¼"Dx81-5/16"H 2 2.25 440 104Lbs.

CF653C 24Volt Nat. 65,000 4" ½" 14-5/16"Wx10¼"Dx87-5/16"H 2 2.25 440 107Lbs.

CF654C 24M)lt L.R 65,000 4" ½" 14-5/16"Wx10¼"Dx87-5/16"H 2 2.25 440 1071bs.

MODELS WITH INTERMITTENT IGNITION

CF357C 24Vott Nat. 35,000 4" ½" 14-5/16"Wx10¼"Dx78-5/8"H 1 2.2 320 95 Lbs.

CF358C 24Volt L.R 35,000 4" ½" 14-5/16"Wx10¼"Dx78-5/8"H 1 2.25 320 95Lbs.

CF557C 24Volt Nat. 55,000 4" ½" 14-5/16"Wx10¼"Dx87-5/16"H 2 2.5 440 107Lbs.

CF558C 24Volt L.R 55,000 4" ½" 14-5/16"Wx10¼"Dx87-5/16"H 2 2.55 440 107Lbs.

Page 2

10.

11.

12.

13.

14.

SAFETY RULES

hnproper installation, adjustment, alteration, service or maintenance can cause property damage, bodily injury or death. If you

do not understand these instructions or your local codes, call local authorities, a qualified installer, selMce agency, gas supplier,

or the manufacturer.

Do not install this fan type wall furnace in a recreational vehicle trailer or mobile home.

Do not operate this fan type wall furnace unless it is connected to a properly installed and maintained vent system. Do not

exhaust flue gases into the room, watt or attic space for any reason.

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

front outlet grill is installed.

Adequate air for combustion and venting must be provided.

If rising water may enter the wall furnace, turn offthe gas immediately and disconnect the electric service. Do not use the wall

furnace if any part has been under water, hmnediately call a qualified service technician to inspect the walt furnace and to replace

any part of the control system or any gas control which has been under water.

Have your fan type wall furnace and vent system inspected at least annually by a qualified service agency.

Before cleaning or servicing the wall furnace, turn offthe gas and allow it to cool. This will prevent burns.

Due to high temperamres_ the furnace should be located out of traffic and away from furniture and draperies.

Children and adults should be alerted to the hazards of hi2h surface temperatures and should stay away to avoid bums or

clothing imfition.

Youn2 children should be carefully supelMsed when they are in the same room as the furnace.

Clothina or other flammable material should not be placed on or near the furnace.

Any safety screen guard or gill removed for servicin_ must be replaced prior to operating the furnace.

Locate the blocked flue switch and the auxiliary limit switch and push in the reset button. This will reset the switch in case it

accidentally opened during shipping.

READ CAREFULLY BEFORE INSTALLING UNIT

These installation instructions are a general guide, and do not supersede applicable local codes and ordinances. Belbre planning or

making the installation, be sure it complies with all phases of the local heating code. Or, in the absence oflocat codes, the latest edition of

the National Fuel Gas Code, ANSI.Z223.1. In Canada, see latest edition of CAN1-B 149.

The appliance, when installed must be electrically grounded in accordance with local codes or, in the absence of local codes, the latest

edition of the National Electrical Code, ANSI/NFPA No. 70. In Canada, see latest edition of CSA C22.1.

The ANSI standards are available from the American Gas Association, 1515 Wilson Blvd., Arlington, Virginia 22209.

The NFPA standards are available from the National Fire Protection Association, Batterymarch Park, Quincy, MA. 02269. Canadian

standards are available from International Approval Services, 178 Rexdale Blvd., Etobicoke, Ontario, Canada M9W 1R3.

VENTING

This appliance must be properly connected to a venting system. Consult local ordinances governing venting. Install only UL listed type

BW 4" oval gas vent. When the vent enters the attic, a listed type B-1 round flue pipe may be used. See Figure 1, Page 4.

Vent pipe must connect to the wall furnace or header plate with a "B" vent base plate and terminate with a cap at a point at least 12 it. above

the bottom of the wall furnace and two feet above any obstacle within a 10 lbot radius and at least 3 foot above the roof.

Provisions must be made lbr adequate combustion and ventilation air. This appliance must not be connected to a chimney flue serving a

separate solid fuel burning appliance.

All type "B" vents shall extend in a generally vertical direction with oft;ets 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 mn of a vent plus the horizontal vent

connector shall be not greater than 75 percent of the vertical height of the vent. Any oft;ets used should be as far above the drafthood as

possible to allow a venting action to begin belbre any restriction is encountered.

Page 3

than 10'

_,,__ 2 Min. '1 :

Chimney-- I

Height above any

roof surface

within 10'

horizontally

3' Min.

VENTING- CONTINUED

FIGURE A

This appliance is equipped with a blocked flue switch.

WARNING: Do not bypass the blocked flue switch. To

do so could expose the consumer to property damage,

personal injury or possible death.

This switch, when activated, will interrupt the electrical circuit between

the transforlner and the gas valve causing the main burner flame to

extin_ish. The main burner will not re-light until the blocked flue switch

has been manually reset. To reset the switch, after locating it between

the bottom of the tan shroud and the top of the draft diverter, simply

push the red button on top of the switch. If the homeowner experiences

this problem, then the vent system must be checked and corrected.

NOTE: An existing vent that has worked for years may not be adequate

t\_r today's appliances because of higher efficiency requirements that

result in lower stack temperatures.

WARNING: Operation of this wall furnace when not connected to a

properly installed and lnaintained venting system or tampering with

the blocked flue switch can result in Carbon Monoxide (CO)

poisoning and possible death.

(SEE LIST OF POSSIBLE CAUSES AND CORRECTIONS ON PAGE 19).

All type "B" vents shall extend in a generally vertical

direction with oft;ets not exceeding 45 degrees, except

that a vent system having not more than one 60 degree

oft_et may be allowed.

Any angle greater than 45 de_ees from the vertical is

considered horizontal. The totalhorizontalrun ofavent

plus the horizontal vent connector shall be not greater

than 75 percent of the vertical height of the vent.

Any oft;ets used should be as tar above the drafthood as

possible to allow a venting action to begin before any

restriction is encountered.

12'

Min.

3' 2' Min.

Ceilin_

Plate

Spacer

Lances

FIG. 1 - VENT INSTALLATION

Draft Diverter

Relief Opening

"CF35" Series Counterflow

Page 4

Listed

Top

Collar

Oval to round

Listed "BW"

Pipe

Plate

Walt

Stud

Red

/Button

Blocked

_Flue

Switch

Draft Diverter

Relief Opening

Red

/Button

Blocked

_Flue

Switch

"CF50'55 65" Series Counterflow

COMBUSTION AND VENTILATION AIR

When installed, this gas appliance must be provided with fiesh

air for combustion, ventilation, and dilution of hot flue gases.

The minimum required volume of the area where the appliance is

installed should be 50 cubic feet per 1,000 btu/hr.

If installed in an area of the home that is considered an unconfined

space, the natural infiltration of air around windows and doors

will be adequate. If the area is considered a confined space (tess

than 50 cubic feet per 1,000 btu), fiesh air can be supplied by

providing two permanent openings into adjoining rooms. Each

opening shall have a minilnum tree area of one square inch per

1,000 btu per horn of the total input rating of all gas appliances in

the confined space, but not less than 100 square inches. One of

the openings shall be within 12 inches of the ceiling and one

within 12 inches of the floor. See Figure A.

Ifthe home is of unusually tight construction (new and remodeled

homes), free air must be supplied through opening(s) to the

outdoors. This can be accomplished by providing 2 permanent

openings, one commencing within 12 inches of the ceiling and

one within 12 inches of the floor. These openings shall

communicate directly with the outdoors, or spaces that

comlnunicate freely with the outdoors, such as a ventilated attic

and crawl space through galvanized or equivalent conosion-

resistant ducts. Exception: unobstructed stud and joist spaces

are acceptable ducts provided that not more than one fire block

is removed. Special provisions must be taken to insure that

these stud and joist spaces cannot be blocked with insulation or

other objects. Each of these openings using vertical ducts shall

have a minimum free area of one square inch per 4,000 bm/hr of

total input rating of all gas appliances. See Figure B and C. If

horizontal ducts are used, the minimum free area shall be one

square inch per 2,000 btu/hr of total input rating of all gas

appliances.

Fresh make-up air can also be provided through a duct to one

permanent opening commencing within 12 inches of the ceiling.

