Empire Comfort Systems DV-210-7SG User Manual

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INSTALLATION INSTRUCTIONS

AND

OWNER'S MANUAL

Installer: Leave this manual with the appliance.

Consumer:Retain this manual for future reference.

WARNING: If the information in these instructionsarenotfollowedexactly, afireorexplosion 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 IFYOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

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

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

DIRECT VENT

WALL FURNACE

MODELS

DV-210-7SG

DV-215-7SG

EFFECTIVE DATE

JANUARY 2007

This appliance may be installed in an aftermarket, permanently located, manufactured home (USA only), or mobile home, where not prohibited by state or local codes.

Thisapplianceisonlyforusewiththetypeofgas indicatedontheratingplate. Thisapplianceis notconvertibleforusewithothergases,unless a certified kit is used.

WARNING: If not installed, operated, and maintainedinaccordancewiththemanufacturer'sinstructions,thisproductcouldexposeyou to substances in fuel or from fuel combustion

which can cause death or serious illness.

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TABLE OF CONTENTS

 

SECTION

PAGE

Important Safety Information ......................................................................................................................

3

Safety Information for Users of LP Gas ......................................................................................................

4

Requirements for Massachusetts..................................................................................................................

5

Introduction..................................................................................................................................................

6

Specifications...............................................................................................................................................

6

Gas Supply...................................................................................................................................................

7

Clearances ...................................................................................................................................................

8

Installation Instructions............................................................................................................................

8-9

Thermostat Location..................................................................................................................................

10

Lighting Instructions .................................................................................................................................

11

Pilot Flame Characteristics .......................................................................................................................

12

Main Burner Flame Characteristics ..........................................................................................................

12

Maintenance...............................................................................................................................................

12

Troubleshooting.........................................................................................................................................

13

How to Order Repair Parts.........................................................................................................................

14

Parts List ...................................................................................................................................................

14

Parts View..................................................................................................................................................

15

Optional Blower Installation Instructions .................................................................................................

16

Service Notes.......................................................................................................................................

17-19

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IMPORTANT SAFETY INFORMATION

• Due to high temperatures the appliance should be located

• DONOTputanythingaroundthefurnacethatwillobstruct

out of traffic and away from furniture and draperies.

 

the flow of combustion and ventilation air.

• Children and adults should be alerted to the hazards of

• DO keep the appliance area clear and free from combus-

high surface temperatures and should stay away to avoid

 

tible material, gasoline, and other flammable vapors and

burns or clothing ignition.

 

liquids.

• Young children should be carefully supervised when they

• DOexamineventingsystemperiodicallyandreplacedam-

are in the same room as the appliance.

 

aged parts.

• Clothingorotherflammablematerialshouldnotbeplaced

DOexamineburnersperiodically. Cleanandreplacedam-

on or near the appliance.

 

aged parts.

• Anysafetyscreenorguardremovedforservicinganappli-

CAUTION: Pilot hole cover must be kept tightly closed

ance must be replaced prior to operating the appliance.

 

during operation.

• Keep burner and control compartment clean.

• DO NOT use this heater if any part has been under water.

• Vent cap hot while furnace is in operation.

Immediately call a qualified service technician to inspect

THIS IS A HEATING APPLIANCE

DO NOT OPERATE THIS APPLIANCE WITHOUT FRONT PANEL INSTALLED.

• Installation and repair should be done by a QUALIFIED

the heater and to replace any part of the control system

and any gas control which has been under water.

SERVICE PERSON. The appliance should be inspected

 

before use and at least annually by a qualified service

 

person.

 

• More frequent cleaning may be required due to excessive

 

lint from carpeting, bedding materials, etc. It is impera-

 

tive that control compartments, burners, and circulating

 

air passageways of the appliance be kept clean.

 

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SAFETY INFORMATION FOR USERS OF LP-GAS

Propane (LP-Gas)is a flammable gas which can cause fires and explosions. In its natural state, propane is odorless and colorless. Youmaynotknowallthefollowingsafetyprecautions whichcanprotectbothyouandyourfamilyfromanaccident. Read them carefully now, then review them point by point

with the members of your household. Someday when there may not be a minute to lose, everyone's safety will depend on knowing exactly what to do. If, after reading the following information, you feel you still need more information, please contact your gas supplier.

LP-GASWARNING ODOR

If a gas leak happens, you should be able to smell the gas because of the odorant put in the LP-Gas.That's your signal to go into immediate action!

• Do not operate electric switches, light matches, use your

• Use your neighbor's phone and call a trained LP-Gasservice

phone. Do not do anything that could ignite the gas.

person and the fire department. Even though you may not

• Get everyone out of the building, vehicle, trailer, or area. Do

continue to smell gas, do not turn on the gas again. Do not

that IMMEDIATELY.

re-enterthe building, vehicle, trailer, or area.

