Louisville Tin and Stove Furnace HEDV403 User Manual

hi-efficient direct  
vent wall furnace  
INSTALLATION AND  
OPERATING INSTRUCTIONS  
R
R
P/N 72903  
/
December 2003  
INSTALLER MUST LEAVE THESE INSTRUCTIONS  
WITH THE CONSUMER, HAVE THEM COMPLETE,  
AND RETURN THE WARRANTY CARD.  
MODEL NUMBERS  
NAT. GAS  
HEDV403  
L.P. GAS  
HEDV404  
WARNING: If the information in these instructions are  
not followed exactly, a fire or explosion may result  
causing property damage, personal injury or loss of life.  
Do not store or use gasoline or other flammable vapors  
and liquids in the vicinity of this or any other appliance.  
WHAT TO DO IF YOU SMELL GAS:  
-
-
-
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any  
-
phone in your building.  
Immediately call your gas supplier from a neighbor’s  
phone. Follow the gas supplier’s instructions.  
If you cannot reach your gas supplier, call the  
fire department.  
-
INSTALLATION AND SERVICE MUST BE PER-  
FORMED BY A QUALIFIED INSTALLER,  
SERVICE AGENCY OR THE GAS SUPPLIER.  
WARNING: Operation of this furnace without the properly installed, factory furnished vent system and  
vent cap could result in Carbon Monoxide (CO) poisoning and possible death. For your safety, this  
furnace and the vent system should be inspected at least annually by a qualified service person.  
May be installed in an aftermarket, permanently located, manufactured home (mobile home) where not  
prohibited by local codes. See owner’s manual for details. This appliance is not convertible for use  
with other gases, unless a certified kit is used.  
This unit is not approved for installation in greenhouses, or environments involving dusty, wet, corro-  
sive, or explosive conditions. Such conditions will invalidate the warranty and may create unsafe  
conditions.  
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SAFETY RULES  
1.  
2.  
3.  
Improper installation, adjustment, alteration, service, or maintenance can cause property damage, bodily  
injury, or death.  
Use in other than a residential application may result in unsatisfactory performance and may void the  
warranty.  
Follow all applicable codes and ordinances. If there are none, follow the latest edition of National Fuel  
Gas Code ANSI Z223.1 A copy may be obtained from the CSA International, or the National Fire Protec-  
tion Association, Batterymarch Park, Quincy, MA. 02269. In Canada, use latest edition of CAN1-B149  
installation code.  
4.  
5.  
6.  
DO NOT INSTALL THIS FURNACE IN A RECREATIONAL VEHICLE OR TRAILER.  
Do not operate wall furnace unless it is connected to the supplied vent system with vent cap in place.  
Check the rating label attached to the wall furnace to be sure it is equipped for the type gas you intend to  
use.  
7.  
Never use a match, candle, flame or other source of ignition to check for gas leaks. Use only soapy water  
or liquid detergent.  
8.  
9.  
10.  
11.  
Have your wall furnace and vent system inspected at least annually by a qualified service technician.  
Before cleaning or servicing, turn off the gas and allow furnace to cool.  
Do not operate wall furnace without all components properly installed (top, front, etc.).  
Due to high temperatures, the wall furnace should be located out of traffic and away from furniture and  
drapes.  
12.  
Children and adults should be alerted to the hazard of high surface temperature and should be kept away to  
avoid burns or clothing ignition.  
13.  
14.  
15.  
Young children should be carefully supervised when they are in the same room with the wall furnace.  
Do not place clothing or other flammable material on or near the furnace.  
INSTALLATION AND REPAIR SHOULD BE DONE BY A QUALIFIED SERVICE PERSON. THE  
WALL FURNACE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY BY A  
PROFESSIONAL SERVICE PERSON. More frequent cleaning may be required  
due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments,  
burner, and circulating air passageways of the furnace be kept clean.  
16.  
17.  
18.  
Do not install in a closet, alcove, or small hallway where the furnace could be isolated from the space to  
be heated by closing a door.  
Do not put anything around the furnace or vent cap that will obstruct the flow of combustion and  
ventilation air.  
The appliance, when installed, must be electrically grounded in accordance with local codes or, in the  
absence of local codes, with the latest edition of National Electrical Code, ANSI/NFPA 70. In Canada, use  
CSA C22.1.  
19.  
20.  
21.  
Never operate this furnace without the sight glass in place or with the glass broken or missing.  
If it is suspected that rising water may enter the furnace, turn off the gas immediately.  
Do not use the appliance if any part has been under water. Immediately call a qualified service technician  
to inspect the appliance and to replace any part of the control system and any gas control which has been  
under water.  
22.  
It is necessary to replace damaged gaskets or sealing material within the vent or air intake system. Failure  
to do so may result in property damage, personal injury or loss of life.  
Any safety screen or guard removed for servicing must be replaced prior to operating heater.  
This appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance.  
23.  
24.  
