COZY W255G User manual

page 1 84502-C
GAS-FIRED VENTED
WALL FURNACE
Installation and Operating Instructions
P/N 84502 / Rev 12-06-16
WARNING - If the information in these instructions is not followed
exactly, a re or explosion may result causing property damage,
personal injury or death.
Do not store or use gasoline or other ammable 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 re department.
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED
INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
THIS UNIT IS NOT TO BE INSTALLED IN MOBILE HOMES.
Installation, maintenance, service, troubleshooting and repairs must be performed by a qualied service agency. MR./
MRS. HOMEOWNER, DO NOT attempt any of these procedures yourself as this could expose you to property damage,
personal injury, or loss of life and will invalidate all warranties.
This unit is for residential use only and is not approved for installation in mobile
homes, greenhouses, or environments involving dusty, wet, corrosive, or explosive
conditions. Such conditions will invalidate the warranty and may create unsafe
conditions.
This appliance is equipped with a blocked
ue switch designed to protect against a
blocked ue condition.
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.
Natural Gas - W255G, W355G, W505G, L.P. Gas - W256G, W356G, W506G
W255G-3, W355G-3, W505G-3, W255G-5, W355G-5, W505G-5
W255G-7, W355G-7, W505G-7
The coating selected to provide longer life to the heat exchanger may
smoke slightly upon initial ring. Please provide adequate ventilation if
this occurs.
This heater may be installed
without recessing into stud
space by using optional FSK
(Free Standing Kit).
WARNING - Operation of this furnace when not connected to a properly installed and maintained venting
system can result in Carbon Monoxide (C.O.) poisoning and possible death. For your safety, this furnace and
the venting system should be inspected at least annually by a qualied service technician.

page 2 84502-C
CONTENTS
READ CAREFULLY BEFORE INSTALLING UNIT
This appliance must be installed in accordance with local codes, if any; if not, follow the National Fuel Gas Code, ANSI
Z223.1/ NFPA 54 or the Natural Gas and Propane Installation Code, CSA-B149.1.
This 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.
ANSI Standards:
THE AMERICAN
GAS ASSOCIATION
1515 Wilson Blvd.
Arlington, Virginia 22209
NFPA Standards:
THE NATIONAL FIRE
PROTECTION ASSOCIATION
Batterymarch Park
Quincy, MA. 02269
Canadian Standards:
INTERNATIONAL
APPROVAL SERVICES
178 Rexdale Blvd.
Etobicoke, Ontario, Canada M9W 1R3
NOTE: If optional rear register kit is to be used, see supplemental installation instructions (No. 84504) and section marked
“Special Instructions for Rear Register Kit Application” prior to installation of Rough-In.
INTRODUCTION
THIS IS A GAS-FIRED, GRAVITY VENTED WALL FURNACE THAT WILL OPERATE SAFELY AND PROVIDE AN
EFFICIENT SOURCE OF HEAT WHEN INSTALLED, OPERATED AND MAINTAINED AS RECOMMENDED IN THESE
INSTALLATION AND OPERATING INSTRUCTIONS. READ THESE INSTRUCTIONS THOROUGHLY BEFORE
INSTALLING, SERVICING, OR USING THE APPLIANCE. IF YOU DO NOT UNDERSTAND ANY PART OF THESE
INSTRUCTIONS, CONSULT LOCAL AUTHORITIES, OTHER QUALIFIED INSTALLERS, SERVICE TECHNICIAN, THE
GAS SUPPLIER OR THE MANUFACTURER.
SPECIFICATIONS
Your vented wall furnace comes packed in a single carton. (For wall thermostat models that includes the thermostat,
thermostat wire, and insulated staples). Before installing the wall furnace 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.
Introduction .................................................................. 2
Specications ........................................... 2
Safety Rules ............................................. 3
Clearances ................................................................... 3
Controls ........................................................................ 3
Combustion & Ventilation Air ..................................... 4-5
Venting ....................................................................... 6-7
Rough-In Instructions ................................................... 7
Installation .................................................................... 9
Wiring Instructions ...................................................... 10
Lighting Instructions ..................................................... 11
Pilot Adjustment .......................................................... 12
Burner Flame Adjustment ........................................... 12
Maintenance Instructions ............................................ 12
BBSK Kit Instructions ............................................. 13-15
WFF81 Fan Instructions ............................................. 16
40542 Rear Register Kit Instrucitons ..................... 17-18
Trouble Shooting Chart ......................................... 19-20
Parts Drawing ............................................................. 21
Parts List ................................................................ 22-23
Warranty ..................................................................... 24
Model Type Type BTU / Hr Vent Gas Ship Rear Reg. Kit Fan Kit
No. Control Gas Input Size Inlet Finished Dimensions Weight Model Weight Model Weight
SINGLE WALL FURNACE
W255G Wall Stat Nat. 25,000 4” 1/2” 16.5” w x 68” h x 6.5” d 90lbs 40542 5lbs WFF81 10lbs
W256G Wall Stat L.P. 25,000 4” 1/2” 16.5” w x 68” h x 6.5” d 90lbs 40542 5lbs WFF81 10lbs
W355G Wall Stat Nat. 35,000 4” 1/2” 16.5” w x 68” h x 6.5” d 90lbs 40542 5lbs WFF81 10lbs
W356G Wall Stat L.P. 33,000 4” 1/2” 16.5” w x 68” h x 6.5” d 90lbs 40542 5lbs WFF81 10lbs
DUAL WALL FURNACE
W505G Wall Stat Nat. 50,000 4” 1/2” 16.5” w x 68” h x 6.5” d 134lbs N/A N/A WFF81 10lbs
W506G Wall Stat L.P. 50,000 4” 1/2” 16.5” w x 68” h x 6.5” d 134lbs N/A N/A WFF81 10lbs
The State of Massachusetts requires that
installation and service of a gas appliance be
performed by a plumber or gas tter licensed in
the Commonwealth of Massachusetts.

