Empire Comfort Systems DV-35-2SG User Manual

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INSTALLATION INSTRUCTIONS

AND

OWNER'S MANUAL

DIRECT VENT

WALL FURNACE

MODELS

DV-25-2SG

DV-35-2SG

Installer: Leave this manual with the appli-

 

 

 

ance.

 

EFFECTIVE DATE

Consumer:Retain this manual for future refer-

 

 

JANUARY 2007

 

ence.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING: If the information in these instruc-

 

 

 

 

 

tionsarenotfollowedexactly, afireorexplosion

 

 

 

 

may result causing property damage, personal

 

 

 

 

injury or loss of life.

 

 

 

 

 

 

 

 

— Do not store or use gasoline or other flamma-

 

 

Thisappliancemaybeinstalledinanaftermarket,

 

ble vapors and liquids in the vicinity of this or

 

 

 

permanently located, manufactured home (USA

 

any other appliance.

 

 

 

only) or mobile home, where not prohibited by

— WHAT TO DO IFYOU SMELL GAS

 

 

state or local codes.

 

• Do not try to light any appliance.

 

This appliance is only for use with the type of gas

 

• Do not touch any electrical switch; do not

 

 

 

indicated on the rating plate. This appliance is

 

use any phone in your building.

 

 

 

not convertible for use with other gases, unless a

 

• Immediately call your gas supplier from a

 

 

 

certified kit is used.

 

neighbor’s phone. Follow the gas suppli-

 

 

 

 

 

er’s instructions.

 

 

 

 

• If you cannot reach your gas supplier, call

 

 

WARNING: If not installed, operated and

 

the fire department.

 

 

 

maintainedinaccordancewiththemanufacturer's

— Installation and service must be performed by

 

 

instructions, this product could expose you to

 

a qualified installer, service agency or the gas

 

substances in fuel or from fuel combustion which

 

supplier.

 

can cause death or serious illness.

 

 

 

 

 

12434-9-0107

Page 1

TABLE OF CONTENTS

 

SECTION

PAGE

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

3

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

4

Requirments for Massachusetts ...................................................................................................................

5

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

6

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

6

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

7

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

8

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

8-10

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

10

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

11

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

12

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

12

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

13

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

13

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

14

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

14

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

15

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

16-17

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

18-19

Page 2

12434-9-0107

IMPORTANT SAFETY INFORMATION

THIS IS A HEATING APPLIANCE

DO NOT OPERATE THIS APPLIANCE WITHOUT FRONT PANEL INSTALLED.

• Duetohightemperaturestheapplianceshouldbelocated

circulating air passageways of the appliance be kept

out of traffic and away from furniture and draperies.

clean.

• Children and adults should be alerted to the hazards of

• DO NOT put anything around the furnace that will ob-

highsurfacetemperaturesandshouldstayawaytoavoid

struct the flow of combustion and ventilation air.

burns or clothing ignition.

• DO keep the appliance area clearand free from combus-

 

• Youngchildrenshouldbecarefullysupervisedwhenthey

tible material, gasoline and other flammable vapors and

are in the same room as the appliance.

liquids.

• Clothingorotherflammablematerialshouldnotbeplaced

• DO examine venting system periodically and replace

on or near the appliance.

damaged parts.

• Anysafetyscreenorguardremovedforservicinganappli-

• DO make a periodic visual check of pilot and burner.

ance must be replaced prior to operating the appliance.

Clean and replace damaged parts.

• Keep burner and control compartment clean.

• CAUTION: Pilot hole cover must be kept tightly closed

• Vent cap hot while furnace is in operation.

during operation.

• DONOTusethisheaterifanyparthasbeenunderwater.