The lninilnum free area of this opening shall be one square inch

per 3,000 bm/hr of the total input rating ofatl gas appliances but

not less than the sum of the areas of all vent connectors in the

space. See Figure D.

When calculating the amount of fiesh air needed you must include

make-up air requirements for the operation of exhaust fans, kitchen

ventilation systems, clothes dryers, and fireplaces.

Additional information can be f\3und in the latest edition of ANSI

Z223.1 (National Fuel Gas Code).

ALL COMBUSTION AIR FROM ADJACENT INDOOR

SPACES THROUGH INDOOR COMBUSTION AIR

OPENINGS

Listed Vent Cap

_ pening

Opening

tti i i t t it i t titit t

ALL COMBUSTION AIR FROM OUTDOORS, INLET

AIR FROM VENTILATED CRAWL SPACE AND

OUTLET AIR TOVENTILATED ATTIC

_Z UL Listed Vent Cap

l_.Listed Gas Vent

Ventilation Louvers (each

ff'll II endofattic)

I II II II 1"_ --.==

"- Outlet Air

/Inlet Air

_t_uvers for unheated crawl space

ALL COMBUSTION AIR FROM OUTDOORS

THROI_YGHVENTILATED ATTIC

UL Listed Vent Cap

UL Listed Gas Vent

Ventilation Louvers (each

end of attic)

Outlet Air

Inlet Air Duct (ends 1 ft.

_01rnn] above floor)

ALL COMBUSTION AIR FROM OUTDOORS

THROUGH SINGLE COMBUSTION AIR OPENING

UL Listed Vent Cap

UL Listed Gas Vent

Opening

Alternate Opening

Location

Page 5D

USING ADJACENT STUD SPACE FOR ALL

COMBUSTION AIR FROM OUTSIDE

HOLES CONNECTING TO

VENTILATED ATTIC

PLATE

AIR

GRILLE

FLOOR

HOLES CONNECTING TOVENTILATED

CRAWL SPACE

BASED ON 4,000 BTU OF TOTAL INPUT RATING

OF ALL GAS APPLIANCES, THE HEATER ONLY

REQUIRES A MINIIVRJMFREE AREA OF:

SQUARE HOLE SQUARE

BTU IN. SIZE IN.

25,000 6.25 1" .785

35,000 8.75 1.5" 1.76

50,000 12.50 2" 3.14

55,000 13.75 2.5" 4.90

65,000 16.25 3" 7.065

ROUGH-IN INSTRUCTIONS

In selecting a location for installation, it is necessary to

provide adequate accessibility clearances for servicing

and proper operation.

Minimum clearance from cabinet to combustible

construction:

SideWall 4"

Floor 0"

Ceiling 4"

See Figure 2. The unit may be recessed and rest

directly against side studs and the inside surface of the

rear wall.

ELECTRICAL ROUGH-IN

Rough in 115 v. wiring, terminating inside the,junction

box located on top of header plate for recessed, or in

a receptacle box (not provided) for flush mount.

Consult local codes or ordinances. See Figure 3.

MODEL NUMBER AMPS

CF353C, CF354C 1.95

CF503C, CF504C 2.25

CF653C, CF654C 2.25

CF357C 2.2

CF358C 2.25

CF557C 2.5

CF558C 2.55

LOCATION AND SPECIAL PRECAUTIONS

The wall furnace should be located near the center of

the house for best heat distribution.

If the area where the appliance is to be installed contains

carpeting, tile or combustible materials, other than wood

flooring, the appliance shall be installed on a metal plate,

wood panel or other non-combustible materials. The use

of ceramic or quarry tile is acceptable and will provide a

surt:ace that is easily cleaned. This material is to extend

the full width and depth of the appliance. If side or rear

warm air outlets are being installed, see figure 14 - lg,

See page 16 and 17.

1II ' _ o r---q

{ _ I_ -4''Minimum

_ _ 4" Minimum

FIGURE 2

ll5VA.C.

J_J_Line_

[[Ill I B_WVent

, Pip[P_

iHeader Plate

(not provided)

FIGURE 3

Z,:4

Stud

Page 6

GAS ROUGH-IN

Check local codes t\_rrequirements as to the size and type of

gas line required. See Figure 5 for location of gas inlet holes

in furnace cabinet.

Compounds used on threaded joints of gas pipe should be

resistant to the action of liquefied petroleum gases. The gas

line joints must be checked t\_r leaks. This should be done

with a soap solution watching for bubbles on all

connections. NEVER USE AN EXPOSED FLAME TO

CHECK FOR LEAKS.

A manual valve equipped with a 1/8" NPT plugged tapping

accessible for test gauge connection should be installed

immediately upstream of the gas supply connection to the

appliance. Some codes and ordinances require that the

manual valve be located outside the appliance. See Figure

The appliance and its individual shut off valve must be

disconnected from the gas supply piping system during any

pressure testing of that system at test pressures in excess of

V2psig.

The appliance must be isolated from the gas supply piping

system by closing its individual manual shut offvalve during

any pressure testing of the gas supply piping system at test

pressures equal to or less than ½ pig.

It is required by the National Fuel Gas Code that a drip line

be installed near the gas inlet. This should consist of a vertical

length of pipe tee connected into the gas line that is capped

on the bottom in which condensation and foreigu particles

may collect.

Gas

Supply

Lin__j

Manual j_v_ 1/8 N.P.T.

cut off Pressure Tap

valve

FIGURE 4

FIGURE 5

Page 7

INSTALLATION /WHEN RECESSED

(UP TO 9-1/4")

STEP 1.Cut out floor plate between 2x4 studs, so heater

will set flat on floor.

STEP 2.Make electrical connection of 115 V wiring into

junction box provided on top of header plate.

STEP 3.Attach the base plate (purchased with the vent pipe)

to the header plate using two No. 8 sheet-metal

screws through the pre-punched holes. See Figure

STEP 4.Square up and nail header plate in place between

2x4 studs placed on 16" centers (14-3/8" between

studs). For distances froln top of header plate to

floor, see Figure 6.

STEP 5.Remove double ceiling plate between studs. Install

one ceiling plate spacer across the cut out in ceiling

plate. Install vent pipe into position, be sure to

lock bottom of vent pipe into the base plate. Nail

second ceiling plate spacer in place. See Figure

STEP 6.If the vent continues through additional stories

within the 2x4-stud space, then fire stop spacers

must be installed at the second and subsequent

ceiling levels. See Figure C.

STEP 7.To place furnace into position, grasp furnace and

lift so furnace flue vent and header plate vent

opening engage. Plug power cord from top of

heater into receptacle on bottom of the header plate,

see Figure 3. Run thermostat wire through a drilled

hole into an adjacent stud space. Do not route it

behind the header plate. To do so may cause the

thermostat wiring to chaff resulting in the

appliance operating continually. Connect

thermostat wire with thermostat wires extending

fiom top of heater. Lift furnace upward and swing

bottom into wall, see Figure 7. Secure furnace in

place using 2 holes provided in bottom of casing.

STEP 8.Make gas connection using connector the same size

as gas connection of furnace. CHECK ALL

CONNECTIONS FOR GAS LEAKS WITH

LEAK DETECTOR SOLUTION. DO NOT USE

OPEN FLAME.

STEP 9.Replace and _hsten fiont panels to furnace.

NOTE: FOR PROPER COMBUSTION, MAKE

SURE UNITS ARE LEVEL FRONT TO BACK

AND SIDE TO SIDE.

INSTALLATION

WHEN INSTALLED FLUSH TO WALL

STEP 1.After locating furnace, cut 3-1/2"xl 2" rectangular hole

in ceiling between ceiting joists. Make sure gasket is in

position on the top of the furnace casing around the

flue vent opening. Relnove vent collar from top of header

plate and place over flue extension and fasten to

matching holes in casing top, using screws fiom header

plate. Install B vent type base plate (not supplied) to

top of vent collar. Install ceiling plate spacer to back

wall, centered between studs. Install B type vent to top

of furnace, terminating at least 12' above the floor and

at least 2' above the roof line.

STEP 2.Fasten furnace to wall. To secure top of furnace to wall,

loosen top screws on back casing and raise tabs up.

Tighten screws. Screw through hole in top of tabs into

anchors (not provided). Secme bottom using two holes

providedinbottolnofcasing. (Optional) Cover exposed

vent with a vent enclosure kit, Part Number 16VE-A or

36VE-A (not included).

