COZY CF403D-H User manual

24VOLTSYSTEM NATURALGAS CF403D-H CF553D-H
WITHLOW-BTU
PILOT L.P. GAS CF404D-H CF554D-H
COUNTERFLOW
WALL FURNACE
INSTALLATION AND
OPERATING INSTRUCTIONS
P/N 78111 / REV. 06/2013
RR
MODEL NUMBERS
24VOLTSYSTEM NATURALGAS CF407D-H CF557D-H
WITHINTERMITTENT
IGNITION(I.I.D.) L.P. GAS CF408D-H CF558D-H
This appliance is equipped
with a blocked flue switch
designed to protect against
improper venting of combus-
tion products.
THISUNITISNOTTOBE
INSTALLEDINMOBILE
HOMES.
- Donotstore or usegasolineor other flammablevaporsand liquids inthe
vicinityofthisoranyotherappliance.
WHATTO DO IFYOUSMELLGAS:


Donottryto light any appliance.


Donottouchanyelectricalswitch;donotuseany phone in your building.


Immediatelycallyourgassupplierfroma neighbor’s phone.
Followthe gas supplier’s instructions.


Ifyoucannotreachyourgassupplier, call the firedepartment.
- INSTALLATIONANDSERVICEMUSTBEPERFORMED
BYAQUALIFIED INSTALLER,SERVICEAGENCYOR
THEGASSUPPLIER.
WARNING: If the information in this manual is not followed exactly, a fire or
explosionmayresult causingpropertydamage, personalinjuryorlossof life.
WARNING: Operation of this furnace when not connected to a properlyinstalled and maintained venting
systemcanresultin Carbon Monoxide (C.O.)poisoningand possible death. Foryoursafety, this furnace
andthe venting system shouldbe inspected atleastannually by aqualified service technician.
The coating selected to provide longer life to the heat exchanger may smoke slightly upon initial firing. Please provide
adequate ventilation if this occurs.
Thisunitisforresidentialuse onlyandis notapprovedfor installationinmobile homes,greenhouses,or environmentsinvolving
dusty,wet,corrosive,orexplosive conditions. Suchconditionswillinvalidatethewarrantyandmaycreateunsafe conditions.
INSTALLER: Leavethismanualwiththeappliance.
CONSUMER: Retainthis manualfor future reference.
Installation,maintenance,service, troubleshootingand repairsmust beperformedbyaqualified serviceagency. Mr./
Mrs. Homeowner, DONOTattemptany of these procedures yourselfasthis could expose you topropertydamage,
personalinjuryorlossoflifeandwillinvalidateallwarranties.

INTRODUCTION
THISISAGAS-FIRED, GRAVITYVENTEDWALLFURNACETHATWILLOPERATESAFELYANDPROVIDEANEFFICIENT
SOURCEOF HEATWHENINSTALLED,OPERATEDANDMAINTAINEDASRECOMMENDEDINTHESEINSTALLATION
ANDOPERATINGINSTRUCTIONS. READTHESEINSTRUCTIONSTHOROUGHLYBEFOREINSTALLING,SERVICING,OR
USING THEAPPLIANCE. IF YOU DO NOT UNDERSTAND ANYPART OF THESE INSTRUCTIONS CONSULT LOCAL
AUTHORITIES,OTHERQUALIFIEDINSTALLERS,SERVICETECHNICIAN,THEGASSUPPLIER,ORTHEMANUFACTURER.
COUNTERFLOW WALL FURNACE SPECIFICATIONS
Your counterflow wall furnace is packed in a single carton that also includes thermostat, thermostat wire, and insulated staples.
The thermostat, wire, and staples are packed in the burner compartment and are accessible by removing the burner access door.
While the burner access door is open, check the rating plate to verify that the model number is correct and that the wall furnace
is equipped for the type gas you intend to use.
Vent Approx.
Model Type Type BTU/HR. Size Gas Blower Shipping
Number Control Gas Input (Oval) Inlet Finished Dimensions Speed Amps CFM Weight
MODELSWITHLOW-BTUSTANDINGPILOT
CF403D-H 24Volt Nat. 40,000 4” ½” 14-5/16”Wx10¼”Dx81-5/16”H 2 2.25 440 104Lbs.
CF404D-H 24Volt L.P. 40,000 4” ½” 14-5/16”Wx10¼”Dx81-5/16”H 2 2.25 440 104Lbs.
CF553D-H 24Volt Nat. 55,000 4” ½” 14-5/16”Wx10¼”Dx87-5/16”H 2 2.25 440 107Lbs.
CF554D-H 24Volt L.P. 55,000 4” ½” 14-5/16”Wx10¼”Dx87-5/16”H 2 2.25 440 107lbs.
MODELSWITHINTERMITTENTIGNITION
CF407D-H 24Volt Nat. 40,000 4” ½” 14-5/16”Wx10¼”Dx81-5/16”H 2 2.55 440 104Lbs.
CF408D-H 24Volt L.P. 40,000 4” ½” 14-5/16”Wx10¼”Dx81-5/16”H 2 2.55 440 104Lbs.
CF557D-H 24Volt Nat. 55,000 4” ½” 14-5/16”Wx10¼”Dx87-5/16”H 2 2.55 440 107Lbs.
CF558D-H 24Volt L.P. 55,000 4” ½” 14-5/16”Wx10¼”Dx87-5/16”H 2 2.55 440 107Lbs.
Page 2
CONTENTS
Contents……………………………………………........... 2
Introduction…………………………………………. 2
Specifications……………………………………….. 2
Safety Rules………………………………………… 3
HelpfulInstallationInformation……………….........…. 3
ConnectingtheVent……………………………....…..… 3,4
CombustionandVentilationAir...................................... 5
FurnaceLocation………………………………….....…. 6
Rough-InInstructions…………………………..…..…. 6,7
Installation……………………………………….......….. 8
Controls…………………………………………........….. 9
PilotFlameAdjustment…………………………......….. 9
Lighting& Re-LightingInstructions……………….. 10,11
Operation………………………………………….....…. 12
TerminalBlockWiringDiagram……………….....…… 13
ManualReset…………………………………....…….. 13
MaintenanceInstructions…………………….……… 13
WiringDiagram……………………………….....…….. 14
Side&RearDischargeKits……………………...……15,16
TroubleShootingChart…………………………..…..17-19
RepairParts(breakdown)………………………..…..20-25
RepairPartsList…………………………………....….20-25
PossibleCauses& CorrectiveAction........................ 19
Warranty………………………………………….....…. 26
The State of Massachusetts requires that installation and service of a gas appliance be performed
byaplumber or gas fitterlicensed in the Commonwealthof Massachusetts.