page 3 84502-C
SAFETY RULES
A) The wall furnace should be located near the
center of the house for best heat distribution.
B) Due to high temperatures, the appliance should
be located out of trafc and away from furniture
and draperies.
C) Children and adults should be alerted to the
hazards of high surface temperature and should
stay away to avoid burns or clothing ignition.
D) Young children should be carefully supervised
when they are in the same room as the
appliance.
E) Do not place clothing or other ammable
material on or near the appliance. Precautions
should be taken so as not to place furniture,
drapes, or other articles directly in front of grille
or lower access door that would obstruct air
openings as proper air ow is critical to proper
operation of unit.
F) Any safety screen guard or casing front
removed for servicing an appliance must be
replaced prior to operating the appliance.
G) Heater must be installed with legs resting on the
2x4 oor sill plate (recessed) or the factory FSK
Kit (ush mount). The header plate shall then
be installed at a height 65-3/4 inches above top
surface of the plate that the heater legs rest on.
This provides the listed 2 inch minimum oor
clearance.
If the area where the heater is installed contains
carpeting, tile, etc., the listed 2 inch minimum
oor clearance must be maintained from the
top surface of these materials. If the heater is
installed DIRECTLY on carpeting, tile or any
combustible material other than wood ooring,
the heater shall be installed on a metal or wood
panel secured to the oor, extending the full
width and depth of the heater.
H) Installation and repair must be done by a
qualied installer or service technician. The wall
furnace must be inspected before use and at
least annually by a qualied service technician.
CLEARANCES
As viewed from front of heater, the
minimum clearance from cabinet to
combustible construction:
Side Wall 1”
Floor 2”
Ceiling 11”
In selecting a location for installation
it is necessary to provide adequate
accessibility clearances for
servicing and proper operation. This
appliance must not be connected to
a chimney flue that serves to vent
a solid-fuel burning (wood or coal)
appliance, or a multi-vent system.
CONTROLS
All controls are preassembled
at the factory.
The normal manifold pressure should be 3.5” w.c. on Natural Gas
and 10” w.c. on L.P. Gas. The maximum inlet pressure in the gas
supply pipe should never exceed 14” w.c. on L.P. Gas or 7.0” w.c.
on Natural Gas.
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 ½ psig.
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 ½ psig.
The minimum inlet pressure in the gas supply pipe should be 5.0”
w.c. on Natural Gas or 11” w.c. on L.P. Gas, “for purpose of input
adjustment”.
The appliance is oriced at the factory for elevations between sea
level and 2,000 feet. If installed above 2,000 feet, the BTU input
must be reduced 4% per 1,000 feet that the furnace is above
sea level. See the following orice chart for the proper orice for
a specic elevation. A blank orice is shipped in the high altitude
kit with each heater. This orice(s) will have to be drilled to correct
size by a qualied installer, service technician or the gas supplier.
2”
11” 1”
NATURAL GAS
Model 0’ - 2,000’ - 4,000’ - 6,000’ - 8,000’ -
No. 2,000’ 4,000’ 6,000’ 8,000’ 10,000’
W255G 43 44 45 47 48
W355G 36 38 40 41 43
ORDER KIT #49820 45-1 High Altitude Kit
W505G 43 44 45 47 48
ORDER KIT #49850 2287-2 High Altitude Kit
L.P, GAS
Model 0’ - 2,000’ - 4,000’ - 6,000’ - 8,000’ -
No. 2,000’ 4,000’ 6,000’ 8,000’ 10,000’
W256G 1.45mm 54 54 55 55
W356G 52 52 52 53 54
ORDER KIT #49820 45-1 High Altitude Kit
W506G 1.45mm 54 54 55 55
ORDER KIT #49850 2287-2 High Altitude Kit

page 4 84502-C
When installed, this gas appliance must be provided with fresh air for combustion, ventilation, and dilution of hot flue
gases. The minimum required volume of the area where the appliance is installed should be 50 cubic feet per 1,000
btu/hr.
If installed in an area of the home that is considered 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 Figure A-1 (on page 5).
If the home is of unusually tight construction (new and remodeled 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 A-2 and
A-3. 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 A-4.
When calculating the amount of fresh air needed you must include make-up air requirements for the operation of
exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces.
Additional information can be found in the latest edition of ANSI Z223.1 (National Fuel Gas Code).
COMBUSTION AND VENTILATION AIR

