Page 1
INSTALLATION INSTRUCTIONS
AND
OWNER'S MANUAL
DIRECT VENT
WALL FURNACE
MODELS
DV-25-2SG
DV-35-2SG
Installer: Please leave these instructions with
the consumer.
Consumer: Please retain these instructions
for future use.
WARNING: If the information in this
manual is not followed exactly, a fir e or
explosion 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 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.
— Installation and service must be
performed by a qualified installer , service
agency or the gas supplier.
EFFECTIVE DATE
SEPTEMBER 2003
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.
WARNING: If not installed, operated and
maintained in accordance with the
manufacturer's instructions, this product
could expose you to substances in fuel or
from fuel combustion which can cause death
or serious illness.
12434-3-0903
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Page 2
TABLE OF CONTENTS
SECTION PAGE
Important Safety Information ..................................................................................................................... 3
Safety Information for Users of LP Gas..................................................................................................... 4
Introduction ................................................................................................................................................ 5
Specifications ............................................................................................................................................. 5
Gas Supply.................................................................................................................................................. 6
Clearances................................................................................................................................................... 7
Installation Instructions ........................................................................................................................... 7-9
Thermostat Location................................................................................................................................... 9
Lighting Instructions ................................................................................................................................ 10
Pilot Flame Characteristics....................................................................................................................... 11
Main Burner Flame Characteristics.......................................................................................................... 11
Maintenance.............................................................................................................................................. 12
Troubleshooting........................................................................................................................................ 12
How to Order Repair Parts ....................................................................................................................... 13
Parts List ................................................................................................................................................... 13
Parts View ................................................................................................................................................ 14
Optional Blower Installation Instructions............................................................................................15-16
12434-3-0903Page 2
Page 3
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
combustible material, gasoline and other flammable
vapors and liquids.
• DO examine venting system periodically and replace
damaged parts.
• DO make a periodic visual check of pilot and burner.
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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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. You may not know all the following safety precautions which can protect both you and your family from an
accident. Read them carefully now, then review them point
LP-GAS WARNING 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
phone. Do not do anything that could ignite the gas.
• Get everyone out of the building, vehicle, trailer, or area. Do
that IMMEDIATELY.
• Close all gas tank or cylinder supply valves.
• LP-Gas is heavier than air and may settle in low areas such
as basements. When you have reason to suspect a gas leak,
keep out of basements and other low areas. Stay out until
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-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
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.
• Use your neighbor's phone and call a trained LP-Gas service
person and the fire department. Even though you may not
continue to smell gas, do not turn on the gas again. Do not reenter the building, vehicle, trailer, or area.
• Finally, let the service man and firefighters check for
escaped gas. Have them air out the area before you return.
Properly trained LP-Gas service people should repair the
leak, then check and relight the gas appliance for you.
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, 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-Gas may 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. If you detect any odor, treat it as a serious leak.
Immediately go into action as instructed earlier.
SOME POINTS TO REMEMBER
• Learn to recognize the odor of LP-gas. Your local LP-Gas
Dealer can give you a "Scratch and Sniff" pamphlet. Use it to
find out what the propane odor smells like. If you suspect that
your LP-Gas has a weak or abnormal odor, call your LP-Gas
Dealer.
• If you are not qualified, do not light pilot lights, perform
service, or make adjustments to appliances on the LP-Gas
system. If you are qualified, consciously think about the odor
of LP-Gas prior to and while lighting pilot lights or performing service or making adjustments.
• Sometimes a basement or a closed-up house has a musty
smell that can cover up the LP-Gas odor. 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 of LP-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
have any question about the gas odor, call your LP-gas
dealer. A periodic sniff test of the LP-gas is a good safety
measure under any condition.
• If, at any time, you do not smell the LP-Gas odorant and you
think you should, assume you have a leak. Then take the same
immediate action recommended above for the occasion when
you do detect the odorized LP-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.
