Sig Marine 10400 Assembly Manual

Sig Marine Products

#101-17728 66 Ave

Surrey B.C.

Canada V3S 7X1

www.sigmarine.com

[e-mail]

Cozy Cabin Heater Propane Bottom Assembly

#10400

This manual must be read and the requirements carried out

to ensure satisfactory performance.

SIG MARINE RESERVES THE RIGHT TO MAKE CHANGES TO PRODUCTS

Instruction Manual

OR DOCUMENTS AT ANY TIME

WARNING!

THIS IS A LOW PRESSURE

PROPANE GAS APPLIANCE.

YOU MUST HAVE A

SEPARATE 11” W/C LOW

PRESSURE REGULATOR

INSTALLED CORRECTLY

OR OPERATION WILL

RESULT IN A

DANGEROUS FIRE AND

WILL DAMAGE YOUR

UNIT.

**PLEASE READ YOUR INSTRUCTION MANUAL

BEFORE USE OF THIS APPLIANCE**

SIG MARINE PROPANE BOTTOM ASSEMBLY

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Form#7.2-69 Issue#2

Keep your proof of purchase and product serial number for warranty

INTRODUCTION

Thank you for selecting the Sig Marine Cozy Cabin Propane bottom assembly. Your unit
was carefully inspected and tested at our factory.

Because of the continuing refinement of our product designs, your heater may possess
features that are not discussed in this manual. We have tried to supply all the information
you might need, so please take time to read this manual before installing and using your
Cozy Cabin Heater.

The most important reason to carefully read this manual is that many of its instructions
are essential to the safe operation of your Cozy Cabin Heater.

Should any question arise requiring personal help, we ask that you contact your dealer or
Sig Marine, quoting both the model and serial number printed on the product
identification label.

SAFETY AND INSTALLATION

General

The Cozy Cabin Heater Bottom Assembly # 10400 is manufactured for the Model 10000,
and is designed to be fuelled only by low pressure liquid propane gas (LPG). If
compressed natural gas (CNG) is used in this heater the burner flame will be inadequate
for heating.

Propane is an excellent and convenient fuel if used in accordance with rules, safety and
common sense.

Propane (LPG) Fuel System

1. Buy your cylinder, gauge, master solenoid valve and hose from a reputable marine
dealer, or your local LPG service center.

a) We specifically recommend that only a high quality regulator be used with

your Sig Marine Cozy Cabin Heater. It must be set at 11” water column.
(In Europe this is sometimes expressed as .0274bar and is close to .5psi).

2. Locate the cylinder and regulator in a locker vented to the open air (preferably on
the deck or cabin top) isolated from the hull interior by a vapor tight enclosure.
Refer to local codes or Coast Guard requirements for details.

3. Propane is heavier than air. Therefore, the locker in which the cylinder is
installed must be vented at the bottom. Position the vent above the water line, and
at least two feet from any hull opening to the boat interior or engine exhaust.

a) We recommend the installation of a vapor monitor on your boat with all

propane fueled devices.

4. Propane is a two-phase (liquid/vapor) fuel, and only vapor withdrawal from the
tank is safe. Firmly mount the cylinder, right side up, to ensure that liquid
withdrawal does not occur.

a) We recommend that a solenoid valve, which can be controlled by a switch

located in your cabin, be installed next to the manual cylinder valve. The
cylinder valve outlet and the 9V or 12V DC solenoid valve should be
clean and dry when they are connected to each other.

5. Unnecessary attempts to seal this connection with substances like pipe dope or
Teflon tape can result in the introduction of foreign materials into the system that
can plug the tiny appliance orifices.

6. A 0-300 psi (0-20 bar) pressure gauge should be installed next to the solenoid
valve on its downstream side. Again, the fittings should be clean and dry. It is
not necessary to use pipe dope or Teflon tape for these connections.

7. Install the regulator downstream from the pressure gauge with its vent port
pointing downward, which prevents spray or deck wash from entering the fuel
system.

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Form#7.2-69 Issue#2

Recommended LPG System Installation

** In some cases the solenoid valve is installed on the low pressure side of the system

(i.e. after the LPG regulator). See solenoid manufacturers' instructions for
proper installation.

8. Starting from the propane tank itself, the fuel line attachments should occupy the
following positions: (a) the tank shut-off valve, (b) the solenoid valve, (c) the
pressure gauge, (d) the regulator, and (e) the range itself.

