COZY W255GPPD, Installation And Operating Instructions Manual

Page 1: ...eat exchanger may smoke slightly upon initial firing Please provide adequate ventilation if this occurs This unit is NOT to be installed in mobile homes Cozy Heating Systems LLC cozyheaters com 855 589 5380 3230 Industrial Pkwy Jeffersonville IN 47130 Installation maintenance service troubleshooting repairs must be performed by a qualified service agency DO NOT attempt any of these procedures if y...

Page 2: ...ordinances Before planning or making the installation be sure it complies with all phases of the local heating code Or in the absence of local codes with the latest edition of National Fuel Gas Code ANSI Z223 1 or CAN1 B149 The appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the latest edition of National Electrical Code A...

Page 3: ...This heater may be installed without recessing into stud space by using optional FSK Free Standing Kit IPI Intermittent Pilot Ignition Type of Pilot used with IID Heaters MODEL NUMBERS Gas Type Type of Control Height Width Depth Input BTU HR Type of Pilot Vent size Gas Inlet Approximate Shipping Weight Rear Model Num Register Kit Weight Fan Kit Model Num Weight W355GPPR W355GPPD Natural Millivolt ...

Page 4: ...epth of the heater 8 Installation and repair must be done by a qualified installer or service technician The wall furnace must be inspected before use and at least annually by a qualified service technician SAFETY The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in...

Page 5: ...orrect size by a qualified installer service technician or the gas supplier CONTROLS Model 0 2 000 4 000 6 000 8 000 No 2 000 4 000 6 000 8 000 10 000 W255GPPR 43 44 45 47 48 W255GPPD 43 44 45 47 48 W355GPPR 36 38 40 41 43 W355GPPD 36 38 40 41 43 ORDER KIT 49820 45 1 High Altitude Kit Model 0 2 000 4 000 6 000 8 000 No 2 000 4 000 6 000 8 000 10 000 W505GPPR 43 44 45 47 48 W505GPPD 43 44 45 47 48 ...

Page 6: ...ked with insulation or other objects Each of these openings using vertical ducts shall have a minimum free area of one square inch per 4 000 btu hr of total input rating of all gas appliances See Figure 1 B and 1 C If horizontal ducts are used the minimum free area shall be one square inch per 2 000 btu hr of total input rating of all gas appliances Fresh make up air can also be provided through a...

Page 7: ...g season Manual Reset Switch The switch when activated will break the thermostat circuit turning off the main burner flame Before the burner will relight the switch must be manually reset See Figure 4 A on page 8 for location of the manual reset blocked flue switch To reset the switch insert a slender rigid object i e screwdriver through the front panel louvers and push the reset button down See F...

Page 8: ... plate to anchor and seal the vent system See Figure 6 FIG 3 Chimney More than 10 10 2 Min 3 Min Height above any roof surface within 10 horizontally Ridge 10 or Less 2 Min 3 Min Chimney Ridge FIG 4 B FIG 4 A Draft Diverter Relief Opening Combustion Chamber Man Reset Blocked Flue Switch Switch Gas Control Wire Reset Button FIG 6 Installation of B W Gas Vent for one story buildings or for first flo...

Page 9: ...ugh floor plate See Fig 7 A STEP 4 Remove double ceiling plate between studs Install one ceiling plate spacer across the cut out in ceiling plate Install vent pipe into position be sure to lock bottom of vent pipe into the base plate Nail the second ceiling plate spacer in place See Figure 6 on page 8 FIG 7 C NOTE Front panel must be in front of plaster ground channel Do not hang it over front of ...

Page 10: ...ll opening until legs rest on floor plate and are flush to finished wall For proper combustion level heater front to back and side to side Nail legs to studs DO NOT BEND LEGS as this will put the entire unit into a bind and cause expansion noises See Figure 8 A STEP 8 A drip leg and a manual valve equipped with a 1 8 N P T plugged tapping accessible for test gauge connection should be installed im...

