Gas-Fired Vented FLOOR FURNACE
Gas-Fired Vented FLOOR FURNACE
P/N 74521 REV. 10/08
INSTALLATION AND OPERATING INSTRUCTIONS
MODEL NUMBERS
R
NATURAL GAS
MILLIVOLT CONTROL SYSTEM 90N30A 90N50A 90N65A
90N75A
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. - Do not store or use gasoline or other flammable vapors and liquids in the vicinity 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.
INSTALLER: Leave this manual with the appliance. CONSUMER: Retain this manual for future reference.
- INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
The coating selected to provide longer life to the heat exchanger may smoke slightly upon initial firing. Please provide adequate ventilation if this occurs.
WARNING: Operation of this furnace when not connected to a properly installed and maintained venting system can result in Carbon Monoxide (C.O.) poisoning and possible death. For your safety, this furnace and the venting system should be inspected at least annually by a qualified service person.
THIS UNIT IS NOT APPROVED FOR INSTALLATION IN MOBILE HOMES, GREENHOUSES, OR ENVIRONMENTS INVOLVING DUSTY, WET, CORROSIVE, OR EXPLOSIVE CONDITIONS. SUCH CONDITIONS WILL INVALIDATE THE WARRANTY AND MAY CREATE UNSAFE CONDITIONS.
The State of Massachusetts requires that installation and service of a gas appliance be performed by a plumber or gas fitter licensed in the Commonwealth of Massachusetts.
CONTENTS: Introduction............................................... 2 Specifications ............................................ 2 Safety Rules............................................... 2 Helpful Installation Information................. 3 Installation Requirements........................... 3 Furnace Location....................................... 4 Fresh Air for Combustion & Venting.......... 4 Cutting the Floor Opening.......................... 5 Setting the Floor Furnace........................... 5 Installing the Draft Hood............................ 6 Connecting the Vent....................................6 Gas Supply and Piping................................ 8 Checking the Gas Piping........................... 9 Thermostat Installation............................. 10 Lighting.................................................... 11 To Turn Off Gas....................................... 11 Adjusting the Pilot Flame..........................12 Orifice Charts........................................... 12 Adjusting the Main Burner........................ 12 Optional Operation....................................13 Maintenance..............................................14 Trouble Shooting.......................................15 Repair Parts...............................................16 Warranty....................................................18
INTRODUCTION THIS IS A GAS-FIRED, GRAVITY VENTED FLOOR FURNACE THAT WILL OPERATE SAFELY AND PROVIDE AN EFFICIENT SOURCE OF HEAT WHEN INSTALLED, OPERATED AND MAINTAINED AS RECOMMENDED IN 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. FLOOR FURNACE SPECIFICATIONS Your floor furnace and drafthood are packed together in one master carton. The carton containing the floor furnace also contains the thermostat, thermostat wire, insulated staples, furnace key and lighter rod. The drafthood is packed in its own carton within the master pack and contains screws and rope-like gasket material for attaching and sealing the draft hood to the floor furnace. Check the model numbers on the two cartons to be sure they match.
MODEL NUMBER NAT. GAS Hourly BTU Input Width and Length Overall Height Overall Grille Size Size of Floor Opening Gas Pipe Size at Furnace Vent Pipe Size Floor to Center Line of Vent
90N30A 30,000 14"x32" 29-1/4" 16"x34-c" 143"x323" " 4" 22"
90N50A 50,000 22"x32" 29-1/4" 24"x34" 222"x322" " 4" 22"
90N65A 62,000 24"x38" 29-7/8" 26"x40" 242"x382" " 5" 22"
90N75A 75,000 26"x42" 30-7/8" 28"x44" 262"x422" " 5" 22"
Page 2
SAFETY RULES
1. WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. INSTALLATION AND SERVICE MUST BE PERFORMED BYA QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. KEEP BURNER AND CONTROL COMPARTMENT CLEAN. SEE INSTALLATION AND OPERATING INSTRUCTIONS ACCOMPANYING APPLIANCE. DUE TO HIGH SURFACE TEMPERATURES KEEP CHILDREN, CLOTHING AND FURNITURE AWAY. FOLLOWALLAPPLICABLE CODESAND ORDINANCES. IF THERE ARE NONE, FOLLOW THE INSTALLATION STANDARDS, LATEST EDITION OF NFPA54/ANSI.Z223.1. A COPY MAY BE OBTAINED FROM THE AMERICAN GAS ASSOCIATION, 1515 WILSON BLVD., ARLINGTON, VA. 22209, OR THE NATIONAL FIRE PROTECTION ASSOCIATION, BATTERYMARCH PARK, QUINCY, MA. 02269. DO NOT INSTALL THIS FLOOR FURNACE IN A RECREATIONAL VEHICLE, TRAILER OR MOBILE HOME. DO NOT OPERATE THIS FLOOR FURNACE UNLESS IT IS CONNECTED TO A PROPERLY INSTALLED AND MAINTAINED VENT SYSTEM. DO NOT EXHAUST FLUE GASES UNDER THE FLOOR FOR ANY REASON. BE SURE THIS FLOOR FURNACE IS EQUIPPED FOR THE TYPE GAS YOU INTEND TO USE. LOCATE THE THERMOSTAT IN A ROOM OR SPACE THAT CANNOT BE SEPARATED BY A DOOR OR OTHER MEANS FROM THE ROOM OR SPACE IN WHICH THE FLOOR FURNACE GRILL IS INSTALLED. NEVER USE A MATCH, CANDLE, FLAME OR OTHER SOURCE OF IGNITION TO CHECK FOR GAS LEAKS. USE ONLY SOAPY WATER OR LIQUID DETERGENT. ADEQUATE AIR FOR COMBUSTION AND VENTING MUST BE PROVIDED. IF IT IS SUSPECTED THAT RISING WATER OR SEEPAGE MAY ENTER THE FLOOR FURNACE, TURN OFF THE GAS IMMEDIATELY. DO NOT USE THIS FLOOR FURNACE IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FLOOR FURNACE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER. HAVE YOUR FLOOR FURNACE AND VENT SYSTEM INSPECTED AT LEAST ANNUALLY BY A QUALIFIED SERVICE TECHNICIAN. THE GRILL BECOMES HOT WHEN THE FLOOR FURNACE IS IN OPERATION. CHILDREN MUST BE CLOSELY SUPERVISED WHEN IN THE PRESENCE OF ANY HEATING APPLIANCE. CONTACT WITH BARE SKIN MAY RESULT IN SEVERE BURNS. KEEP CHILDREN OFF THE GRILL. BEFORE CLEANING OR SERVICING THE FLOOR FURNACE, TURN OFF THE GAS AND ALLOW IT TO COOL. THIS WILL PREVENT BURNS. ALWAYS LEAVE THE GRILL IN PLACE EXCEPT WHEN CLEANING OR SERVICING THE FLOOR FURNACE. NEVER OPERATE THE FLOOR FURNACE WITHOUT THE SIGHT GLASS ASSEMBLY IN PLACE, OR WITH THE GLASS BROKEN OR MISSING.