page 5 84502-C
ALL COMBUSTION AIR FROM ADJACENT
INDOOR SPACES THROUGH INDOOR
COMBUSTION AIR OPENINGS.
Fig. A-1
Fig. A-3
Fig. A-2
Fig. A-4
ALL COMBUSTION AIR FROM OUTDOORS
THROUGH VENTILATED ATTIC.
ALL COMBUSTION AIR FROM OUTDOORS. INLET
AIR FROM VENTILATED CRAWL SPACE AND
OUTLET AIR TO VENTILATED ATTIC.
ALL COMBUSTION AIR FROM OUTDOORS
THROUGH SINGLE COMBUSTION AIR OPENING.
UL Listed Vent Cap
UL Listed Gas Vent
Opening
Opening
COMBUSTION AND VENTILATION AIR
UL Listed Vent Cap
UL Listed Gas Vent
Ventilation
louvers for unheated crawl space
Outlet Air
Ventilation Louvers
(each end of attic)
Inlet Air
UL Listed Vent Cap
UL Listed Gas Vent
Ventilation Louvers
(each end of attic)
Outlet Air
Inlet Air Duct
(Ends 1 ft. [300mm]
above floor)
Inlet
Grille
Inlet
Grille
UL Listed Vent Cap
UL Listed Gas Vent
Opening
Alternate
Opening
Location

page 6 84502-C
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 ue pipe may be used. See Figure G-5 (on page 8).
Vent pipe must connect to the wall furnace header plate with a “B” vent
base plate and terminate with a cap at a point at least 12 foot above
the bottom of the wall furnace, 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 is equipped with a manual reset blocked ue switch
designed to protect against a blocked ue condition, which would
cause combustion products to spill back into the living quarters.
NOTE: A partially blocked, inadequate, or disconnected vent
system may not activate the switch.
Discoloration of the grille is an indication of a bad vent. If this occurs,
the vent can be checked by a qualied serviceman using a draft gauge.
After 15 minutes the gauge should read between -.02 up to -.04 inches
w.c. Vent must be checked at the beginning of each heating season.
The switch when activated will break the thermostat circuit turning off
the main burner ame. Before the burner will relight, the switch must
be manually reset. See Figure D-1 (on page 7) for location of the
manual reset blocked ue switch. To reset the switch, insert a slender
rigid object (i.e. screwdriver) through the front panel louvers and push
the reset button down. See Figure D-2. However, you may have to
remove the front panel, then reset the switch and re-install the front
panel before turning the burner on. If homeowner experiences this
problem, the vent system must be checked and corrected.
NOTE: A preexisting vent that has worked for years may not
be adequate for todays design because of higher efciency
requirements that result in lower stack temperatures. See “Possible
Causes and Corrective Action” on Page 20.
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.
USING ADJACENT
STUD SPACE FOR ALL
COMBUSTION AIR
FROM OUTSIDE
BASED ON 4,000 BTU OF
TOTAL INPUT RATING OF ALL
GAS APPLIANCES, THE HEATER
ONLY REQUIRES A MINIMUM
FREE AREA OF:
BTU Square In. Hole Size Square In.
25,000 06.25 1” 0.785
33/35,000 08.75 1.5” 1.760
50,000 12.50 2” 3.140
VENTING
Holes Connecting to Ventilated Attic
Holes Connecting to Ventilated Crawl Space.
Air
Grille
Floor
Plate
Ceiling
Plate
Fig. B

page 7 84502-C
ROUGH-IN INSTRUCTIONS
NOTE: Maximum wall thickness for a dual wall (W505,
W506) installation is 5-3/8”.
STEP 1.
Attach the base plate (purchased with the vent pipe) to
the header plate using two No. 8 sheet-metal screws
through the pre-punched holes. The heater may not
vent properly without a base plate to anchor and seal
the vent system. See Figure F (below).
Fig. F
Fig. E: Gas Supply
WARNING: Do not bypass the blocked flue switch. To do so could expose
the consumer to property damage, personal injury or possible death.
Fig. C
Fig. D-1 Fig. D-2
Reset
Button
Draft
Diverter
Relief
Opening
Combustion
Chamber
Man. Reset
Blocked
Flue Switch
Switch/
Gas
Control
Wire
Installation of B-W Gas Vent for
one story buildings or for
rst oor of multi-story
buildings.
Header plate of vented wall furnace.
(also acts as restop)
Use manufacturer’s method of
fastening pipe to base plate.
Sheet metal screw base plate to header.
Studs on 16” centers.
Plate cut away for full
width of stud space to
provide ventilation.
Ceiling plate spacers to
center B-W gas vent in
stud space - nail securely
at both ends.
To Heater Gas
Control Valve
Drip Leg
1/8” NPT
Pressure Tap
Gas
Supply
Line
Manual Cut-Off-Valve
STEP 2.
Cut out an opening between the studs of 14-3/8” x
66-1/2” above the oor plate. Embed the rear ange of
the channel on top of header into either the drywall or
the plastered wall. This provides part of the required re
stop. Square up and nail the header in place with the top
front of header located 65-3/4” above oor plate.
(See arrow on right side of header and
Figures G-1, G-2 and G-3 on Page 8).
STEP 3.
Rough in ½” gas supply on center line of left stud either
4” above top of oor plate or 4” to right of left stud
through oor plate.
(See Figure G-1 on Page 8).
Chimney
More than 10’
10’
2’ Min.
3’ Min.
Height above
any roof surface
within 10’
horizontally
Ridge
10’ or Less
2’ Min.
3’ Min.
Chimney
Ridge