Page 11: ...LOWING STEPS MOUNTING PLATE MUST BE MOUNTED AS DIRECTED BELOW OR WIRE HARNESS WILL NOT REACH 1 PLEASE NOTE A OF THIS STEP Do not mount the PilotPro any higher than the top of the access door of the housing 2 PLEASE NOTE B OF THIS STEP Align the PilotPro very close to the back edge of the housing 3 PLEASE NOTE C OF THIS STEP Be sure to face the notch cutout of the mounting plate 30 toward the wall ...

Page 12: ...ed wall and slide down until rear flange of top outer panel is wedged tight against the front of the plaster ground channel and flush with wall CAUTION DO NOT HANG FRONT PANEL BEHIND OVER FRONT LIP THE PLASTER GROUND CHANNEL AS THIS COULD RESULT IN EXCESSIVE NOISE Open bottom door of front panel and place sheet metal screw into locking latch Secure top of front panel to header plate with screw pro...

Page 13: ...ate 30 On the inside of the heater you will see orange and black wires extending from the burner Lead the orange pilot ignitor wire 40 and black flame sensor wire 42 out of the heater beside the wires you have just directed in 29 30 42 40 42 40 Tuck the wires around the edge of the heater housing against the wall and inside the heater ...

Page 14: ...sure it is firmly seated 29 40 I STEP 2 Plug the black flame sensor wire 42 into the port labeled S on the control module 29 Ensure it is firmly seated 29 42 NOTE Base of the connector terminal may be slightly exposed 42 S ELECTRICAL CONNECTION WARNING Please Use Caution While Installing the Electrical Connection ...

Page 15: ...re that all of the connections are tightened firmly orange wire TH TP THTP black wire green wire STEP 3 Run a cable tie 48 through the small hole beside the notch on the mounting plate 30 Gather all the wires from the control module 29 with the cable tie 48 Guide any excess wire length back into the heater 48 30 29 ELECTRICAL CONNECTION WARNING Please Use Caution While Installing the Electrical Co...

Page 16: ...ing or death 38 R e d W i r e A Connect bare brown SWI wire from the control module wiring harness 38 to the white thermostat wire B Connect the brown male blade quick connect SWI wire from the control module wiring harness 38 to the blue female quick connect from safety switch A B C Connect the bare blue wire from safety switch to the red thermostat wire C ELECTRICAL CONNECTION WARNING Please Use...

Page 17: ...ify proper operation after servicing and secure wires away from sharp edges flames or hot surfaces inside and outside the unit RED ORANGE IGNITION BLACK TP BLACK SENSOR BLACK GREEN TH BROWN BLUE BLUE ORANGE THTP BROWN RED WHITE IID Pilot Assembly Battery Pack Ignition Control Module IID Valve Safety Switch Thermostat ELECTRICAL CONNECTION WARNING Please Use Caution While Installing the Electrical ...

Page 18: ... bracket Fix the wires in place neatly by attaching them with a cable tie 48 to the valve bracket 50 Do not allow the bundled wires to hang beyond the edge of the valve bracket C and keep the bundled wires below the lower part of the burner D NOTE Keep all wires away from the burner continue to page 20 B 48 D C 50 48 48 FOLLOW THIS STEP IF THE PILOT PRO IS ON THE RIGHT SIDE OF THE HOUSING Proceed ...

Page 19: ...ped bracket inside the liner B Lead the bundle of wires through the gap between the valve and valve bracket Do not allow the bundled wires to hang beyond the edge of the valve bracket C and keep the bundled wires below the lower part of the burner D NOTE Keep all wires away from the burner FOLLOW THIS STEP IF THE PILOT PRO IS ON THE LEFT SIDE OF THE HOUSING Go back to step 7 A if the Pilot Pro is ...

Page 20: ...ies 46 in the Battery pack 28 2a Initial startup of the pilot pro system may take several minutes due to air in the PILOT gas line 2b After turning up thermostat the ignitor will begin to spark After 1 minute it will stop 2c IF PILOT DOES NOT LIGHT Lower thermostat to OFF then turn it back up 2d Ignitor will start to spark 2e Repeat steps 2b through 2d until the pilot lights 2f Visually determine ...