STEP 3.Make electrical connection of 115 V. wiring into

receptacle box (not provided) mounted on a wall. Plug

power cord from top of heater into receptacle. Connect

thermostat wire with thermostat wires extending from

top of heater. According to installation instructions with

thermostat, do not run wires in same stud space with

vent system. Thermostat should be a minimum of 4'

from heater and 5' froln floor.

STEP 4. Make gas connection using connector the same size as

gas connection of furnace. CHECK ALL

CONNECTIONS FOR GAS LEAKS WITH LEAK

DETECTOR SOLUTION. DO NOT USE OPEN

FLAME.

STEP 5. Replace and thsten all front panels.

FIGURE 6

B-W Vent

Header

ate

FIGURE 7

Page 8

Installation of B&V Gas Vent

%1 one-stray buildings ol %1

firs flooof 1 -so T

building_ N

Ceiling plate spacexs to centel

B-W Gas Vent m stud space -

nail _ecmely at both ends¸

width of sttld space to

Srads oi2

16 inch centers

Sheet metal screw base

plate to header

--Use maimfacmrer's method of

fastening pipe to base plate¸

Header plate of vented wail fi_nace

(also acts as fires_p)

FIGURE B

CONTROLS

All controls are pre-assembled at the factory. The normal

mani%td pressure should be 3.5" w.c. for Natural Gas and

10" w.c. tbr L.P. Gas. The maximum inlet pressure in the

gas supply pipe should never exceed 7.0" w.c. tSr Natural

Gas or 14" w.c. for L.P. Gas. The minimum inlet pressure

in the gas supply pipe should never be lower than 4.5"

w.c. for Natural Gas or 11" w.c. tbr L.P. Gas.

Pilot Adj.

Screw

ROBERTSHAW

7200ER-SO4

STANDING PILOT

FIGURE 10-A

Pilot Adj.

Screw

ROBERTSHAW

7100IPER-SO4

H.D. PILOT

FIGURE 10-B

The appliance is orificed at the factory for elevations up

to 2,000 feet. If installed above 2,000 feet, the BTU input

must be reduced 4% per 1,000 feet. See the tbllowing

orifice chart for the proper orifice %r a specific elevation.

PILOT ADJUSTMENT

Locate the pilot adjustment screw on the valve. The pilot

flame should surround at least the top 3/8" of the powerpile

(pilot generator) or flame sensor (see Figure 8). The pilot

is unregulated so it will be operating at inlet line pressure

(maximum 7" w.c. for Natural Gas and 11" w.c. %r

Propane Gas). To decrease the pilot flame, turn the screw

clockwise (approximately six full turns to bottom of pilot

light channel) until you produce sufficient flame at the

minimum noise level.

PILOT FLAME ADJUSTMENT

Installation of B-W Gas Vent

fol each subsequent ceiling or

floor level ofmultistory buildings¸

Firestop spacels supplied

manut'actm el of B-W

Ga s _n_

Plate cut away

of B-Yq Ga _ E_nt

Nail filestop spacel sect e y

FIGURE CNATURAL GAS

SPECIFIC ELEVATIONS

Model 0 to 2,000 - 4,000 - &000 - 8.000 -

No. 2.000' 4.000' 6.000' 8.000' 10.000'

CF353C 34 36 37 38 41

CF357C 34 36 37 38 41

CF503C 3.4mm 31 31 32 35

CF557C 29 30 30 31 32

CF653C 26 27 28 29 30

ORDER KIT #49840 2287-1 HIGH ALTITUDE KIT

L.P. GAS

SPECIFIC ELEVATIONS

Model 0 to 2,000 - 4,000 - 6,000 - 8.000 -

No. 2.000' 4,000' 6,000' 8,000' 10,000'

CF354C 50 52 52 53 54

CF358C 50 52 52 53 54

CF504C 45 47 48 49 50

CF558C 2.15mm 45 47 48 49

CF654C 42 43 44 45 47

ORDER KIT #49840 2287-1 HIGH ALTITUDE KIT

___. 3/8" TO 1/2"

STANDING PILOT

FIGURE 8-A

' TO

1/2"

I.I.D. PILOT

FIGURE 8-B

PILOT FLAME SHOULD ENVELOP 3/8 TO V_,INCH

OF THE TIP OF THE GENERATOR. Page 9

WARNING:

CF353C, CF354C, CF503C, CF504C, CF653C, CF654C - -

STANDING PILOT

FOR YOUR SAFETY READ BEFORE LIGHTING

If you do not follow these instructions exactly, a fire or explosion may result

causing property damage, personal injury or loss of life.

This appliance has a pilot, which must be lighted by

hand. When lighting the pilot, follow these instruc-

tions exactly.

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.

Ilnmediately call yore 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 mm the gas control

kalob. Never use tools. If the kalob will not push in or

mm 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. Ilnmediately 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 int\_rlnation on the safety label.

2. Set thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. Remove cabinet door.

5. Push in gas control lever slightly and slide right to i"N

"OFF".

MAX. (HIGH)

PRE SSURE REGULATOR Gas Control

NOTE: Lever

cannot be

moved to

"OFF" unless

it is pushed

in slightly.

Do not force.

STEP PRESSURE REGULATOR

6. 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 int\_rlnation on the safety

label. If you don't smell gas, go to the next step.

7. Locate red piezo ignitor button. Locate pilot. (Follow

metal pilot tube from gas control).

The pilot is located

on the side of the h

burner

8. Slide gas control lever left _ to "SET" and hold

hnlnediately begin a series of pushing and releasing

the red piezo ignitor button, while observing the pilot.

Continue to spark until pilot is lit. Continue to hold

the gas control lever to "SET" for about one (1)

minute after the pilot is lit. Release the gas control

lever and it will return to "PILOT". Pilot should

remain lit. If pilot goes out, repeat steps 5 thru 8.

• If gas control lever does not return to "PILOT" when

released, STOP and immediately call your service

technician or gas supplier.

• If the pilot will not stay lit after several tries, slide the

gas control lever to "OFF" and call your service

technician or gas supplier.

9. Slide gas control lever left _ to "ON".

10. Replace cabinet.

11. Turn on all electric to the appliance.

12. Set thermostat to desired setting.

TO TURN OFF GAS TO APPLIANCE

1. Turn thermostat to lowest setting. 4.

2. Turn off all electric power to the appliance if service is

to be performed. 5.

3. Remove cabinet door.

Page 10

Push in gas control lever slightly and slide right i'X

to "OFF". Do not _\_rce.

Replace cabinet door.

CF357C, CF358C, CF557C, CF558C -I.I.D. PILOT

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.

\. This appliance is equipped with an ignition device • If you cannot reach your gas supplier, call the tire

which automatically lights the pilot. Do not try to department.

light the pilot by hand.

BEFORE LIGHTING smell alt around the appliance C.

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. D.

Do not touch any electric switch; do not use any

phone in your building.

Ilnmediately call your gas supplier flom a neighbor's

phone. Follow the gas supplier's instructions.

Use only your hand to push in or mm the gas control

kalob. Never use tools. If the kalob will not push in or

mm by hand, don't try to repair it, call a qualified service

technician. Force or attempted repair may result in a tire

or explosion.

Do not use this appliance if any part has been under

water. Ilnmediatety 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 int\)rlnation on the safety label.

2. Set the thermostat to its lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device

which automatically lights the pilot. Do not try to

light the pilot by hand.

5. Remove cabinet door.

ft. Push in gas control lever slightly and slide right

to "OFF".

GAS CONTROL

LEVER

_--_[-'_ ] NOTE: Cexer

_)i_ O _ i Imovedto

pushed in

*__l slightly.

Do not

0 ibrce.

STEP PRESSURE REGULATOR

MAXIMUM (HIGH)

PRESSURE REGULATOR

PRESSURE REGULATOR GAS CONTROL

Wait five (5) minutes to clear out aW 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.

Slide gas control lever left _ to "ON".

MAXIMUM (HIGH)

|LEVER

, o. (..,__.NOTE

Ir.:.. =... cannot be

moVed*o

"_ it is

_ slightly.

IN[I.._J] Donot

O force.

STEPPRESSURE REGULATOR

9. Replace cabinet door.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, t\_llow the instructions

"TO TURN OFF GAS TO APPLIANCE" and call your

service technician or gas supplier.