SAFETYRULES
1. Improper installation, adjustment, alteration, service or maintenance can cause property damage, bodily injury or death. If you
do not understand these instructions or your local codes, call local authorities, a qualified installer, service agency, gas supplier,
or the manufacturer.
2. Do not install this fan type wall furnace in a recreational vehicle trailer or mobile home.
3. Do not operate this fan type wall furnace unless it is connected to a properly installed and maintained vent system. Do not
exhaust flue gases into the room, wall or attic space for any reason.
4. Locate the thermostat in a room or space that cannot be separated by a door or other means from the room or space in which the
front outlet grill is installed.
5. Adequate air for combustion and venting must be provided.
6. If rising water may enter the wall furnace, turn off the gas immediately and disconnect the electric service. Do not use the wall
furnaceifany part has beenunderwater. Immediately call aqualifiedservice technician to inspectthe wall furnace andtoreplace
any part of the control system or any gas control which has been under water.
7. Have your fan type wall furnace and vent system inspected at least annually by a qualified service technician.
8. Before cleaning or servicing the wall furnace, turn off the gas and allow it to cool. This will prevent burns.
9. Due to high temperatures, the furnace should be located out of traffic and away from furniture and draperies.
10. Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or
clothing ignition.
11. Young children should be carefully supervised when they are in the same room as the furnace.
12. Clothing or other flammable material should not be placed on or near the furnace.
13. Any safety screen guard or gill removed for servicing must be replaced prior to operating the furnace.
14. Locate the blocked flue switch and the auxiliary limit switch and push in the reset button. This will reset the switch in case it
accidentally opened during shipping.
READCAREFULLYBEFOREINSTALLINGUNIT
The installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code,ANSI Z223.1/
NFPA54 or the Natural Gas and Propane Installation Code, CSAB149.1.
The appliance, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, the
latest edition of the National Electrical Code,ANSI/NFPA70. In Canada, see latest edition of CSAC22.1 if an external electrical source
is utilized.
TheANSI standards are available from theAmerican GasAssociation, 1515Wilson Blvd.,Arlington,Virginia 22209.
The NFPA standards are available from the National Fire Protection Association, Batterymarch Park, Quincy, MA. 02269. Canadian
standards are available from International Approval Services, 178 Rexdale Blvd., Etobicoke, Ontario, Canada M9W 1R3.
VENTING
This appliance must be properly connected to a venting system. Consult local ordinances governing venting. Install only UL listed type
BW 4” oval gas vent. When the vent enters the attic, a listed type B-1 round flue pipe may be used. See Figure 1, Page 4.
Vent pipe must connect to the wall furnace or header plate with a “B” vent base plate and terminate with a cap at a point at least 12 ft. above
the bottom of the wall furnace and two feet above any obstacle within a 10 foot radius and at least 3 foot above the roof.
Provisions must be made for adequate combustion and ventilation air. This appliance must not be connected to a chimney flue serving a
separate solid fuel burning appliance.
All type “B” vents shall extend in a generally vertical direction with offsets not exceeding 45 degrees, except that a vent system having not
more than one 60 degree offset may be allowed.
Any angle greater than 45 degrees from the vertical is considered horizontal. The total horizontal run of a vent plus the horizontal vent
connector shall be not greater than 75 percent of the vertical height of the vent. Any offsets used should be as far above the drafthood as
possible to allow a venting action to begin before any restriction is encountered.
Page 3

VENTING - CONTINUED
This appliance is equipped with a blocked flue switch.
WARNING: Do not bypass the blocked flue switch. To
do so could expose the consumer to property damage,
personal injury or possible death.
This switch, when activated, will interrupt the electrical circuit between
the transformer and the gas valve causing the main burner flame to
extinguish. Themain burnerwillnot re-lightuntil theblockedflue switch
has been manually reset. To reset the switch, after locating it between
the bottom of the fan shroud and the top of the draft diverter, simply
push the red button on top of the switch. If the homeowner experiences
this problem, then the vent system must be checked and corrected.
NOTE: An existing vent that has worked for years may not be adequate
for today’s appliances because of higher efficiency requirements that
result in lower stack temperatures.
WARNING: Operation of this wall furnace when not connected to a
properly installed and maintained venting system or tampering with
the blocked flue switch can result in Carbon Monoxide (CO)
poisoning and possible death.
(SEELISTOFPOSSIBLECAUSESANDCORRECTIONSONPAGE19).
All type “B” vents shall extend in a generally vertical
direction with offsets not exceeding 45 degrees, except
that a vent system having not more than one 60 degree
offset may be allowed.
Any angle greater than 45 degrees from the vertical is
considered horizontal. The total horizontal run of a vent
plus the horizontal vent connector shall be not greater
than 75 percent of the vertical height of the vent.
Any offsets used should be as far above the drafthood as
possible to allow a venting action to begin before any
restriction is encountered.
3’ 2’ Min. Listed
Vent Top
Storm Collar
Roof
Flashing
Oval to round
adapter
Listed “BW”
Vent Pipe
Base Plate
Header
Plate
2x4 Wall
Stud
Ceiling
Plate
Spacer
Lances
12’
Min.
FIG. 1 - VENT INSTALLATION
More
than 10’
10’
Ridge 2’ Min.
Height above any
roof surface
within 10’
horizontally
3’ Min.
Chimney
10’ or
Less
Ridge 2’ Min.
3’ Min.
Chimney
FIGURE A
Page 4
Red
Button
Blocked
Flue
Switch
Draft Diverter
Relief Opening
“CF40/55-D” Series Counterflow