2.
3. 4. 5. 6. 7. 8. 9.
10. 11. 12. 13. 14.
HELPFUL INSTALLATION INFORMATION
Do not attempt to heat through more than one doorway in any direction to adjoining rooms. Always over-estimate the amount of heat required rather than under-estimate it. Always use the next size floor furnace above your actual heating requirements. Seal all cracks around windows, doors, and attic access doors or significant heat loss will occur.
INSTALLATION REQUIREMENTS
Listed below are steps that are part of a floor furnace installation. You must see that each step is followed closely so that the floor furnace will provide maximum efficiency with safe operation. YOU MUST: 1. Locate the floor furnace in the best available space for safe and efficient operation. 2. Provide fresh air for combustion and venting. 3. Cut and frame the floor opening so that the floor furnace fits properly. 4. Attach the draft hood and connect the vent pipe in compliance with applicable codes. 5. Connect an adequate gas supply to the floor furnace. 6. Select the best location for the thermostat. 7. Check and adjust the floor furnace for safe and efficient operation. If you have any doubts about the correct way to install a floor furnace, contact local authorities or agency, or your gas supplier. If local or state codes require that your floor furnace installation be inspected by local authorities, do so after the floor furnace is installed and before it is put into service. Page 3
FLOOR FURNACE LOCATION
Choose a central location such as a hallway but where occupant traffic is minimal and where there is at least 18 inches of room from two adjoining sides of the grill to the nearest wall so that occupants may pass without stepping on the grill. See Figure Number 1. Bedroom Bath Kitchen Vent Pipe Thermostat Bedroom 18" Minimum Living Room
WALL
8" Minimum
FIGURE 1
FIGURE 2
Give consideration to available air for combustion, location in relation to chimney or vent system, thermostat location, clearance under floor, clearance to combustibles, and heat circulation. Any open foundation is unacceptable as wind can cause pilot outage and reduced efficiency. Keep furniture, drapes, doors, and other combustible materials at least 12 inches from the edge of the grill. Never locate the floor furnace closer than 8 inches to a wall and never in a corner. See Figure 2. Two adjoining sides of the floor furnace must have a minimum clearance of 18". See Figure 1. FLOOR JOIST FLOOR FURNACE FLOOR JOIST 6" Minimum Draft Vent Pipe Hood Ground Level 6" Minimum After selecting a location in the home, go beneath the floor and check the position of the floor furnace in relation to joists, supporting columns, electric wires, water pipes and walls. There must be a minimum of 6 inches clearance between the top of the draft hood and floor joists. There must also be at least 6 inches clearance between the bottom of the floor furnace and the ground. See Figure 3. In order to find the location beneath the floor it may be necessary to drill a 1/16 inch hole through the floor approximately in the center of the selected floor furnace location to use as a reference point when measuring under the floor.
FIGURE 3 FRESH AIR FOR COMBUSTION AND VENTING
Adequate air for combustion and venting must be provided. Any reduction in the necessary amount of fresh air
can result in an oxygen starved flame that emits Carbon Monoxide (C.O.) an odorless, colorless gas that can cause serious injury or death. A ventilated crawl space will usually provide enough fresh air. However, you
must check to see that there is 1 square inch of free area of ventilation opening for each 1,000 BTU's input of your floor furnace. EXAMPLE: 50,000 BTU floor furnace ) 1,000 = 50 square inches. If another gas burning appliance such as a water heater is installed within the same crawl space or basement, add the B.T.U.'s of the other appliance to those of the floor furnace before calculating the total ventilation needed. EXAMPLE: 50,000 B.T.U. floor furnace plus 40,000 B.T.U. water heater equals 90,000 B.T.U. ) 1,000 = 90 square inches. To compensate for the loss of square inches of ventilation due to the use of louvers, grills, or screens add approximately 50% to the square inches calculated. Screen all openings with mesh not less than inch to prevent animals or insects from entering the crawl space. All type "B" vents shall extend in a generally vertical direction with offsets not exceeding 45 degrees, except that a vent system having not more than one 60 degree offset may be allowed. Any angle greater than 45 degrees from the vertical is considered horizontal. The total horizontal run of a vent plus the horizontal vent connector shall be not greater than 75 percent of the vertical height of the vent. Any offsets used should be as far above the drafthood as possible to allow a venting action to begin before any restriction is encountered.