Page 3  
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Vent Terminal  
Air Supply Inlet  
Area where terminal is not permitted  
VENT TERMINAL CLEARANCES  
REFERENCE LETTER TO  
CANADIAN  
INSTALLATIONS¹  
12 Inches (30 cm)  
DRAWING  
A = Clearance above grade,  
veranda, porch, deck, or  
balcony  
B = Clearance to window or door 12 Inches (30 cm)  
that may be opened  
C = Clearance to permanently  
closed window  
12 Inches (30 cm)  
18 Inches (46 cm)  
D = Vertical clearance to  
ventilated soffit located above  
the terminal within a horizontal  
distance of 2 Feet (61 cm) from  
the center line of the terminal  
E = Clearance to unventilated  
soffit  
18 Inches (46 cm)  
F = Clearance to outside corner  
G = Clearance to inside corner  
H = Clearance to each side of  
center line extended above  
meter/ regulator assembly  
12 Inches (30 cm)  
12 Inches (30 cm)  
3 Feet (91 cm) within a hei  
15 Feet (4.5m) above the  
meter/regulator assembly  
I = Clearance to service regulator 3 Feet (91 cm)  
vent outlet  
J = Clearance to nonmechanical 12 Inches (30 cm)  
air supply inlet to building or the  
combustion air inlet to any other  
appliance  
K = Clearance to a mechanical  
air supply inlet  
6 Feet (1.83 m)  
L = Clearance above paved  
sidewalk or paved driveway  
located on public property  
7 Feet (2.13m) A vent shal  
not terminate directly abo  
a sidewalk or paved drivew  
th t
 
i l  
t d
 
b t  
t
Page 4  
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CLEARANCES  
1.  
2.  
3.  
4.  
As you face the heater, the clearance to a side wall on the right side is 0” (Fig. 1), and the left side is 1”  
(Fig. 2).  
The minimum clearance from the top of the heater to the ceiling or any projecting overhang is 10”.  
(See Figure 3).  
The minimum clearance from the bottom of the heater to the floor, or the top surface of carpeting, tile, etc.  
is 0”. (See Figure 4).  
When the furnace is installed directly on carpeting, tile or other combustible material other than wood  
flooring, the furnace shall be installed on a metal or wood panel extending the full width and depth of the  
furnace.  
5.  
6.  
The minimum clearance from the edge of the vent cap to any overhanging obstruction, perpendicular side  
wall, or corner of building is 12”. (See Figure 5).  
Vent cap must be located at least 9” from any opening that would allow combustion products to enter the  
building, windows, doors, etc., and 12” above the ground or shrubbery (See Figure 5). Do not install vent  
cap in a window well. Provisions must be made to prevent snow accumulation from infringing on vent cap  
clearances.  
Ceiling or Overhang  
1” (2.54 cm)  
10” (25.4 cm)  
FIGURE 2  
FIGURE 1  
FIGURE 3  
FIGURE 5  
Page 5  
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CLEARANCES  
7.  
RESIDENTIAL GARAGE INSTALLATION: Gas utilization equipment in residential garages  
shall be installed so that all burners and burner ignition devices are located not less than 18 inches  
(46 cm) above the floor. You must build a platform 18” above floor, the full width and depth of  
the heater, including the rear trim kit. HEATER IS NOT DESIGNED TO HANG ON WALL.  
Unit should be located or protected so it is not subject to damage by a moving vehicle. Use care  
in selecting a good location whith in the grage. DO NOT locate the appliance where heated air  
will be directed onto a nearby parked vehicle. Paint may discolor or rubber may harden and  
crack. DO NOT allow open or closed containers of paint, gasoline or other liquids having flam-  
mable vapors to be stored or used in the same area as the heater.  
LOCATION  
1.  
2.  
The wall furnace must be installed on an outside wall, unless optional Kit No. HEVK-5 is used.  
For most efficient performance, locate furnace as centrally as possible in the area to be heated and  
where occupants may move about freely without coming into contact with the cabinet, and within  
reach of a 115V wall outlet.  
3.  
If the furnace is installed in a basement, a 12” clearance must be maintained between ground level  
and the bottom of the vent cap. Do not install furnace where vent cap will terminate in a window  
well or any other opening below ground level. Do not allow snow accumulation to build up  
within 12” of the vent cap.  
OPTIONAL KITS  
1.  
HEVK-5 - To extend vent 5 foot from heater. This will allow vent cap to be installed above grade  
from basement or to an outside wall. A total of 3 kits with 2 additional elbows may be used.  
rade  
tion  
Page 6  
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INSTALLATION  
Failure to follow these instructions carefully could result in poor performance, property damage, personal injury, or  
death.  
STEP 1. LOCATE VENT OPENING (Requires 3-1/2” diameter wall opening)  
a)  
Select area on wall where heater will be installed. Using template (packed with heater) mark shaded area  
where hole can be cut and to locate the wall brackets.  
b)  
c)  
d)  
e)  
Locate studs on each side of this area.  
Mark location for 3-1/2” diameter hole between studs. Hole should be offset to miss studs. (See Figure 6).  
Check outside wall at this location for proper clearances around vent cap.  
Cut vent openings into both the inside and outside walls, being sure to maintain level across both openings.  
Template  
Shaded  
Area  
Wall  
Studs  
16” O.C.  
FIGURE 6  
1/8” N.P.T. Plugged Hole  
for Pressure Gauge  
Gas  
Valve  
Manual Shut  
Off Valve  
Ground Joint  
Union  
Gas Supply  
Inlet  
3” (76mm) Min.  
FIGURE 7  
STEP 2. ROUGH-IN GAS SUPPLY (See Figure 7)  
a)  
Install a 1/2” gas supply line. The gas line will enter the heater from the 5” spacing between the heater  
back and the wall.  
b)  
Install a drip leg in gas supply line immediately upstream from the gas connection to heater, (see local  
codes), and provide a 1/8” N.P.T. plugged tapping, accessible for test gauge connection and a individual  
manual shut off valve. The furnace and its individual shut off valve must be disconnected from the gas  
supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig  
(3.5Pa). The furnace must be isolated from the gas supply piping system by closing its individual manual  
shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less  
than 1/2 psig (3.5Pa).  
Page 7  
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INSTALLATION - CONTINUED  
STEP 3 INSTALLING VENT SYSTEM 5” - 32” WALL THICKNESS (12.7 cm - 81.3 cm)  
a)  
Use only factory supplied parts. Do not attempt to modify in any way. To do so could cause a system  
imbalance resulting in poor performance and/or unsafe operating conditions.  
b)  
Slide collection box pipes through cutout and secure collection box to inside wall. Anchors (not supplied)  
may be required. (See Figure 8).  
c)  
d)  
From outside house, mark collection box pipes and cut off 1/2” beyond outside wall.  