COMBUSTIONANDVENTILATIONAIR
When installed, this gas appliance must be provided with fresh
air for combustion, ventilation, and dilution of hot flue gases.
Theminimumrequired volume of theareawhere the appliance is
installed should be 50 cubic feet per 1,000 btu/hr.
Ifinstalled in anarea of thehome that isconsidered an unconfined
space, the natural infiltration of air around windows and doors
will be adequate. If the area is considered a confined space (less
than 50 cubic feet per 1,000 btu), fresh air can be supplied by
providing two permanent openings into adjoining rooms. Each
opening shall have a minimum free area of one square inch per
1,000 btu per hour of the total input rating of all gas appliances in
the confined space, but not less than 100 square inches. One of
the openings shall be within 12 inches of the ceiling and one
within 12 inches of the floor. See FigureA.
Ifthehome isofunusually tightconstruction(new andremodeled
homes), free air must be supplied through opening(s) to the
outdoors. This can be accomplished by providing 2 permanent
openings, one commencing within 12 inches of the ceiling and
one within 12 inches of the floor. These openings shall
communicate directly with the outdoors, or spaces that
communicate freely with the outdoors, such as a ventilated attic
and crawl space through galvanized or equivalent corrosion-
resistant ducts. Exception: unobstructed stud and joist spaces
are acceptable ducts provided that not more than one fire block
is removed. Special provisions must be taken to insure that
these stud and joist spaces cannot be blocked with insulation or
other objects. Each of these openings using vertical ducts shall
have a minimum free area of one square inch per 4,000 btu/hr of
total input rating of all gas appliances. See Figure B and C. If
horizontal ducts are used, the minimum free area shall be one
square inch per 2,000 btu/hr of total input rating of all gas
appliances.
Fresh make-up air can also be provided through a duct to one
permanent opening commencing within 12 inches of the ceiling.
The minimum free area of this opening shall be one square inch
per 3,000 btu/hr of the total input rating of all gas appliances but
not less than the sum of the areas of all vent connectors in the
space. See Figure D.
Whencalculating the amountof freshair needed youmust include
make-upair requirementsfor theoperation ofexhaustfans,kitchen
ventilation systems, clothes dryers, and fireplaces.
Additionalinformationcan be found inthe latest edition ofANSI
Z223.1(National Fuel GasCode).
ALLCOMBUSTIONAIRFROMADJACENTINDOOR
SPACESTHROUGHINDOORCOMBUSTIONAIR
OPENINGS
ALLCOMBUSTIONAIRFROMOUTDOORS,INLET
AIRFROMVENTILATEDCRAWLSPACEAND
OUTLETAIRTOVENTILATEDATTIC
ALLCOMBUSTIONAIRFROMOUTDOORS
THROUGHVENTILATEDATTIC
ALLCOMBUSTIONAIRFROMOUTDOORS
THROUGHSINGLECOMBUSTIONAIROPENING
ULListedVent Cap
ULListed GasVent
Opening
Opening
ULListedVent Cap
ULListedVent Cap
ULListedVent Cap
ULListed GasVent
ULListed GasVent
ULListed GasVent
Ventilation Louvers (each
end of attic)
Outlet Air
Inlet Air
Ventilation Louvers for unheated crawl space
Ventilation Louvers (each
end of attic)
Outlet Air
Inlet Air Duct (ends 1 ft.
[300mm]above floor)
Opening
Alternate Opening
Location
F
I
G
U
R
E
A
F
I
G
U
R
E
B
F
I
G
U
R
E
D
F
I
G
U
R
E
C
Page 5
Inlet
Grille
Inlet
Grille

LOCATIONANDSPECIALPRECAUTIONS
Thewall furnaceshouldbe locatednearthe centerofthe
areato beheated for optimalheat distribution.
Ifthewallfurnaceisinstalleddirectlyoncarpeting,tileorany
combustiblematerial otherthan woodflooring, thewall fur-
naceshallbeinstalled onametalplateorwoodpanelsecured
to the floor, extending the full width and depth of the wall
furnace..
Ifa side or rearregister kit is tobeinstalled, see figures 14–
18 on pages 15 and 16.
ROUGH-ININSTRUCTIONS
Inselectingalocationforinstallation, itisnecessary to
provideadequateaccessibilityclearancesforservicing
andproper operation.
Minimumclearancefromcabinettocombustible
construction:
SideWall - 4”
Floor - 0”
Ceiling - 4”
SeeFigure2. Theunitmayberecessedandrest
directlyagainstsidestudsandtheinsidesurfaceofthe
rearwall.
ELECTRICALROUGH-IN
Roughin115v.wiring,terminatinginsidethejunction
boxlocated on top of header plate for recessed, or in
areceptacle box(not provided)forflush mount.
Consultlocal codes or ordinances. See Figure 3.
MODEL NUMBER AMPS
CF403D, CF404D 2.25
CF553D, CF554D 2.25
CF407D, CF557D 2.55
CF408D, CF558D 2.55 Page 6
115V.A.C.
Line
In B-WVent
Pipe 2x4
Stud
Header Plate
Wire Nut (not provided)
SwitchBoxCover Plate
FIGURE3
USINGADJACENTSTUDSPACE FORALL
COMBUSTIONAIR FROM OUTSIDE
HOLESCONNECTINGTO
VENTILATEDATTIC
CEILING
PLATE
AIR
GRILLE
FLOOR
PLATE
HOLESCONNECTINGTOVENTILATED
CRAWLSPACE 4”Minimum
4”Minimum
FIGURE2
BASEDON4,000BTUOFTOTALINPUTRATING
OFALLGASAPPLIANCES,THEHEATERONLY
REQUIRESAMINIMUMFREEAREAOF:
SQUARE HOLE SQUARE
BTU IN. SIZE = IN.
25,000 6.25 1” .785
35,000 8.75 1.5” 1.76
40,000 10.00 1.75” 2.4
50,000 12.50 2” 3.14
55,000 13.75 2.5” 4.90
65,000 16.25 3” 7.065

GAS ROUGH-IN
Check local codes for requirements as to the size and type of
gas line required. See Figure 5 for location of gas inlet holes
in furnace cabinet.
Compounds used on threaded joints of gas pipe should be
resistant to the action of liquefied petroleum gases. The gas
line joints must be checked for leaks. This should be done
with a soap solution – watching for bubbles on all
connections. NEVER USE AN EXPOSED FLAME TO
CHECK FOR LEAKS.
A manual valve equipped with a 1/8” NPT plugged tapping
accessible for test gauge connection should be installed
immediately upstream of the gas supply connection to the
appliance. Some codes and ordinances require that the
manual valve be located outside the appliance. See Figure
4.
The appliance and its individual shut off valve must be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess of
½ psig.
The appliance must be isolated from the gas supply piping
system by closing its individual manual shut off valve during
any pressure testing of the gas supply piping system at test
pressures equal to or less than ½ pig.
It is required by the National Fuel Gas Code that a drip line
beinstallednear the gas inlet. This shouldconsist 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.
Page 7
1-1/2” Dia.
Knockout
1-1/2” Dia.
Gas Inlet
Hole
4”
8”
5”
2”
FIGURE 5
FIGURE 4
Drip
Leg
Manual cut off valve
1/8N.P.T.
Pressure Tap
Gas
Supply
Line
To heater gas control valve