page 8 84502-C
ROUGH-IN INSTRUCTIONS
Fig. G-5: Vent Installation
STEP 4.
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 F (on page 7).
STEP 5.
If the vent continues through additional stories within the
2x4-stud space, then re-stop-spacers must be installed
at the second and subsequent ceiling levels.
See Figure G-4 (below).
Fig. G-4
Fig. G-1
Fig. G-2: Dry Wall
Fig. G-3: Plaster Wall
NOTE: For proper combustion, make sure units are
level, front to back and side to side.
Listed Vent Top
Storm Collar
Roof Flashing
Oval to Round
Adapter
Listed “BW”
Vent Pipe
Base Plate
Header
Plate
2 x 4
Wall Studs
Ceiling
Plate
Spacer
Lances
12’ Min.
Ceiling
Plate
Spacers
Ceiling
Plate
Spacers
2’ Min.
Installation of B-W gas vent
for each subsequent ceiling
or oor level of
multi-story buildings.
Firestop spacers
supplied by
manufacturer of
B-W gas vent.
Plate cut away to
provide passage
of B-W gas vent.
Nail restop
spacer securely.
4”
4”
*65 3/4”
*This
measurement
must be taken
from top of
oor plate
Dry-Wall
Dry-Wall
B-W Type Vent
B-W Type Vent
Screw
Screw
Front
Panel
Front
Panel
Plaster
Ground
Plaster
Ground
ROUGH-IN
DIMENSIONS
14 1/4”
Min.
14 1/2”
Max.
NOTE: Front panel must be in front of plaster ground
channel. Do not hang it over front of plaster ground.
NOTE: Front panel must be in front of plaster ground
channel. Do not hang it over front of plaster ground.

page 9 84502-C
STEP 6.
To place furnace into position, grasp furnace and lift so
furnace ue vent and header plate vent opening engage.
Do not use burner or gas control to lift heater. Lift furnace
upward and swing bottom into wall opening until legs rest
on oor plate and are ush to nished wall. For proper
combustion, level heater front to back and side to side.
Nail legs to studs. DO NOT BEND LEGS as this will put
the entire unit into a bind and cause expansion noises.
(See Figure H-1)
STEP 7.
A drip leg and a manual valve equipped with a 1/8 N.P.T.
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.
STEP 8.
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 9.
For wall thermostat units, see “Wiring” section for
thermostat connections. Make sure all connections are
correct and connector stems are not touching.
STEP 10.
To fasten front panel to furnace, be sure exposed portion
of header is free of debris. Place outer panel over furnace
with top of panel about one inch above header and
centered in opening. Keep front panel ush to nished
wall and slide down until rear ange of top outer panel
is wedged tight against the front of the plaster ground
channel and ush with wall. CAUTION: Do not hang
front panel behind (over front lip) the plaster ground
channel as this could result in excessive noise. Open
bottom door of front panel and place sheet metal screw
into locking latch. Secure top of front panel to header
plate with screw provided. This will hold front panel
securely to wall.
See Figures G-2 and G-3 (on page 8), and H-3.
Fig. H-1
Fig. H-2
Fig. H-3
INSTALLATION
B-W Vent
Burner Shelf
Casing “Z Bracket
Front Panel
Front
Panel
Door

page 10 84502-C
CAUTION:
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.
WIRING INSTRUCTIONS
GRAVITY WALL FURNACE
Follow the instructions included with the thermostat.
Locate the thermostat approximately ve (5’) feet above
the oor and four feet (4’) from appliance. Always mount
the thermostat on an inside wall where it won’t be
affected by heat or cold sources such as direct sunlight,
televisions, replaces, hidden hot or cold water pipes,
drafts, etc. The thermostat must never be installed in an
adjoining room where a door can be closed between the
thermostat and wall furnace. This wall furnace is equipped
with a self generating control system. Never connect to a
24 volt transformer or to the household electrical system.
Do not use more thermostat wire than is included with
the wall furnace. Do not run thermostat wire in same stud
space with vent. Conceal wire inside wall or secure to
wall with insulated staples that are included.
YOUR FURNACE IS SHIPPED
WITH A WALL THERMOSTAT (Figure I).
You may convert control to built-in bulb control with
the optional BBSK kit. See pages 13, 14 and 15 for
installation instructions.
Fig. I
WIRING INSTRUCTIONS
WARNING - Failure to locate the thermostat
properly or to wire the furnace correctly may
result in continuous operation, control damage
or failure to operate. This can cause property
damage, personal injury, or loss of life.
Pilot
Generator
Thermostat
Manual
Reset Blocked
Flue Switch
Wire
Nut
Gas Valve