Slide vent cap pipes onto collection box pipes and push in until flange is flush against house. Secure vent  
cap assembly to outside wall with a slight downward slope. This will prevent water from entering and  
allow and condensation to drain. Caulk around the edges of the vent cap mounting plate. NOTE: It may  
be necessary to build a metal or wood frame to provide a flat surface for the mounting plate to be flush  
against or to attain the 5” minimum wall thickness.  
Vent Cap  
Assembly  
BRACKETS  
Collection Box  
Assembly  
Vent Cap  
Mounting  
Plate  
FIGURE 9  
Page 8  
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STEP 4. INSTALLING HEATER  
a)  
b)  
c)  
d)  
e)  
Screw wall brackets to wall. Location marked with template. (See Step 1a)  
Screw trim kit brackets to back of heater. (See Figure 9).  
Slide heater to within approximately 5” from wall.  
Attach air intake hose to collector box outlet and burner box inlet with clamps provided. (See Figure 10).  
Attach vent exhaust tube to exhaust pipe on collector box and draft inducer outlet on back of heater.  
Secure with clamps provided. (See Figure 10).  
f)  
GAS CONNECTION. Make gas connection between manual shut off valve and furnace valve with  
approved connectors. Compounds used on threaded joints of gas piping shall be approved for use with  
L.P. gas. The gas lines must be checked for leaks by the installer with soapy water or liquid detergent,  
never an open flame. If connections are not exposed, a pressure test must be run. Be sure to disconnect  
the gas supply line from the appliance valve before pressure testing. The manifold pressure is pre-set at  
the factory and should be 3.5” w.c. for Natural Gas and 10” w.c. for L.P. gas. The minimum inlet  
pressure for Natural Gas is 4.5” w.c. and 11” w.c. for L.P. Gas, “for purpose of input adjustment”. The  
maximum inlet pressure should never exceed 7.0” w.c. on Natural Gas or 14” w.c. on L.P. Gas.  
STEP 5. INSTALLING REAR TRIM KIT  
a)  
b)  
c)  
d)  
Secure right and left trim kit sides to the wall and trim kit brackets with eight #8 screws provided. See  
figure 11. The back of the heater should now be spaced 5” from the wall.  
Remove the temperature sensing unit from the back of the heater. Save the nylon attachment clip and the  
#8 screw.  
Slide the temperature sensing unit through the 1/2” bushing located on the right trim kit side. Viewed from  
the front of the heater.  
Secure the temperature sensing unit to the outside of the right trim kit side using the nylon clip and #8  
screw saved from step B. Engagement hole provided.  
e)  
f)  
g)  
Secure trim kit top panel to trim kit sides with four #8 screws provided.  
Plug power supply cord into a 115V grounded electrical outlet.  
Turn the manual gas supply valve to the “on” position.  
HEATER IS NOW INSTALLED, FOLLOW LIGHTING INSTRUCTIONS.  
Trim Kit Top  
Trim Kit  
Right Side  
Trim Kit  
Left Side  
1/2” Bushing  
Trim Kit  
Bracket (4)  
FIGURE 11  
Page 9  
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FOR YOUR SAFETY READ BEFORE OPERATING  
WARNING: If you do not follow these instructions exactly, a fire or explosion may result  
causing property damage, personal injury or loss of life.  
A.  
B.  
This appliance does not have a pilot. It is  
equipped with an ignition device which  
automatically lights the burner. Do not try  
to light the burner by hand.  
• If you cannot reach your gas supplier, call  
the fire department.  
C.  
D.  
Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair  
it, call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
BEFORE OPERATING smell all around the  
appliance area for gas. Be sure to smell next  
to the floor because some gas is heavier than  
air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS:  
• Do not try to light any appliance.  
• Do not touch any electric switch; do not  
use any phone in your building.  
• Immediately call your gas supplier from a  
neighbor’s phone. Follow the gas supplier’s  
instructions.  
Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
OPERATING INSTRUCTIONS  
1.  
2.  
3.  
4.  
STOP! Read the safety information above on  
5.  
6.  
Remove front panel.  
this label.  
Pull the gas control lever DOWN clockwise 6  
to “OFF”. Do not force.  
Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you  
smell gas, STOP! Follow “B” in the safety  
information above on this label. If you don’t  
smell gas, go to the next step.  
Set the thermostat to lowest setting.  
Turn off all electric power to the appliance.  
This appliance does not have a pilot. It is  
equipped with an ignition device which auto-  
matically lights the burner. Do not try to  
light the burner by hand.  
7.  
8.  
Push gas control lever UP counterclockwise 7  
to “ON”.  
9.  
10.  
11.  
12.  
Replace front panel.  
Turn on all electric power to the appliance.  
Set thermostat to desired setting.  
If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance”  
and call your service technician or gas supplier.  
Gas control  
knob shown  
in “OFF”  
Gas  
Inlet  
position  
TO TURN OFF GAS TO APPLIANCE  
1.  
2.  
Set the thermostat to lowest setting.  
4.  
Pull the gas control lever DOWN clockwise 6  
to “OFF”. Do not force.  
Replace front panel.  
Turn off all electric power to the appliance  
if service is to be performed.  
Remove front panel.  
5.  
3.  
Page 10  
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PROPER BURNER FLAME  
Primary Flame  
Burner  
The burner flame may be observed by raising the sight  
glass cover. A proper flame will have a dark blue inner  
mantle, with a lighter blue outer mantle that extends from  
the burner into the heat exchanger tube, (see Figure 12).  