Page 21: ...tion with the appliance burner both cold and hot Perform this step as many times as is necessary to satisfy yourself that the automatic intermittent pilot system is operating properly Sequence the appliance through at least three 3 operating cycles Ensure Ignitor sparks only against the hood of the pilot Ignitor should not spark against the flame sensor brackets heating chamber burner etc Adjust i...

Page 22: ...e dampers 5 Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously 7 Test for spillage fr...

Page 23: ...1018454 D Page 23 MODELS W255GPPR W255GPPD W355GPPR W355GPPD W505GPPR W505GPPD LIGHTING INSTRUCTIONS IID PILOT ...

Page 24: ... of the appliance be kept clean STEP 2 If the appliance has been equipped with the optional WFF81 C fan kit assembly the bearings of the motor should be oiled every six months with approximately 2 drops of S A E 20 oil STEP 3 The appliance area must be kept clear and free of any combustible materials gasoline and other flammable vapors and liquids STEP 4 It is essential that the flow of combustion...

Page 25: ...s advised that the burner flames be checked at least twice during the heating season for any changes in burner characteristics Vacuum burner compartment at start of heating season or as often as needed BURNER FLAME ADJUSTMENT Stainless Steel Burner IID PILOT LADDER SCHEMATIC W255GPPR W255GPPD W355GPPR W355GPPD W505GPPR W505GPPD WARNING If any of the original wire as supplied with the appliance mus...

Page 26: ...on over plaster ground and attach with sheet metal screws provided STEP 5 Damper as shown in Figure 13 C on page 27 can be adjusted from full open for maximum heat to fully closed 40542 A REAR REGISTER KIT Optional Accessory Installation Instructions for Gravity Vented Wall Furnaces FIG 12 A ROUGH IN DIMENSIONS FOR REAR REGISTER STUD PLASTER STUD PLASTER HOLE FOR BACK REGISTER OPENING 7 8 FROM EAC...

Page 27: ...ions for Gravity Vented Wall Furnaces FIG 13 A FIG 13 C INNER PANEL REAR REGISTER GRILLE 2 X 4 UPRIGHT FINISHED WALL CASING OPEN POSITION DAMPER CLOSED POSITION PLASTER GROUND FRAME FIG 13 B RETAINER SCREW HOLES CASING OPENING HEATER CASING PLASTER GROUND FRAME REAR REGISTER GRILLE FINISHED WALL ...

Page 28: ...ed STEP 4 Remove junction box and connect 115v power supply in accordance with the wiring diagram Replace junction box STEP 5 Set fan kit on top of wall furnace front panel Slot should align with the nut sert Secure fan kit to wall mounting bracket with thumb screw provided NOTE This fan kit is to be installed after installation of the wall furnace and with the wall furnace front panel in place FI...

Page 29: ...1018454 D Page 29 TROUBLESHOOTING W255GPPR W255GPPD W355GPPR W355GPPD W505GPPR W505GPPD Cozy Heating Systems LLC cozyheaters com 855 589 5380 3230 Industrial Pkwy Jeffersonville IN 47130 ...

Page 30: ...t air mixer opening around the shutter Clean as necessary 1 Clean flue passageways to remove blockage 2 Adjust air shutter to increase primary air supply See Page 25 1 Gas leak 2 Chimney or flue obstruction 3 Drafts around appliance Gas Odor 1 Shut off gas service immediately Check piping Call gas company See Page 1 2 Clean flue 3 Eliminate drafts 1 Pilot flame too small 2 Burner ports clogged nea...

Page 31: ...ut 70 of input Your gas company or installer can supply you with this information If appliance is undersized replace with correct size unit 2 Raise setting of Temperature Dial See Lighting Shutting Down Instructions on page 23 3 See page 5 for gas pressure 1 Check or clean the pilot orifice See page 5 for gas pressure 2 Clean pilot orifice with air or solvent do not ream 3 Replace entire combinati...