TO TURN OFF GAS

1. Turn thermostat to it's lowest setting.

2. Turn off all electric power to the appliance if

service is to be performed.

3. Remove cabinet door.

TO APPLIANCE

4. Push in gas control lever slightly and slide right _ to

"OFF". Do not force.

5. Replace cabinet door.

Page 11

PROPER BURNER FLAME OPERATION

A proper flame will have adark blue inner mantle

that sits right on top of the burners with a lighter

blue outer mantle rising above the burner, (See

Figure 11). There may be some yellow where the

pilot flame and burner flame meet. There is no

primary air adjustment on the burner, and proper

flame is assured since the correct manifold pressure

and orificing has been done at the factory. NOTE:

It is advised that the burner flames be checked at

least twice during the heating season for any changes

in burner flame characteristics. The appliance area

must be kept clear and free from combustible

materials, gasoline, and other flamlnable vapors and

liquids. This heater comes from the factory with

the proper burner orifice for elevations up to 2,000

feet. Heaters installed above 2,000 feet must be

derated 4% for every 1,000 feet. For the proper

orifice size find the Model Number and elevation

on the orifice chart (See CONTROLS). Replace

burner orifice.

This unit uses a "step open" valve. When heat is

called for the gas valve opens at a reduced manifold

(outlet) pressure to insure a safe, quiet ignition.

After 10 - 20 seconds the valve automatically steps

up to norlnal manifold outlet pressure to provide

proper BTU input for the remainder of the heat

cycle.

After the heat exchanger has warmed sufficiently,

the tan will automatically come on to efficiently

transfer the heat into the room. NOTE: All but the

35,000 BTU unit (which is one speed) have an

automatic two-speed tan. In a new installation or

on fall start-up in a very cold room, some on-off

cycling of the fan may occur if the heat exchanger

cools too much. The burner, however, will continue

to operate and the fan cycle until the thermostat is

satisfied.

FIGURE 11

Page 12

TERMINAL BLOCK WIRING DIAGRAM

-FAN/LIMIT SWITCH (Brown)

[-POWER CORD (Black)

/ IFTRANSF°R-_ER

] J L (Black) LIMIT

Ek--i ii!:

OMOTOR (White) (_

POWER _ _ FAN

dN-

(Green) (Black)

FERMINAL BOARDA l [ t-MOTOR (Black)

3ROE_rND(Green) ] L ,,V[-_:A:S;(_R_:i_

MOTOR (Green) (Black)

P/N91122

CF353C, CF354C, CF357C, CF358C

I--FAN LIMIT SWITCH (Brown)

SELECTOR /

| FPOWERCORD(Black)

SWITCH 71 IF TRANSF°RMER(Black)

2_1 _ II r7 LIMIT

_,_OTOR- _L_ q II_--- SWlTC.

(Red) MOTOR.L(White) O (Blue)

POWER _ _ SELECTOR

CORD-------+ll1 _'_#lkA_ _'LII_---SWITCH

(Green) T/ I--I/ (Black)

FERMINAL BOARD[ [

3ROUND (Green) • I IL-'_TOsR(BI_Ik)

MOTOR (Green) _ L _-TRANFORM R (Black)

POWER CORD (White)

P/Ngl123

CF503C, CF504C, CF557C, CF558C, CF653C, CF654C

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper

and dangerous operation. Verify proper operation after servicing.

AUXILIARY LIMIT SWITCH

For your safety this furnace is equipped with a manual reset auxiliary limit switch. In case of failure by the

primary limit switch, this switch will shut the valve down completely before unsafe temperatures are reached.

After a cool down period, switch must be manually reset. If outages persist, call a qualified service person.

MAINTENANCE INSTRUCTIONS

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 caE_eting, bedding material, etc. It is imperative that control

compartments, burners, pilot burners, circulating air passageways and venting systems of the appliance

be kept clean.

The bearings of the motor should be oiled every six months with S.A.E. 20 oil.

The appliance area must be kept clear and free of any combustible materials, gasoline and other

flammable vapors and liquids.

It is essential that the flow of combustion and ventilation air not be obstructed.

Periodic examination of the entire ventilation system as a routine part of the safety performance check

is recommended on an annual basis.

IMPORTANT: Keep burner and control compartment clean. Vacuum burner compamnent at the start of

the heating season or as often as needed.

NOTE: It is advised that the burner flames be checked at least twice during the heating season for any

changes in burner flame characteristics.

115 VAC 60 HZ - Less than 12 Amps. If any of the original wire as supplied with this appliance must be

replaced, it must be replaced with type thermoplastic 105-degree C wire or its equivalent.

Page 13

CF353C, CF354C

THEtLMO STAT POWER

+o+

SPILL

SWITCH

AUXILIARY

LIMIT SWITCH

STANDING PILOT CF503C, 504C, 653C, 654C

CF353C, CF354C

PICTORIAL SCHEMATIC

BLL_

BL_CK

LIMIT FAN

S_TCH SWITCH

THERMOSTAf

SPILL

7ITCH

__! AUXILIAR,_

POWER CF503C, CF504C

cow CF653C, CF654C

PICTORIAL SCHEMATIC

BLACK

! _ /LACK

I TRANSFORMER ]

LIMIT SELECTO FAN

SWITCH

,O AMPS

1.95

+ @

SWITCH

-9o

LIMIT

SWITCH

TRANSFORMER

THERMOSTAf

_@ CF353C

CF354C

LADDER

q SCHEMATIC

SPILL AUXILIARY

--_-

Page 14

AMPS

2.25

FAN

SWITCH

- r0

LIMIT

SWITCH

SELECTO@:

S_ ETCH

T_R

THEP&IOSTAT

CF503C, CF504C

SPILL

SWITCH

CF653C, CF654C

LADDER

SCHEMATIC

AUXILIARY

LIMIT SWITCH

CF357C, CF358C I.I.D. CF557C, CF558C

CF357C, CF358C

TEIEPcMOSTAT PICTORIAL SCHEmaTIC

POWER

CORD

J V_IITE

,., , ,T_-%II'...._j

_. _ BLACK

SPILL _ _TCH I

VtTCH

PV GAS VALVE

IGNITION s.....

MODULE TR

GND

IGN

CF357C, CF358C

THERMOSTAT PICTORIAL SCHEMATIC

IT_ANSP°_'IERI Illl _.....

B2 UE

SWITCH

_ LIMIT SWITCH SELECTOR FAN

{rF?_ _ XA_cH

1 _wJLI_._LIMIT SV,_TCH

IGNITION sen_ b----7---,.k-- I _ P I

MODULE _,_;x<_ _ cII

€..,,. JMODEL NO. AMP S

CF357C 2.2

CF358C 2.25

FAN SWITCH

LIMIT SWITCH

-_ lx__

TRANSFOtLMER

THERMOSTAT 2t_4 _'_

I_@ CF357C

CF358C

LADDER

iSCHEMATIC

SPILL AUXILIARY

SWITCH LIMIT SWITCH

IGNITION

MODELNO.

CF557C

CF558C

FAN

SWITCH

AMPS

2.5

2.55 SELECTOR

LIMIT SWITCH

THERMOSTAT

[

SPILL AUXILIARY

SWITCH LIMIT fITCH

IGNITION

CF557C

CF558C

LADDER

SCHEMATIC

Page 15

ROUGH-INS FOR REAR OR SIDE DISCHARGE

Install plastergrounds as shown in Figure 12 and Figure 13.

NOTE: When side discharge is being used, furnace should be set exactly 4" from side wall.

f--aZ/p 1/2 ,,

(;round

FIGURE 12

REAR

_ Plaster

FIGURE 13

10.

OPTIONAL ACCESSORY KITS

REAR REGISTER KIT (Flush Mount)

(See Figure 14)

Use optional kit No. 406RR-A.

Cut openings in drywall as shown in Figure 12.

Position plasterground as shown in Figure 12

(Optional).

Cut out and remove elnbossed section on casing

rear.

Remove knockout on inner liner.

Put heater into position.

Place inner boot into position, mark and cut boot

flush with wall. Place damper into cutout end of

inner boot, mark (4) holes liom damper onto inner

boot, top and bottom, and drill (4) 1/8" hole. Place

outer boot into position, mark and cut boot flush

with wall.

Attach inner boot to liner. Attach damper to inner

boot (screws provided). Attach outer boot to casing

back.

Place grill in position and secure to wall.

Final installation will appear as Figmre 14.