12434-3-0903Page 4
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:
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 Standard 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, 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 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. (.796kPa) for
Natural Gas and from 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 Above Furnaces
Blower Package DRB-1 DRB-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. 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.
Recommended Gas Pipe Diameter
Pipe Length Schedule 40 Pipe Tubing, Type L
(Feet) Inside Diameter Outside Diameter
Nat. L.P. Nat. L.P.
0-10 1/2" 3/8" 1/2" 3/8"
1.3 cm 1.0 cm 1.3 cm 1.0 cm
10-40 1/2" 1/2" 5/8" 1/2"
1.3 cm 1.3 cm 1.6 cm 1.3 cm
40-100 1/2" 1/2" 3/4" 1/2"
1.3 cm 1.3 cm 1.9 cm 1.3 cm
100-150 3/4" 1/2" 7/8" 3/4"
1.9 cm 1.3 cm 2.2 cm 1.9 cm
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.
NPT NIPPLE
Figure 1
Consult the current National Fuel Gas Code, ANSI Z223.1 CAN/
CGA-B149 (.1 or .2) installation code.
Installing a New Main Gas Cock
Each appliance should have its own manual gas cock.
In the state of Massachusetts the gas cock must be a T handle type.
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.
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!
A gas valve and ground joint union should be installed in the gas
line upstream of the gas control to aid in servicing. It is required
by the National Fuel 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-in pressure
regulator in the gas valve. Natural gas models will have a
manifold pressure of approximately 4.0" w.c. (.996kPa) at the
valve outlet with the inlet pressure 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).
A 1/8" (3mm) N.P.T. plugged tapping, accessible for test gauge
connection, is located on the outlet side of the gas control.
12434-3-0903Page 6
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. The minimum clearances from casing to combustible
construction is 48" (121cm) on top, 6" (152mm) on each side
and 4" (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-25 and DV-35 minimum wall depth is 4 1/2"
(114mm) (and the maximum is 13" (330mm). The use of
tubes not supplied by the manufacturer results in
unsatisfactory performance.
INSTALLATION INSTRUCTIONS
Location of Furnace
Pick a location on an outside wall with a clear space of 28"
(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.
Figure 3 will position the furnace four inches (102mm) off the
floor. 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.
The vent terminal of a direct vent appliance, with an input of
50,000 (14.6 KW) BTU per hour or less shall be located at least
9" (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) feet distance will reduce the chance of
gas entering the vent cap.
INCHES (mm)
4 1/2 (114) MIN. WALL DV-25, DV-35
(DV-25-2 SHOWN)
UNIT IS SUPPORTED
BY WALL BRACKET
13 (330) MAX. WALL DV-25, DV-35
MOUNTING PLATE
(CAULK UNDER FLANGE)
VENT CAP
FLUE OUTLET TUBE EXTENDS
2 1/2 (64) BEYOND WALL
AIR INLET TUBE EXTENDS
1/2 (13) BEYOND WALL
WALL MOUNTING
BRACKET
A
28
(711)
B
27 3/16
(691)
GAS INLET
TO VALVE
12434-3-0903
(356)
7 1/2 (191) DIA.
WALL OPENING
17 3/4
(451)
21 1/2
(546)
14
37
(940)
Figure 3
11
(279)
15 1/2
(394)
INCHES (mm)
2 x 4 ((51 x 102) STUDS
16 (406) ON CENTER
C
19 3/4
(502)
4 (102) MIN.
OUTER CASING
OF UNIT
4 (102) MIN.
OUTSIDE WALL
UNIT FASTENED TO WALL
WITH (2) SCREWS
4
(102)
GAS INLET TO REAR OF CASING
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 (air inlet tube) to prevent insulation from coming in
contact 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.
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INSTALLATION INSTRUCTIONS (continued)
On solid wall, when using wall studs for attachment of wall
mounting 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.
On sheet rock, when using wall studs for attachment of wall
mounting 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
Hang furnace on wall mounting bracket by aligning (2) tabs on
wall mounting bracket with (2) slots located on inner casing top.