There is no primary air adjustment on the burner, and proper  
flame is assured since the correct manifold pressure and  
orificing has been done at the factory.  
Secondary Flame  
Heat Exchanger Tube  
TO REMOVE MAIN BURNER FOR INSPEC-  
TION AND CLEANING  
FIGURE 12  
NOTE: THE FURNACE AND ALL COMPO-  
NENTS MUST BE INSPECTED AT LEAST  
ANNUALLY BY A QUALIFIED SERVICE PER-  
SON. THIS SHOULD INCLUDE THE  
BURNER, HEAT EXCHANGER, AND VENT  
SYSTEM. BE SURE THAT THE FLOW OF  
COMBUSTION AND VENTILATION AIR ARE  
NOT OBSTRUCTED AND THAT ALL HOSES  
ARE UNDAMAGED, AND ALL CLAMPS ARE  
SECURELY TIGHTENTED.  
1.  
2.  
3.  
4.  
5.  
6.  
Turn off all electrical supply to heater.  
Turn off gas supply.  
Remove front panel.  
Unplug wire to ignitor and sensor. (See Fig. 13.)  
Disconnect vacuum hose from burner box.  
Remove screws holding burner box top to burner  
box. (See Figure 13.)  
Remove burner plate and burner box top. Take  
care not to contact, or strain ignitor in any way  
as it is extremely fragile. (See Figure 13.)  
Remove 2 nuts holding burner bracket. (See  
Figure 13).  
7.  
8.  
9.  
Slide burners toward heat exchanger and lift up  
from rear and back. (See Figure 13).  
Clean or replace as needed.  
Valve  
10.  
11.  
Burner  
Box  
Reinstall by reversing Steps 9 - 1.  
Top  
Burner  
Burner  
BURNER ORIFICE  
Mani-  
fold  
Box  
Plate  
Sensor  
This appliance is orificed at the factory for elevations up to  
2,000 ft. If installed above 2,000 ft., the BTU input must  
be reduced 4% per 1,000 ft. See the following orifice chart  
for the proper orifice for a specific elevation.  
Nut  
Burner Bracket  
Ignitor  
Vacuum  
Hose  
SPECIFIC ELEVATIONS  
FIGURE 13  
MODEL  
NO.  
0 to  
2,000’  
4,000’  
4,000’  
6,000’  
6,000’  
8,000’  
8,000’ -  
10,000’  
2,000’  
NATURAL GAS  
HEDV403  
HEDV404  
45  
55  
47  
48  
49  
56  
50  
57  
L.P. GAS  
55  
56  
NOTE: If this heater is installed above an elevation of 8,000 feet, the factory installed pressure switch may not  
function properly. If you experience a problem with the pressure switch, contact a qualified service agency to  
replace the factory installed pressure switch with a high altitude pressure switch P/N 72521. To order see your  
local Cozy dealer or contact the factory.  
Page 11  
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WIRING  
WARNING  
This appliance is equipped with a three prong grounding  
plug. For your protection against shock hazard, this ap-  
pliance should be plugged directly into a properly grounded  
three-prong receptacle. Do not cut or remove the ground-  
ing prong from this plug.  
THIS IS A GAS-FIRED APPLIANCE. KEEP THE  
AREA CLEAR OF GASOLINE AND OTHER FLAM-  
MABLE VAPORS AND LIQUIDS. ALL COMBUS-  
TIBLE MATERIAL MUST BE KEPT CLEAR OF THIS  
AREA TO AVOID FIRE OR EXPLOSION.  
NOTE: If any of the original wire supplied with this ap-  
pliance has to be replaced, it must be replaced with type  
105EC wire or its equivalent.  
CAUTION: Label all wires prior to disconnection when  
servicing controls. Wiring errors can cause improper and  
dangerous operation.  
Verify proper operation after servicing.  
Pressure  
Switch  
Gas Valve  
Circulating  
Blower  
Black  
Black  
XFMR  
Draft  
Inducer  
Circulating  
Blower  
L 1  
Yellow  
Yellow  
EAC/LSPD  
White  
Red  
Heat  
Hum  
M 1  
Black  
White  
W
Ignitor  
M 2  
C
R
Y
Thermostat  
Flame  
Yellow  
Sensor  
Yellow  
Neutrals  
115 VAC  
Draft  
Inducer  
White  
Transformer  
Primary  
White  
24 VAC  
Black  
White  
Green  
Transformer  
Flame  
Sensor  
Secondary  
24 VAC  
Brown  
White  
Black  
3 Amp  
Fuse  
High  
Limit  
Thermostat  
Limit  
Switch  
Pressure  
Switch  
Gas  
Valve  
MODEL HEDV 403, 404  
Page 12  
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SEQUENCE OF OPERATION - HEDV403/4  
@t=0  
THERMOSTAT  
CALLS FOR  
HEAT  
@t=X  
Thermostat  
is satisfied  
t=20 sec.  
t=10 sec.  
t=15 sec.  
t=50 sec.  
t=X+15 sec.  
t=x sec.  
t=X+120 sec.  
Power to  
Combust.  
Fan  
Gas  
Flow  
IGNITION  
PROVED?  
Blower  
On  
Blower  
Off  
Fan  
Proved  
Power to  
Ignitor  
Burners  
Off  
YES  
YES  
Combust.  
Fan Off  
NO  
NO  
NO  
Three  
Attempts  
Made?  
10 SEC  
PURGE  
YES  
10 SEC  
PURGE  
Three  
Attempts  
Made?  
NO  
YES  
STEP #  
STEP #  
1)  
2)  
3)  
4)  
5)  
6)  
7)  
8)  
Thermostat calls for heat.  
Combustion fan turns on.  
