Empire Comfort Systems DV-215-7SG User Manual

INSTALLATION INSTRUCTIONS
AND
OWNER'S MANUAL
DIRECT VENT
WALL FURNACE
MODELS DV-210-7SG DV-215-7SG
Installer: Leave these instructions with the consumer.
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.
— Do not store or use gasoline or other
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
EFFECTIVE DATE
JUNE 2006
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.
This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used.
— Installation and service must be performed
by a qualified installer, service agency, or the gas supplier.
Page 112433-5-0606
TABLE OF CONTENTS
SECTION PAGE
Important Safety Information ......................................................................................................................3
Safety Information for Users of LP Gas ......................................................................................................
Requirements for Massachusetts ..................................................................................................................5
Introduction ..................................................................................................................................................6
Specifications ...............................................................................................................................................
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 .........................................................................................................................................
How to Order Repair Parts .........................................................................................................................14
13
4
6
Parts List ...................................................................................................................................................14
Parts View ..................................................................................................................................................
Optional Blower Installation Instructions .................................................................................................16
Service Notes ....................................................................................................................................... 17-19
15
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IMPORTANT SAFETY INFORMATION
THIS IS A HEATING APPLIANCE
DO NOT OPERATE THIS APPLIANCE WITHOUT FRONT PANEL INSTALLED.
• Due to high temperatures the appliance should be located out of traffic and away from furniture and draperies.
• Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing ignition.
• Young children should be carefully supervised when they are in the same room as the appliance.
• Clothing or other flammable material should not be placed on or near the appliance.
• Any safety screen or guard removed for servicing an appli­ance must be replaced prior to operating the appliance.
• Keep burner and control compartment clean.
• Vent cap hot while furnace is in operation.
• Installation and repair should be done by a QUALIFIED 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 impera­tive that control compartments, burners, and circulating air passageways of the appliance be kept clean.
• DO NOT put anything around the furnace that will obstruct the flow of combustion and ventilation air.
• DO keep the appliance area clear and free from combus tible material, gasoline, and other flammable vapors and liquids.
• DO examine venting system periodically and replace dam­aged parts.
• DO examine burners periodically. Clean and replace dam­aged parts.
• CAUTION: Pilot hole cover must be kept tightly closed during operation.
• DO NOT use this heater if any part has been under water. Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water.
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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-gas is 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-Gas also are subject to oxidation. This fading can occur if there is rust inside the storage tank or in iron gas pipes.
The odorant in escaped gas can adsorb or absorb onto or into walls, masonryng 󴊡󳞡󳚦󱾥󶾦󴾢-g󴂡 "󴾦󰾡󲂹󵾡MR󱾥󸏱M󰾡󲂹󰎦MR󱾥󶾢󰞹󳞡MMThis 5󳞡󹒑Mco e i"󴾥󶾦󶾡M
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REQUIREMENTS FOR MASSACHUSETTS
Page 512433-5-0606
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:
Any change to this furnace or its control can be dangerous. 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
This furnace is design certified in accordance with American National Standard/CSA Standard Z21.86 and CSA 2.32 by the Canadian Standards Association, 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 rating plate is the responsibility of the person and company making 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 smoke will occur. To prevent triggering of smoke alarms, 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
Installation and replacement of gas piping, gas utilization equipment or accessories and repair and servicing of equipment shall be performed only by a qualified agency. The term "qualified agency" means any individual, firm, corporation or company which either in 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.
The installation must conform with local codes or, in the absence of 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 should be reduced at the rate of 4 percent for each 1,000 feet (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) to 3.2" w.c. (.797kPa) for Natural Gas and from
10.0" w.c. (2.49kPa) to 8.0" w.c. (1.99kPa) for Propane Gas.
Installation on Rugs and Tile
If this appliance is to be installed directly on carpeting, tile, or other combustible material, other than wood flooring, the appliance shall 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-proof base as used on wood stoves. The protection is primarily for rugs that may be extremely thick and light-color tile 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. The gas line opening should be made at this time. Location of the opening 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 Z21.24 Appliance Connectors of Corrugated Metal Tubing and
Fittings
— ANS Z21.45 Assembled Flexible Appliance Connectors of Other
Than All-Metal Construction
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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1. In selecting a location for installation, it is necessary to provide adequate accessibility clearances for servicing and proper installation.