The inner casing bottom is to be fastened to the wall. On solid
wall, 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
placed as far as possible onto the collar of the air drop
assembly. Mark the 6" (152mm) diameter air inlet tube 1/2"
(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) diameter
flue outlet tube from collar of flue outlet on combustion
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. Place provided caulking beneath the edge of the outside
mounting 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. Apply furnace cement to 4" (102mm) diameter flue outlet
collar on combustion chamber and to 4" (102mm) diameter
collar on vent cap. Attach 4" (102mm) diameter flue outlet
tube onto flue outlet collar on combustion chamber. Attach
vent cap into the 4"(102mm) diameter flue outlet tube. Attach
vent cap to outside mounting plate with (3) #10 x 1/2" (13mm)
screws provided.
4. Installation is completed.
Reassembly And Resealing Vent-Air Intake System
When vent-air intake system is removed for servicing the
furnace, the following steps will assure proper reassembly and
resealing of the vent-air intake assembly.
1. Remove old furnace cement from flue outlet collar on
combustion 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 mounting plate. Use additional caulking to
correct uneven wall 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. Apply furnace cement to 4" (102mm) diameter flue outlet
collar on combustion chamber and to 4" (102mm) diameter
collar on vent cap. Attach 4" (102mm) diameter flue outlet
tube onto flue outlet collar on combustion chamber. Attach
vent cap into the 4" (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-air intake system is
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-25 and DV-35. (See Figure 5)
12434-3-0903Page 8
Page 9
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 vinyl 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 DV-25 and DV-35. (See
Figure 5a)
Warning: When vinyl siding vent kit, DV-822 or 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 the flue outlet tube or air inlet tube. An
air tight seal is required for both tubes. Refer to Parts
List, page 13 to order tubes.
APPLY CAULKING
OUTSIDE MOUNTING PLATE
Figure 5
APPLY CAULKING
2 x 4 (51 x 102) FRAMING
OUTSIDE MOUNTING PLATE
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.
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 (Figure 6)
A millivolt meter is required to check the system. Millivolt
readings should be:
• Across the thermopile terminals, 400-450 millivolts with
thermostat OFF.
• Across the thermopile terminals, 150-250 millivolts 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.)
VENT CAP EXTENSION
Figure 5a
INCHES (mm)
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.
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.
12434-3-0903
Figure 6
Page 9
Page 10
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or explosion 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 applicable).
4. Remove casing front assembly.
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
qualified 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.
8. Find pilot - follow metal tube
from gas control. The pilot is
behind the pilot access cover.
9. Turn knob on gas control counterclockwise
to "PILOT."
10. Push in control knob all the way and hold in. Immediately 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.
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.
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 casing front assembly.
11. Replace pilot access cover.
12. Turn gas control knob counterclockwise
"ON."
13. Replace casing front assembly.
14. Turn on all electric power to the appliance (if applicable).
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 casing front assembly.
12434-3-0903Page 10
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Page 11
PILOT FLAME CHARACTERISTICS
The correct flame will be almost horizontal, blue and will extend
past the thermopile 1/4" (6mm). The flame will surround the
thermopile just below the tip.
On propane (LP-gas) slight yellow might occur where the pilot
flame and burner flame meet.
Natural gas pilots require adjusting when the inlet pressure is
above 5" w.c. (1.25kPa) Turn adjustment screw clockwise to
reduce flame.
Propane (LP-gas) will not require adjusting.
MAIN BURNER FLAME CHARACTERISTICS
Figure 7
There will be a short blue inner flame with a much larger lighter
blue secondary flame. The burner flame may have a yellow tip
when hot. See the burner drawing showing the approximate
heights of each part of the flame. Dust in the combustion air will
produce an orange or red flame. Do not mistake the orange or red
flame for an improper yellow flame. After use, cleaning may be
required for the proper flame.