• InstallationandrepairshouldbedonebyaQUALIFIED

Immediately call a qualified service technician to inspect

SERVICEPERSON. Theapplianceshouldbeinspected

the heater and to replace any part of the control system

before use and at least annually by a qualified service

and any gas control which has been under water.

person. More frequent cleaning may be required due to

 

excessive lint from carpeting, bedding materials, etc. It

 

is imperative that control compartments, burners and

 

 

 

12434-9-0107

Page 3

SAFETY INFORMTAION FOR USERS OF LP-GAS

Propane (LP-Gas)is a flammable gas which can cause fires

by point with the members of your household. Someday

and explosions. In its natural state, propane is odorless and

when there may not be a minute to lose, everyone's safety

colorless.You may not know all the following safety precau-

will depend on knowing exactly what to do. If, after read-

tions which can protect both you and your family from an

ing the following information, you feel you still need more

accident. Read them carefully now, then review them point

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

in LP-Gasalso are subject to oxidation. This fading can occur if

odor of the chemical put into the gas. You must find out if you

there is rust inside the storage tank or in iron gas pipes.

can smell the odorant in propane. Smoking can decrease your

Theodorantinescapedgascanadsorborabsorbontoorintowalls,

ability to smell. Being around an odor for a time can affect your

masonry and other materials and fabrics in a room. That will take

sensitivity or ability to detect that odor. Sometimes other odors

some of the odorant out of the gas, reducing its odor intensity.

in the area mask the gas odor. People may not smell the gas odor

LP-Gasmay stratify in a closed area, and the odor intensity could

or their minds are on something else. Thinking about smelling a

gas odor can make it easier to smell.

vary at different levels. Since it is heavier than air, there may be

The odorant in LP-gasis colorless, and it can fade under some

more odor at lower levels.Always be sensitive to the slightest gas

odor. If you detect any odor, treat it as a serious leak. Immediately

circumstances. For example, if there is an underground leak, the

go into action as instructed earlier.

movement of the gas through soil can filter the odorant. Odorants

 

SOME POINTS TO REMEMBER

Learn to recognize the odor ofLP-gas. Your local LP-Gas

to set too long before refilling. Cylinders and tanks which

Dealer can give you a "Scratch and Sniff" pamphlet. Use it

have been out of service for a time may develop internal rust

to find out what the propane odor smells like. If you suspect

which will cause odor fade. If such conditions are suspected

that your LP-Gashas a weak or abnormal odor, call your

to exist, a periodic sniff test of the gas is advisable. If you

LP-GasDealer.

haveanyquestionaboutthegasodor,callyourLP-gasdealer.

• If you are not qualified, do not light pilot lights, perform

A periodic sniff test of the LP-gasis a good safety measure

under any condition.

service, or make adjustments to appliances on the LP-Gas

 

system. If you are qualified, consciously think about the odor

• If, at any time, you do not smell the LP-Gasodorant and you

of LP-Gasprior to and while lighting pilot lights or perform-

thinkyoushould,assumeyouhavealeak.Thentakethesame

ing service or making adjustments.

immediateactionrecommendedabovefortheoccasionwhen

• Sometimes a basement or a closed-uphouse has a musty

you do detect the odorized LP-Gas.

 

smell that can cover up the LP-Gasodor. Do not try to light

• If you experience a complete "gas out," (the container is un-

pilot lights, perform service, or make adjustments in an area

der no vapor pressure), turn the tank valve off immediately.

where the conditions are such that you may not detect the

If the container valve is left on, the container may draw in

odor if there has been a leak of LP-Gas.

some air through openings such as pilot light orifices. If this

• Odor fade, due to oxidation by rust or adsorption on walls

occurs, some new internal rusting could occur. If the valve is

left open, then treat the container as a new tank. Always be

of new cylinders and tanks, is possible. Therefore, people

sure your container is under vapor pressure by turning it off

should be particularly alert and careful when new tanks or

at the container before it goes completely empty or having it

cylinders are placed in service. Odor fade can occur in new

refilled before it is completely empty.

tanks, or reinstalled old tanks, if they are filled and allowed

 

Page 4

12434-9-0107

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 shallbetheresponsibilityofthepropertyownertosecure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors

a.Intheeventthatthesidewallhorizontallyventedgas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-upmay be installed on the next adjacent floor level.

b.Intheeventthattherequirementsofthissubdivision can not be met at the time of completion of installation,theownershallhaveaperiodofthirty(30)days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2.APPROVED CARBON MONOXIDE DETECTORS. Eachcarbonmonoxidedetectorasrequiredinaccordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3.SIGNAGE.Ametalorplasticidentificationplateshallbe permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half(1/2) inchinsize,“GASVENTDIRECTLYBELOW.KEEP

CLEAR OFALL OBSTRUCTIONS”.