• Close all gas tank or cylinder supply valves.

Finally,lettheservicemanandfirefighterscheckforescaped

LP-Gasis heavier than air and may settle in low areas such

gas. Have them air out the area before you return. Properly

as basements. When you have reason to suspect a gas leak,

trained LP-Gasservice people should repair the leak, then

keep out of basements and other low areas. Stay out until

check and relight the gas appliance for you.

firefighters declare them to be safe.

 

NO ODOR DETECTED - ODOR FADE

Some people cannot smell well. Some people cannot smell the odor of the chemical put into the gas. You must find out if you can smell the odorant in propane. Smoking can decrease your ability to smell. Being around an odor for a time can affect your sensitivity or ability to detect that odor. Sometimes other odors in the area mask the gas odor. People may not smell the gas odor or their minds are on something else. Thinking about smelling a gas odor can make it easier to smell.

The odorant in LP-gasis colorless, and it can fade under some circumstances. For example, if there is an underground leak, the movement of the gas through soil can filter the odorant. Odorants

in LP-Gasalso are subject to oxidation. This fading can occur if there is rust inside the storage tank or in iron gas pipes.

Theodorantinescapedgascanadsorborabsorbontoorintowalls, masonry and other materials and fabrics in a room. That will take some of the odorant out of the gas, reducing its odor intensity.

LP-Gasmay stratify in a closed area, and the odor intensity could vary at different levels. Since it is heavier than air, there may be more odor at lower levels.Always be sensitive to the slightest gas odor.Ifyoudetectanyodor,treatitasaseriousleak.Immediately go into action as instructed earlier.

SOME POINTS TO REMEMBER

Learn to recognize the odor of LP-gas.Your localLP-GasDealer can give you a "Scratch and Sniff" pamphlet. Use it to find out what the propane odor smells like. If you suspect that yourLP-Gashas a weak or abnormal odor, call yourLP-GasDealer.

If you are not qualified, do not light pilot lights, perform service, or make adjustments to appliances on the LP-Gassystem.Ifyouarequalified,consciouslythinkabouttheodor ofLP-Gasprior to and while lighting pilot lights or performing service or making adjustments.

Sometimes a basement or a closed-uphouse has a musty smell that can cover up theLP-Gasodor. Do not try to light pilot lights, perform service, or make adjustments in an area where the conditions are such that you may not detect the odor if there has been a leak ofLP-Gas.

Odor fade, due to oxidation by rust or adsorption on walls of new cylinders and tanks, is possible. Therefore, people should be particularly alert and careful when new tanks or cylinders are placed in service. Odor fade can occur in new tanks, or reinstalled old tanks, if they are filled and allowed

to set too long before refilling. Cylinders and tanks which have been out of service for a time may develop internal rust which will cause odor fade. If such conditions are suspected to exist, a periodic sniff test of the gas is advisable. If you haveanyquestionaboutthegasodor,callyourLP-gasdealer.A periodic sniff test of theLP-gasis a good safety measure under any condition.

If, at any time, you do not smell the LP-Gasodorant and you thinkyoushould,assumeyouhavealeak.Thentakethesame immediateactionrecommendedabovefortheoccasionwhen you do detect the odorizedLP-Gas.

If you experience a complete "gas out," (the container is under no vapor pressure), turn the tank valve off immediately. If the container valve is left on, the container may draw in some air through openings such as pilot light orifices. If this occurs, some new internal rusting could occur. If the valve is left open, then treat the container as a new tank. Always be sure your container is under vapor pressure by turning it off at the container before it goes completely empty or having it refilled before it is completely empty.

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REQUIREMENTS FOR MASSACHUSETTS

For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1.INSTALLATIONOFCARBONMONOXIDEDETECTORS.Atthetimeofinstallationofthesidewallhorizontal vented gas fueled equipment, the installing plumber or gasfittershallobservethatahardwiredcarbonmonoxide detectorwithanalarmandbatteryback-upisinstalledonthe floor level where the gas equipment is to be installed. Inaddition,theinstallingplumberorgasfittershallobserve that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It

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INTRODUCTION

Introduction

Always consult your local Building Department regarding regulations, codes or ordinances which apply to the installation of a direct vent wall furnace.

Instructions to Installer

1.Installer must leave instruction manual with owner after installation.

2.Installermusthaveownerfilloutandmailwarrantycardsupplied with furnace.

3.Installer should show owner how to start and operate furnace and thermostat.

Warning:

Anychangetothisfurnaceoritscontrolcanbedangerous. This is a heating appliance and any panel, door or guard removed for servicing an appliance must be replaced prior to operating the appliance.