Pressure switch closes.  
Power to Ignitor.  
Ignitor warm up period.  
Gas flow to burner.  
Burner ignition proven.  
Circulating blower on.  
NOTE: If there is a mal-  
function in any of the  
above steps, the sequence  
will stop at that point and  
8) Continued...  
return to Step 2. If after 3 attempts  
malfunction still occurs, furnace will  
go into lockout mode for one hour.  
This one hour mode can be bypassed  
by resetting thermostat.  
9)  
Thermostat satisfied.  
10) Gas valve closes.  
11) Combustion fan off.  
12) Blower off.  
HEATER NOW IN STAND-BY MODE.  
Page 13  
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HEVK-5  
5’ VENT EXHAUST KIT  
INSTALLATION INSTRUCTIONS  
WARNING: Use only Louisville Tin & Stove Company factory supplied parts and kits. Failure to do so could result in  
loss of life, personal injury, property damage, or unsatisfactory performance.  
CONTENTS OF KIT  
1 only P/N 72532 2”x3” Steel Coupling  
1 only P/N 72575 2”x5’ Black Flocked Tube  
1 only P/N 72612 2”x6’ Black Flex Tubing  
2 only P/N 41515 Support Brackets  
1 only P/N 41520 Center Bracket  
8 only P/N 72593 2” Hose Clamps  
1 only P/N 72578 2”x3” Black Silicone  
Wrapped Coupling  
STEP 1 - LOCATE VENT OPENING  
a)  
b)  
c)  
d)  
e)  
Select location on outside wall that vent will exit through.  
Check outside for proper clearances around vent cap. See installation instructions.  
Mark and cut 3-1/2” hole through both inside and outside walls, being sure to maintain level across both openings.  
Measure wall thickness. Mark and cut off both intake and exhaust pipes to 1/2” beyond outside wall.  
Secure collection box to wall. Wall anchors, not provided, may be required.  
STEP 2 - INSTALL HEATER  
a)  
b)  
c)  
Select location on wall where heater will be installed.  
Using wall template supplied with heater, mark location for trim kit wall brackets.  
Attach brackets to wall (wall anchors, not provided may be required) and back of heater. Using screws provided on  
back of heater.  
d)  
e)  
f)  
Slide heater into position and secure brackets togehter. This should position back of heater 5” off wall.  
Select direction vent will exit trim kit, left, right, or straight up.  
Before installing trim kit remove knockout on this side.  
STEP 3 - INSTALL VENT  
a)  
b)  
c)  
Remove and discard P/N 72611 2”x24” black flex tubing from air inlet. (Save hose clamp).  
Attach P/N 72612 2”x6’ black flex tubing to air inlet. Secure with P/N 72593 2” hose clamp.  
Slide P/N 72575 2”x5’ flocked tube through trim kit opening (knockout) and attach to P/N 72610 orange silicone  
90E elbow supplied with heater. Secure with 2” hose clamp.  
d)  
Attach P/N 41515 support brackets to wall. Wall anchors, not provided, may be required. Postion support brackets  
within 8” from side of trim kit and end of pipe. Secure flex tubing and flocked tube to brackets using 2” hose  
clamps.  
e)  
Attach P/N 41520 center bracket 2-1/2’ from pipe end and insert flex tube through bracket. This will prevent the  
flex tube from touching the black flocked exhaust tube.  
f)  
Connect flex air intake tube and flocked exhaust tube to collection box.  
Complete gas connection and attach trim kit to brackets.  
g)  
h)  
Follow lighting instructions.  
SPECIAL NOTES  
a)  
You may use up to three HEVK-5 Kits for a total of 15’ vent extension with two additional elbows. DO NOT  
EXTEND VENT BEYOND 15’ OR USE MORE THAN THREE TOTAL ELBOWS (one elbow is attached to  
heater outlet).  
b)  
c)  
To connect two vent kits together use P/N 72532 2”x3” steel coupling. Secure with 2” hose clamps.  
If you are using one, two, or three kits, after installation is complete you will discard 2 P/N 72593 hose clamps and  
one P/N 72532 steel coupling.  
d)  
e)  
If you need to make a 90E offset you will need to order P/N HEEL-1 90E Elbow Kit. Two offsets require two kits.  
If complete vent extension is horizontal, pipes may be sloped down slightly to allow any condensate to  
drain through the exhaust pipe to the outside. DO NOT ALLOW TO DRAIN ONTO WALKWAY. If any part of  
vent extension is vertical or local codes do not allow draining of condensate to outside you must add P/N HECK-1  
Condensate Kit.  
f)  
For cosmetic purposes, the addition of the HEVK-5 Kit can be enclosed by adding a HEVE-5 Vent Enclosure Kit.  
To completely enclose the HEVK-5 Kit one HEVE-5 will be needed for each HEVK-5 used.  
P/N 72612  
2”x6’ Black  
Flex Tubing  
P/N 72532  
Use only if connecting  
flex tubing of 2 or  
more ktis  
P/N 72578 2”x3”  
P/N 41515  
Black Silicone  
Support  
Wrapped Coupling  
Brackets (2)  
P/N 41520  
Center Bracket  
P/N 72575 2”x5’  
Black Flocked Tube  
P/N 72593  
2” Hose Clamps  
Page 14  
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HEVE-5  
HECK-1  
VENT ENCLOSURE KIT  
INSTALLATION INSTRUCTIONS  
CONDENSATE KIT  
INSTRUCTIONS  
STEP 1)Position end of Part No. 41610 enclosure body to  
heater trim kit where pipes exit trim kit, centering  
pipes inside body and attach to wall. Wall anchors,  
not provided, may be required. Collector box may  
be behind HEVE-5 Kit.  