page 11 84502-C
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 oor because some gas is
heavier than air and will settle on the oor.
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.
FOR YOUR SAFETY READ BEFORE LIGHTING
MODELS: W255G W256G / W355G W356G / W505G W506G
• If you cannot reach your gas supplier,
call the re department.
C. Use only your hand to push in or turn
the gas control knob. Never use tools. If
the knob will not push in or turn by hand,
don’t try to repair it, call a qualied service
technician. Force or attempted repair may
result in a re or explosion.
D. Do not use this appliance if any part has
been under water. Immediately call a
qualied service technician to inspect the
appliance and to replace any part of the
control system and any gas control which
has been under water.
NOTE: Knob cannot be turned from “PILOT” to “OFF”
unless knob is pushed in slightly. Do not force.
5. Wait ve (5) minutes to clear out any gas. Then smell
for gas, including near the oor. 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.
6. Locate the pilot. (Follow metal pilot tube from gas
control).
7. Turn gas control knob counterclockwise
to “PILOT”.
LIGHTING INSTRUCTIONS
WARNING:
If you do not
follow these
instructions
exactly, a re
or explosion
may result
causing
property
damage,
personal
injury or loss
of life.
LIGHTING INSTRUCTIONS
TURNING OFF GAS TO APPLIANCE
1. STOP! Read the information on the safety label.
2. Set thermostat to it’s lowest setting.
3. Open cabinet door.
4. Depress and turn gas control knob clockwise
to “OFF”.
1. Set the thermostat to it’s lowest setting.
2. Open cabinet door.
3. Push in gas control knob slightly and turn clockwise
to “OFF”. Do not force.
4. Close cabinet door.
8. Push gas control
knob and hold in.
Immediately light
the pilot with a
match. Continue
to hold the gas
control knob in for
about one (1)
minute after the pilot is lit. Release gas control
knob and it will pop back up. Pilot should remain
lit. If pilot goes out, repeat steps 4 through 8.
• 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.
9. Turn gas control knob counterclockwise
to “ON”.
10. Close the cabinet door.
11. Set thermostat to desired setting.
Pilot is
located
on side of
burner
Manifold
Pressure Tap
Gas Control Knob
Internal Manifold Pressure RegulatorPilot Adjustment Screw Cap
Fig. J-1
Fig. J-2

page 12 84502-C
1 2 3
1. FLAME TOO SOFT -
Yellow Flame. Open air shutters
until yellow tipping disappears.
2. FLAME TOO HARD - Deep Blue Coloration. Closing
air shutters to a point where yellow tipping begins,
re-open slightly to eliminate yellow tipping. Air shutter
adjustment is now correct
3. NORMAL FLAMES
Air
Shutter
Locate the pilot adjustment screw on the valve. The pilot
ame should surround at least the top 3/8” of the powerpile
(pilot generator) or thermocouple (see below). The pilot is
unregulated so it will be operating at inlet line pressure (Max.
7” w.c. for natural gas and 11” w.c. for propane). To decrease
the pilot ame, turn the screw clockwise (approximately
seven to nine full turns to bottom of pilot light channel) until
you produce sufcient ame at the minimum noise level.
NOTE: It is advised that the burner flames be checked at least twice during the heating season for any changes in
burner characteristics. Vacuum burner compartment at start of heating season or as often as needed.
PILOT ADJUSTMENT MAINTENANCE INSTRUCTIONS
STEP 1.
Installation and repair must be done by a qualied
service person. The appliance should be inspected
before use and at least annually by a professional
service person. More frequent cleaning may be required
due to excessive lint from carpeting, bedding material,
etc. It is imperative that control compartments, burners,
pilot burners, circulating air passageways and venting
systems of the appliance be kept clean.
STEP 2.
If the appliance has been equipped with the optional
WFF81-C fan kit assembly, the bearings of the motor
should be oiled every six months with approximately 2
drops of S.A.E. 20 oil.
STEP 3.
The appliance area must be kept clear and free of any
combustible materials, gasoline and other ammable
vapors and liquids.
STEP 4.
It is essential that the ow of combustion and ventilation
air not be obstructed.
STEP 5.
Periodic examination of the entire ventilation system
as a routine part of the safety performance check is
recommended on an annual basis.
Fig. K: Pilot Flame Adjustment
PILOT FLAME SHOULD ENVELOP 3/8 TO 1/2 INCH
OF THE TIP OF THE GENERATOR.
3/8 TO 1/2 INCH
Burner Flame Adjustment - Stainless Steel Burner
Fig. L