INSTALLATION / WHEN RECESSED
(UP TO 9-1/4”)
STEP 1.Cut out floor plate between 2x4 studs, so heater
will set flat on floor.
STEP 2.Make electrical connection of 115 V. wiring into
junction box provided on top of header plate.
STEP 3.Attach thebase plate (purchased withthevent pipe)
to the header plate using two No. 8 sheet-metal
screws through the pre-punched holes. See Figure
B.
STEP 4.Square up and nail header plate in place between
2x4 studs placed on 16” centers (14-3/8” between
studs). For distances from top of header plate to
floor, see Figure 6.
STEP 5.Remove double ceiling plate between studs. Install
one ceiling plate spacer across the cut out in ceiling
plate. Install vent pipe into position, be sure to
lock bottom of vent pipe into the base plate. Nail
second ceiling plate spacer in place. See Figure
B.
STEP 6.If the vent continues through additional stories
within the 2x4-stud space, then fire stop spacers
must be installed at the second and subsequent
ceiling levels. See Figure C.
STEP 7.To place furnace into position, grasp furnace and
lift so furnace flue vent and header plate vent
opening engage. Plug power cord from top of
heaterintoreceptacle on bottom oftheheader plate,
see Figure 3. Run thermostat wire through a drilled
hole into an adjacent stud space. Do not route it
behind the header plate. To do so may cause the
thermostat wiring to chaff resulting in the
appliance operating continually. Connect
thermostat wire with thermostat wires extending
from top of heater. Lift furnace upward and swing
bottom into wall, see Figure 7. Secure furnace in
place using 2 holes provided in bottom of casing.
STEP 8.Make gas connectionusing connector the samesize
as gas connection of furnace. CHECK ALL
CONNECTIONS FOR GAS LEAKS WITH
LEAK DETECTOR SOLUTION. DO NOT USE
OPEN FLAME.
STEP 9.Replace and fasten front panels to furnace.
INSTALLATION
WHEN INSTALLED FLUSH TO WALL
STEP 1.After locating furnace, cut 3-1/2”x12” rectangular hole
in ceiling between ceiling joists. Make sure gasket is in
position on the top of the furnace casing around the
flueventopening. Remove ventcollarfrom topofheader
plate and place over flue extension and fasten to
matching holes in casing top, using screws from header
plate. Install B vent type base plate (not supplied) to
top of vent collar. Install ceiling plate spacer to back
wall, centered between studs. Install B type vent to top
of furnace, terminating at least 12’ above the floor and
at least 2’ above the roof line.
STEP 2.Fasten furnace to wall. To secure top of furnace to wall,
loosen top screws on back casing and raise tabs up.
Tighten screws. Screw through hole in top of tabs into
anchors (not provided). Secure bottom using two holes
providedinbottom of casing. (Optional) Cover exposed
vent with a vent enclosure kit, Part Number 16VE-A or
36VE-A (not included).
STEP 3.Make electrical connection of 115 V. wiring into
receptacle box (not provided) mounted on a wall. Plug
power cord from top of heater into receptacle. Connect
thermostat wire with thermostat wires extending from
top of heater. According to installation instructions with
thermostat, do not run wires in same stud space with
vent system. Thermostat should be a minimum of 4’
from heater and 5’ from floor.
STEP 4.Make gas connection using connector the same size as
gas connection of furnace. CHECK ALL
CONNECTIONS FOR GAS LEAKS WITH LEAK
DETECTOR SOLUTION. DO NOT USE OPEN
FLAME.
STEP 5.Replace and fasten all front panels.
B-WVent
Header
Plate
FIGURE 7
NOTE: FOR PROPER COMBUSTION, MAKE
SURE UNITS ARE LEVEL FRONT TO BACK
AND SIDE TO SIDE.
Page 8
FIGURE 6
40,000-82-7/8”
55,000-88-7/8”

Installation of B-W Gas Vent
for one-story buildings or for
first floor of multi-story
buildings.
Ceiling plate spacers to center
B-W Gas Vent in stud space -
nail securely at both ends.
Plate cut away for full
width of stud space to
provide ventilation.
Studs on
16 inch centers
Sheet metal screw base
plate to header
Use manufacturer’s method of
fastening pipe to base plate.
Header plate of vented wall furnace
(also acts as firestop)
Installation of B-W Gas Vent
for each subsequent ceiling or
floor level of multistory buildings.
Firestop spacers supplied
by manufacturer of B-W
Gas Vent
Plate cut away
to provide passage
of B-W Gas Vent
Nail firestop spacer securely
FIGURE B FIGURE C
CONTROLS
All controls are pre-assembled at the factory. The normal
manifold pressure should be 3.5” w.c. for Natural Gas and
10” w.c. for L.P. Gas. The maximum inlet pressure in the
gas supply pipe should never exceed 7.0” w.c. for Natural
Gas or 14” w.c. for L.P. Gas. The minimum inlet pressure
in the gas supply pipe should never be lower than 4.5”
w.c. for Natural Gas or 11” w.c. for L.P. Gas.
The appliance is orificed at the factory for elevations up to 2,000
feet. If installed above 2,000 feet, the BTU input must be reduced
4%per 1,000feet. Orificechange mustbe completedbya qualified
installer or service technician. See the following orifice chart for
the proper orifice for a specific elevation.
PILOT ADJUSTMENT
Locate the pilot adjustment screw on the valve. The pilot
flameshouldsurround at least thetop3/8” of the powerpile
(pilot generator) or flame sensor (see Figure 8). The pilot
is unregulated so it will be operating at inlet line pressure
(maximum 7” w.c. for Natural Gas and 11” w.c. for
Propane Gas). To decrease the pilot flame, turn the screw
clockwise (approximately six full turns to bottom of pilot
light channel) until you produce sufficient flame at the
minimum noise level.
PILOT FLAME ADJUSTMENT
PILOT FLAME SHOULD ENVELOP 3/8 TO ½ INCH
OF THE TIP OF THE GENERATOR.
3/8”TO1/2”
STANDINGPILOT
FIGURE8-A
Page 9
NATURAL GAS
SPECIFICELEVATIONS
Model 0 to 2,000 - 4,000 - 6,000 - 8,000 -
No. 2,000’ 4,000’ 6,000’ 8,000’ 10,000’
CF403D 32 34 35 36 40
CF407D 32 34 35 36 40
CF553D 29 30 30 31 32
CF557D 29 30 30 31 32
ORDERKIT#49840 2287-1HIGHALTITUDEKIT
L.P. GAS
SPECIFICELEVATIONS
Model 0 to 2,000 - 4,000 - 6,000 - 8,000 -
No. 2,000’ 4,000’ 6,000’ 8,000’ 10,000’
CF404D 49 50 51 52 52
CF408D 49 50 51 52 52
CF554D 2.15mm 45 47 48 49
CF558D 2.15mm 45 47 48 49
ORDERKIT#49840 2287-1HIGHALTITUDEKIT
I.I.D.PILOT
FIGURE8-B
3/8” TO 1/2”
HONEYWELL
VR8204HSERIES
I.I.D.PILOT
FIGURE 10-B
PilotAdj.
Screw
PilotAdj.
Screw
HONEYWELL
VR8200HSERIES
STANDINGPILOT
FIGURE 10-A