Page 4
CUTTING THE FLOOR OPENING
Consult the specification chart on Page 2 for the correct floor opening size for the floor furnace to be installed. Lay out the opening size on the floor by using masking tape or cutting a piece of cardboard to the opening size. The opening must be cut square. If you have determined that there is nothing under the floor to interfere with the installation, you are now ready to cut the opening. Start by drilling inch holes inside the lines of each corner. Use a keyhole saw or a properly grounded saber saw to cut along the lines making sure to keep the lines straight and the corners square. If the opening dimensions are not correct, it may be difficult to fit the floor furnace into the opening. Forcing the floor furnace through the opening may create stresses that cause the floor furnace to be excessively noisy. JOIST DOUBLE HEADER FLOOR FURNACE OPENING Most installation will require cutting a floor joist. Cut the floor joist so that double headers of the same size lumber can be used to frame around the floor furnace. Double headers are necessary to maintain the strength of the floor. See Figure 4. If the clearance between the bottom of the floor furnace and the ground is not adequate, dig a pit that will provide clearances of at least 6 inches under the floor furnace, 18 inches on the end where the gas valve is located and 12 inches on the other three sides. Slope the sides of the pit to prevent dirt from caving into the pit. See Figure 5. FLOOR JOIST
FIGURE 4
FLOOR JOIST
FLOOR FURNACE
6" Minimum DRAFT HOOD
Vent Pipe
18" Minimum 6" Minimum
12" Minimum
FIGURE 5
If there is any possibility that water may accumulate in the pit, a drain must be provided. If a drain cannot be provided, fabricate a waterproof pan of at least 16 ounce per square foot sheet copper or a suitable substitute. Size the pan to provide 6 inches clearance to the bottom of the floor furnace, 18 inches on the side where the gas valve is located and 6 inches on the other three sides. The sides of the pan must extend at least 4 inches above the ground. Anchor the pan to prevent it from floating
up against the bottom of the floor furnace when water is present. Failure to do so may result in the pan rising to seal off air for combustion and venting. If this occurs, carbon monoxide (C.O.) a colorless, odorless gas that can cause serious injury or death may be formed. SETTING THE FLOOR FURNACE
Lay aside the grill and package containing the thermostat, wires, etc., grasp two opposite sides of the outer casing and lower the floor furnace gently through the opening. Support the furnace evenly by the flange at the top of the outer casing. Trim back carpet, padding, and other types of floor covering so that the entire flange rests directly on the floor. If not evenly supported on all four sides, stresses may be created that cause excessive expansion and contraction noises as the floor furnace heats and cools. Anchor the floor furnace in place by driving two galvanized roofing nails through each side of the outer casing into the double headers approximately 1 inch below the flange. Place the grill into position making sure it lays flat against the outer casing flange. Leave the grill in place until time to light the furnace to keep occupants from falling into the furnace.
Page 5
INSTALLING THE DRAFT HOOD
The draft hood must be installed in the same atmospheric pressure zone as the combustion air inlet. The draft hood is packed in its own carton within the master pack. Make sure the draft hood received is the correct one for the floor furnace being installed. Included in the carton are two rope-like gaskets and 7 sheet metal screws. Begin by pressing the rope-like gasket material into the groove provided around the two male vent outlets on the floor furnace. See Figure 6. Slip the two female couplings in the draft hood over the male outlets extending through the outer casing, making sure the gaskets remain in place. Press the draft hood tight against the casing and use the 7 sheet metal screws to secure it tightly. All 7 screws must be used to prevent leakage of vent gases. Never install or operate a floor furnace
E AC RN G FU SIN CA
GASKET MATERIAL
DR
A
HO FT
OD
FIGURE 6
without a draft hood. To do so could result in serious injury, property damage or death. CONNECTING THE VENT
Refer to the specifications on Page 2 for the correct vent pipe size. Familiarize yourself with local codes or contact authorities to determine the approved material and method of installing the vent. NOTE: An existing vent that has worked for years may not be adequate for todays design because of higher efficiency requirements that result in lower stack temperatures.
Improper or unsafe venting presents a hazard that may result in property damage, bodily injury or loss of life. Listed below are some guidelines to observe when installing the vent system. 1. Never reduce the vent pipe to a size smaller than the outlet on the draft hood. 2. Never run pipe more than 15 feet horizontally. 3. The total horizontal run of a vent plus the horizontal vent connector shall be not greater than 75 percent of the vertical height of the vent. 4. Slope horizontal pipe upwards at least inch per lineal foot. 5. Do not use more than one elbow. An elbow restricts the flow of vent gases by approximately 10%. 6. Use a noncombustible thimble when connecting vent pipe to a masonry chimney. 7. Do not insert vent pipe farther than inch into the interior of the chimney. 8. Single wall pipe must not be used. 9. Never connect the vent pipe to any chimney or vent system serving a solid fuel-burning appliance. 10. If another appliance is being vented through the vent system with the floor furnace, the vent pipe must be increased to compensate for the additional load. 11. Never install any kind of damper in the vent system. 12. Do not use transite or any other type of ceramic pipe for venting.