BURNER FLAME
PRIMARY FLAME 1/4" (6mm) TO 1/2" (13mm)
SECONDARY FLAME 4" (102mm) TO 6" (152mm)
Figure 8
Primary Air Adjustment (Figure 9)
An air adjustment bolt is located on the chamber support bottom.
The four inch (102mm) clearance between the furnace and the
floor allows access to the air adjustment bolt. The air adjustment
bolt is above the rectangular opening on the inner casing bottom.
On Propane gas, if a whistling noise (resonation) occurs, screw
air adjustment bolt into the chamber support in order to reduce the
amount of primary air. If the whistling noise (resonation) is not
eliminated when the air adjustment bolt is screwed into the
chamber support this may indicate the air adjustment bolt is
misaligned. Grasp air adjustment bolt and pivot (push) air
adjustment bolt away from yourself. Observe the main burner
flame as you push air adjustment bolt and when the main burner
flame begins to develop a yellow flame, you should stop pushing
on the air adjustment bolt. Screw air adjustment bolt out of the
chamber support until the yellow flame on the main burner is
eliminated. The air adjustment bolt should now be properly
aligned. The reduction in primary air will soften the main burner
flame and will eliminate the whistling noise (resonation).
On Propane or Natural gas, if a yellow flame occurs, screw air
adjustment bolt out of the chamber support but do not completely
remove air adjustment bolt from chamber support. The
repositioning of the air adjustment bolt will increase the amount
of primary air. The increase in primary air will sharpen the main
burner flame and will eliminate the yellow flame.
AIR BOLT
FLOOR
4" (102mm)
12434-3-0903
Figure 9
Page 11
Page 12
MAINTENANCE
Removing Main Burner
1. Disconnect the thermopile and pilot supply line at the pilot
burner.
2. Remove the burner compartment cover.
3. Remove orifice shield.
4. Remove bolt on each side of burner and lift out.
Cleaning Main Burner
The main burner may be cleaned by forcing water into the ports
and the throat of the burner. The main burner should be blown dry
or heated to remove water from main burner.
Removing Main Burner Orifice
1. Open the brass union located after the gas valve.
2. Loosen valve bracket.
3. Remove the 3/8" (10mm)manifold pipe that is attached to the
union elbow until the manifold pipe is free.
4. The main burner orifice is at the end of the manifold pipe.
Removing Pilot Orifice
1. Disconnect the pilot supply line at the pilot burner.
2. Remove pilot orifice from pilot burner. It may be necessary to
tap on pilot burner in order to remove the pilot orifice.
Cleaning Pilot Orifice
After use, cleaning of the pilot burner may be required for the
proper flame. Also, cleaning of the pilot burner may be required
due to spiders (spider webs). The pilot orifice can be cleaned with
high pressure air or by placing under running water. Pilot orifice
must be dry before replacement. Use a pipe cleaner to clean inside
the pilot after the pilot orifice has been removed.
Cleaning Combustion Chamber
When the main burner and vent cap are removed, all internal areas
of the combustion chamber are accessible for cleaning with a
vacuum hose.
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 pilot 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. See Page 11, "Primary Air Adjustment".
b. Remove main burner to check for obstructions in throat and
ports.
c. Install new main burner orifice and pilot orifice. Refer to
Parts List, page 13.
7. On Propane gas, if a whistling noise (resonation) occurs.
a. See Page 11, "Primary Air Adjustment".
b. Reduce manifold pressure.
c. Size main burner orifice with a drill bit. For DV-25 use #54
drill bit. For DV-35 use #50 drill bit.
12434-3-0903Page 12
Page 13
HOW TO ORDER REPAIR PARTS
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
PARTS LIST
PLEASE NOTE: When ordering parts, it is very important that part number and description of part coincide.