CF403D-H, CF404D-H, CF553D-H, CF554D-H - - STANDING PILOT
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 instruc-
tions 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 electric 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.
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. PN91217 02/05
LIGHTING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
Page10
1. STOP! Read the information on the safety label.
2. Set thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. Remove lower front panel.
5. Push in gas control knob slightly and and turn
clockwise to “OFF”.
6. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas,
STOP! Follow “B” in the information on the safety
label. If you don’t smell gas, go to the next step.
7. Locate red piezo ignitor button. Locate pilot. (Follow
metal pilot tube from gas control).
8. Turn gas control knob counterclockwise to
“PILOT”.
9. Push in pilot control knob and hold in. Immediately
begin a series of pushing and releasing the red piezo
ignitor button, while observing the pilot. Continue to
spark until pilot is lit. Continue to hold the pilot control
knob in for about one (1) minute after the pilot is lit.
Release the pilot control knob and it will pop back up.
Pilot should remain lit. If pilot goes out, repeat steps 5
thru 9.
•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.
10. Turn gas control knob counterclockwise to “ON”.
11. Replace lower front panel.
12. Turn on all electric to the appliance.
13. Set thermostat to desired setting.
PN 91217 02/05
1. Turn thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is
to be performed.
3. Remove lower front panel.
4. Push in gas control knob slightly and turn clockwise
to “OFF”. Do not force.
5. Replace lower front panel.
PN 91217 02/05
Pilot Control Knob
NOTE: Knob
can not be
turned from
“PILOT”to
“OFF” unless
knob is pushed
in slightly.
Do not force.
Gas Control Knob

CF407D-H, CF408D-H, CF557D-H, CF558D-H - - I.I.D. PILOT
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.
LIGHTING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
Page11
1. Turn thermostat to it’s lowest setting.
2. Turn off all electric power to the appliance if
service is to be performed.
3. Remove lower front panel.
4. Push in gas control knob slightly and turn clockwise
to “OFF”. Do not force.
5. Replace lower front panel. PN91214 02/05
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
B. BEFOREOPERATINGsmellall aroundthe 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.
WHATTODOIFYOUSMELLGAS:
•Do not try to light any appliance.
•Do not touch any electric 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.
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.
PN91214 02/05
1. STOP! Read the information on the safety label.
2. Set thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
5. Remove lower front panel.
6. Push in gas control knob slightly and turn clockwise
to “OFF”.
9. Replace lower front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
“TO TURN OFF GAS TO APPLIANCE” and call your
service technician or gas supplier. PN91214 02/05
7. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor. If you smell gas, STOP!
Follow “B” in the information on the safety label. If you
don’t smell gas, go to the next step.
8. Turn gas control knob counterclockwise to “ON”.
NOTE: Knob
cannot be
turned to
“OFF” unless
knob is pushed
in slightly. Do
not force.
Gas Control Knob
GASCONTROL
KNOB

PROPER BURNER FLAME
A proper flame will have a dark blue inner mantle
that sits right on top of the burners with a lighter
blue outer mantle rising above the burner, (See
Figure 11). There may be some yellow where the
pilot flame and burner flame meet. There is no
primary air adjustment on the burner, and proper
flame is assured since the correct manifold pressure
and orificing has been done at the factory. NOTE:
It is advised that the burner flames be checked at
leasttwice duringtheheating seasonforany changes
in burner flame characteristics. The appliance area
must be kept clear and free from combustible
materials,gasoline, and other flammable vapors and
liquids. This heater comes from the factory with
the proper burner orifice for elevations up to 2,000
feet. Heaters installed above 2,000 feet must be
derated 4% for every 1,000 feet. For the proper
orifice size find the Model Number and elevation
on the orifice chart (See CONTROLS). Replace
burner orifice.
OPERATION
Thisheaterisequippedwithaslowopeninggascontrol.
Ona call forheat the gasvalvedoes not snap-opento
fullmanifoldpressure,butopenswithagradualincrease
tonormalmanifold pressure. Thetime lapsefromthe
callforheattonormaloperatingpressureistwo tofive
seconds. The slow open feature assures a safe, less
noisyignition.
After the heat exchanger has warmed sufficiently,
the fan will automatically come on to efficiently
transfer the heat into the room. NOTE: All models
haveanautomatictwo-speedfan. Inanewinstallation
or on fall start-up in a very cold room, some on-off
cyclingofthefanmayoccuriftheheatexchangercools
toomuch. Theburner,however,willcontinuetooperate
andthefancycleuntilthethermostatissatisfied.
5” to 7”
Approx.
1”
FIGURE11
Page12

TERMINAL BLOCK WIRING DIAGRAM
CAUTION: Labelall wirespriorto disconnectionwhenservicing controls. Wiring errorscan cause improper
and dangerous operation. Verify proper operation after servicing.
AUXILIARYLIMIT SWITCH
For your safety this furnace is equipped with a manual reset auxiliary limit switch. In case of failure by the
primary limit switch, this switch will shut the valve down completely before unsafe temperatures are reached.
Afteracooldown period,switch mustbe manuallyreset. If outagespersist, calla qualifiedservice technician.
MAINTENANCE INSTRUCTIONS
1. Installationand repair mustbe done byaqualified service technician. Theappliance should beinspected
beforeuseandatleastannuallybyaprofessionalservicetechnician. Morefrequentcleaningmayberequired
due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments,
burners,pilotburners,circulatingairpassagewaysandventingsystemsoftheappliancebekeptclean.
2. The bearingsof themotorshould beoiled everysixmonths withS.A.E. 20oil.
3. The appliance area must be kept clear and free of any combustible materials, gasoline and other
flammable vapors and liquids.
4. It is essential that the flow of combustion and ventilation air not be obstructed.
5. Periodic examination of the entire ventilation system as a routine part of the safety performance check
is recommended on an annual basis.
IMPORTANT: Keep burner and control compartment clean. Vacuum burner compartment at the start of
the heating season or as often as needed.
NOTE: It is advised that the burner flames be checked at least twice during the heating season for any
changes in burner flame characteristics.
115 VAC 60 HZ – Less than 12 Amps. If any of the original wire as supplied with this appliance must be
replaced, it must be replaced with type thermoplastic 105-degree C wire or its equivalent.
Page13
CF403D-H, CF404D-H, CF407D-H, CF408D-H, CF553D-H, CF554D-H, CF557D-H, CF558D-H
POWER
CORD
(Green)
TERMINAL BOARD
GROUND (Green)
MOTOR (Green) POWER CORD (Black)
TRANSFORMER (Black)
MOTOR (Black)
LIMIT
SWITCH
(Blue)
TRANSFORMER(Black)
POWER CORD (White)
FAN/LIMIT SWITCH (Brown)
SELECTOR
SWITCH
(Red)
MOTOR
(Red) MOTOR (White)
SELECTOR
SWITCH
(Black)
P/N91123