page 13 84502-C
STEP 1. Select left or right side of front panel for most convenient location of the temperature control knob.
Remember to choose the side that allows adequate clearance for accessibility to adjust the control knob.
STEP 2. On selected side, locate three (3) vertical dimples beginning approximately 20-½” above bottom of the front
panel. See Figure M-1 (on page 14).
*On Gravity Wall Furnaces manufactured prior to November 2005 (without bracket hole
dimples in the left and right side), you may use the gravity BBSK bracket as a template
to locate holes. Measure 20-1/2” up on the preferred side, to locate lowest hole.
STEP 3. Using these three (3) dimples as locator, drill three ¼” holes.
STEP 4. Remove the BBSK control switch from the packing set. Remove the control switch mounting bracket from the
control switch by removing the two M4 screws holding it to the switch. See Figure M-2 (on page 14).
STEP 5. Secure P/N 1016901 switch bracket to the BBSK control switch using the two M4 screws removed previously.
See Figure M-2 (on page 14).
STEP 6. NOTE: Bend louvers on front panel as necessary to allow sufficient
clearance for BBSK control switch and wire terminals.
Place BBSK control switch inside front panel, align engagement holes with clearance holes in P/N 1016900
heat shield and the ¼” drilled holes in the front panel. Attach using two (2) #8x½” screws provided. Make sure
heat shield is between the BBSK control switch and the heat exchanger.
STEP 7. Connect each end of the black wires to the two outside terminals on the BBSK control switch, route wires
down the inside of the front panel. See Figure M-3 (on page 14).
STEP 8. Straighten the bulb capillary tube using extreme care not to bend or damage the tube, route the tube down
the inside of the front panel.
STEP 9. Install the front panel onto the wall furnace.
STEP 10. Insert the control knob onto the control rod. See Figure M-2 (on page 14).
STEP 11. Open the front panel door.
STEP 12. Connect one black wire to the stripped end of the blue blocked flue switch wire. Connect the other black wire
to the “TH/TP” terminal on the gas valve. See Figure M-3 (on page 14).
NOTE: If you are replacing an existing wall thermostat, you must first disconnect
the thermostat wires from the gas valve.
STEP 13. Secure the sensing bulb to the bottom of the gas valve using the nylon clamp and blunt screw provided.
See Figure M-4 (on page 14).
STEP 14. Close the front panel door.
STEP 15. Follow the lighting instructions to place the heater in operation.
BBSK INSTALLATION INSTRUCTIONS - GRAVITY WALL FURNACE

page 14 84502-C
GAS VALVE
SENSING BULB
NYLON CLIP
10 - 24 x 3/8 SCREW
BBSK INSTALLATION INSTRUCTIONS - GRAVITY WALL FURNACE
Fig. M-1 Fig. M-2
Fig. M-3
Fig. M-4
SIDE VIEWS / FRONT PANEL
LEFT
SIDE
VIEW
RIGHT
SIDE
VIEW
20 1/2”
(Removed for Installation)
CONTROL ROD
1016900
HEAT SHIELD
1016901
SWITCH BRACKET
BBSK
CONTROL
SWITCH
SENSING
BULB
CAPILLARY
TUBE #8 x 1/2 (2) SCREW
CONTROL
KNOB
M4 (2) SCREW
FRONT PANEL
SIDE
GAS VALVE
BBSK CONTROL SWITCH
BLACK WIRE
BLUE WIRE
BLUE WIRE
BLOCKED
FLUE SWITCH

page 15 84502-C
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 oor because some gas is
heavier than air and will settle on the oor.
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.
FOR YOUR SAFETY READ BEFORE LIGHTING
• If you cannot reach your gas supplier,
call the re department.
C. Use only your hand to push in or turn
the gas control knob. Never use tools. If
the knob will not push in or turn by hand,
don’t try to repair it, call a qualied service
technician. Force or attempted repair may
result in a re or explosion.
D. Do not use this appliance if any part has
been under water. Immediately call a
qualied service technician to inspect the
appliance and to replace any part of the
control system and any gas control which
has been under water.
5. Wait ve (5) minutes to clear out any gas. Then smell
for gas, including near the oor. 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.
6. Locate the pilot. (Follow metal pilot tube from gas
control).
7. Turn gas control knob counterclockwise
to “PILOT”.
BBSK KIT LIGHTING INSTRUCTIONS
WARNING:
If you do not
follow these
instructions
exactly, a re
or explosion
may result
causing
property
damage,
personal
injury or loss
of life.
LIGHTING INSTRUCTIONS
TURNING OFF GAS TO APPLIANCE
1. Turn temperature control knob clockwise
to “LO”.
2. Open cabinet door.
3. Push in gas control knob slightly and turn clockwise
to “OFF”. Do not force.
4. Close cabinet door.
8. Depress gas
control knob and
hold in. Immediately
light the pilot with a
match. Continue to
hold the gas control
knob in for about
one (1) minute after
the pilot is lit. Release gas control knob and it will
pop back up. Pilot should remain lit. If pilot goes
out, repeat steps 4 through 8.
• 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.
9. Turn gas control knob counterclockwise
to “ON”.
10. Close the cabinet door.
11. Turn temperature control knob to desired setting.
1. STOP! Read the information on the safety label.
2. Turn temperature control knob clockwise to
“LO”.
3. Open cabinet door.
4. Depress and turn gas control knob clockwise
to “OFF”.
Pilot is
located
on side of
burner
NOTE: Knob cannot
be turned from “PILOT”
to “OFF” unless knob is
pushed in slightly.
Do not force.
GAS
CONTROL
KNOB
Fig. N-1
Fig. N-2