Index Part
No. Number Description
1 DV-769 Vent Cap
2 DV-131 Outside Mounting Plate
3 DV-548 Air Inlet Tube
4 DV-524 Flue Outlet Tube
5 DV-757 Vent Kit
6 DV-899 Wall Mounting Bracket
7 DV-900 Inlet Air Drop Chute
8 DV-762 Gasket - Air Drop Chute
& DV-763 (2 Each Required)
9 DV-951 Casing Top
10 DV-901 Heat Shield
11 DV-902 Inner Casing (US version)
11 15665 Inner Casing (Canada version)
12 RH-705 Casing Side (2 Required)
13 712036 Gasket - Flue Outlet Support
14 DV-903 Combustion Chamber (DV-25)
14 DV-904 Combustion Chamber (DV-35)
15 712098 Gasket - Lighting Hole
16 DV-781 Lighting Hole Cover Assembly
with Clear Mica
17 DV-064 Cover Plate
18 DV-988 Burner (DV-25)
18 DV-990 Burner (DV-35)
19 672063 Thermopile
20 DV-1004 Pilot Tubing w/Ferrells
21 RH-238 Burner Door
22 DV-778 Gasket - Burner Door
23 712051 Gasket - Pilot Burner
Index Part
No. Number Description
24 DV-994 Pilot Shield
25 R-2224 Pilot Burner with Orifice (Nat)
25 R-2223 Pilot Burner with Orifice (LP)
26 DV-772 Electrode and Wire
27 DV-913 Casing Front
28 742155 Burner Orifice, (DV-25 Nat)
28 742238 Burner Orifice, (DV-25 LP)
28 P-86-38 Burner Orifice, (DV-35 Nat)
28 742233 Burner Orifice, (DV-35 LP)
29 P-190 Manifold
30 R-191 Manifold Union Assembly
31 R-5600 Gas Valve (Nat) 7000 MVRLC
31 R-5601 Gas Valve (LP) 7000 MVRLC
32 DV-1003 Valve Bracket
33 DV-764 Gasket - Chamber Support
& DV-765 (2 Each Required)
34 DV-908 Valve Shield
35 R-2313 Piezo Ignitor
Not Shown 742158 Pilot Orifice (Nat)
Not Shown 742266 Pilot Orifice (LP)
Not Shown 662021 Wall Thermostat - Millivolt
Not Shown DV-885 Hardware Package
Not Shown 922113 Operator Section - Nat
Not Shown 922217 Operator Section - LP
Not Shown 652121 Regulator - Nat
Not Shown 652211 Regulator - LP
Not Shown DV-1001 Thermostat Bracket
USE ONLY MANUFACTURER'S REPLACEMENT PARTS. USE OF ANY OTHER PARTS COULD CAUSE INJURY OR DEATH.
12434-3-0903
Page 13
Page 14
PARTS VIEW
12434-3-0903Page 14
Page 15
OPTIONAL BLOWER INSTALLATION INSTRUCTIONS
OPTIONAL BLOWER DRB-1
Vented Room Heaters RH-25-(1, 2, 4, 5, 6) and RH-35-(1, 2, 4, 5, 6)
Direct Vent Wall Furnaces DV-25-(1, 2)SG and DV-35-(1, 2)SG
Installing Optional DRB-1 Blower
1. For RH-25-(1, 2, 4, 5, 6) and RH-35-(1, 2, 4, 5, 6), remove
casing front.
1. For DV-25-(1, 2)SG and DV-35-(1, 2)SG, remove casing
front and heat shield.
2. When facing appliance, insert blower assembly into the left
section of the casing (adjacent to the combustion chamber).
3. For RH-25-(1, 2, 4, 5, 6) and RH-35-(1, 2, 4, 5, 6), route
cord set through opening in casing back. The opening in
casing back is located adjacent to gas control.
3. For DV-25-(1, 2)SG and DV-35-(1, 2)SG, route cord set
through opening in casing bottom. The opening in casing
bottom is located beneath gas control.
4. Align the (2) screw holes on the inner side panel and the (2)
screw holes on casing back with the (4) clearance holes on
the blower assembly. Attach blower assembly to the casing
back and inner side panel with (4) #10 x 1/2" (13mm)
screws provided. The blower assembly must be attached
first to the casing back and then to the casing side panel.