STEP 1)Attach condensate trap to back of heater using 2 #8  
screws provided, as shown below. End of trap  
should extend through back of heater and into  
bottom of condensate pan.  
STEP 2)Remove and discard cap from bottom of draft  
inducer drain tube.  
STEP 2)Cut to fit enclosure panel 1” beyond end of vent  
run. Insert Part No. 41620 End Cap and attach  
using three #8 screws provided.  
STEP 3)Connect 1/4” plastic line from draft inducer drain  
tube to condensate trap. Secure with 2 1/4” hose  
clamps, provided.  
SPECIAL INSTRUCTIONS  
STEP 3)If more than one HEVE-5 Kit is used, attach Part  
No. 72604 Trim Kit where ends meet.  
STEP 4)Fill condensate pan with water.  
STEP 4)If making a 90E turn, measure 1” beyond outside  
turn and cut off enclosure panel. Notch panel on  
surface of direction turn is being made to allow  
pipes to pass through into next HEVE-5 Kit.  
Attach second panel to wall and attach Part No.  
72604 Trim Kit where two bodies meet. Install  
WARNING:  
Keep condensate pan filled with water.  
The water provides a seal to prevent combustion products  
from being pushed through the drain into the house.  
BACK OF HEATER  
end cap Part No. 41620.  
Exhaust  
Drain Tube  
From Draft  
1/4” Clear Tubing  
Inducer  
Condensate  
Trap  
Condensate trap empties through back  
of heater into a condensate pan below  
heat exchanger.  
HEEL-1  
90E ELBOW KIT  
Contains 1 only P/N 72613 90/ Elbow 2”  
Page 15  
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MAINTENANCE INSTRUCTIONS  
For proper and safe operation keep furnace and furnace area clean. At regular intervals turn control valve to off, let  
cool and clean inside control and heat exchanger compartment. To clean front panel use only a damp cloth, do not  
use any kind of solvent or cleaning fluid that could leave a residue to burn or give off fumes when furnace is turned  
on.  
Remove the blower filter from back of heater and clean as needed. Filter can be cleaned with garden hose, in bathtub,  
sink, etc. Use only water or air to clean. DO NOT USE ANY CLEANING SOLUTION AS THEY COULD BE  
FLAMMABLE AND COULD CAUSE ODORS. Dry thoroughly and re-install. Do not operate heater without filter  
in place.  
Have the furnace checked, cleaned, and repaired by a qualified service person. Check venting system, and burner  
operation prior to use each year.  
Follow a regular service and maintenance schedule for safe and efficient operation.  
Do not obstruct combustion and ventilation air. Examine the venting system as a routine part of the safety perfor-  
mance check on an annual basis.  
If the heat exchanger is removed, check the heat exchanger intake gasket and draft inducer gasket and replace if there  
is any sign of damage. Be sure all gaskets are in place when the heat exchanger is replaced.  
Failure to replace any gasket that has been damaged may result in property damage, personal injury or loss of life.  
Oil the bearings of the fan motor every 6 months with S.A.E. 20 oil.  
SERVICE RECORD  
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Page 16  
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TROUBLE SHOOTING CHART  
SYMPTOM  
Flame too large  
POSSIBLE CAUSES  
1. Defective operator section of valve.  
2. Burner orifice too large.  
CORRECTIVE ACTION  
1. Replace valve.  
2. Check with local gas company for proper  
orifice - size and replace.  
3. If installed above 2,000 ft.  
1. Clogged burner ports.  
3. See burner orifice section, Page 11.  
Yellow burner flame  
1. Remove burners and check for obstruc-  
tions in throats, ports, and orifices. Clean -  
but do not enlarge ports or orifices.  
2. Make sure area around vent cap is clear, be  
sure vent system is sealed.  
2. Obstruction around vent cap.  
Gas odor  
1. Gas leak.  
1. See Page 1.  
Delayed Ignition  
1. Low gas pressure.  
2. Igniter not peroperly located.  
1. Check gas supply pressure.  
2. Check ignitor location and correct if  
necessary.  
Failure to ignite  
1. Main gas off.  
1. Open all manual gas valves.  
2. Set temperature dial or thermostat to  
higher temperature.  
3. Clean burner orifices (do not enlarge).  
4. Check wiring diagram.  
2. Temperature dial or thermostat not set high  
enough to call for heat.  
3. Clogged burner orifice.  
4. Incorrect wiring.  
5. Defective valve.  
5. Replace valve.  
6. No power to unit.  
6. Plug in power supply cord. Check 115 V.  
wall outlet.  
Burner won’t  
turn off  
1. Defective or damaged thermostat wire,  
or thermostat.  
1. Can be checked by removing wire from con-  
trol board terminal. If burner goes off, replace  
thermostat.  
2. Thermostat sensor location on back of heater.  
2.Thermostat sensor attached to back of heater  
to re-locate out of drafts, hot, or cold spots.  
3. Defective or sticking valve.  
4. Excessive gas pressure.  
5. Defective or damaged sensor.  
1. Gas input not checked.  
2. Clogged orifices.  
3. Replace valve.  
4. Contact utility supplying gas.  
5. Replace thermostat.  
1. Re-check gas input.  
2. Clean orifices with a smooth wood toothpick,  
do not enlarge.  
Incorrect gas  
input  
Not enough heat  
1. Furnace undersized.  
1. This is especially true when a dwelling or  
room is enlarged. Have the heat loss  
calculated and compare to furnace output.  
Your gas company can supply you with this  
information. If furnace is undersized,  
replace with correct size unit.  