Class "B" double wall pipe is acceptable to most codes, and if installed in accordance with the pipe manufacturers instructions provides the safest and most efficient vent system. Class "B" pipe has an integral lock for securing sections together. These locks must be properly fitted together. Fasten pipe to draft hood using at least three self-tapping sheet metal screws at equal intervals around the circumference of the pipe. Support horizontal pipe at three-foot intervals with metal strapping attached to joists. The floor furnace you have selected was carefully designed to operate both safely and efficiently when vented with the proper size vent listed for each furnace on Page 2 of these instructions. We do not recommend doing so, but if you must vent into a masonry chimney use the following instructions. Continued next page Page 6
CONNECTING THE VENT - Continued
1/4"
SAFE FIGURE 7A
UNSAFE FIGURE 7B
RECOMMENDED FIGURE 7C
If the floor furnace is vented into a masonry chimney, the chimney must be inspected to determine that it is clear and free of obstructions and that it is safe for the intended use. The inside of the chimney must be at least 6 inches in diameter or 6 inches by 6 inches if rectangular. Insert the vent pipe into the chimney through a masonry or noncombustible corrosion-resistant thimble of the correct diameter. Do not push the pipe farther than inch into the inside of the chimney. See Figure 7A. Pushing the pipe farther into the inside of the chimney may cause partial or complete blockage as illustrated in Figure 7B. Even following these instructions you may still have a venting problem because of the larger area to be heated inside the chimney. This could cause pilot outage, odors coming from the furnace, or noise due to excessive heat not being vented out of the combustion chamber. If you experience any of these problems, we recommend running the proper size "B" type vent pipe down the chimney and connecting to the horizontal run of vent pipe with a 90-degree elbow inside the chimney. See Fig. 7C. Extend the vent system at least 3 feet above the point where it exits the roof and at least two feet higher than any part of the roof system within 10 feet. Terminate with a listed or approved cap. See Figure 9.
MORE THAN 10 FEET 10' RIDGE 2' Minimum CHIMNEY OR METAL PIPE 3' MINIMUM RIDGE
10' OR LESS
2' Minimum
CHIMNEY OR METAL PIPE 3' MINIMUM
FIGURE 9
Page 7
FIGURE 9
CONNECTING THE VENT - Continued
Typical Installation Using Class "B" Vent Pipe 1. 2. 3. 4. 5. 6. 7. Adequate clearances around floor furnace. Draft Diverter 6" from combustibles. Adequate clearances around vent pipe. Horizontal vent pipe sloping upward 1/4" per foot. Pipe supported with metal straps. Adequate height of vent system. Listed vent cap.
If more than one gas appliance is vented through a common vent system, the vent should be increased in size to accommodate the increased load. Consult your local code or the tables in the latest edition of NFPA54/ANSI.Z223.1 for the correct size. If no local codes apply, use the following alternate method for sizing a vent connected to more than one appliance. The effective area of the vent must be not less than the area of the largest vent connection plus 50 percent of the areas of additional draft hood outlets. The homeowner appreciates neatness in workmanship and the neat installation usually functions better than the sloppy one. Double check your work to verify that all clearances around the floor furnace and vent system are adequate and that the vent system is installed to code or pipe manufacturers specifications. See Figure 10.
FIGURE 10 GAS SUPPLY AND PIPING
The gas piping system must meet the requirements of local codes or the specifications of the servicing gas supplier. It must have adequate capacity to supply the floor furnace and any other appliance within the home with enough gas to maintain the full rated capacities without excessive pressure drop when all appliances are operating at full rate. GAS PIPE SIZES - CAPACITY - *NATURAL GAS
Length of INSIDE PIPE DIAMETER Pipe - Feet 1/2" 3/4" 1" 10 132,000 278,000 520,000 20 92,000 190,000 350,000 Capacity 30 73,000 152,000 285,000 B.T.U. 40 63,000 130,000 245,000 Per Hour 50 56,000 115,000 215,000 Input 60 50,000 105,000 195,000 *Based on heating value of 1,000 btu per cubic foot (specific gravity of 0.6) @ 0.5 PSIG and a pressure drop of 0.3 inch water column.
GAS TUBINGAND PIPE SIZES - CAPACITY *L.P. GAS
Length of **Copper Tubing **Steel Pipe Pipe/Tubing Outside Diameter Inside Diameter Feet 1/2" 3/4" 1/2" 3/4" 10 92,000 329,000 275,000 567,000 20 62,000 216,000 189,000 393,000 Capacity 30 50,000 181,000 152,000 315,000 B.T.U. 40 41,000 145,000 129,000 267,000 Per Hour 50 37,000 131,000 114,000 237,000 Input 60 35,000 121,000 103,000 217,000 *Undiluted Liquefied Petroleum Gas @ 11 inches water column inlet pressure. Based on a pressure drop of 0.5 inches water column. **Copper tubing must comply with limitations of NATIONAL FUEL GAS CODE reference 2.6.3 metallic tubing. ***Steel pipe should be of at least standard weight (Schedule 40).
Support the piping or tubing at regular intervals with metal pipe strapping. See chart below.
Nominal Steel Pipe Size 1/2" 3/4" or 1" Spacing of Supports 6' 8' Nominal size of tubing O.D. 1/2" 5/8" or 3/4" Spacing of Supports 4' 6'
Where local conditions include earthquake, tornado, unstable ground or flood hazards, give special consideration to increased strength and flexibility of piping supports and connections. Consult local authorities for recommendations. All unused openings in the piping system must be securely closed gas-tight.
Page 8
CONNECTING THE GAS PIPING To heater gas control valve
Refer to Figure 11 for the basic fittings you will need at the furnace. 1. Use black iron or steel pipe and fittings or other pipe and fittings that are approved by local codes. Use pipe joint compound that is resistant to the action of Liquefied Petroleum (L.P.) Gas or to any other chemical constituents of the gases to be conducted through the piping only on male threads. Use two wrenches when making the connection to the valve to keep from bending the mounting bracket or manifold pipe. Do not overtighten as damage to the valve can occur. Provide a 1/8" nominal pipe thread (NPT) plugged tapping for test gauge connection immediately upstream of the gas supply connection to the floor furnace. Provide a sediment trap at least 6 inches long to trap dirt and moisture. Provide space to permit cleaning or emptying. Use a ground joint union. Install an approved manual shut-off valve.
Manual cut-off valve
2.
3.
1/8" NPT Pressure Tap Drip Leg FIGURE 11
Gas Supply Line
4.