I.I.D.
CF407/408D-H, CF557/558D-H
Page14
FAN
SWITCH
LIMIT
SWITCH
SELECTOR
SWITCH MOTOR
THERMOSTAT
GAS
VALVE
TRANSFORMER
AUXILIARY
LIMIT SWITCH
SPILL
SWITCH
115 V.A.C.
24 V.A.C.
AMPS
2.25
CF403D-H,
CF404D-H
CF553D-H,
CF554D-H
LADDER
SCHEMATIC
CF403D-H, CF404D-H
CF553D-H, CF554D-H
PICTORIAL
SCHEMATIC
THERMOSTAT
POWER
CORD
WHITE
RED
BLACK
RED BROWN
BLACK
TRANSFORMER
BLUE
MOTOR
GREEN
BLACK
WHITE
GREEN
WHITE
BLACK
BLACK
YELLOW
BLACK
BROWN
FAN
SWITCH
LIMIT
SWITCH
AUXILIARY
LIMIT SWITCH
SPILL
SWITCH
GASVALVE
SELECTOR
SWITCH
BLACK
BLACK
BLACK
RED
BLUE
TH TR
STANDING PILOT
CF403/404D-H, CF553/554D-H
BLACK
BLACK
YELLOW
AUXILIARY
LIMIT SWITCH
SPILL
SWITCH
PILOT
IGNITION
MODULE
MV/PV
GAS VALVE
LIMIT
SWITCH FAN
SWITCH
SELECTOR
SWITCH
BLACK
BROWN
BLUE
TRANSFORMER
MOTOR
WHITE
BLACK
BLACK
BROWN
BLACK
GREEN
WHITE
WHITE
BLACK
THERMOSTAT
POWER
CORD
RED
RED
GREEN
CF407/8D-H,CF557/8D-H
PICTORIAL
SCHEMATIC
BLACK
RED
BLUE
BLACK
Spark
Sense
24 V
24 V
Gnd.
Gnd.(Burner)
PV
MV/PV
MV
MV
PV
FAN
SWITCH
SELECTOR
SWITCH
LIMIT SWITCH
MOTOR
SPILL
SWITCH AUXILIARY LIMIT SWITCH
GAS
VALVE
THERMOSTAT
IGNITION
MODULE
TRANSFORMER
115 V.A.C.
24 V.A.C.
MODELNO. AMPS
CF407/557D-H 2.55
CF408/558D-H 2.55
CF407D-H / CF557D-H
CF408D-H / CF558D-H
LADDER
SCHEMATIC

ROUGH-INS FOR REAR OR SIDE DISCHARGE
Installplastergrounds asshown inFigure 12and Figure13.
This kit must be installed by a qualified installer or service technician.
NOTE: Whenside dischargeis beingused,furnace shouldbe setexactly4” fromside wall.
14-3/8”
10-3/
16”
Plaster
Ground
SIDE
FIGURE13
REAR
OPTIONAL ACCESSORYKITS
REAR REGISTER KIT (Flush Mount)
(See Figure 14)
1. Use optional kit No. 406RR-A.
2. Cut openings in drywall as shown in Figure 12.
3. Position plasterground as shown in Figure 12
(Optional).
4. Cut out and remove embossed section on casing
rear.
5. Remove knockout on inner liner.
6. Put heater into position.
7. Place inner boot into position, mark and cut boot
flush with wall. Place damper into cutout end of
inner boot, mark (4) holes from damper onto inner
boot, top and bottom, and drill (4) 1/8” hole. Place
outer boot into position, mark and cut boot flush
with wall.
8. Attach inner boot to liner. Attach damper to inner
boot (screws provided). Attach outer boot to casing
back.
9. Place grill in position and secure to wall.
10. Final installation will appear as Figure 14.
REAR DISCHARGE KIT (Recessed)
1. Use optional kit No. 407RR-A.
2. Cut openings in wall as shown in Figure 13.
3. Cut out and remove embossed section on casing
rear.
4. Remove knockout from inner liner.
5. Place inner boot from kit through opening,
matching flanges of boot and knockout.
6. Mark screw holes and remove boot.
7. Drill holes with a 1/8” drill.
8. Repeat steps 5 & 6 for outer boot.
9. After unit has been set in wall, shove the inner
boot through the back wall and up against the liner.
Secure boot with screws provided. Attach damper
to inner boot with screws provided.
10. Repeat Step 9 for outer boot.
11. Place grille in place and secure to wall.
12. Final installation will appear as Figure 15.
FIGURE 14 FIGURE 15
(OPTIONAL KITS
CONTINUED -
REVERSE SIDE)
Page15
FIGURE12
Plaster
Ground 14-11/16”
14-1/2”
1/2”