10.

11.

12.

REAR DISCHARGE KIT (Recessed)

Use optional kit No. 407RR-A.

Cut openings in walt as shown in Figure 13.

Cut out and remove embossed section on casing

rear.

Remove knockout from inner liner.

Place inner boot from kit through opening,

matching flanges of boot and knockout.

Mark screw holes and remove boot.

Drill holes with a 1/8" drill.

Repeat steps 5 & 6 l\_r outer boot.

After unit has been set in wall, shove the inner

boot through the back wall and up against the liner.

Secure boot with screws provided. Attach damper

to inner boot with screws provided.

Repeat Step 9 l\)r outer boot.

Place grille in place and secure to wall.

Final installation will appear as FimJre 15.

ttt

FIGURE 14

ttt

FIGURE 15

Page 16

(OPTIONAL KITS

CONTINUED -

REVERSE SIDE)

OPTIONAL KITS -CONTINUED

SIDE DISCHARGE ON CASING SIDE DISCHARGE (With Extension Boot)

Use optional kit No. 306SR-A.

Cut out and remove embossed area on casing side.

Remove knockout from inner liner.

Place 1-1/2" boot from kit through opening, matching

flanges of boot to knockout on inner boot.

Mark screw holes and remove boot.

Drill holes with a 1/8" &ill.

Attach inner boot with screws provided.

Place grille into position, &ill holes into casing, and

attach with screws provided.

I--tl II II II

0 r---n

4--

FIGURE 16

90 Degree

Outside Comer

FIGI_JRE18

MODEL Length of bottom section

NUMBER (Rel' 4) plastic raceway

CF35 5-5/16 Inches

CF50 8 Inches

CF55 14 Inches

CF65 14 Inches

NOTE: Above lengths terminate

approxilnately 2 inches above floor.

Use optional kit No. 30SRB-A.

Cut opening in drywall as shown in Fig. 17.

Position plasterground as shown in Fig. 17 (optional).

Cut out and remove embossed section on casing side.

Remove knockout on inner liner.

Put heater into position.

Place inner boot into position, mark and cut boot flush with

wall. Place outer boot into position, mark and cut boot flush

with wall.

Place boot trim into position, slide inner boot through wall

from adjacent room and attach to inner liner. Slide outer

boot through wall from adjacent room and attach to casing

side.

Place grille into position and secure to wall.

III II r

FIGURE 17

14PEK-A PLUG EXTENSION KIT INSTRUCTIONS

FOR NON-RECESSED INSTALLATION ONLY

[;NITS WITH TERMINAL BOARD

STEP 1. Turn heater off following Section 3 in "Lighting Instructions" and allow

to cool.

STEP 2. Turn off all electricity to heater.

STEP 3. Remove top louver assembly, fan shroud and fan blade.

STEP 4. Loosen two screws on romex connector.

STEP 5. Remove junction box cover plate.

STEP 6. Disconnect three power cord temlinals and pull power cord out of top

of heater.

STEP 7. Insert power cord provided in kit through romex connector and plug

onto terminal board following wiring diagram found in lighting and

operating instructions.

STEP 8. Tighten two screws on romex connector.

STEP 9. Replace junction box cover plate.

STEP 10. Replace fan blade, fan shroud and top louver assembly.

STEP 11. Snap 90 Degree outside corner (Ref. 1) onto 3 ft. section (Ref. 2)

plastic raceway. Insert power cord and remove blue backing from

adhesive strip on raceway and apply to side of heater. See Figure 18.

STEP 12. Insert power cord into second 3 It. section of raceway (Ref. 3) and

remove blue backing and apply to side of heater, butting up agianst

bottom of other section. See Fig. 18.

STEP 13. Cut 14 inch long bottom section to required length (see chart), insert

power cord, remove backing and apply to side of heater. See Fig. 18.

STEP 14. Plug power cord into wall receptacle, see Fig.18.

STEP lg. Light the heater following lighting instructions.

Page 17

SYMPTOM

Flame too large

Noisy Flame

Yellow tip flame (some

yellow tipping on LP

_as is permissible

Floating Flame

Gas Odor

Delayed Ignition

Failure to Ignite

Condensation of

Water Vapor

Burner won't

turn off

Incorrect Gas Input

Not enough heat

Too much heat

Burner won't

turn on

TROUBLE SHOOTING CHART for qualified serviceman -MAIN BURNER

POSSIBLE CA[ SES CORRECTIVE ACTION

i. Defective operator section of'gas valve, i. Replace complete valve.

2. Burner orifice too large. 2. Check with local gas company for proper

orifice size and replace.

3. If installed above 2,000 ft. 3. Refer to orifice chart on Page 9.

1. Noisy pilot. 1. Reduce pilot gas with adjusting screw on combination

gas control valve.

2. Burr in orifice (if it whistles or resonates). 2. Remove bun" or replace orifice (do not enlarge orifices)

3. Excessive gas input. 3. See "Flame Too Large" above.

i. Clogged main burner ports. 1. Clean main burner ports. (Do not enlarge ports).

2. Clogged draft hood. 2. Clean draft hood.

3. Linted up mixer opening. 3. Check for dust or lint at air mixer opening.

i. Blocked venting, i. Clean flue passageways to remove blockage.

i. Gas leak. i. Shut off gas service immediately. Check piping.

Call gas company. See "For Your Safety", Page 1.

2. Chinmey or flue obstruction. 2. Clean flue.

3. Drafts around appliance. 3. Eliminate drafts.

1. Pilot flame too small. 1. Check pilot orifice. Increase pilot gas flow if

necessary by adjusting inlet pressure from gas

source (meter if natural gas or second stage

regulator if propane - maxinmm 7" w.c. for

Natural and 11" w.c. for propane).

2. Bumer ports clogged near pilot. 2. Clean burner ports (do not enlarge ports).

3. Low gas pressure. 3. Check gas supply inlet pressure. Check gas outlet

(manifold) pressure for "minimum step" pressure

dbr "step" pressure chart see "Operation").

4. Pilot decreases in size when main 4. Supply piping inadeqnately sized or incorrect

bumers come on. inlet pressure.

5. Drafts around appliance. 5. Eliminate drafts.

6. Bad venting. 6. See "Venting".

i. Main gas ofT. i. Open all manual gas valves.

2. Defective gas valve. 2. Replace gas valve.

I. Improper venting, i. See "Venting".

i. Defective or sticking automatic valve, i. Replace valve.

2. Excessive gas pressure (The supply gas 2. To correct this situation contact the utility

pressure must not exceed 1/2 psi or supplying the gas.

14" w.c.

i. Gas input not checked. 1. Re-check gas mput.

2. (:logged orifice. 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).

i. Appliance undersized, i. This is especially true when a dwelling or room is

enlarged. Have the heat loss calculated and compare

to the appliance output (approx. 70% of input).

Your gas company or installer can supply you with

this inibrmation. If appliance is undersized, replace

with con'ect size unit.

2. Incorrect supply pressure. 2. Check supply pressure as outlined above.

i. Combination control valve sticks open. i. Replace combination control valve.

TROUBLE SHOOTING CHART - PILOT AND VALVE

i. Gas valve not turned on. 1. Tuna gas valve to "on" position".

2. No voltage to valve.

3. Defective thermostat.

4. No 115 Volt Line Voltage.

5. Auxiliary limit switch open.

6. Blocked flue switch open.

7. Gas valve defective.

2. Check for 24 Volts to Valve.

3. Check wall themmstat.

4. Jump tim switch to check for voltage (fan will

conle on).

5. Push on red buton to close.

6. Push red button in to close.

7. Revlace _as valve

Page 18

TROUBLE SHOOTING CHART - PILOT AND VALVE -CONTINUED

_YMPTOM

?ilot won't light,

3r stay lit

'STANDING PILOT)

?ilot won't light,

3r stay lit

'I.I.D. PILOT)

POSSIBLE CAUSES

1. Air in line.

2. Defective thennocouple.

3. Pilot flame too low.

4. Manual reset switch not engaged.

1. Sparker won't work.

2. Sparker won't light pilot.

3. Manual reset switch not engaged.

CORRECTIVE ACTION

1. Bleed line.

2. Replace thermocouple.

3. Adjust pilot flame.

4. Push on button.

1. Check wire connections.

2.a. Pilot flame too lean.

2.b. Turn valve to "on" position.

2.c. Check for pilot restriction.