General Information

ThisfurnaceisdesigncertifiedinaccordancewithAmericanNational Standard/CSA Standard Z21.86 and CSA 2.32 by the Canadian StandardsAssociation, as a Gravity DirectVentWall Furnace to be installed on an outside wall according to these instructions.

Any alteration of the original design, installed other than as shown in these instructions or use with a type of gas not shown on the ratingplateistheresponsibilityofthepersonandcompanymaking the change.

Important

All correspondence should refer to complete Model No., Serial No. and type of gas.

Notice: During initial firing of this unit, its paint will bake out and smokewilloccur. Topreventtriggeringofsmokealarms,ventilate the room in which the unit is installed.

Installation in Residential Garages

Gas utilization equipment in residential garages shall be installed so that all burners and burner ignition devices are located not less than 18" (457mm) above the floor.

Such equipment shall be located, or protected, so it is not subject to physical damage by a moving vehicle.

Qualified Installing Agency

Installationandreplacementofgaspiping,gasutilizationequipment or accessories and repair and servicing of equipment shall be performedonlybya qualifiedagency. Theterm"qualifiedagency" meansanyindividual,firm,corporationorcompanywhicheitherin person or through a representative is engaged in and is responsible for (a) the installation or replacement of gas piping or (b) the connection, installation, repair or servicing of equipment, who is experienced in such work, familiar with all precautions required and has complied with all the requirements of the authority having jurisdiction.

State of Massachusetts: The installation must be made by a licensed plumber or gas fitter in the Commonwealth of Massachusetts.

Theinstallationmustconformwithlocalcodesor,intheabsenceof local codes, with the National Fuel Gas Code ANSI Z223.1/NFPA 54* Natural Gas and Propane Installation Code, CSA B149.1.

*Available from the American National Standards Institute, Inc., 11 West 42nd St., New York, N.Y. 10036.

High Altitudes

For altitudes/elevations above 2,000 feet (610m) , input ratings shouldbereducedattherateof4percentforeach1,000feet(305m) above sea level. Canadian High Altitudes for locations having an elevation above mean sea level between 2,000 feet (610m) and 4,500 feet (1370m), the manifold pressure is to be decreased from 4.0"w.c.(.996kPa)to3.2"w.c.(.797kPa)forNaturalGasandfrom 10.0" w.c. (2.49kPa) to 8.0" w.c. (1.99kPa) for Propane Gas.

Installation on Rugs and Tile

Ifthisapplianceistobeinstalleddirectlyoncarpeting,tile,orother combustiblematerial,otherthanwoodflooring,theapplianceshall be installed on a metal or wood panel extending the full width and depth of the appliance.

The base referred to above does not mean the fire-proofbase as used on wood stoves. The protection is primarily for rugs that may be extremely thick andlight-colortile that may discolor.

SPECIFICATIONS

Model

DV-210

DV-215

Input BTU/HR (KW/H)

10,000 (2.9)

15,000 (4.4)

Height

21 3/8" (543mm)

24 7/8" (632mm)

Width

16 1/4 (413mm)

20 1/4" (514mm)

Depth

9 3/8" (239mm)

9 3/8" (239mm)

Gas Inlet

1/2" (13mm)

1/2" (13mm)

 

Options for Above Furnances

 

Blower

DVB-1

DVB-1

Vinyl Siding Vent Kit

DV-822

DV-822

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Locating Gas Supply

The gas line can enter the unit either through the floor or outside wall. Thegaslineopeningshouldbemadeatthistime. Locationoftheopening will be determined by the position of floor joists and the valve and union used for servicing.

Note: Never use plastic pipe. Check to confirm whether your local codes allow copper tubing or galvanized.

Note: Since some municipalities have additional local codes, it is always best to consult your local authority and installation code.

The use of the following gas connectors is recommended:

ANS Z21.24Appliance Connectors of Corrugated MetalTubing and Fittings

ANS Z21.45 Assembled Flexible Appliance Connectors of Other Than All-MetalConstruction

The above connectors may be used if acceptable by the authority having jurisdiction. The state of Massachusetts requires that a flexible appliance connector cannot exceed three feet in length.

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CLEARANCES

1.In selecting a location for installation, it is necessary to provide adequate accessibility clearances for servicing and proper installation.

2.Althoughcertifiedfor0clearancetothefloor,the unitisheldin placebyawallbracket. Enoughclearance[2"(51mm)suggested] to allow changing or adding floor covering is recommended. Other clearances to combustible construction:

Sides 1" (25mm) and 12" (305mm) from the top.

3.Note the position of the vent relative to the center of the unit. The DV-210has the vent in the center. TheDV-215vent is 2" (51mm) off center to the right.