4.INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspectorobservescarbonmonoxidedetectorsandsignage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b)EXEMPTIONS:Thefollowingequipmentisexempt from 248 CMR 5.08(2)(a)1 through 4:

1.The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2.ProductApproved side wall horizontally vented gas fueled equipment installed in a room or structureseparatefromthedwelling,buildingor structure used in whole or in part for residential purposes.

(c)MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a ventingsystemdesignorventingsystemcomponents with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1.Detailed instructions for the installation of the venting system design or the venting system components; and

2.Acompletepartslistfortheventingsystemdesign or venting system.

(e)Acopy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for ventinginstructions,and/orallventingdesigninstructions shall remain with the appliance or equipment at the completion of the installation.

12434-9-0107

Page 5

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.Installer must have owner fill out and mail warranty card supplied 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 StandardAssociation, as a Gravity Direct Vent Wall 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, NY 10036.

High Altitudes

For altitudes/elevations above 2,000 feet (610m), input ratings should be reduced at the rate of 4 percent for each 1,000 (305m) feet above sea level. Canadian HighAltitudes 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.(.796kPa)forNaturalGasandfrom 10.0" w.c. (2.49kPa) to 8.0" w.c. (1.992kPa) for Propane Gas.

SPECIFICATIONS

Model

DV-25

DV-35

Input BTU/HR (KW/H)

25,000 (7.3)

35,000 (10.3)

Height

27 3/4" (705mm)

27 3/4" (705mm)

Width

37" (940mm)

37" (940mm)

Depth

11 1/2" (292mm)

11 1/2" (292mm)

Gas Inlet (Pipe)

1/2" (13mm)

1/2" (13mm)

Accessories for the Above Furnaces

 

 

Blower Package

DRB-1

DRB-1

Vinyl Siding Vent Kit

DV-822

DV-822

Page 6

12434-9-0107

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

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.

GAS SUPPLY

NPT NIPPLE

TEE HANDLE

 

FLEX TUBING

 

FLARE SHUT OFF VALVE

FLARE FITTING

CLOSE NIPPLE

NPT NIPPLE

TEE HANDLE

 

SHUT OFF VALVE

 

NPT GAS SUPPLY

NPT UNION

Figure 1

Consult the current National Fuel Gas Code, ANSI Z223.1 CAN/CGAB149 (.1 or .2) installation code.

Installing a New Main Gas Cock

Each appliance should have its own manual gas cock.

A manual main gas cock should be located in the vicinity of the unit. Where none exists, or where its size or location is not adequate, contact your local authorized installer for installation or relocation.

12434-9-0107

Compounds used on threaded joints of gas piping shall be resistant to the action of liquefied petroleum gases. The gas lines must be checked for leaks by the installer. This should be done with a soap solution watching for bubbles on all exposed connections, and if unexposed, a pressure test should be made.

Never use an exposed flame to check for leaks. Appliance must be disconnected from piping at inlet of control valve and pipe capped or plugged for pressure test. Never pressure test with appliance connected; control valve will sustain damage!

Agasvalveandgroundjointunionshouldbeinstalledinthegaslineupstream ofthegas controltoaidinservicing.Itisrequiredby theNationalFuel Gas Code that a drip line be installed near the gas inlet.This should consist of a vertical length of pipe tee connected into the gas line that is capped on the bottom in which condensation and foreign particles may collect.

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 11.0" w.c. (2.739kPa) for the purpose of input adjustment to a maximum of 13.0" w.c. (3.237kPa).

A1/8"(3mm)N.P.T.pluggedtapping,accessiblefortestgaugeconnection, is located on the outlet side of the gas control.

Page 7

CLEARANCES

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

2.Unit is supported by a wall bracket secured to the wall.

3.Theminimumclearancesfromcasingtocombustibleconstruction is48"(121cm)ontop,6"(152mm)oneachsideand4"(102mm) from the floor or from the top surface of carpeting, tile or other floor covering and 0" (0mm) to rear wall.

4.The minimum distance from the center of the vent cap to the nearest outside corner or obstruction is 24" (610mm).