2. Although certified for 0 clearance to the floor , the unit is held in place by a wall bracket. Enough clearance [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-210 has the vent in the center. The DV-215 vent 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-215 minimum 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.
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.
The vent terminal of a direct vent appliance, with an input of 10,000 Btu per hour (3 kW) or less shall be located at least 6" (150mm) from any air opening into a building, and such an appliance with an 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:
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.
The nearest point of the vent cap should be a
Page 8 12433-5-0606
3" (76mm) diameter flue outlet tube. Attach vent cap to outside wall plate with (3) #10 x 1/2" (13mm) screws provided.
5. Rea ssembly and resea ling vent-ai r int ake system i s completed.
Installing a Vent Near a Window Ledge, Other Type of Projection 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.
When the vent cap is to be installed on vinyl siding or it appears that a projection within 6" (152mm) of any side of the air inlet section could shield the air inlet section, the entire vent should be supported 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)
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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:
• Across the thermopile terminals, 400-450 millivolts with ther­mostat OFF.
• Across the thermopile terminals, 150-250 milllivolts 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.
Figure 6
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PILOT BURNER
THERMOPILE
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or explo-
sion may result causing property damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these instructions exactly.
B. BEFORE LIGHTING smell all around the appliance
area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any 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.
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance (if appli cable).
4. Remove control access panel (front panel).
5. Push in gas control knob slightly and turn clockwise to "OFF".
• If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it; call a quali fied service technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service techni­cian to inspect the appliance and to replace any part of the control system and any gas control which has been under water.
9. Turn knob on gas control counterclockwise
to "PILOT."
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10. Push in control knob all the way and hold in. Imme diately light the pilot with the Piezo Pilot Ignitor or a match. Continue to hold the control knob in for about one (1) minute after the pilot is lit. Release knob, and it will pop back up. Pilot should remain lit. If it goes out, repeat steps 5 through 10.
• If knob does not pop up when released, stop and immediately call your service technician or gas supplier.
• If the pilot will not stay lit after several tries, turn the gas control knob to "OFF" and call your service technician or gas supplier.
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NOTE: Knob cannot be turned from "PILOT" to "OFF"
unless knob is pushed in slightly. Do not force.
6. Wait ten (10) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above. If you don't smell gas, go to the next step.
7. Remove the pilot access cover located on the combustion chamber.
8. Find pilot - follow metal tube
from gas control. The pilot is behind the pilot access cover.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to appliance if service is to be performed (if applicable).
3. Remove control access panel (front panel).
11. Replace pilot access cover.
12. Turn gas control knob counterclockwise "ON."
13. Replace control access panel (front panel).
14. Turn on all electric power to the appliance (if appli cable).
15. Set thermostat to desired setting.
16. CAUTION: Pilot access cover must be kept tightly closed during operation.
4. Push in gas control knob slightly and turn clockwise
to "OFF." Do not force.
5. Replace control access panel (front panel).
to
Page 1112433-5-0606
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On the main burner, the burning gas forms a primary flame and a secondary flame. The primary flame is blue and about 3/16" (5mm) high. The secondary flame is very pale blue, 3 inches (76mm) to 5 inches (127mm) high. Dust in the combustion air will produce an orange flame. Do not mistake it for an improper yellow flame.
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TROUBLESHOOTING
1. Lit match goes out as it enters lighter port. a. Certain wind conditions will blow out match. Ignite
match, and as it flares, thrust match through opening.
b. Open nearby door or window and relight pilot.
2. Pilot flames but goes out when knob is released. a. See Lighting Instructions. Relight Pilot. b. Relight the pilot and hold knob down longer and harder.
Close lighter hole cover just after igniting. Check for a good pilot flame.
c. Defective thermopile or defective magnet in safety section
of valve. Replace.
3. Yellow pilot flame. a. Obstruction at pilot orifice. b. Clean and properly size orifice.
4. Pilot and main burner go out during normal operation. a. Check millivolts. b. Check for proper size of pilot flame.
c. Check for defective or weak thermopile. d. Check input, reduce as needed. e. Cover on pilot lighter hole must be air tight. f. Check for tight fit of air and flue tubes at both ends of vent
assembly. No obstruction around vent that would prevent the wind from hitting all of the vent equally.