4.The minimum distance from the center of the outside vent to the nearest outside corner or obstruction is 16" (406mm).

5.The DV-210/DV-215minimum wall depth is 4 1/2" (114mm) and maximum wall depth is 13" (330mm). The use of tubes not supplied by the manufacturer result in unsatisfactory performance.

Theventterminalofadirectventappliance,withaninputof10,000 Btu per hour (3 kW) or less shall be located at least 6" (150mm) fromanyairopeningintoabuilding,andsuchanappliancewithan input over 10,000 Btu per hour (3 kW) but not over 50,000 Btu per hour (14.7 kW) shall be installed with a 9" (229mm) vent terminal clearance and the bottom of the vent terminal and the air intake shall be located at least 12" (305mm) above grade.

WARNING: The nearest point of the vent cap should be a minimum horizontal distant of six (6) feet (1.8m) from any pressure regulator. In case of regulator malfunction, the six

(6) feet (1.8m) distance will reduce the chance of gas entering the vent cap.

INSTALLATION INSTRUCTIONS

The furnace is to be located on an outside wall. Locate wall studs so that wall opening will be located between wall studs. One wall stud can be used for attachment of inside wall plate. The wall opening required as shown in Figure 3 is a minimum diameter of 6 1/4 (159mm) inches. The inside wall plate and the outside wall plate are large enough to permit a wall opening diameter of 8 inches (203mm).

A template is provided in furnace carton for positioning furnace on the wall. Also, refer to Figure 3 for positioning the furnace on wall and for locating gas line connection.

(1) toggle bolt provided.

(64mm)

(13mm)

Figure 4

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Eigure 3Installing Inside Wall Plate

3" (76mm) diameter flue outlet tube.Attach vent cap to outside wall plate with (3) #10 x 1/2" (13mm) screws provided.

5. Reassembly and resealing vent-airintake system is completed.

InstallingaVentNearaWindowLedge,OtherTypeofProjection or on Siding (vinyl, aluminum, etc.)

Direct vent furnaces are designed to be installed on a uniform outside wall. When the wind comes from any angle (up, down or from either side), it must hit the vent cap equally over both the air inlet and the flue outlet portions of the vent. Any wall projection, such as a door or window casing, which disturbs the wind on one side of the air inlet section will result in back pressure on the flue section smothering the flame and eventual pilot outage.

When the vent cap is to be installed on siding or it appears that a projection within 6" (152mm) of any side of the air inlet section couldshieldtheairinletsection,theentireventshouldbesupported away from the wall at least the distance of the projection. 2" x 4" (51mm x 102mm) framing whose outside dimensions match the overall dimensions of the mounting plate is recommended. The 2" x 4" (51mm x 102mm) framing protects siding from possible warpage or discoloration.All joints can then be sealed and painted. The wall depth plus the additional depth of the 2" x 4" (51mm x 102mm) framing should not exceed a total depth of 13" (330mm)

for DV-210/DV-215.(See Figure 5)

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These heating thermostats are specially designed for use on selfgenerating systems. They should never be used on line or low voltage A.C. circuits.

Exterior Wall — The thermostat may be mounted on an exterior wall above the heater if it is located in the same stud space as the vent tubes and is a minimum of 6" (152mm) above the heater.

Interior Wall — The thermostat should be installed on an inside wall away from the unit but in the same room.

It is important to use wire of a gauge proper for the length of the wire:

RECOMMENDED WIRE GAUGES

 

Maximum Length

Wire Gauge

 

1' to 10'

18

 

10' to 25'

16

Figure 6

25' to 35'

14

 

Proper operation depends on a good pilot flame. The flame must cover the top of the thermopile. Cleaning of the pilot orifice and burner may be required due to spiders.

System Check

A millivolt meter is required to check the system. The millivolt readings should be:

Across the thermopile terminals, 400-450millivolts with thermostat OFF.

Across the thermopile terminals, 150-250milllivolts with thermostat ON.

Across the thermostat wires at the valve, less than 30 millivolts with thermostat ON.

Across the thermostat wires at the thermostat, less than 5 millivolts with thermostat ON. (Strong winds, dirty pilot and low pressure will reduce readings.)

Piezo Pilot Ignitor Instructions

Depressing the piezo ignitor button completely causes a spark to occur at the pilot. This is a substitute for a match which requires opening the pilot hole cover.

To light the pilot, it is important that the electrode be 1/8" (3mm) from the thermopile. The spark must occur at the point the burner flame hits the thermopile. The end of the electrode will be red hot with the pilot on.

On a new installation with air in the gas line, it is suggested that a match be used. The match will light the pilot faster than the piezo under this condition.

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