5.The DV-25andDV-35minimum wall depth is 4 1/2" (114mm) (andthemaximumis13"(330mm). Theuseoftubesnotsupplied by the manufacturer results in unsatisfactory performance.

Theventterminalofadirectventappliance,withaninputof50,000 (14.6KW)BTUperhourorlessshallbelocatedatleast9"(229mm) from any opening through which flue gases could enter a building. 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) (1.83m) feet from any pressure regulator. In case of regulator malfunction, the six

(6)(1.83m)feetdistancewillreducethechanceofgasentering the vent cap.

INSTALLATION INSTRUCTIONS

Location of Furnace

Pickalocationonanoutsidewallwithaclearspaceof28"(711mm) high by 49" (124cm) wide in the room.

Locating Wall Opening

The furnace is to be located on an outside wall. Locate wall studs so that wall opening will be located between wall studs. The wall studs can be used for attachment of wall mounting bracket. The wall opening required as shown in Figure 3 is a diameter of 7 1/2 inches (191mm).

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.

Figure3willpositionthefurnacefourinches(102mm)offthefloor. If it is desired to position the furnace higher on the wall, add the difference to the "A," "B" and "C" dimensions.

Note: The vent opening is not in the center of the furnace.

DV-25-2SHOWN

UNIT IS SUPPORTED

BY WALL BRACKET

4”

102mm

4”

102mm

4 ½”(114mm)MIN. WALL DV-25,DV-3513” (330mm) MAX. WALLDV-25,DV-35

MOUNTING PLATE (CAULK UNDER FLANGE)

VENT CAP

FLUE OUTLET TUBE EXTENDS 2 ½”(64mm) BEYOND WALL

AIR INLET TUBE EXTENDS ½”(13mm) BEYOND WALL

OUTSIDE WALL

UNIT FASTENED TO WALL

WITH (2) SCREWS

Figure 4

Installing Wall Mounting Bracket

Locate and cut wall opening. If there is insulation above the wall opening (air inlet tube) a barrier should be installed above the wall opening(airinlettube)topreventinsulationfromcomingincontact with the air inlet tube. The barrier must not penetrate into the 7 1/2" (191mm) diameter wall opening. Place the flat surface of the wall mounting bracket toward the wall. Insert half round flange of wall mounting bracket into and at the top of the wall opening. The half round flange of the wall mounting bracket must be in contact with the sheetrock or wood at the top of the wall opening. Level the wall mounting bracket in the wall opening.

Figure 3

Page 8

12434-9-0107

INSTALLATION INSTRUTIONS (continued)

Onsolidwall,whenusingwallstudsforattachmentofwallmounting bracket, fasten wall mounting bracket to wall studs with (2) #10 x 1 1/2" (38mm) screws provided and fasten (2) additional #10 x 1 1/2" (38mm) screws provided through the wall mounting bracket and into the solid wall.

Onsheetrock,whenusingwallstudsforattachmentofwallmounting bracket, fasten wall mounting bracket to wall studs with (2) #10 x 1 1/2" (38mm) screws provided and by using wall opening for access, fasten 2 additional #10 x 1 1/2" (38mm) screws and (2) Tinnerman nuts provided through the wall mounting bracket and into the sheet rock.

Attaching Furnace To Wall Mounting Bracket

Hangfurnaceonwallmountingbracketbyaligning(2)tabsonwall mounting bracket with (2) slots located on inner casing top.

Theinnercasingbottomistobefastenedtothewall. Onsolidwall, fasten inner casing bottom with (2) #10 x 1 1/2" (38mm) screws provided. On sheet rock wall, fasten inner casing bottom with (2) toggle bolts provided.

Cutting Vent Tubes

This is the most important part of the installation. With the furnace installed on wall the 6" (152mm) diameter air inlet tube and the 4" (102mm) diameter flue outlet tube are to be marked and cut using the following procedure.

1.Attach 6" (152mm) diameter air inlet tube onto the collar of air drop assembly. Be sure 6" (152mm) diameter air inlet tube is placedasfaraspossibleontothecollaroftheair dropassembly. Markthe6"(152mm)diameterairinlettube1/2"(13mm)beyond the outside wall. Remove 6" (152mm) diameter air inlet tube from collar of air drop assembly.