5. For RH-25-(1, 2, 4, 5, 6) and RH-35-(1, 2, 4, 5, 6), replace
casing front.
5. For DV-25-(1, 2)SG and DV-35-(1, 2)SG, replace heat
shield and casing front.
Attention: Wiring harness on blower is factory assembled
and installed. If wiring harness becomes disassembled use the
following steps to reassemble the wiring harness.
Wiring
The appliance, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, with
the National Electrical Code, ANSI/NFPA 70 or Canadian
Electrical Code, CSA C22.1, if an external electrical source is
utilized. This appliance is equipped with a three-prong
[grounding] plug for your protection against shock hazard
and should be plugged directly into a properly grounded
three-prong receptacle. Do not cut or remove the grounding
prong from this plug. For an ungrounded receptacle, an
adapter, which has two prongs and a wire for grounding, can
be purchased, plugged into the ungrounded receptacle and its
wire connected to the receptacle mounting screws. With this
wire completing the ground, the appliance cord plug can be
plugged into the adapter and be electrically grounded.
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after servicing.
WARNING:
Unplugging of blower accessory will not stop the heater
from cycling. To shut heater off: Turn temperature
dial or thermostat to lowest setting. Turn knob on gas
control to "OFF", depressing slightly. Do not force.
1. Attach (1) pin terminal from black (hot) wire, smooth
insulation on cord set to (1) socket terminal on fan control
assembly.
2. Attach (1) pin terminal from black (neutral) wire, ribbed
insulation on cord set to (1) socket terminal from white
(neutral) wire on motor.
3. Attach (1) pin terminal on fan control assembly to (1)
socket terminal from black (hot) wire on motor.
4. Attach green ground wire beneath one of the #10 x 1/2"
(13mm) screws on the blower housing.
Fan Control
The automatic fan control is located in the switch box. The
switch box is attached to the front of the blower assembly.
The switch box is adjacent to the combustion chamber. The
fan control is a non-adjustable automatic type. The fan control
will require between 5 and 10 minutes of main burner operation
before the fan control "closes" and activates the blower. The
blower will continue to run between 5 and 10 minutes after the
main burner shuts off, before the fan control "opens" and
deactivates the blower.
12434-3-0903
Page 15
Page 16
OPTIONAL BLOWER INSTALLATION INSTRUCTIONS (continued)
-3-0903
Cleaning
The blower wheel will collect lint and could require cleaning
once a year. If the air output decreases or the noise level
increases, it indicates a dirty wheel. Complete removal of the
wheel and scrubbing it with a brush under flowing water is
recommended.
Oiling
The blower motor has an oil hole located on each end of the
motor. Use #20 motor oil only. It is best to oil the motor several
times during the heating season using 2 or 3 drops each time. If
the motor fails to start and hums, it could be a tight bearing due
to lack of oil. This may be corrected by pouring kerosene in the
oil holes, allowing to stand for a few hours and then oiling
properly.
PARTS LIST
Index Part
No. No. Description
1 R-2090 Motor
2 632016 Motor Cushion
3 RH-036 Motor Support
4 642030 Blower Wheel
5 RH-710 Blower Housing Assembly
6 9120106 Fan Control Switch
7 872087 Heyco Bushing
8 DV-806 Switch Box
9 DV-807 Switch Box Cover
10 R-2091 Wire Assembly 19" (483mm)
11 8720161 Heyco Bushing
12 R-2099 Cord Set 72" (1.83m)
Empire Comfort Systems, Inc.
Nine Eighteen Freeburg Ave.
Belleville, Illinois 62220-2623
PH: 1-618-233-7420
PH: 1-800-851-3153
FAX: 1-618-233-7097
FAX: 1-800-443-8648
E-MAIL: info@empirecomfort.com
WEB SITE: www.empirecomfort.com
12434-3-0903Page 16
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