3. Push on button.

THE FOLLOWING IS A LIST OF POSSIBLE CAUSES AND CORRECTIVE ACTIONS

FOR BLOCKED FLUE SWITCH PROBLEMS

POSSIBLE CAUSES

1. Blockage in vent pipe

CORRECTIVE ACTION

1. A) Check vent pipe tbr blockage, such as bird nest, wasp nest, twigs, leaves, etc.

1. B) Check inside the bottom of the vent pipe to make sure the top of the draft

diverter did not rip the inner liner causing it to block part of the vent opening.

1. C) Check that no insulation tiom the header plate got caught on top of the draft

diverter when the heater was inserted into the wall.

1. D) Check that the vent cap is properly installed, not shoved too far down on the

vent pipe.

2. Burner is overfiring 2. A)

2. B)

Check the manifold pressure.

Check the rate, NOTE: This appliance was orificed for elevations up to 2,000

feet. When installed at higher elevations refer to orifice chart in "Controls"

section of instructions f\_rproper orifice size.

3. Improper vent system.

A) Vent too short

B) Restriction in vent

system caused by

ofl;ets

C) Incorrect vent pipe

3. Correct vent system.

A) The vent should terminate a lninilnum of 12 feet above the floor. See Figure 1.

Also, the top of the vent must be at least 2 f\_otabove any obstacle within a

10 toot radius, including the roof. See Figure A on Page 4.

B) All type "B" vents shall extend in a generally vertical direction with ofl;ets not

exceeding 45 degrees, except that a vent system having not more than one 60

de_ee ofl;et may be allowed.

Any angle _eater than 45 de_ees 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.

C) Use listed BW type vent pipe. Do not use transite or any other type of ceramic

pipe for venting. Do not use single wall pipe. When venting into a masonry

chimney the chimney must be properly lined and sized for this gas furnace.

The use of type B or a flexible chimney liner is recommended.

_. Incorrect header plate

location.

5. Vent pipe not down on the

header plate securely

5. Loose connections on the

4. Consult Figure 6 for correct header plate height.

5. You must use a base plate (obtained from the vent pipe manufacturer) on top of the

header plate, or wall furnace. This wilt lock the vent pipe down and prevent the

draft diverter from shoving it up.

6. Check the connections on both the switch and the gas valve. Tighten if necessary.

vent safe wirin_ harness

DO NOT BYPASS THE BLOCKED FLUE SWITCH: TO DO I

SO COULD EXPOSE THE CONSUMER TO PROPERTY DAMAGE,

PERSONAL INJURY OR POSSIBLE DEATH.

Page 19

COUNTERFLOW WALL FURNACE /STANDING PILOT

Prices and specifications subject to

change without notice. All

prices are F.O.B. factory.

MODELS:

NAT.GAS L.P.GAS

CF353C-R CF354C-R

CF503C-R CF504C-R

CF653C-R CF654C-R ,,,o""_]_ [:l-@

REVI 04/97 IPage20 (_(_

Mr. Contractor, we only sell parts through

our wholesalers, but the prices listed are for I

?'our comenience. For prompt parts service,

contact the wholesaler from which you I

purchased yonr Cozy heater. NOTE: Parts &

schematic drawings on current models are

shown at www.cozyheaters.com.

HOW TO PROPERLY ORDER PARTS: In addition to part description and part number, please give model number, serial

number, and type of gas used. This information can be found on the rating plate that is attached to heater.

MODEL NUMBER

PART DESCRIPTION

Casing Side, Right

Casing Side. Left

Center Back Assembly

Top Assembly

Upper Back Assembly

Lower Back Assembly

Bottom

Liner Assemblv

Header Assembly Complete

Heat Exchanger Assembly

Draft Diverter Assembly

Fan Shroud Assembly

Top Louver w/Insulation

Center Front Panel w Insulation

Bottom Louver Assembly w/Insulation

Upper Front Shield

Switch Box

Switch Box Cover

Lower Front Shield

Motor Mountina Bracket

Junction Box Cover

Burner

\Mve. 7200ERSO4 NATURAL GAS

Valve, 7200ERSO4 L.P. GAS

Manifold

Orifice,NATURAL

Orifice, L.P.

Fan Motor

Fan Blade

Rnbber Grommet

Limit Switch 60TI1-LIS0

Fan Switch 60T12-FI20

Speed Switch 60T13-FI60-30

Auxiliary Limit Switch 60T15-L350

24 VOLT SYSTEM WITH LOW-B.T.U. STANDING PILOT

NATURAL CF353C-R CF503C-R

L.P. CF354C-R CFS04C-R

PART LIST

NUMBER PRICE

30055 $48.40

30060 $48.40

30114 $37.10

30025 $13.30

30070 $22.30

30219 $30.60

30246 $9.80

30120 $73.30

31399 $38.60

30133 $210.60

30180 $31.30

30200 $21.60

30087 $17.60

30089 $24.90

30100 $31.60

30250 $3.50

30252 $7.10

30253 $2.80

30256 $5.10

* 30079 $2.10

30033 $3.70

72107 $38.20

72090 $137.90

72091 $137.90

78006 $12.30

72182 $3.40

95271 $3.40

72108 $73.90

78101 $24.20

78010 $3.00

78065 $5.90

78067 $6.10

HA NiA

78086 $9.30

PART LIST

N_IMBER PRICE

30325 $49.00

30330 $49.00

30364 $34.20

30025 $13.30

30070 $22.30

30219 $30.60

30246 $9.80

30370 $74.00

31399 $38.60

30379 $216.10

30400 $42.30

30200 $21.60

30087 $17.60

30359 $26.70

30100 $31.60

30250 $3.50

30450 $7.20

30253 $2.80

30256 $5.10

*30079 $2.10

30033 $3.70

72107 $38.20

72090 $137.90

72091 $137.90

78006 $12.30

78160 $3.40

78163 $3.40

78111 $85.80

78101 $24.20

78010 $3.00

78065 $5.90

78067 $6.10

78066 $8.90

78086 $9.30

Thermostat 24 Volt

Transformer

Flue Pipe Adapter

Plug Bracket

Casing Mounting Brackets

Flue Pipe Gasket

Draft Diverter Gasket

Casing Top Gasket

Element Support Gasket

Pilot.NAT. 0.140.512

Pilot, L.P.. 0.140.502

Cozy Handle

Power Cord

Snap-in Outlet

Thermostat Wire

Thermocouple Q309A-2135

Insulated Staples

Door Catch

Blocked Flue Switch

Blocked Flue Switch Wire

Terminal Board

Pilot Tubin_ w/Fittings

Piezo Sparker

Electrode Wire

Burner Pan Assembly

Valve Support Bracket Assembly

Pilot Mounting Bracket

Burner Mounting Plate

Lighting Instructions "CF'

REF.

NUMBER

32b

32c

32d

34b

78355

78069

40061

30047

*30260

78050

78051

78049

78052

72020

72021

84003

78213

78058

74518

78095

74209

80005

78108

78230

78300

78452

80016

72022

30286

30290

30299

30296

91272

$20.00

$23.50

$2.00

$1.90

$1.20

$4.40

$22.70

$2.30

$4.70

$1.30

$11.40

$1.20

_1 20

$9.30

$1.50

$5.00

$5.40

$5.70

$4.70

$15.90

$4.70

$2.40

$2.80

78355

78069

40061

30047

*30260

78050

78051

78049

78052

72020

72021

84003

78213

78058

74518

78095

74209

80005

78109

78230

78300

78452

80016

72022

30286

30290

30299

30296

91272

$20.00

$23.50

$2.00

$1.90

$1.20

$4.40

$22.70

$2.30

$4.70

$1.30

$11.40

$1.20

$I 20

$9.30

$1.50

$5.00

$5.40

$5.70

$4.70

$15.90

$4.70

$2.40

$2.80

NiC

PART

N_IMBER

30525

30530

30544

30025

30070

30219

30246

30550

31399

30563

30400

30200

30087

30534

30100

30250

30450

30253

30256

*30079

30033

72107

72090

72091

78006

78169

95273

78111

78101

78010

78065

78067

78066

78086

78355

78069

40061

30047

*30260

78050

78051

78049

78052

72020

72021

84003

78213

78058

74518

78095

74209

80005

78109

78230

78300

78452

80016

72022

30286

30290

30299

30296

91272

CF653C-R

CF654C-R

LIST

PRICE

$52.10

$36.80

$13.30

$22.30

$30.60

$9.80

$80.20

$38.60

$216.10

$42.30

$21.60

$17.60

$28.80

$31.60

$3.50

$7.20

$2.80

$5.10

$2.10

$3.70

$38.20

$137.90

$12.30

$3.40

$85.80

$24.20

$3.00

$5.90

$6.10

$8.90

$9.30

$20.00

$23.50

$2.00

$1.90

$1.20

$4.40

$22.70

$2.30

$4.70

$1.30

$11.40

$1.20

$1 20

$9.30

$1.50

$5.00

$5.40

$5.70

$4.70

$15.90

$4.70

$2.40

$2.80

NiC

REV. 07/99

*REQUIRES TWO. Page 21 MARCH 2005

COUNTERFLOW WALL FURNACE /I.I.D. PILOT

Prices and specifications subject to change

without notice. All prices are F.O.B. factory.