page 16 84502-C
STEP 1. This appliance, when installed,
must be electrically grounded in
accordance with local codes, or in
the absence of local codes, with the
latest edition of the National Electric
Code, ANSI/NFPA No. 70. In
Canada, see the current Canadian
Electrical Code CSA C22.1.
STEP 2. Set fan kit on top of the wall furnace
front panel. Using the back top edge
of the fan kit cabinet as a guide,
mark a horizontal line across the
wall. Mark a small vertical line which
aligns with the slot located toward
the rear of the fan kit casing.
STEP 3. Using the four one inch screws
provided, secure the wall mounting
bracket to wall 1/8” below the horizontal
line. Fan attachment bracket must be
up and threaded nut sert aligned
with the small vertical line.
MODEL WFF81-C OPTIONAL FAN KIT - INSTALLATION INSTRUCTIONS
WFF81 - C WIRING SCHEMATIC
Fig. O
Fig. P
NOTE: This fan kit is to be installed after installation of wall furnace and with the wall furnace front panel in place.
Note: Anchors (not provided) may be required.
STEP 4. Remove junction box and connect 115v power supply in accordance with the wiring diagram. Replace junction box.
STEP 5. Set fan kit on top of wall furnace front panel. Slot should align with the nut sert. Secure fan kit to wall mounting
bracket with thumb screw provided.
Thumb Screw
Threaded Nut Sert
Wall Mounting Bracket
Fan
Attachment
Bracket
One
Inch
Screw (4)
Wall Furnace
Front Panel
Junction Box
Wiring
Diagram
Slot
Fan Kit
WHITE
Ground
L1 Black
115 VAC
BLACK
FAN SWITCH
GREEN GROUND WIRE
L2 White
115 VAC
BLACK
BLACKBLACKWHITE
BLACK
L2
White
MOTOR
L1
Black
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.

page 17 84502-C
STEP 1. Cut hole within stud space behind heater in the back wall 8-1/4” high by 12-5/8” wide. The lower edge of the
hole to be 45-3/4” above the floor plate or 47” from the floor (with standard 2”x4” floor base) as shown in
Figure Q-1 (below).
STEP 2. Install plaster ground frame for rear register in hole and nail frame to stud as shown in Figure Q-2 (below).
STEP 3. REAR REGISTER INSTALLATION: Cut and remove embossed plates in inner and outer casing. Follow
instructions for installation of regular furnace.
STEP 4. After furnace is installed, attach rear register grille as shown in Figures R-2 & R-3 (on page 18) by insertion
over plaster ground and attach with sheet metal screws, provided.
STEP 5. Damper as shown in Figure R-3 (on page 18) can be adjusted from full open for maximum heat to
fully closed.
40542-A REAR REGISTER KIT (Optional Accessory)
Installation Instructions for Gravity Vented Wall Furnaces
ROUGH-IN DIMENSIONS FOR REAR REGISTER
Fig. Q-1
Fig. Q-3: 40542-A Rear Register Kit 40542 Rear Register Kit
( Used on Single Wall Models Only ) ( W25/35 Series Only )
Part Description Ref. No. Part No.
Damper 22 40375
Damper Spring 23 40377
Frame Assembly 24 40365
Register Chain 25 40379
Bell, Pull 26 85003
Register Assembly 27 40355
Installation Instructions - - 84504
Fig. Q-2
PLACING FRAME FOR REAR REGISTER
Plate
Stud
Plaster
Plaster
Stud
Hole for
Back
Register
Opening 7/8”
From Each
Stud
Plaster
14-3/8”
8-1/4”
12-5/8”
Plaster
Nail to Stud
Stud
Plaster
Plate
Plaster
24
27
25
26 23
22
Stud
45-3/4”

page 18 84502-C
Fig. R-1
Fig. R-2
Fig. R-3
40542-A REAR REGISTER KIT ( OPTIONAL ACCESSORY ) - Continued
Installation Instructions for Gravity Vented Wall Furnaces
Inner Panel
Rear
Register
Grille
2” x 4”
Upright
Finished Wall
Casing
Open
Position
Damper
Closed
Position
Plaster
Ground
Frame
Retainer
Screw
Holes
Casing Opening
Heater Casing
Plaster Ground Frame
Rear Register Grille
Finished Wall