5.
6. 7.
ADDITIONAL L.P. GAS REQUIREMENTS
8. 9. 10. Have all connections made at the storage tank by a licensed L.P. Gas installer. Have L.P. Installer check all lines, piping, and connections from the storage tank to the floor furnace when the floor furnace is connected to the storage tank. The regulator on the storage tank should be set at 11 inches water column.
CHECKING THE GAS PIPING
All joints must be tested for leaks by applying pressure to the piping system. If the test pressure is equal to or less than PSIG the floor furnace must be isolated from the gas supply piping system by closing the manual gas shut-off valve on the floor furnace. If the test pressure exceeds PSIG, the floor furnace and its manual gas shut-off valve must be disconnected from the gas piping system before testing. Failure to do so may result in damage to the pressure regulator
in the gas valve resulting in overfiring. Overfiring can result in combustion chamber failure, property damage, bodily injury or death.
Use a mixture of soap and water or liquid detergent to check each joint. Leaks will be indicated by bubbles forming. Correct even the smallest leak at once. Since some soaps may cause corrosion, or stress cracking, rinse the gas piping exterior with water after testing to remove the soap.
WARNING Never use a match, candle, open flame or other method which could provide a source of ignition to test for leaks. To do so may result in property damage, bodily injury or death.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
Page 9
CHECKING THE GAS PIPING - CONTINUED
Limit Switch Wires When you have determined that there are no leaks in the gas piping system you may purge the system of air. Disconnect the pilot supply tubing from the right side of the valve. See Figure 12. Turn the knob on the gas valve to the pilot position. Press the knob down and hold until you smell gas at the pilot supply opening. Release the knob and turn it to the off position. Reconnect the pilot supply tubing and check for leaks with soap and water or liquid detergent. Pilot Supply Tubing Pressure Tap
Pilot Adjustment
WARNING
When purging gas piping, the area around the floor furnace must be well ventilated to allow any gas to dissipate. Liquid Petroleum (L.P.) Gas is heavier than air and may puddle in low places under the floor. Check thoroughly to determine that no gas is present before lighting the floor furnace. Failure to do so could result in property damage, bodily injury or death.
FIGURE 12
THERMOSTAT INSTALLATION
Follow the instructions included with the thermostat. Locate the thermostat approximately five feet above the floor. Always mount the thermostat on an inside wall where it won't be affected by heat or cold sources such as direct sunlight, televisions, fireplaces, hidden hot or cold water pipe, drafts, etc. The thermostat must never be installed in an adjoining room where a door can be closed between the thermostat and floor furnace. This floor furnace is equipped with a self-generating control system. Never connect to a 24-volt transformer or to the household electric system. Do not use more thermostat wire than is included with the floor furnace. WIRE AS INDICATED: (See Figure 13) Connect black limit switch wire to black thermostat wire using wire nut. (Nut not furnished). Connect white thermostat wire to terminal on gas valve marked "TH PP". Connect white limit switch wire to terminal on gas valve marked "TH". Connect the thermostat wires to the thermostat following the instructions provided by the thermostat manufacturer.
Step 1. Step 2. Step 3. Step 4.
LIMIT SWITCH WIRES THERMOSTAT WIRE NUT POWERPILE GENERATOR
Limit Switches
Black
Thermostat
Red
Powerp ile Genera tor
TERMINAL BLOCK ON GAS VALVE
TH TP
TP TH Terminal Block
FIGURE 13
Page 10
White
White
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS: Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.
LIGHTING INSTRUCTIONS
1. 2. 3. 4. STOP! Read the information on the safety label. Set thermostat to lowest setting. Remove the floor grille. Place the furnace key on the control rod, push down slightly and turn clockwise to "ALL OFF". BURNER Control Rod NOTE: Control rod cannot be turned from "PILOT" to "ALL OFF" unless the control rod is pushed down slightly.
Pilot Burner
Pilot is located on the side of and toward control end of burner
PILOT
ALL OFF 5.
6. 7. 8.
Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B' in the information on the safety label. If you don't smell gas, go to the next step. Remove the sight glass assembly from the opening on top of the heat exchanger. Locate the pilot burner looking down through the sight glass opening. Turn the control rod counterclockwise until the pointer is on "PILOT".
9. Locate the red piezo igniter button beside the control rod. 10. Press down on the control rod with the furnace key. Immediately begin a series of pushing and releasing the red piezo igniter while observing the pilot through the sight glass opening, continue to spark until pilot is lit or use the lighter rod with match. Continue to hold the control rod down for about one (1) minute after the pilot is lit. If it goes out, repeat steps 4 through 10. If control rod does not pop up when released, STOP and immediately call your service technician or gas supplier. If the pilot will not stay lit after several tries, turn the control rod to "OFF" and call your service technician or gas supplier. 11. Replace the sight glass assembly and turn the control rod counterclockwise to "BURNER" position. Remove furnace key and replace the floor grille. 12. Set thermostat to desired temperature.
TO TURN OFF GAS TO APPLIANCE
1. 2. 3. 4. Set the thermostat to it's lowest setting. Allow floor grille to cool, then remove. Place furnace key on control rod, push slightly and turn clockwise to "ALL OFF". Do not force. Replace floor grille.
Page 11
VENT SYSTEM
After the floor furnace has been burning for five minutes, hold a match or candle under the draft hood at the air intake area. If the vent system is working properly, the flame will be pulled into the air inlet of the draft hood. If the vent system is not working properly, turn the floor furnace off immediately and refer to the installation instructions or local code for proper installation procedure. PILOT FLAME ADJUSTMENT Pilot flame should envelop 3/8 to 1/2 inch of the tip of the generator.