5. Thermostat does not turn the main burner on. a. Check wiring. b. Check all millivolt readings. c. Check for spider in main burner orifice.
6. Yellow main burner flame soot on the vent cap. a. Remove main burner to check for obstructions in throat,
ports and orifices.
b. Install new main burner orifice and pilot orifice. Refer to
Parts List on Page 14.
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Parts can be ordered only through your service person or dealer. For best results, the service person or dealer should order parts through the distributor. Parts can be shipped directly to the service person/dealer.
All parts listed in the Parts List have a Part Number. When ordering parts, first obtain the Model Number from the name plate on your equipment. Then determine the Part Number (not the Index Number) and the Description of each part from the following appropriate illustration and list. Be sure to give all this information.
Furnace Model Number Part Description
Furnace Serial Number Part Number
Type of Gas (Propane or Natural)
Do not order bolts, screws, washers or nuts. They are standard hardware items and can be purchased at any local hardware store.
Shipments contingent upon strikes, fires and all causes beyond our control.
Empire Comfort Systems, Inc. Nine Eighteen Freeburg Ave. Belleville, IL 62222-0529
1 TH-100 WALL MOUNTING PLATE 2 TH-104 GASKET - FOR WALL MOUNTING
PLATE 3 TH-015 AIR DROP ASSEMBLY - DV-210 3 TH-018 AIR DROP ASSEMBLY - DV-215 4 11757 OUTER CASING - DV-210 4 11758 OUTER CASING - DV-215 5 TH-142 INNER CASING - DV-210 5 TH-143 INNER CASING - DV-215 6 TH-008 FRONT PANEL - DV-210 6 TH-009 FRONT PANEL - DV-215 7 TH-024 COMBUSTION CHAMBER - DV-210 7 TH-027 COMBUSTION CHAMBER - DV-215 8 712098 GASKET - OBSERVATION HOLE
COVER 9 DV-781 OBSERVATION HOLE COVER 10 DV-064 COVER PLATE - OBSERVATION HOLE 11 852098 NUT FOR ORIFICE FITTING 12 742134 BURNER ORIFICE - DV-210 NAT 12 742133 BURNER ORIFICE - DV-215 NAT 12 742297 BURNER ORIFICE - DV-210 LPG 12 742282 BURNER ORIFICE - DV-215 LPG 13 742038 ORIFICE FITTING 14 732016 ELECTRODE AND WIRE 15 722049 MANIFOLD 16 R-5598 GAS VALVE 7000 MVRLC - NAT 16 R-5599 GAS VALVE 7000 MVRLC - LPG 17 R-2890 PILOT BURNER W/ORIFICE - LPG 17 R-2893 PILOT BURNER WITH ORIFICE - NAT 18 TH-335 PILOT SHIELD 19 712051 GASKET - PILOT BURNER 20 TH-133 CHAMBER DOOR WITH GASKET
- DV-210
20 TH-134 CHAMBER DOOR WITH GASKET
- DV-215 21 TH-365 VALVE BRACKET 22 TH-336 PILOT TUBING - 1/4" (6.4mm) WITH
FERRELLS (NAT.)
22 TH-367 PILOT TUBING - 1/4" (6.4mm) WITH
FERRELLS (LP) 23 672064 THERMOPILE - GENERATOR 24 R-2708 PIEZO IGNITOR 25 TH-289 IGNITOR BRACKET 26 TH-275 BURNER - DV-210 26 TH-267 BURNER - DV-215 27 TH-109 3" (76mm) DIA FLUE OUTLET TUBE 28 TH-107 5" (127mm) DIA AIR INLET TUBE 29 TH-331 OUTSIDE MOUNTING PLATE 30 TH-334 VENT CAP 31 TH-123 VENT KIT COMPLETE 32 R-5788 WALL THERMOSTAT - MILLIVOLT NOT SHOWN 742158 ORIFICE FOR PILOT - NAT NOT SHOWN 742266 ORIFICE FOR PILOT - LPG NOT SHOWN TH-300 GASKET FOR CHAMBER DOOR - DV-
210 NOT SHOWN TH-281 GASKET FOR CHAMBER DOOR - DV-
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DVB-1 For Direct Vent Wall Furnaces DV-210-(7, 9)SG and DV-215-(7, 9)SG
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SERVICE NOTES
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SERVICE NOTES
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SERVICE NOTES
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