Empire Comfort Systems DV-215-7SG User Manual

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INSTALLATION INSTRUCTIONS

AND

OWNER'S MANUAL

Installer: Leave these instructions with the consumer.

Consumer: Retaintheseinstructionsforfuture use.

DIRECT VENT WALL FURNACE

MODELS

DV-210-7SG

DV-215-7SG

EFFECTIVE DATE

JUNE 2006

WARNING: Iftheinformationinthismanual isnotfollowedexactly,afireorexplosionmay 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.

Ifyoucannotreachyourgassupplier,call the fire department.

Installationandservicemustbeperformed by a qualified installer, service agency, or the gas supplier.

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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Page 1

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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12433-5-0606

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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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, masonryng

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REQUIREMENTS FOR MASSACHUSETTS

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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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GAS SUPPLY

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.

Recommended Gas Pipe Diameter

 

Pipe Length

Schedule 40 Pipe

Tubing, Type L

 

Inside Diameter

Outside Diameter

 

Nat.

L.P.

Nat.

L.P.

0-10feet

1/2”

3/8”

1/2”

3/8”

0-3meters

12.7mm

9.5mm

12.7mm

9.5mm

10-40feet

1/2”

1/2”

5/8”

1/2”

4-12meters

12.7mm

12.7mm

15.9mm

12.7mm

40-100feet

1/2”

1/2”

3/4”

1/2”

13-30meters

12.7mm

12.7mm

19mm

12.7mm

100-150feet

3/4”

1/2”

7/8”

3/4”

31-46meters

19mm

12.7mm

22.2mm

19mm

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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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Figure 2

Method of Installing a Tee Fitting Sediment Trap

Pressure Testing of the Gas Supply System

1.To check the inlet pressure to the gas valve, a 1/8" (3mm) N.P.T. plugged tapping, accessible for test gauge connection, must be placed immediately upstream of the gas supply connection to the appliance.

2.The appliance and its individual shutoff 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 (3.5 kPa).

3.The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa).

Attention! If one of the above procedures results in pressures in excess of 1/2 psig (14" w.c.) (3.5 kPa) on the appliance gas valve, it will result in a hazardous condition.

Checking Manifold Pressure

Both Propane and Natural gas valves have a built-inpressure regulator in the gas valve. Natural gas models will have a manifold pressure of approximately4.0"w.c.(.996kPa)atthevalveoutletwiththeinletpressure to the valve from a minimum of 5.0" w.c. (1.245kPa) for the purpose of input adjustment to a maximum of 10.5" w.c. (2.61kPa). Propane gas models will have a manifold pressure approximately 10.0" w.c. (2.49kPa) at the valve outlet with the inlet pressure to the valve from a minimum of

11.MAN0" w.c. (2.MZ223739kPa).1forCANthe purpose of input adjustment to a maximum of 13.0" w.c. (3.237kPa).

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12433-5-0606

Page 7

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.

g

l

v

(64mm)

(13mm)

Page 8

12433-5-0606

INSTALLATION INSTRUCTIONS (continued)

tubes.

Installing The Vent Assembly

1.Place provided caulking beneath the edge of the outside wall plate. Use additional caulking to correct uneven wall surface, such as clapboard.

2.Attach 5" (127mm) diameter air inlet tube onto the collar of air drop assembly. Attach caulked, outside wall plate into the 5" (127mm) diameter air inlet tube. Position the outside wall plate sothat5"(127mm)diameterairinlettubehasaslightdownward slopetotheoutside.Thedownwardslopeisnecessarytoprevent the entry of rainwater.Attach outside wall plate to exterior wall with (4) #10 x 1 1/2" (38mm) screws provided.

3.Apply furnace cement to 3" (76mm) diameter flue outlet collar on combustion chamber and to 3" (76mm) diameter collar on vent cap. Attach 3" (76mm) diameter flue outlet tube onto flue outlet collar on combustion chamber. Attach vent cap into the 3" (76mm) diameter flue outlet tube.Attach vent cap to outside wall plate with (3) #10 x 1/2" (13mm) screws provided.

4.Installation is completed.

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

InstallingaVentNearaWindowLedge,OtherTypeofProjection or on Vinyl Siding

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.

Whentheventcapistobeinstalledonvinylsidingoritappearsthat 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 vinyl 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)

Reassembly And Resealing Vent-AirIntake System

When vent-airintake system is removed for servicing the furnace, the following steps will assure proper reassembly and resealing of thevent-airintake assembly.

1. Removeoldfurnacecementfromflueoutletcollaroncombustion

 

chamber and collar of vent cap. Remove old furnace cement

 

from both ends of 3" (76mm) diameter flue outlet tube.

 

2. Removeoldcaulkingbeneaththeedgeoftheoutsidewallplate.

 

Apply new caulking beneath the edge of the outside wall plate.

 

Use additional caulking to correct uneven wall surface, such as

 

clapboard.

 

3. Attach 5" (127mm) diameter air inlet tube onto the collar of air

 

drop assembly. Attach caulked, outside wall plate into the 5"

 

(127mm) diameter air inlet tube. Position the outside wall plate

 

sothat5"(127mm)diameterairinlettubehasaslightdownward

 

slopetotheoutside.Thedownwardslopeisnecessarytoprevent

 

the entry of rainwater.Attach outside wall plate to exterior wall

 

with (4) #10 x 1" (25mm) screws provided.

 

4. Apply furnace cement to 3" (76mm) diameter flue outlet collar

 

on combustion chamber and to 3" (76mm) diameter collar on

 

vent cap. Attach 3" (76mm) diameter flue outlet tube onto flue

 

outlet collar on combustion chamber. Attach vent cap into the

 

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Page 9

Cuttingtheubesfollowing.RefVentr oprocTubPartsedureList,. page 14 to order tubes.

THERMOSTAT LOCATION

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.

Note: Use 16 gauge wire to prevent excessive loss of millivolts.

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:

Figure 6

Across the thermopile terminals, 400-450millivolts with ther-

 

 

mostat OFF.

 

Across the thermopile terminals, 150-250milllivolts with ther-

 

 

mostat 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 mil-

 

 

livolts 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.

Page 10

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