ADJUSTING THE PILOT FLAME Refer to Figure 17 for the correct size pilot flame. If adjustment is necessary, refer to Figure 12 for the location of the pilot adjustment screw. Using a standard screwdriver, remove the pilot adjustment screw cover. Insert a small screwdriver into the pilot adjustment screw and turn clockwise to decrease the flame or counterclockwise to increase the flame. If the flame is too low, the safety pilot may cause all of the gas to be cut off. NOTE: The gas supply to the pilot is unregulated. When line pressure exceeds 7" Natural Gas, or 11" L.P. Gas, a pilot adjustment must be made. BURNER ORIFICE
3/8 to 1/2"
FIGURE 17
This 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 following orifice chart for the proper orifice for a specific elevation.
SPECIFIC ELEVATIONS Model No. 0 to 2,000 - 4,000 - 6,000 - 8,000 2,000' 4,000' 6,000' 8,000' 10,000' 90N30A 38 41 42 43 44 90N50A 30 31 31 32 35 90N65A 26 28 29 30 30
ORDER KIT #49800 44-1 HIGH ALTITUDE KIT
NATURAL GAS
SPECIFIC ELEVATIONS Model No. 0 to 2,000 - 4,000 - 6,000 - 8,000 2,000' 4,000' 6,000' 8,000' 10,000' 90P30A 1/16 53 53 54 54 90P50A 47 49 49 50 51 90P65A 43 44 45 47 48
ORDER KIT #49800 44-1 HIGH ALTITUDE KIT
L.P. GAS
90N75A
33
36
37
38
41
90P75A
51
52
52
53
54
ORDER KIT #49850 2287-2 HIGH ALTITUDE KIT
ORDER KIT #49850 2287-2 HIGH ALTITUDE KIT
ADJUSTING THE BURNER
After the floor furnace has been burning 15 minutes, remove the bottom pan from the outer casing exposing the complete burner assembly. Loosen the screw at the bottom side of the sliding air shutter. Slide the air shutter closed until yellow tips start to appear at the top of the flame. See Figure 19. (75,000 BTU floor furnace has two burners, both of which may need adjustment). Now open the shutter slightly beyond the point that the yellow disappears and the flame burns blue. (See Figure 20). Airborne dust particles may cause flashes or streaks of yellow flame as they are drawn into the flame but will have no effect on the efficiency of the floor furnace. If you are satisfied that the burner is properly adjusted, tighten the set screw to lock the shutter in position. Replace the bottom pan. Check air shutter setting at least twice each season to assure that changing conditions are not causing yellow tipping. Sliding Air Shutter BURNER
Set Screw
Manifold Tube YELLOW IMPROPER FLAME ADJUSTMENT BLUE
CORRECT FLAME ADJUSTMENT
FIGURE 18
FIGURE 19
Page 12
FIGURE 20
ADJUSTING THE BURNER Continued
If difficulty in adjusting the burner is experienced, it may be the result of incorrect gas supply pressure or manifold pressure. Pressure can only be checked and adjusted by a trained service technician using instruments designed for that purpose.
WARNING: Do not attempt to change pressure settings without proper training and instruments. To do so may cause your floor furnace to malfunction resulting in property damage, bodily injury, or death.
The following information is provided for use by a trained service technician with measuring instruments. Minimum Inlet Pressure, Natural Gas............................................................. Minimum Inlet Pressure, Liquefied Petroleum (L.P.) Gas...................................... 4.5 Inches Water Column 11.0 Inches Water Column
Maximum Inlet Pressure for Natural Gas......................................................... 7.0 Inches Water Column Maximum Inlet Pressure, Liquefied Petroleum (L.P.) Gas..................................... 14.0 Inches Water Column (If the inlet pressure is found to exceed 14.0 inches water column, check the performance of the control valve thoroughly as damage may have occurred. If manifold pressure cannot be adjusted, replace the control valve). Manifold Pressure, Natural Gas.................................................................... Manifold Pressure, Liquefied Petroleum (L.P.) Gas............................................ 3.5 Inches Water Column 10.0 Inches Water Column
OPTIONAL OPERATION
Your floor furnace has been designed to meet all safety requirements of the American National Standards Institute and government regulations by offering two modes of operation. OPTION 1. Place the furnace key on the damper control rod (See Figure 21) and turn counterclockwise until the warning flag is concealed and the damper is open. Your floor furnace will now cycle on and off maintaining a moderate grill temperature and an even room temperature. Your floor furnace will function best on this setting during mild weather. OPTION 1 In mild weather, operate furnace with damper open. Furnace will cycle on and off maintaining a moderate grill temperature and an even room temperature. OPTION 2. Turn the furnace key clockwise until the warning flag reading "WARNING GRILL IS HOT Keep off can cause burns" is visible and the damper is closed. The limit control will now cease to function and the floor furnace will now put out the maximum amount of heat until the room temperature reaches the thermostat setting. Use this option only in extremely cold weather. If furnace continues to cycle on limits, assure that damper door is 100% closed by adjusting damper door pin if necessary. OPTION 2 In extremely cold weather, close damper (which exposes warning plate). Furnace will then put out maximum amount of heat until room temperature reaches setting on wall thermostat.
Damper Open
Damper Closed
FIGURE 21 WARNING FLOOR FURNACE GRILLS BECOME HOT WHEN FURNACE IS IN OPERATION. CONTACT OF BARE SKIN WITH GRILL MAY RESULT IN SEVERE BURNS. KEEP CHILDREN OFF, PROVIDE FENCE OR REGISTER GUARD FOR THEIR PROTECTION.