9. The LPG supply line should be 3/8” (10mm) soft copper line, on which your
plumber will install the flare nuts when you tell him how long to make it (see
figure 1). It can also be a flexible fire-resistant hose, UL or CGA approved hose
for use with propane, complete with 3/8” (10mm) flare nuts on each end. A single
continuous line or hose without couplings or tees is a must. Every connection is a
potential leak.

10. Because every connection is a potential leak, the fuel line should be one
continuous length of hose or tubing. Do not make a “T” off ant fuel line between
an existing appliance and the gas cylinder to feed another appliance. (You may
install a “T” connection only within the fuel tank’s enclosure, so any leakage is
contained.)

11. Be sure you do not kink the hose or piping connecting the regulator with the range
by bending it too sharply during installation.

12. Protect the hose against vibration and damage by securing it tightly to bulkheads
and hull side with non-corrosive ties or clamps which will not cut, abrade or pinch
it.

13. Fuel lines must be protected by close-fitting grommets and sealants where they
pass through decks or bulkheads, and the passage must be made vapor-tight. They
should be installed so that they are readily accessible to inspection.

Fuel System Testing

Test your fuel system for leaks each time the cylinder supply valve(s) are opened for
appliance use. Use the following procedure for the test.

First, close burner valve by turning the controls to the OFF position. Next, open the
manual cylinder and solenoid valves and make a note of the reading on the pressure
gauge. Now close the manual cylinder valve. The pressure should remain constant for at
least 10 minutes. If it does not, gas is leaking out of the system.

The leak(s) should be located by applying a mixture of liquid of detergent and water to all
connections and other suspect points and checking for bubbles. Do not attempt to locate
leaks by using an open flame. Repair and re-test the system before putting it into
operation.

For more detailed general instructions on the installation of Propane systems on boats,
please refer to the American Boat and Yacht Council’s pamphlets #A-1 and #A-22
respectively. These pamphlets may be ordered directly from A.B.Y.C.

If you are replacing an older diesel/kerosene or an older propane version you may need to
drill out the old pop rivets with ( 1/8” drill ) connecting the burner bottom base to the
heater. Place the new base so the bottom of the base is flush with the bottom of the heater
and mark 2 holes on each side of the heater flanges. Drill with 3/16” and use 8-32 or M6
size screws and nuts. Some versions may have the 4 holes already tapped to fit 8-32
thread screws.

OPERATING INSTRUCTIONS

1. Check all gas connections for possible leaks. Turn the valve on your heater to the
“OFF” position. Open valve on gas supply tank. Using a strong solution of half
liquid soap and half water check each gas connection, one at a time, by brushing
the soap and water solution over all the connections. Presence of bubbles
indicates a leak. Tighten fitting and re-check for leaks. Do not use an open
flame to check for gas leaks.

2. The first time you use your heater you will have to purge the air out of the supply
lines before it will light. Turn the knob to the “pilot” position and push in. You
may hear a hissing sound. Keep the knob pushed in until you smell gas, then
immediately turn the knob to the “OFF” position. Wait a few moments before
lighting to allow any excess propane to dissipate. Purging air can take quite a
while if you have a long supply line. This is only necessary when the supply line
is disconnected from the fuel supply.

3. Do not forget to remove any plastic before using.

4. Push control knob in, hold it in and turn counter-clockwise to pilot position. If this
is the first time or the first time in a while that the heater is being used, push in the
knob on the pilot setting for 60 second or until you smell gas. This will purge the
pilot light parts of air. Then, with the knob depressed on pilot, push in the black
spark-ignition button to ignite pilot. Once ignited, hold control knob in for 10 to
20 seconds. If it does not light, repeat this procedure. If it still does not light,
purge the line some more or hold match over pilot.

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Form#7.2-69 Issue#2

5. When the oxygen depletion pilot flame comes on, you must hold the knob in for
10 to 20 seconds. During this time the pilot flame heats up the thermocouple.
When the thermocouple is hot it generates a small amount of voltage, which will
energize a small solenoid coil inside the gas valve. This energized coil permits the
valve to regulate propane into the burner.

6. Adjust the burner by turning counter-clockwise to Low. To extinguish, turn the
knob all the way clockwise to off.

Caution: This heater consumes oxygen. You must supply sufficient outside
air to replace the oxygen used by the heater. This unit is equipped with an
oxygen depletion device which will turn off the pilot flame when the oxygen
level drops to 95% of normal. This, in turn, cools off the thermocouple,
which shuts off the main valve.