Page 32: ...ned from the vent pipe manufacturer on top of our header plate This will lock the vent pipe down and prevent the draft diverter from shoving it up Check the connection on both the switch and the gas valve Tighten if necessary Correct vent system A The vent should terminate a minimum of 12 feet above the floor See Figure 7 E on page 10 Also the top of the vent must be at least 2 foot above any obst...

Page 33: ...1018454 D Page 33 PARTS LIST W255GPPR W255GPPD W355GPPR W355GPPD W505GPPR W505GPPD Cozy Heating Systems LLC cozyheaters com 855 589 5380 3230 Industrial Pkwy Jeffersonville IN 47130 ...

Page 34: ...IID Models see diagram on pg 36 BURNER ASSEMBLY When ordering any component in the Burner Assembly specify either Honeywell or Robertshaw components For IID Models see diagram on pg 36 THERMOSTAT 21 THERMOSTAT 21 NOTE Parts schematic drawings on current models are shown at cozyheaters com Specifications subject to change without notice HOW TO PROPERLY ORDER PARTS In addition to the part descriptio...

Page 35: ...arry Over Tapping 84071 14 Orifice Coupling 84631 84631 15 Elbow 3 8 90 Degree 84124 84124 ORIFICES 16 Nat Orifice for IID 84639 43 84642 36 95274 43 16 Nat Orifice for 0 2 000 ft 84639 43 84642 36 95274 43 16 Nat Orifice for 2 4 000 ft 95102 44 95009 38 72141 44 16 Nat Orifice for 4 6 000 ft 80025 45 95010 40 78163 45 16 Nat Orifice for 6 8 000 ft 80120 47 80167 41 95272 47 17 Manifold 84072 17A ...

Page 36: ...ts schematic drawings on current models are shown at cozyheaters com Specifications subject to change without notice 34 32 34 32 36 36 36 36 36 34 34 31 29 30 28 34 36 36 33 33 Gravity Wall Furnace IID IID Pilot Assembly 42 38 39 27 50 51 51 52 35 40 49 41 37 ...

Page 37: ... 1018001 39 Outlet Plug 1 1018037 40 Ignitor Pilot 1 1018634 41 Flame Sensor 1 1018350 42 Wire Flame Sensor 1 1018302 43 Label Ladder Schematic 1 1018045 1018045SP 1018045FR 44 Label Wiring Diagram 1 1018044 1018044SP 1018044FR 45 Lighting Instructions 1 1018055 1018053 1018054 46 1 5V D Cell Battery 2 1018416 47 Electrical Sleeving 6 1018501 48 Tie Cable 7in 8 B 6395 49 Nut Flame Sensor 1 1018351...

Page 38: ...n Single Wall Models Only 71 73 72 74 69 70 NOTE Parts schematic drawings on current models are shown at cozyheaters com Specifications subject to change without notice HOW TO PROPERLY ORDER PARTS In addition to the part description and numbers please be prepared to provide Model number serial number type of gas used This information can be found on the rating plate that is attached to the heater ...

Page 39: ...per Right Side 1 40416 56 Upper Front 1 40418 57 Left Side Assembly 1 40422 PART DESCRIPTION REF QTY PART NO 40542 A REAR REGISTER KIT W25 35 Models Only 69 Damper 1 40375 70 Damper Spring 1 40377 71 Frame Assembly 1 40365 72 Register Chain 1 40379 73 Bell Pull 1 85003 74 Register Assembly 1 40355 Installation Manual 1 84504 PART DESCRIPTION REF QTY PART NO WFF81 C FAN KIT Fits All Models 58 Fan C...

Page 40: ...ller In the event service under this warranty is needed the user of the product shall request such service directly from the installer If the user is unable to locate the installer the user should write directly to the manufacturer and the name of an alternative service source will be supplied The product safety registration card packed inside the appliance must be completed and returned to the fa...