2. Temperature dial set too low.  
3. Incorrect supply pressure.  
2. Raise temperature setting.  
3. Check supply pressure.  
Too much heat  
1. Temperature dial set too high.  
2. Combination control valve stuck open.  
1. Lower temperature setting.  
2. Replace combination control valve.  
Main burner  
goes out  
1. Defective flame sensor.  
2. Input too high.  
1. Check voltage and replace if low.  
2. Check input rate.  
during normal  
operation  
3. Cover around pilot lighter hole not air  
tight.  
4. Vent tubes not properly installed or  
sealed.  
3. Tighten wing nuts securing cover and sight  
glass. Check and replace gasket if needed.  
4. Follow instructions. Check both exhaust and  
air intake tubes, and vent cap. Be sure all  
gaskets are in place and properly sealed. Use  
only tubes and vent cap supplied. Do not  
alter vent tubes or cap.  
5. Limit switch opens.  
5. Clean air filter.  
6. Exhaust or Air Intake tubes blocked.  
6. Remove obstruction. Check for snow  
accumulation around vent cap.  
Page 17  
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TROUBLE SHOOTING CONTROL BOARD  
To improve diagnosing and servicing, this control board is equipped with a self diagnosing  
green status light (see wiring diagram). To indicate stand by mode and proper operation  
this light will remain on. If there should be a malfunction, the light will flash a varying  
number of times with a pause between each series of flashes. The number of flashes will  
indicate the circuit to check.  
# of  
Reason for Indication  
Possible Causes  
Corrective Action  
Flashes  
1
Failed ignition attempts  
Hot Surface Ignitor:  
Hot Surface Ignitor:  
(3 times)  
a) Broken  
a) Replace  
This puts heater into one hour  
lockout mode. This one hour  
lockout can be bypassed by  
resetting the thermostat.  
b) Loose or damaged wire.  
b) Connect or replace wire  
No Gas to Burner:  
No Gas to Burner:  
a) Turn to “ON”  
b) Open gas supply valve.  
c) Connect or replace wire.  
d) Replace or clean sensor.  
a) Valve in “OFF” position.  
b) Gas supply turned OFF.  
c) Loose or damaged wire to valve.  
d) Defective or dirty flame sensor.  
2
3
Pressure switch stuck closed  
Pressure switch failed to close  
Defective switch.  
Replace switch.  
a) Vacuum hose disconnected or damged.  
b) Defective switch.  
a) Reconnect or replace vacuum hose.  
b) Replace switch.  
c) Wire disconnected or damaged.  
d) Obstruction in vent pipe.  
c) Connect or replace wire.  
d) Remove obstruction.  
4
5
Limit switch circuit open  
a) Defective limit switch.  
b) Disconnected or damaged wire.  
a) Replace limit switch.  
b) Replace or connect wire.  
Gas valve energized with no  
call for heat  
a) Defective gas valve.  
b) Sensor defective.  
a) Replace gas valve.  
b) Replace sensor.  
c) Short in sensor wire.  
c) Replace sensor wire.  
6
Polarity reversal  
a) Hot and neutral electrical supply  
wire reversed in junction box.  
a) Unplug supply cord from wall  
socket. Open junction box and  
switch the hot and neutral wires.  
very  
rapid  
Page 18  
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MODEL NUMBERS  
HEDV403 - NAT. GAS  
HEDV404 - L.P. GAS  
HI-EFFICIENT DIRECT VENT  
WALL FURNACE  
Prices and specifications subject  
to change without notice.  
All prices are F.O.B. factory.  
51  
46  
44  
45  
6
36  
37  
39  
34  
52  
35  
48  
43  
33  
38  
5
41  
7
4
40  
42  
32  
28  
31  
47  
27  
26  
3
24  
23  
29  
50  
25  
22  
21  
30  
2
53  
49  
20  
8
9
1
14  
10  
12  
19  
13  
15 16  
54  
18  
11  
5
17  
Mr. Contractor, we only sell parts through our wholesalers, but the prices listed are for your convenience. For prompt parts  
service, contact the wholesaler from which you purchased your Cozy heater. NOTE: Parts & schematic drawings on current  
models are shown at www.cozyheaters.com.  
Page 19  
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HOW TO PROPERLY ORDER PARTS: In addition to part description and part number, please give model number, serial  
number, and type of gas used. This information can be found on the rating plate that is attached to heater.  
Model Number  
HEDV403  
HEDV404  
REF.  
LIST  
LIST  
PART DESCRIPTION  
Bottom Louver Panel  
Center Front Panel  
Upper Front Panel  
Left Side Panel Insulation  
Cabinet Side Panel  
Circulating Blower Assembly  
Limit Switch  
Front Heat Shield Assy.  
Heat Exchanger Assembly  
Cabinet Base Assembly  
Leg Leveler (4 per unit)  
Draft Inducer Gasket  
Draft Inducer Assembly  
Sight Glass Frame  
Sight Glass  
Flame Sensor  
Sight Glass Gasket  
Ignitor  
Burner Orifice (2 per unit)  
Manifold  
Burner Box  
Burner Box Top Gasket  
Burner Box Top  
Gas Valve  
Gas Valve Bracket  
Burner Box Mounting Gasket  
Transformer  
NO.  
1
PART NO.  
72690  
41080  
72691  
72665  
41085  
72500  
80091  
41165  
72530  
41100  
80009  
72602  
72505  
41215  
70150  
72570  
72600  
72550  
72156  
72640  
41185  
72606  
41210  
72540  
41220  
72605  
78069  
72510  
72685  
72520  
41120  
72523  
72633  
72611  
72593  
41300  
72608  
41230  
72607  
72587  
72610  
41275  
41270  
41050  
41262  
41255  
41260  
72615  
72533  
72534  
72692  
72693  
41217  
41212  
PRICE  
$37.50  
$36.60  
$37.50  
$1.90  
$23.00  
$229.30  
$9.30  
$26.00  
$126.80  
$60.00  
$1.50  
$11.70  
$135.70  
$1.60  
$1.20  
$10.60  
$2.10  
$21.10  
$3.40  
$18.80  
$30.90  
$5.90  
PART NO.  