SIDEDISCHARGEONCASING
1. Use optional kit No. 306SR-A.
2. Cut out and remove embossed area on casing side.
3. Remove knockout from inner liner.
4. Place 1-1/2” boot from kit through opening, matching
flanges of boot to knockout on inner boot.
5. Mark screw holes and remove boot.
6. Drill holes with a 1/8” drill.
7. Attach inner boot with screws provided.
8. Place grille into position, drill holes into casing, and
attach with screws provided.
SIDEDISCHARGE(WithExtensionBoot)
1. Use optionalkit No. 30SRB-A.
2. Cut opening in drywall as shown in Fig. 17.
3. Position plasterground as shown in Fig. 17 (optional).
4. Cut out and remove embossed section on casing side.
5. Remove knockout on inner liner.
6. Put heater into position.
7. Place inner boot into position, mark and cut boot flush
with wall. Place outer boot into position, mark and cut
boot flush with wall.
8. Place boot trim into position, slide inner boot through
wallfromadjacent room and attachtoinner liner. Slide
outer boot through wall from adjacent room and attach
to casing side.
9. Place grille into position and secure to wall.
OPTIONALKITS -CONTINUED
Thiskitmustbe installed by aqualifiedinstaller or service technician.
14PEK-A PLUG EXTENSION KIT INSTRUCTIONS
FOR NON-RECESSED INSTALLATION ONLY
UNITS WITH TERMINAL BOARD
STEP 1. Turn heater off following Section 3 in “Lighting Instructions” and allow
to cool.
STEP 2. Turn off all electricity to heater.
STEP 3. Remove top louver assembly, fan shroud and fan blade.
STEP 4. Loosen two screws on romex connector.
STEP 5. Remove junction box cover plate.
STEP 6. Disconnect three power cord terminals and pull power cord out of top
of heater.
STEP 7. Insert power cord provided in kit through romex connector and plug
onto terminal board following wiring diagram found in lighting and
operating instructions.
STEP 8. Tighten two screws on romex connector.
STEP 9. Replace junction box cover plate.
STEP 10. Replace fan blade, fan shroud and top louver assembly.
STEP 11. Snap 90 Degree outside corner (Ref. 1) onto 3 ft. section (Ref. 2)
plastic raceway. Insert power cord and remove blue backing from
adhesive strip on raceway and apply to side of heater. See Figure 18.
STEP 12. Insert power cord into second 3 ft. section of raceway (Ref. 3) and
remove blue backing and apply to side of heater, butting up agianst
bottom of other section. See Fig. 18.
STEP 13. Cut 14 inch long bottom section to required length (see chart), insert
power cord, remove backing and apply to side of heater. See Fig. 18.
STEP 14. Plug power cord into wall receptacle, see Fig.18.
STEP 15. Light the heater following lighting instructions.
Page16
FIGURE18
90 Degree
Outside Corner
3 FT.
SECTION
3 FT.
SECTION
BOTTOM SECTION
WALL
18”
Min.
FIGURE16
FIGURE17
MODEL Length of bottom section
NUMBER (Ref. 4) plastic raceway
CF40 8 Inches
CF55 14 Inches
NOTE: Above lengths terminate
approximately 2 inches above floor.

Page17
SYMPTOM POSSIBLE CAUSES CORRECTIVEACTION
Flame too large 1. Defective operator section of gas valve. 1. Replace complete valve.
2. Burner orifice too large. 2. Check with local gas company for proper
orifice size and replace.
3. If installed above 2,000 ft. 3. Refer to orifice chart on Page 9.
Noisy Flame 1. Noisy pilot. 1. Reduce pilot gas with adjusting screw on combination
gas control valve.
2. Burr in orifice (if it whistles or resonates). 2. Remove burr or replace orifice (do not enlarge orifices).
3. Excessive gas input. 3. See “Flame Too Large” above.
Yellow tip flame (some 1. Clogged main burner ports. 1. Clean main burner ports. (Do not enlarge ports).
yellow tipping on LP 2. Clogged draft hood. 2. Clean draft hood.
gas is permissible 3. Linted up mixer opening. 3. Check for dust or lint at air mixer opening.
Floating Flame 1. Blocked venting. 1. Clean flue passageways to remove blockage.
Gas Odor 1. Gas leak. 1. Shut off gas service immediately. Check piping.
Call gas company. See “For Your Safety”, Page 1.
2. Chimney or flue obstruction. 2. Clean flue.
3. Drafts around appliance. 3. Eliminate drafts.
Delayed Ignition 1. Pilot flame too small. 1. Check pilot orifice. Increase pilot gas flow if
necessary by adjusting inlet pressure from gas
source (meter if natural gas or second stage
regulator if propane - maximum 7” w.c. for
Natural and 11” w.c. for propane).
2. Burner ports clogged near pilot. 2. Clean burner ports (do not enlarge ports).
3. Low gas pressure. 3. Check gas supply inlet pressure. Check gas outlet
(manifold) pressure for “minimum step” pressure
(for “step” pressure chart see “Operation”).
4. Pilot decreases in size when main 4. Supply piping inadequately sized or incorrect
burners come on. inlet pressure.
5. Drafts around appliance. 5. Eliminate drafts.
6. Bad venting. 6. See “Venting”.
Failure to Ignite 1. Main gas off. 1. Open all manual gas valves.
2. Defective gas valve. 2. Replace gas valve.
Condensation of 1. Improper venting. 1. See “Venting”.
Water Vapor
Burner won’t 1. Defective or sticking automatic valve. 1. Replace valve.
turn off 2. Excessive gas pressure (The supply gas 2. To correct this situation contact the utility
pressure must not exceed 1/2 psi or supplying the gas.
14” w.c.
Incorrect Gas Input 1. Gas input not checked. 1. Re-check gas input.
2. Clogged orifice. 2. Check orifice for clogging. If clogged, clean out
the hole carefully with a smooth wood toothpick.
(Do not in any way enlarge or distort it).
Not enough heat 1. Appliance undersized. 1. This is especially true when a dwelling or room is
enlarged. Have the heat loss calculated and compare
to the appliance output (approx. 70% of input).
Your gas company or installer can supply you with
this information. If appliance is undersized, replace
with correct size unit.
2. Incorrect supply pressure. 2. Check supply pressure as outlined above.
Too much heat 1. Combination control valve sticks open. 1. Replace combination control valve.
TROUBLE SHOOTING CHART - PILOT AND VALVE
Burner won’t 1. Gas valve not turned on. 1. Turn gas valve to “on” position”.
turn on 2. No voltage to valve. 2. Check for 24 Volts to Valve.
3. Defective thermostat. 3. Check wall thermostat.
4. No 115 Volt Line Voltage. 4. Jump fan switch to check for voltage (fan will
come on).
5. Auxiliary limit switch open. 5. Push on red buton to close.
6. Blocked flue switch open. 6. Push red button in to close.
7. Gas valve defective. 7. Replace gas valve
TROUBLE SHOOTING CHART for qualified service technician - MAIN BURNER