FIGURE 22 LIMIT SWITCH
TEMPERATURE SETTINGS 90{N,P}30A.......................... 90{N,P}50A.......................... 90{N,P}65A.......................... 90{N,P}75A.......................... Page 13 140N 160N 180N 170N
MAINTENANCE INSTRUCTIONS
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. For proper operation, Floor Furnace must be kept clean. At regular intervals turn control valve to off, let cool, remove register and clean dust and foreign material from jacket with vacuum cleaner. Have the Floor Furnace checked by a qualified service technician for venting system, pilot, and burner operation prior to its use each year. Follow a regular service and maintenance schedule for safe and efficient operation. Keep flammable materials away from floor furnace area. Be sure not to obstruct combustion and ventilation air.
WARNING Do not use any kind of solvent or cleaning fluid to clean your floor furnace. It may leave a residue or invisible coating that will burn or smell when you turn your floor furnace on. Use only a damp cloth. Repair service must be performed by qualified persons. The floor furnace must be inspected before initial use. An annual cleaning of floor furnace and safety performance check should be made by a qualified service person. More frequent cleaning may be required when exposed to the excessive lint conditions due to carpeting and bedding material, etc. It is imperative that the control compartment, burners, and circulating air passageways of the floor furnace be kept clean. Any safety screen or guard removed for servicing the floor furnace must be replaced prior to operating heater.
Examine the entire venting system as a routine part of the safety performance check on an annual basis.
TO CLEAN BURNER
1. 2. 3. 4. 5. 6. 7. Remove bottom pan from outer casing. Remove 2 screws from burner support bracket. Remove 2 screws from pilot bracket allowing burner to slide off of manifold and out of floor furnace. Examine the burner. If any distortion is noticed, replace burner. Clean burner ports by inserting a toothpick in ports to remove any debris that might have accumulated. Inspect burner for spider webs or dust buildup during the off-season. If necessary, wash out with garden hose. Re-install and adjust burner.
WARNING This is a gas-fired floor furnace. Keep the area clear of gasoline and other flammable vapor and liquids. All combustible material must be kept clear of this area to avoid fire or explosion.
SERVICE RECORD
SERVICE RECORD
SERVICE RECORD
SERVICE RECORD
Page 14
TROUBLE SHOOTING CHART - MAIN BURNER
SYMPTOM
Flame too large
POSSIBLE CAUSES
1. Defective operator section of gas valve. 2. Burner orifice too large. 3. If installed above 2,000 ft. Too much primary air. 1. Too much primary air. 2. Noisy pilot.
CORRECTIVE ACTION
1. Replace complete valve. 2. Check with local gas company for proper orifice size and replace. 3. Refer to Burner Orifice Section, Pg. 12. Adjust air shutter. See Page 12. 1. Adjust air shutter. See Page 12. 2. Reduce pilot gas with adjusting screw marked pilot on combination gas control valve. See Page 12. 3. Remove burr or replace orifice. (Do not enlarge orifices). 4. See "Flame Too Large" above. 1. Adjust air shutter. See page 12. 2. Clean main burner ports. (Do not enlarge ports). 3. Clean draft hood. 4. Check for dust or lint at air mixer opening and around the shutter. 1. Clean flue passage ways to remove blockage. 2. Adjust air shutter to increase primary air supply. 1. Clean chimney or vent - replace if necessary. 2. Eliminate drafts. 3. See Page 1. 1. Check pilot orifice, close, increase pilot gas flow if necessary by adjusting at combination control valve. See Page 12. 2. Clean burner ports (Do not enlarge ports). 3. Check gas supply pressure. 4. Supply piping is inadequately sized. Consult local gas utility or competent installer. 5. Close air shutter to proper setting as outlined in these instructions (slight yellow tipping is allowable on L.P. gas). 6. Eliminate drafts. 7. See "Venting". 1. Open all manual gas valves. 2. Replace gas valve. 1. See "Venting. 1. Clean or replace valve. 2. To correct this situation contact the utility supplying the gas. 1. Recheck gas input. 2. Check orifice for clogging. If clogged, clean out the hole carefully with a smooth wood toothpick. (Do not in any way enlarge or distort it. 1. This is especially true when a dwelling or room is enlarged. Have the heat loss calculated and compare to the appliance output (70% of input). Your gas company or installer can supply you with this information. If appliance is undersized, replace with correct size unit. 2. Setting of thermostat. See "Lighting and Shutting Down Instructions". 3. Check supply pressure as outlined above. 1. Lower setting of temp. dial. See "Lighting and Shutting Down Instructions". 2. Replace combination control valve.
Flame pops back Noisy Flame
Yellow tip flame (some yellow tipping on L.P. gas is permissible)
3. Burr in orifice (if it whistles or resonates). 4. Excessive gas input. 1. Too little primary air. 2. Clogged main burner ports. 3. Clogged draft hood. 4. Linted up air shutter. 1. 2. 1. 2. 3. 1. Blocked venting. Insufficient primary air. Chimney or vent obstruction. Drafts around appliance. Gas leak. Pilot flame too small.
Floating flame Gas odor
Delayed ignition
2. Burner ports clogged near pilot. 3. Low gas pressure. 4. Pilot decreases in size when main burners come on. 5. Air shutter open too far.
6. 7. Failure to ignite 1. 2. Condensation of water vapor 1. Burner won't turn off 1. 2.
Incorrect gas input
Drafts around appliance. Bad venting. Main gas off. Defective gas valve. Improper venting. Defective or sticking automatic valve. Excessive gas pressure (The supply gas pressure must not exceed 1/2 psi or 14" water column). 1. Gas input not checked. 2. Clogged orifice.
Not enough heat
1. Appliance undersized
2. Thermostat set too low. 3. Incorrect supply pressure. 1. Thermostat set too high. 2. Combination control valve sticks open.