2.Attach 4" (102mm) diameter flue outlet tube onto flue outlet collar on combustion chamber. Be sure 4" (102mm) diameter flue outlet tube is placed as far as possible onto the collar of flue outlet. Mark the 4" (102mm) diameter flue outlet tube 2 1/2" (64mm) beyond the outside wall. Remove 4" (102mm) diameterflueoutlettubefromcollarofflueoutletoncombustion chamber.

3.Mark or wrap tape completely around the tubes at the marked points to help in making a true cut. Do not crimp or enlarge tubes.

Installing Vent Assembly

1.Placeprovidedcaulkingbeneaththeedgeoftheoutsidemounting plate. Use additional caulking to correct uneven wall surface, such as clapboard.

2.Attach 6" (152mm) diameter air inlet tube onto the collar of air drop assembly. Attach caulked, outside mounting plate into the 6" (152mm) diameter air inlet tube. Position the outside mounting plate so that 6" (152mm) diameter air inlet tube has a slight downward slope to the outside. The downward slope is necessary to prevent the entry of rainwater. Attach outside mounting plate to exterior wall with (4) #10 x 1 1/2" (38mm)screws provided.

3.Applyfurnacecementto4"(102mm)diameterflueoutletcollar on combustion chamber and to 4" (102mm) diameter collar on ventcap. Attach4"(102mm)diameterflueoutlettubeontoflue outlet collar on combustion chamber. Attach vent cap into the

4"(102mm)diameterflueoutlettube. Attachventcaptooutside mounting plate with (3) #10 x 1/2" (13mm) screws provided.

4. Installation is completed.

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 4" (102mm) diameter flue outlet tube.

2.Remove old caulking beneath the edge of the outside mounting plate. Apply new caulking beneath the edge of the outside mountingplate. Useadditionalcaulkingtocorrectunevenwall surface, such as clapboard.

3.Attach 6" (152mm) diameter air inlet tube onto the collar of air drop assembly. Attach caulked, outside mounting plate into the 6" (152mm) diameter air inlet tube. Position the outside mounting plate so that 6" (152mm) diameter air inlet tube has a slight downward slope to the outside. The downward slope is necessary to prevent the entry of rainwater. Attach outside mounting plate to exterior wall with (4) #10 x 1 1/2" (38mm) screws provided.

4.Applyfurnacecementto4"(102mm)diameterflueoutletcollar on combustion chamber and to 4" (102mm) diameter collar on ventcap. Attach4"(102mm)diameterflueoutlettubeontoflue outletcollaroncombustionchamber. Attachventcapintothe4" (102mm) diameter flue outlet tube. Attach vent cap to outside mounting 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. The2"x4"(51mmx102mm)framingprotectssidingfrompossible warpageordiscoloration. Alljointscanthenbesealedandpainted. 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-25andDV-35.(See Figure 5)

Vinyl siding vent kit, DV-822,is available from Empire Comfort Systems, Inc. The depth is 3" (76mm), which enables the vent cap to be extended away from siding or projections. The wall depth plus the additional 3" (76mm) depth of the vinyl siding vent cap extension should not exceed a total depth of 13" (330mm) for DV25 andDV-35.(See Figure 5a)

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Warning: When vinyl siding vent kit,DV-822or 2" x 4" (51mm x 102mm) framing is added to an existing installation (furnace is installed) do not attempt to add sections of pipe to theflueoutlettubeorairinlettube. Anairtightsealisrequired for both tubes. Refer to Parts List, page 14 to order tubes.

Figure 5

Figure 5a

THERMOSTAT LOCATION

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

Interior Wall — The thermostat should be installed on an inside wall away from the furnace 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

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 (Figure 6)

Amillivoltmeterisrequiredtocheckthesystem. Millivoltreadings should be:

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

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

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

Acrossthethermostatwiresatthethermostat,lessthan5millivolts withthermostatON. (Strongwinds, dirtypilotandlowpressure will reduce readings.)

Piezo Pilot Ignitor Instructions

Depressing the red 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.

Figure 6

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