Page18
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
Pilot won't light 1. Air in line. 1. Bleed line.
or stay lit 2. Defective thermocouple 2. Replace thermocouple.
(STANDING 3. Pilot flame too low. 3. Adjust pilot flame.
PILOT) 4. Manual reset switch not engaged. 4. Push on button.
Pilot won't light, 1. Sparker won't work. 1. Check wire connections.
or stay lit 2. Sparker won't light pilot. 2.a. Pilot flame too lean.
(I.I.D. PILOT) 2.b. Turn valve to "on" position.
2.c. Check for pilot restriction.
3. Manual reset switch not engaged. 3. Push on button.
TROUBLE SHOOTING CHART - FOR USE BY QUALIFIED INSTALLER OR
SERVICE TECHNICIAN - PILOT AND VALVE - CONTINUED
Green LED
Flash Code
(XxY)ª Indicates Next SystemAction Recommended Service Action
OFF No "Call for Heat" Not applicable None
Flash Fast Startup - Flame sense Not applicable None
calibration
Heartbeat Normal operation Not applicable None
2 5 minute Retry Delay Initiate new trial for ignition after If systemfails to light on next trial for
retry delay completed. ignition check gas supply, pilot burner,
Pilot flame not detected spark and flame sense w iring, flame rod
during trial for for ignition contaminated or out of position, burner
ground connection.
3 Recycle Initiate new trial for ignition. Flash If systemfails to light on next trial ignition
code will remain through the ignition check gas supply, pilot burner, flame
Flame failed during run trial until flame is proved. sense w iring, contamination of flame rod,
burner ground connection.
4 Flame sensed out of If situation self corrects w ithin 10 seconds, Check for pilot flame. Replace gas
sequence control returns to normal sequence. If valve if pilot flame present. If no
flame out of sequence remains longer than pilot flame, cycle "Call for Heat".
10 seconds, control goes to Flash Code If error repeats, replace control.
6+4 (see below).
7 Flame sense leakage to Control remains in wait mode. When the Check flame sense lead w ire for damage or
ground fault corrects, control resumes normal shorting. Check that flame rod is in proper
operation after a one minute delay. position. Check flame rod ceramic for
cracks, damage or tracking.
8 Low secondary voltage Control remains in wait mode. When the Check transformer and AC line for proper
supply - (below 15.5 Vac) fault corrects, control resumes normal input voltage to the control. Check w ith
operation after a one minute delay. full system load on the transformer.
6 + 2 5 minute Retry Delay - On Initiate new trial for ignition after Check gas supply, pilot burner, spark and
every third retry on the retry delay completed. flame sense w iring, flame rod contaminated
same "Call for Heat" or out of position, burner ground connectiion.
6 + 3 On every 6th flame failure 5 minute retry delay, then initiate Check gas supply, pilot burner, flame sense
during run on the same new trial for ignition. w iring, contamination of flame rod, burner
"Call for Heat" ground connection.
6 + 4 Flame sensed out of Control w aits until flame is no longer Check for pilot flame. Replace gas valve if
sequence - longer than 10 sensed and then goes to soft lockout. Flash pilot flame present. If no pilot flame, cycle
seconds code continues. Control auto resets from "Call for Heat". If error repeats, replace
soft lockout after one hour. control.
ON Soft lockout due to error Control auto resets fromsoft Reset by cycling "Call for Heat". If error
detected during self check lockout after one hour. repeats, replace the control.
sequences
TROUBLE SHOOTING CHART FOR INTERMITTENT IGNITION SYSTEM (I.I.D)
POSSIBLE CAUSES & CORRECTIVEACTIONS - SEE PAGE 19

Page19
POSSIBLE CAUSES CORRECTIVE ACTION
1. Blockage in vent pipe 1.A) Checkvent pipe forblockage,such as bird nest, wasp nest, twigs, leaves, etc.
1. B) Checkinside the bottomofthe vent pipe to make sure the top ofthe draft
diverterdid not rip the innerliner causing it to blockpart of the vent opening.
1. C) Checkthat no insulation fromthe headerplate got caught on top ofthe draft
diverter when the heaterwas inserted into the wall.
1. D) Checkthat the vent cap is properly installed, not shoved too far down on the
vent pipe.
2. Burner is overfiring 2. A) Check the manifold pressure.
2. B) Checkthe rate, NOTE: This appliance was orificed for elevations up to 2,000
feet. When installed at higher elevations refer to orifice chart in "Controls"
section ofinstructions for proper orifice size.
3. Impropervent system. 3. Correct vent system.
A) Vent too short A) The vent should terminate a minimumof12feet above the floor. See Figure 1.
Also, the top of the vent must be at least 2 foot above any obstacle within a
10 foot radius, including the roof. See Figure A on Page 4.
B) Restriction in vent B) Alltype "B" vents shallextend in a generally verticaldirection with offsets not
systemcaused by exceeding 45degrees,except that a vent systemhaving not more than one 60
offsets degree offset may be allowed.
Any angle greater than 45degrees fromthe verticalis considered horizontal.
The totalhorizontalrun ofa vent plus the horizontalvent connectorshallbe
not greaterthan 75percent of the verticalheight ofthe vent.
C) Incorrect vent pipe C) Use listed BW type vent pipe. Do not use transite orany othertype ofceramic
pipe forventing. Do not use single wallpipe. When venting into a masonry
chimney the chimney must be properly lined and sized forthis gas furnace.
The use of type Bora flexible chimney lineris recommended.
4. Incorrect header plate 4. Consult Figure 6forcorrect headerplate height.
location
5. Vent pipe not down on 5. You must use a base plate (obtained fromthe vent pipe manufacturer)on top of
the headerplate the headerplate,orwallfurnace. This willlockthe vent pipe down and prevent
securely the draft diverterfromshoving it up.
6. Loose connections on 6. Checkthe connections on both the switch and the gas valve. Tighten if
the safety wiring necessary.
harness
DO NOT BYPASS THE BLOCKED FLUE SWITCH: TO DO SO COULD EXPOSE THE
CONSUMER TO PROPERTY DAMAGE, PERSONAL INJURY OR POSSIBLE DEATH.
THE FOLLOWING IS A LIST OF POSSIBLE CAUSES AND CORRECTIVE
ACTIONS FOR BLOCKED FLUE SWITCH PROBLEMS - FOR USE BY A
QUALIFIED INSTALLER OR SERVICE TECHNICIAN.

REV.04/13
COUNTERFLOW WALL FURNACE / STANDING PILOT
Page20
ATTN: Contractors and Service Technicians, we only sell parts through
our wholesalers, but the prices listed are for your convenience. For prompt
parts service, contact the wholesaler from which you purchased your Cozy
heater. NOTE: Parts & schematic drawings on current models are shown at
www.cozyheaters.com.
16
22/23
26
24
14
25
34
5
10 11
4
27
29 28
12 30 13
35 1f
31
1e
1
1b
1d
1c
32d
34b
3
32b
33
32c39
1a
52
15
32
45
46
6
37
9
8
72
19
Prices and specifications subject to
change without notice.All
prices are F.O.B. factory.
MODELS:
NAT. GAS L.P.GAS
CF403D-H CF404D-H
CF553D-H CF554D-H
USEONLYFACTORYSUPPLIED
REPLACEMENTPARTS
CONTROL
ASSEMBLY 21 36
42
17/18
59
60
16
22/
23