page 19 84502-C
Flame Too
Large
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
TROUBLESHOOTING CHART ( FOR QUALIFIED SERVICE TECHNICIAN ) - MAIN BURNER
1. Defective operator section
of gas valve.
2. Burner orice too large.
3. If installed above 2,000 ft.
1. Too much primary air.
1. Too much primary air.
2. Noisy pilot.
3. Burr in orice
(if it whistles or resonates).
4. Excessive gas input.
1. Too little primary air.
2. Clogged main burner ports.
3. Clogged draft hood.
4. Linted up air shutter.
1. Blocked venting.
2. Insufcient primary air.
1. Gas leak.
2. Chimney or ue obstruction.
3. Drafts around appliance.
1. Main gas off.
2. Defective gas valve.
1. Defective or sticking
automatic valve.
2. Excessive gas pressure
(The supply gas pressure
must not exceed 1/2 psi or
14” water column).
1. Gas input not checked.
2. Clogged orice.
1. Temperature dial set too high.
2. Combination control
valve sticks open.
1. Appliance undersized.
2. Temperature dial set too low.
(Bulb type valves).
3. Incorrect supply pressure.
1. Pilot ame too small.
2. Burner ports clogged near pilot.
3. Low gas pressure.
4. Pilot decreases in size when
main burners come on.
5. Air shutter open too far.
6. Drafts around appliance.
7. Bad venting.
Flame Pops
Back
Noisy
Flame
Yellow Tip
Flame (Some
yellow tipping on
L.P. gas is
permissible)
Floating
Flame
Gas
Odor
Failure
to Ignite
Burner Won’t
Turn Off
Incorrect
Gas Input
Too Much
Heat
Not
Enough
Heat
Delayed
Ignition
1. Replace complete valve.
2. Check with local gas company for proper orice size & replace.
3. Refer to orice chart, Page 3.
1. Adjust air shutter. (See Page 12).
1. Adjust air shutter. (See Page 12).
2. Reduce pilot gas with adjusting screw on combination gas
control valve.
3. Remove burr or replace orice (Do not enlarge orices).
4. See “Flame Too Large” above.
1. Adjust air shutter. (See Page 12).
2. Clean main burner ports. (Do not enlarge ports).
3. Clean draft hood.
4. Check for dust or lint at air mixer opening and around the shutter.
Clean as necessary.
1. Clean ue passageways to remove blockage.
2. Adjust air shutter to increase primary air supply. (See Page 12).
1. Shut off gas service immediately. Check piping. Call gas company.
(See Page 1).
2. Clean ue.
3. Eliminate drafts.
1. Open all manual gas valves.
2. Replace gas valve.
1. Clean or replace valve.
2. To correct this situation contact the utility supplying the gas.
1. Re-check gas input.
2. Check orice for clogging. If clogged, clean out the hole carefully with a smooth
wood toothpick. (Do not in any way enlarge or distort it).
1. Lower setting of temperature dial. See “Lighting & Shutting Down Instructions”
on page 11.
2. Replace combination control valve.
1. This is especially true when a dwelling or room is enlarged. Have the heat loss
calculated and compare to the appliance output (70% of input). Your gas company or
installer can supply you with this information. If appliance is undersized, replace with
correct size unit.
2. Raise setting of Temperature Dial. See “Lighting & Shutting Down Instructions”
on page 11.
3. Check supply pressure as outlined above.
1. Check pilot orice, increase pilot gas ow if necessary by adjusting inlet pressure.
2. Clean burner ports (Do not enlarge ports).
3. Check gas supply pressure.
4. Supply piping is inadequately sized. Consult local gas utility or competent installer.
5. Close air shutter to proper setting as outlined in these instructions (slight yellow
tipping is allowable on L.P. Gas). (See Page 12).
6. Eliminate drafts.
7. See “Venting”.
1. Improper venting.
Condensation
of Water Vapor
1. See “Venting”.

page 20 84502-C
Burner Won’t
Turn On
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
TROUBLESHOOTING CHART - AUTOMATIC PILOT & VALVE
TROUBLESHOOTING CHART ( FOR QUALIFIED SERVICE TECHNICIAN ) - BLOCKED FLUE SWITCH
1. Pilot ame too large or too small.
2. Dirt in pilot orice.
3. Defective automatic pilot section in
combination control valve.
4. Defective pilot generator.
5. Defective combination control valve.
6. Manual reset blocked ue switch tripped.
1. Blockage in
Vent Pipe
2. Burner is
Overfiring
4. Incorrect Header
Plate Location
5. Vent Pipe not Down on the
Header Plate Securely
6. Loose Connections on the
Vent Safety Wiring Harness
3. Improper Vent System
A. Vent too short
B. Restriction in vent
system caused by
offsets
C. Incorrect vent pipe
1. Re-adjust pilot ame using adjustment on combination control valve.
2. Clean pilot orice with air or solvent, do not ream.
3. Replace entire combination control valve.
4. Replace pilot generator.
5. Replace valve.
6. Reset switch, see Page 6 and blocked ue section below.
A. Check vent pipe for blockage, such as bird nest, wasp nest, twigs, leaves, etc.
B. Check inside the bottom of the vent pipe to make sure the top of the draft diverter did not rip the
inner liner causing it to block part of the vent opening.
C. Check that no insulation from the header plate got caught on top of the draft diverter when the
heater was inserted into the wall.
D. Check that the vent cap is properly installed, not shoved too far down on the vent pipe.
A. Check the manifold pressure.
B. Check the rate. NOTE: The appliance is orificed at the factory for elevations between sea level
and 2,000 feet. If installed above 2,000 feet, refer to orifice chart (on page 3) in controls section of
instructions for proper orifice size and re-orifice accordingly.
The header plate must be 65-3/4” above the floor plate. See rough-in instructions (on page 8).
Use a base plate (obtained from the vent pipe manufacturer) on top of our header plate. This will lock
the vent pipe down and prevent the draft diverter from shoving it up.
Check the connection on both the switch and the gas valve. Tighten if necessary.
Correct vent system.
A. The vent should terminate a minimum of 12 feet above the floor. See Figure G-5 (on page 8).
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-1 (on page 5).
B. 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.
C. Use listed BW type vent pipe. Do not use tansite or any other type of ceramic pipe for venting.
Do not use single wall pipe. When venting into a masonry chimney the chimney must be properly
lined and sized for this gas furnace. The use of type B or flexible chimney liner is recommended.
POSSIBLE CAUSES CORRECTIVE ACTION
DO NOT BYPASS THE BLOCKED FLUE SWITCH
To do so could expose the consumer to property damage, personal injury or possible death.