TROUBLESHOOTING

Gas Smell

1. Extinguish all open flames and smoking materials, close both manual and solenoid

cylinder valves immediately. Make sure that the appliance valve is closed.

2. Ventilate all interior compartments thoroughly. Maintaining as much ventilation as

possible, open cylinder valves. Make sure that the appliance valve is still closed.
Apply a mixture of liquid detergent and water to all connections, checking for bubbles
indicating a leak. Do not use a flame to check for leaks.

3. When repair of the leak(s) has been completed, test the system with the aid of the

pressure gauge.

Inadequate Heat - Flame Burning Low or Gas Out

1. Your system may be low on fuel - check your tank pressure gauge.

2. The gas cylinder valve may not be fully open - make sure the handle is turned as far as

it will go in the counter-clockwise direction.

3. The burner orifice may be obstructed. Let the burner cool, then remove the 4 machine

screws (2 each side) which secure the burner and valve assembly to the heater body.
Remove burner assembly, take off the burner cap, and remove the orifice (you will
require a long 7mm or 9/32” socket or nut driver). Clean out the orifice and reinstall
the part.

4. LPG gas will not flow as readily if the outside temperature is very low, i.e. below

freezing. There is not much you can do about this condition until the propane
cylinder locker warms up.

5.

Ignition System Fails to Spark

1. Check that the ignition lead is connected to the spark plug.

2. Inspect the ignition lead from the valve to the spark plug, ensuring that the lead is not

shorting out before reaching the spark plug.

3. Clean the spark plug electrode to ensure a strong spark is evident. Brass wool or light

grit sandpaper work well.

Burner does not Stay Lit

1. Check to make sure the pilot is still on. If it has been accidentally extinguished,

voltage will no longer be generated, and the valve will have snapped back to the
closed position by the stainless steel spring.

2. There could be a problem with the thermocouple. The small bulb-like attachment

protruding into the pilot flame is one end of the thermocouple.

3. Check first that the thermocouple is screwed into the valve tightly enough. A loose

connection will not transfer the 1.5 millivolt. If it has been tightened too much, the
insulating washer will have been crushed, shorting out the thermocouple, and so will
not generate the 1.5 millivolt. It must, therefore, be replaced.

4. Heaters are tested at the factory and thermocouple failure problems should be very,

very rare. If necessary, however, remove the valve end of the thermocouple from the
valve as described on the following page. Lightly sand the end which has been
removed from the valve with very fine sandpaper. Replace in the valve and test. If
this does not work, the thermocouple must have failed and will have to be replaced

5. The electromagnet (solenoid) inside the valve may have failed and will have to be

replaced.

6. Once your heater is completely reassembled and connected, mix some liquid soap and

water and perform the standard test for leaks with your fuel system. Test in a well
ventilated area, with no open flames.

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Form#7.2-69 Issue#2

LIMITED WARRANTY

Sig Marine Company warranties new products to the original consumer to be free from
defective material(s) and workmanship while under normal use and service. This limited
warranty extends for one year.

Terms and Conditions

During the warranty period, Sig Marine Company will, at its option and without charge,
repair and/or replace but not remove or re-install the faulty product

The buyer will return defective products to the address stated on the warranty form. No
product will be accepted by Sig Marine Company without prior written or verbal
authorization, and in accordance with instructions from Sig Marine Company. The
authorization number must accompany returned merchandise. Return of defective
products must be accompanied by written details of the problems and proof of purchase.

The buyer shall be responsible for shipping and insurance charges, if any, on the products
returned for repair under the terms of this warranty.

This limited warranty applies only to products that have been installed and used in
accordance to printed instructions of Sig Marine Company and does not cover improper
use, vandalism, negligence or accidents. As some states do not allow limitations on the
length of an implied warranty nor limitations or exclusions of incidental or consequential
damages, the above limitations or exclusions may or may not apply. This warranty gives
you specific legal rights and you may also have other rights that vary from state to state.

WARRANTY REGISTRATION FORM

Purchaser’s Name:
Address:
City: State/Province:
Country: Zip/Postal Code:
Telephone:
Model No.: Cozy Cabin Bottom #10400 Serial No.:
Date Purchased:
Purchaser’s signature:

This Warranty Registration must be filled in and mailed,

Within ten (10) days from date of purchase, to:

SIG MARINE PRODUCTS

#101-17728 66 Avenue

Surrey, BC Canada V3S 7X1

[e-mail]

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Form#7.2-69 Issue#2