Too much heat
TROUBLE SHOOTING CHART - AUTOMATIC PILOT & VALVE
Burner won't turn on 1. Pilot flame too large or too small. 2. Dirt in pilot orifice. 3. Defective automatic pilot section in combination control valve. 4. Defective Thermocouple. 1. Readjust pilot flame using adjustment screw marked "Pilot" on combination control valve. See Page 10. 2. Clean pilot orifice with air or solvent, do not ream. 3. Replace entire combination control valve. 4. Replace thermocouple.
Page 15
MODELS INCLUDED: 90N30A NAT. 90N50A NAT. 90N65A NAT. 90N75A NAT.
GAS FLOOR FURNACE LIST PRICES Prices and specifications subject to change witout notice. All prices are F.O.B. factory. Specify model number when ordering parts.
3 42
1 4 10 2 13 12 14
18 26 15 44 22 45 43 36 37 38 39 41 40 34
BURNER ASSEMBLY FOR: 90N30A 90N50A 90N65A
16
17
28
41 39 38
36
29 33 31 32 40 31
BURNER ASSEMBLY FOR: 90N75A
32
27
33
34
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 16
MARCH 2007
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 NAT.
90N30A
LIS T PRICE
90N50A
PART NO. LIST PRICE
90N65A
PART NO. LIST PRICE
90N75A
PART NO. LIS T PRICE
REF. PART PART DES CRIPTION NO. NO. Heat Exchanger w/Gasket 1 23074 Gasket, Heat Exchanger N/A 74530 Liner, Complete Assembly 2 23001 Grille, Floor 3 23145 Casing, Complete Assembly 4 23040 Vision Cap, Complete Assy. 10 24048 Lighter Rod 11 74510 Valve Rod 12 24035 Washer, Valve Rod 13 24044 Key, Furnace 14 74205 Instruction Plate, Lighting 16 91256 Valve Rod Indicator Plate 17 24045 Drafthood Assembly w/Gasket 18 23200 Drafthood Gasket w/Screws 19 23225 Thermostat, Millivolt 22 74592 Wire, Thermostat 20' 23 74518 Staples, Thermostat Wire 24 74209 Valve, VS821A1061 Nat.W/74414 Bushing 26 & 37 74315 Disappearing Bushing 1/4x3/8 37 74414 L.P. Conversion Kit N/A 49200 Left Burner w/Pilot Bracket 75 27 N/A Right Burner 75 28 N/A Burner w/Pilot Brkt. & Air Adj. 29 74401 Pilot Generator, Q313A1014 M.V. 31 70098 Pilot Burner w/Orifice Q350A1271 N. 32 74410 Pilot Burner w/Orifice Q350A1589 LP 32 74415 Mounting Screws, Pilot (2) 33 50107 Pilot Tubing w/Fittings 34 74452 Burner Support, Front 36 24036 Burner Support, Rear N/A 24038 Manifold 38 74416 Burner Orifice, Natural Gas 39 74390 Burner Orifice, L.P. Gas 39 74609 Warning Flag 41 24068 Limit Control 60T11 42 *74306 Wiring Harness N/A 74320 Piezo Ignitor 43 70050 Ignitor Wire 44 74351 Electrode 45 74350 Bottom Burner Cover N/A 24039
$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $
$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $
229.50 4.70 186.60 158.40 178.00 15.70 2.30 4.10 1.40 1.40 5.00 2.10 82.80 4.10 22.30 1.50 1.40 182.90 2.20 25.20 N/A N/A 24.80 35.90 10.90 10.90 1.40 7.80 5.70 2.90 7.40 3.80 3.80 10.90 10.40 9.30 6.30 5.70 4.10 9.10
24099 74530 23980 24175 24002 24048 74510 24035 24044 74205 91256 24045 24075 24077 74592 74518 74209 74315 74414 49210 N/A N/A 74401 70098 74410 74415 50107 74452 24036 24038 74416 74406 74606 24068 *74307 74321 70050 74351 74350 24039
$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $
$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $
324.00 4.70 165.70 201.20 203.70 15.70 2.30 4.10 1.40 1.40 5.00 2.10 90.30 5.30 22.30 1.50 1.40 182.90 2.20 25.20 N/A N/A 24.80 35.90 10.90 10.90 1.40 7.80 5.70 2.90 7.40 3.80 3.80 10.90 10.40 9.60 6.30 5.70 4.10 9.10
24499 74532 24380 24475 24402 24048 74510 24035 24044 74205 91256 24045 24477 24077 74592 74518 74209 74315 74414 49220 N/A N/A 74402 70098 74410 74415 50107 74452 24036 24430 74416 74407 74607 24068 *74308 74322 70050 74351 74350 24431
$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $
$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $
369.40 6.60 179.20 256.50 234.40 15.70 2.30 4.10 1.40 1.40 5.00 2.10 93.30 5.30 22.30 1.50 1.40 182.90 2.20 25.20 N/A N/A 27.10 35.90 10.90 10.90 1.40 7.80 5.70 3.20 7.40 3.80 3.80 10.90 10.40 10.60 6.30 5.70 4.10 11.60
24699 74535 24580 24675 24602 24048 74510 24642 24044 74205 91256 24045 24676 24077 74592 74518 74209 74315 74414 49330 74403 74404 N/A 70098 74410 74415 50107 74452 24036 24627 74412 *74408 *74608 24068 *74309 74323 70050 74351 74350 24628
$ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $
412.20 8.10 225.80 300.70 252.80 15.70 2.30 4.20 1.40 1.40 5.00 2.10 98.50 5.30 22.30 1.50 1.40 182.90 2.20 25.20 26.50 24.30 N/A 35.90 10.90 10.90 1.40 7.80 5.70 3.80 26.70 3.80 3.80 10.90 10.40 11.10 6.30 5.70 4.10 13.00
Mr. Contractor, we only sell parts through our wholesalers, but the prices listed a