PRICE  
$37.50  
$36.60  
$37.50  
$1.90  
$23.00  
$229.30  
$9.30  
$26.00  
$126.80  
$60.00  
$1.50  
$11.70  
$135.70  
$1.60  
$1.20  
$10.60  
$2.10  
$21.10  
$3.40  
$18.80  
$30.90  
$5.90  
72690  
41080  
72691  
72665  
41085  
72500  
80091  
41165  
72530  
41100  
80009  
72602  
72505  
41215  
70150  
72570  
72600  
72550  
72139  
72640  
41185  
72606  
41210  
72541  
41220  
72605  
78069  
72510  
72685  
72520  
41120  
72523  
72633  
72611  
72593  
41300  
72608  
41230  
72607  
72587  
72610  
41275  
41270  
41050  
41262  
41255  
41260  
72615  
72533  
72534  
72692  
72693  
41217  
41212  
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
$5.00  
$77.30  
$5.00  
$5.00  
$77.30  
$5.00  
$5.90  
$5.90  
$23.50  
$116.90  
$18.80  
$28.10  
$48.50  
$72.70  
$4.40  
$9.80  
$1.70  
$60.20  
$1.90  
$239.30  
$1.20  
$23.50  
$116.90  
$18.80  
$28.10  
$48.50  
$72.70  
$4.40  
$9.80  
$1.70  
$60.20  
$1.90  
$239.30  
$1.20  
Control Board  
Wiring Harness  
Pressure Switch  
Casing Back Assy.  
Thermostat  
Control Knob  
Fresh Air Intake Hose  
2" Hose Clamp (4 per unit)  
Vent Cap Assembly  
Vent Cap Gasket  
Collector Box Assembly  
Collector Box Gasket  
Collector Box Cap  
Exhaust Tube  
Trim Kit Bracket (4 per unit)  
Wall Mounting Bracket (4 per unit)  
Casing Top Assy.  
Trim Kit Left Side Panel  
Trim Kit Top  
$1.50  
$173.10  
$7.50  
$1.50  
$173.10  
$7.50  
$2.00  
$2.00  
$105.30  
$22.70  
$27.10  
$22.70  
$25.80  
$9.20  
$105.30  
$22.70  
$27.10  
$22.70  
$25.80  
$9.20  
Trim Kit Right Side Panel  
Air Filter  
Burner (2 per unit)  
Burner Mounting Bracket  
End Cap, Left Side  
End Cap, Right Side  
Wire Bracket, HEDV  
Ignitor Bracket, HEDV  
$5.90  
$5.90  
$16.40  
$16.40  
$2.60  
$16.40  
$16.40  
$2.60  
$2.50  
$2.50  
Mr. Contractor, we only sell parts through our wholesalers, but the prices listed above are for your convenience. For prompt  
parts service, contact the wholesaler from which you purchased your Cozy heater. NOTE: Parts & schematic drawings on  
current models are shown at www.cozyheaters.com.  
MARCH 2005  
Page 20  
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IMPORTANT SAFETY BULLETIN ON YOUR GAS CONTROL AND PILOT LIGHT  
SYSTEM FOR HEATING EQUIPMENT  
WHAT YOU DON’T KNOW CAN HURT YOU.  
Your pilot light system has been designed for safe and reliable operation. Although safety mechanisms are built-in, the  
potential for hazard exists. This information is intended to help you avoid these hazards.  
YOUR GAS CONTROL AND PILOT LIGHT  
SYSTEM  
WHAT TO DO IF YOU SMELL GAS . . .  
Your gas control and pilot light system has a safety  
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any  
phone in your building.  
device whose purpose is to shut-off the gas supply  
to the appliance if the pilot light goes out. If you  
have trouble lighting the pilot or keeping it lit, it  
may mean that this safety device is warning you  
that there is a problem with your system.  
Inspection and repairs or replacement must be  
made by a trained gas service technician.  
Immediately call your gas supplier from a  
neighbor’s phone. Follow the gas supplier’s  
instructions.  
If you cannot reach your gas supplier, call the fire  
department.  
Installation and service must be performed by a  
qualified installer, service agency or the gas supplier.  
Do not store or use gasoline or other flammable vapors  
and liquids in the vicinity of this or any other appliance.  
TAMPERING IS DANGEROUS  
The pilot safety system may also not work if you  
do not follow the lighting instructions carefully  
or if you tamper with the gas control that you use  
to light the pilot. Tampering with the gas control,  
particularly with tools, can damage the safety  
mechanism in the control and can allow gas to  
leak. This can result in a fire or explosion causing  
property damage, personal injury or death.  
CRITICAL SAFETY POINTS TO REMEMBER . . .  
Your gas has been odorized so that you can smell  
it. Always smell around for gas before lighting your  
appliance.  
Sniff for L.P.-gas at floor level. LP-gas is heavier  
than air and may temporarily exist at floor level.  
IF YOU SMELL GAS, DON’T LIGHT IT  
If you smell gas, do not attempt to light the pilot.  
Do not cause a spark by turning on or off electrical  
switches or appliances or by using the phone. Turn  
off the gas to the appliances and call your gas  
supplier from another location.  
If your gas control has gotten wet as the result of  
flooding or other wetting, it must be replaced  
immediately by a trained gas service technician.  
Water can lead to damage of the internal safety  
mechanism in the gas control and can create a  
hazardous condition.  
IF YOU CAN’T LIGHT IT,  
DON’T FIGHT IT!  
THIS IS NOT AN ADVERTISEMENT  
Page 21  
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