MODELS:

NAT. GAS L.P.GAS ___

CF357C-R CF358C-R

CF557C-R CF558C-R

ASSEMBLY

Ml: Contractor. we only sell parts through our wholesalers, but

the prices listed are for your convenience. For prompt parts

service, contact the wholesaler from which you purchased your

Cozy heater. NOTE: Parts & schematic drawings on current

models are shown at www.cozyheaters.com

I:1-@

Page 22 IREV. 04/97

HOW TO PROPERLY ORDER PARTS: In addition to part description and part number, please give model number, serial

number, and type of gas used. This information can be found on the rating plate that is attached to heater.

24 VOLT SYSTEM WITH INTERMITTENT

NATURAL CF357C-R CF557C-R

MODEL NUMBERS L.P. CF358C -R CF558C-R

REF. PART LIST PART LIST

PART DES( RIPTION NUMBER NUMBER PRICE NUMBER PRICE

Casing Side, Right 1 30055 $48.40 30525 $52.10

Casing Side. Left la 30060 $48.40 30530 $52.10

Center Back Assembly lb 30114 $37.10 30544 $36.80

Top Assembly lc 30025 $13.30 30025 $13.30

Upper Back Assembly ld 30070 $22.30 30070 $22.30

Lower Back Assembly 1e 30219 $30.60 30219 $30.60

Bottom I f 30246 $9.80 30246 $9.80

Liner Assembly 2 30120 $73.30 30550 $80.20

Header Assembly Complete 3 31399 $38.60 31399 $38.60

Heat Exchanger Assembly 4 30133 $210.60 30562 $217.20

Draft Diverter Assembly 5 30180 $31.30 30400 $42.30

Fan Shroud Assembl'_" 6 30200 $21.60 30200 $21.60

Top Louver w/Insulation 7 30087 $17.60 30087 $17.60

Center Front Panel w/Insulation 8 30089 $24.90 30534 $28.80

Bottom Louver Assembly w/Insulation 9 30100 $31.60 30100 $31.60

Ul_t_er Front Shield 10 30250 $3.50 30250 $3.50

Switch Box 11 30252 $7.10 30450 $7.20

Switch Box (over 12 30253 $2.80 30253 $2.80

Lower Front Shield 13 30256 $5.10 30256 $5.10

Motor Mountin_ Bracket 14 *30079 $2.10 *30079 $2.10

Junction Box Cover 15 30033 $3.70 30033 $3.70

Burner 16 72107 $38.20 72107 $38.20

Valve, NATURAL - I.I.D. 7200IPER 19 72092 $129.00 72092 $129.00

Valve, L.P.. - I.I.D. 7200IPER 20 72093 $129.00 72093 $129.00

Manifold 21 78006 $12.30 78006 $12.30

Orifice, Natural 22 72182 $3.40 78161 $3.40

Orifice. L.P 23 95271 $3.40 78168 $3.40

Fan Motor 24 72108 $73.90 78111 $85.80

Fan Blade 25 78101 $24.20 78101 $24.20

Rubber Grommet 26 78010 $3.00 78010 $3.00

Limit Switch 27 78065 $5.90 78065 $5.90

Fan Switch 60T12-FI20 28 78067 $6.10 78067 $6.10

Speed Switch F160-30 29 NiA NiA 78066 $8.90

Auxiliary Limit Switch 60TG15 350 Deg., Lower 30 78086 $9.30 78086 $9.30

Thermostat 31 78355 $20.00 78355 $20.00

Transformer 32 78069 $23.50 78069 $23.50

Flue Pipe Adapter 32b 40061 $2.00 40061 $2.00

Plug Bracket 32c 30047 $1.90 30047 $1.90

Casing Mounting Brackets 32d *30260 $1.20 *30260 $1.20

Flue Pipe Gasket 33 78050 $1.20 78050 $1.20

Draft Diverter Gasket 34 78051 $1.20 78051 $1.20

Casing Top Gasket 34b 78049 $1.20 78049 $1.20

Element Support Gasket 35 78052 $4.40 78052 $4.40

Cozv Handle 37 84003 $2.30 84003 $2.30

Power Cord 38 78213 $4.70 78213 $4.70

Snap-in Outlet 39 78058 $4.70 78058 $4.70

Thermostat Wire 41 74518 $1.30 74518 $1.30

I_nition Control Box. NAT.. SPT15A 45 78070 $104.50 78070 $104.50

Ignition Control Box. L.P., SP845 46 78088 $143.30 78088 $143.30

Pilot Assembly, Electronic, NAT.. 3S-24 47 72098 $37.30 72098 $37.30

Pilot Assembl?_ Electronic, L.P.., 3S-24 48 72097 $33.70 72097 $33.70

Pilot Bracket. CF-IID 30299 $2.40 30299 $2.40

Sensor, S1 49 78073 $16.40 78073 $16.40

Blocked Flue Switch 50 78108 $9.30 78109 $9.30

Blocked Flue Switch Wire 51 78230 $1.50 78230 $1.50

Terminal Board 52 78300 $5.00 78300 $5.00

Pilot Tnbing w/Fitting 78452 $5.40 78452 $5.40

Burner Pan Assembly 53 30286 $15.90 30286 $15.90

\Idve Support Bracket Assembly 56 30290 $4.70 30290 $4.70

Pilot Mountin_ Bracket 57 30299 $2.40 30299 $2.40

Burner Mounting Plate 58 30296 $2.80 30296 $2.80

Lighting Instructions "CF" 91261 _C 91261 _C

RE_ 04/97

*REQUIRES TWO. Page 23 MARCH2005

NO. 31300-A

TRIM KIT

KIT NO. 406RR-A

REAR REGISTER W/

VENT

ENCLOSURE

NO.

16VE-A

36VE-A

KIT NO.

407RR-A

REAR REGISTER -

RECESS

KIT NO.

306SR-A

SIDE <.

FLUSH "_--/

KIT

30SRB-A

SIDE REGISTER

W/BOOT

Page 24

For description of above

reference numbers,

see reverse side.

REV. 08/981

PARTS LIST FOR ACCESSORIES FOR COUNTERFLOWWALL FURNACE

PART DESCRIPTION

16" Vent Enclosure Side

16" Vent Enclosure Front

24" Vent Enclosure Side

24" Vent Enclosure Front

36" Vent Enclosure Side

36" Vent Enclosure Front

Side /Rear Register

Side Register

Large Outer Boot

Large inner Boot

Small Outer Boot

Small Inner Boot

Boot Trim

Plaster Ground

Side Boot

Cabinet Side Trim Angle

Cabinet Top Trim

Damper Assembly

REENO.

PART NO.

31360

31355

31367

31366

31385

31380

31630

31525

31580

31560

31720

31710

31615

31595

31510

31310

31320

31675

LIST PRICE

$8.20

$10.30

$12.60

$15.40

$15.20

$18.90

$18.00

$23.40

$21.30

$9.70

$9.10

$15.80

$11.60

$9.20

$5.30

$4.60

$20.60

REPLACEMENT WIRING - STANDING PILOT COUNTERFLOW

MODELS CF353C-R & CF354C-R

Black 17-1/2" Fork Term./with Stripped end Transformer (24 V. Side) to The 78200 $1.50

Black 27" Flag Terminal/Flag Terminal Auxiliary Limit Switch to Valve 78205 $2.00

Wiring Harness 78250 $23.50

MODELS CF503C-R &CF504C-R

Black 17-1/2" Fork Term./with stripped end Transformer (24 V.) to Therm

Black 32" Flag Terminal/Flag Terminal Auxiliary Limit Switch - Valve

Black 6" Flag Terminal/Flag Termial Selector Switch - Fan Switch

Wiring Harness

MODELS CF653C-R &CF654C-R

Black 17-1/2" Fork Term./with stripped end Transformer (24 V.) to Therm

Black 32" Flag Terminal/Flag Terminal Auxiliary Limit Switch - Valve

Black 6" Flag Terminal/Flag Terminal Selector Switch to Fan Switch

Wiring Harness

78200

78216

78208

78251

78200

78216

78208

78252

$1.50

$1.90

$1.60

$23.50

$1.50

$1.90

$1.60

$23.50

REPLACEMENT WIRING - I.I.D. !INTERMITTENT IGNITION / COUNTERFLOW

MODELS CF357C-R &CF358C-R

Black 17-1/2" Fork Term./with stripped end Transformer (24V. Side) to Th

Black 30" Flag Terminal/Straight Terminal Auxiliary limit to ignition control

Wiring Harness

MODELS CF557C-R &CF558C-R

Black 17-1/2" Fork Term./with stripped end Transformer (24V.) to Thermo

Black 38" Flag Terminal/Straight Terminal Auxiliary limit to ignition control

Black 6" Flag Terminal/Flag Terminal Selector Swith - Fan Switch

Wiring Harness

78200 $1.50

78214 $1.90

78259 $23.50

78200 $1.50

78258 $2.30

78208 $1.60

78257 $26.90

Ml: Contractor, we only sell parts through our wholesalers, but the prices listed are for your convenience. For prompt parts service,

contact the wholesaler from which you purchased your Cozy heater. NOTE: Parts & schematic drawings on current models are shown

at _v.cozyheatel_.com.

REV. 04/97 Page 25 MARCH 2005

IMPORTANT SAFETY BULLETIN ON YOUR GAS CONTROL AND PILOT LIGHT

SYSTEM FOR HEATING EQUIPMENT

WHAT YOU DON'T KNOW CAN HURT YOU.

Your pilot light system has been designed for safe and reliable operation. Although safety mechanisms are built-in,

the potential for hazard exists. This information is intended to help you avoid these hazards.

YOUR GAS CONTROL AND PILOT LIGHT

SYSTEM

Your gas control and pilot light system has a safety

device whose purpose is to shut-off the gas supply

to the appliance if the pilot light goes out. If you

have trouble lighting the pilot or keeping it lit, it

may mean that this safety device is warning you that

there is a problem with your system. Inspection and

repairs or replacement must be made by a trained

gas service technician.

TAMPERING IS DANGEROUS

The pilot safety system may also not work if you do

not follow the lighting instructions carefully or if you

tamper with the gas control that you use to light the

pilot. Tampering with the gas control, particularly

with tools, can damage the safety mechanism in the

control and can allow gas to leak. This can result in

a fire or explosion causing property damage, personal

injury or death.

WHAT TO DO IF YOU SMELL GAS ...

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any

phone in your building.

• hnmediately call your gas supplier from a neighbor's

phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire

department.

Installation and service must be performed by a qualified

installer, service agency or the gas supplier.

Do not store or use gasoline or other flammable vapors

and liquids in the vicinity of this or any other appliance.

CRITICAL SAFETY POINTS TO REMEMBER...

• Your gas has been odorized so that you call smell it.

Always smell around for gas before lighting your

appliance.

• Sniff for L.R-gas at floor level. LP-gas is heavier

than air and may temporarily exist at floor level.

IF YOU SMELL GAS, DON'T LIGHT IT

IF YOU CAN'T LIGHT IT,

DON'T FIGHT IT!

American Ga s

Association gama

THIS IS NOT AN ADVERTISEMENT

• If you smell gas, do not attempt to light the pilot. Do

not cause a spark by turning on or off electrical

switches or appliances or by using the phone. Turn

offthe gas to the appliances and call your gas supplier

from another location.

• If your gas control has gotten wet as the result of

flooding or other wetting, it must be replaced

immediately by a trained gas service technician.

Water can lead to damage of the internal safety

mechanism in the gas control and can create a

hazardous condition.

The Louisville Tin & Stove (70. warrants to

the original user the accompanying product for the period

specified herein, provided said product is installed,

operated, maintained, serviced, and used according to

the instructions and specifications accompanying the

product. AS OUTLINED IN O[ R INSTRUCTIONS,

ANY WARRANTY CONSIDERATIONS ARE

CONTINGENT ON INSTALLATION BY A

QUALIFIED INSTALLER (CONTRACTOR).

SELF-INSTALLATION IS NOT RECOMMENDED

AND MAY INVALIDATE YOUR WARRANTY.

If within a period of one year from the date of

installation of the product, any part supplied by the

manufacturer proves to be defective due to workmanship

or material, it will replace such part, provided parts have

not been subjected to misuse, alteration, neglect, or

accidents. The term of the warranty for the heat

exchanger is covered in Table A below. Any claim not

made within ten (10) days after the expiration of the

wan'anty period shall be deemed waived by the user.

The manufacturer shall have no liability or

be required to perform any obligation under this warranty

unless, when requested, the user returns, at the user's

expense, the component or product claimed defective,

to the manufacturer for inspection, to enable the

manufacturer to determine if the claimed defect is

covered by this wan'anty.

No charges for freight, labor or other

expenses incurred in the repair, removal, or

replacement of any product or component claimed

to be defective, will be paid by the manufacturer to

the user, and the manufacturer will not be liable for

any expenses incurred, by the user, in remedying any

defect in the product.

Service under this warranty is the

responsibility of the installer. In the event service

under this warranty is needed, the user of the product

shall request such service directly from the installer. If

the user is unable to locate the installer, the user should

write directly to the manufacturer, and the name of an

alternative service source will be supplied.

The product safety registration card (packed

inside the appliance) must be completed and returned to

the factor)'.

THIS WARRANTY IS EXPRESSLY IN LIEU

OF ANY OTHER WARRANTIES, EXPRESS OR

IMPLIED (WHETHER WRITTEN OR ORAL). ANY

IMPLIED WARRANTY OF MERCHANTABILITY OR

OF FITNESS FOR A PARTIC[ LAR PURPOSE IS

EXPRESSLY LIMITED TO THE D[ RATION OF THE

MAN[ FACTURER'S EXPRESS, WRITTEN

V_ARRANTY.

UNDER NO CIRC[ MSTANCES SHALL THE

MAN[ FACTURER BE LIABLE FOR ANY SPECIAL,

INDIRECT OR CONSEQ[ ENTIAL DAMAGES OR

EXPENSES ARISING DIRECTLY OR INDIRECTLY

FROM ANY COMPONENT OR FROM THE USE

THEREOF. THE REMEDIES SET FORTH HEREIN

SHALL BE THE EXCLUSIVE REMEDIES

AVAILABLE TO THE USER AND ARE IN LIEU OF

ALL OTHER REMEDIES.

SOME STATES DO NOT ALLOW

LIMITATIONS ON HOW LONG AN IMPLIED

WARRANTY LASTS, SO THE ABOVE LIMITATIONS

MAY NOT APLY TO YO[.

SOME STATES DO NOT ALLOW THE

EXCLUSION OR LIMITATION OF INCIDENTAL OR

CONSEQUENTIAL DAMAGES, SO THE ABOVE

LIMITATIONS OR EXCL[ SIONS MAY NOT APPLY

TO YO[.

THIS WARRANTY GIVES YO[ SPECIFIC

LEGAL RIGHTS, AND YO[ MAY ALSO HAVE

OTHER RIGHTS, WHICH VARY, FROM STATE TO

STATE.

TABLE A

Warranty for gas appliance heat exchangers only.

Product

Cozy Gas Fired Floor Furnace

Cozy Gas Fired Wall Furnace

Cozy Gas Fired Vented Console Heater

Cozy Gas Fired Direct Vent Heater

Cozy Gas Fired Counterflow Furnace

Cozy Gas Fired Counterflow Direct Vent Furnace

Cozy Gas Fired Mobile Home Direct Vent Furnace

Cozy Gas Fired Hi-Efficient Direct Vent Wall Furnace

Warranty Period

10 Years

LOUISVILLE TIN AND STOVE COMPANY

P.O. Box 2767 Louisville_ Kentucky 40201-2767

COZY Furnace Wall Manual L0805260

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