COZY DVCF402D User manual

WARNING: If the information in these instructions
is not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
-Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
•Open all windows.
•Do not try to light any appliance.
•Do not touch any electrical switch; do not use
any phone or cell phone in your building.
•Extinguish any open flame.
•Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
•If you cannot reach the gas supplier, call the fire
department.
–Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
COUNTERFLOW
DIRECT VENT GAS WALL HEATER
WARNING: This direct-vent furnace is approved for
aftermarket manufactured home installations (once the
manufactured home is sold, installed and stationary)
unless prohibited by local codes. Not for manufactured
home manufacturer (factory) installation. Do not install
any of these furnaces (natural or propane gas) in trailers
or recreational vehicles.
WARNING: This product can expose you to
chemicals including epichlorohydrin which is known to
the State of California to cause cancer and birth defects
and/or other reproductive harm. For information go to
www.p65warnings.ca.gov
WARNING: Improper installation, adjustment,
alteration, service or maintenance can cause injury or
property damage. Refer to this manual. For assistance or
for additional information consult a qualified installer or,
service agency.
MODEL NUMBERS: (natural gas)
DVCF402D / DVCF602D
MODEL NUMBERS: (propane gas)
DVCF401D / DVCF601D
SAVE THIS MANUAL FOR FUTURE REFERENCE.
READ THIS OWNER’S MANUAL CAREFULLY BEFORE YOU
INSTALL YOUR NEW COZY WALL FURNACE.
DISCONTINUED MODELS:
DVCF403C / DVCF553C
250 West Laurel Street, Colton CA 92324 • cozyheaters.com • 1-888-444-1212
40,000 - 60,000 BTU/hr.
OWNER’S MANUAL
INSTALLATION INSTRUCTIONS
VISITEZ NOTRE SITE WEB POUR LA VERSION FRANÇAISE DE CE MANUEL
VISITE NUESTRA PÁGINA WEB PARA LA VERSIÓN EN ESPAÑOL DE ESTE MANUAL
www.cozyheaters.com/product-literature/

2COUNTERFLOW DIRECT VENT GAS WALL HEATER
The manufacturer, Williams Furnace Co., warrants this wall furnace
or heater to the original purchaser under the following conditions:
ANY WARRANTY CONSIDERATIONS ARE CONTINGENT
ON INSTALLATION BY A QUALIFIED INSTALLER
(CONTRACTOR). SELF-INSTALLATION IS PROHIBITED
AND WILL INVALIDATE YOUR WARRANTY.
LIMITED ONE-YEAR WARRANTY
1. Any part thereof which proves to be defective in material or
workmanship within one year from date of original purchase
for use will be replaced at the Manufacturer’s option, FOB to its
factory.
2. No liability is assumed by the Manufacturer for removal or
installation labor costs, nor for freight or delivery charges.
LIMITED EXTENDED WARRANTY
1. In addition to the above limited one year warranty on the
complete unit, any combustion chamber which burns out or
rusts under normal installation, use and service conditions
during a period of nine years following expiration of the
one-year warranty period will be exchanged for a like or
functionally similar part.
2. No liability is assumed by the Manufacturer for removal or
installation labor costs, nor for freight or delivery charges.
LIMITATIONS
1. THIS LIMITED WARRANTY IS THE ONLY WARRANTY MADE BY
THE MANUFACTURER, IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR
PURPOSE ARE LIMITED TO THE SAME ONE YEAR TERM AS
THE EXPRESS WARRANTY. UNDER NO CIRCUMSTANCES
SHALL THE MANUFACTURER BE LIABLE FOR INCIDENTAL,
CONSEQUENTIAL, SPECIAL OR CONTINGENT DAMAGES OR
EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM ANY
DEFECT IN THE PRODUCT OR ANY COMPONENT OR
FROM THE USE THEREOF. THE REMEDIES SET FORTH HEREIN
ARE THE EXCLUSIVE REMEDIES AVAILABLE TO THE USER AND
ARE IN LIEU OF ALL OTHER REMEDIES.
Some states do not allow limitation on how long an implied
warranty lasts, and some states do not allow the exclusion or
limitation of incidental or consequential damages, so the above
limitations or exclusions may not apply to you.
2.
This warranty does not include any charge for labor or installation.
3. This warranty does not extend to painted surfaces or to damage
or defects resulting from accident, alteration, misuses or abuse
or improper installation.
4. This warranty does not cover claims which do not involve
defective workmanship or materials.
DUTIES OF THE CONSUMER
1. The heating equipment must be installed by a qualified installer
and operated in accordance with the installation and
homeowner’s instructions furnished with the equipment.
2. Any travel, diagnostic costs, service labor, and labor to repair
the defective unit will be the responsibility of the owner.
3. A bill of sale, canceled check, payment record or permit should
be kept to verify purchase date to establish the warranty period.
4. Have the installer enter the requested information in the
space below.
GENERAL
1. The manufacturer neither assumes nor authorizes any person
to assume for it any other obligation or liability in connection
with said equipment.
2. Service under this warranty should be obtained by contacting
your dealer. Provide the dealer with the model number, serial
number, and purchase date verification.
3. If, within a reasonable time after contacting your dealer,
satisfactory service has not been received, contact: Customer
Service Department, 250 West Laurel Street, Colton, CA 92324
for assistance.
4. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND
YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM
STATE TO STATE.
WARRANTY
INSTALLATION RECORD
Model No Serial No.
Original Purchaser
Address
City and State Zip
Dealer
Address
City and State Zip
HVAC Installation Date HVAC Installer Name
HVAC Signature
(Dealer or authorized representative who certifies that this appliance is installed in accordance with Manufacturer’s instructions and local codes.)

COUNTERFLOW DIRECT VENT GAS WALL HEATER 3
YOUR COZY WARRANTY
INSTALLATION RECORD
TABLE OF CONTENTS
SAFETY RULES
INTRODUCTION
BASIC TOOLS NEEDED
BASIC MATERIALS NEEDED
HELPFUL INSTALLATION INFORMATION
OPTIONAL ACCESSORIES
UNPACKING YOUR FURNACE
INSTALLING YOUR WALL FURNACE
LOCATING YOUR WALL FURNACE AND THERMOSTAT
RECESSED MOUNT INSTALLATION
THERMOSTAT INSTALLATION
VENT INSTALLATION
MOUNTING YOUR FURNACE
GAS SUPPLY AND PIPING
STARTUP PROCEDURE
OPERATING YOUR FURNACE
LIGHTING INSTRUCTIONS
CARING FOR YOUR FURNACE
INSTALLATIONS IN THE STATE OF MASSACHUSETTS
HARDWIRE ACCESSORY 9940
WIRING DIAGRAMS
FURNACE ASSEMBLY REPLACEMENT PARTS
DVCF40XD MODELS
CONTROL ASSEMBLY REPLACEMENT PARTS
DVCF40XD MODELS
FURNACE ASSEMBLY REPLACEMENT PARTS
DVCF60XD MODELS
CONTROL ASSEMBLY REPLACEMENT PARTS
DVCF60XD MODLES
TROUBLESHOOTING YOUR FURNACE
HINTS AND INFORMATION
Quick Reference
Here’s how to:
INSTALLING YOUR FURNACE
Recessed Mount, Surface Mount,
and Vent Installation are
explained starting on page 8.
OPERATING YOUR FURNACE
Igniting your furnace for the first time.
HOW TO CARE FOR YOUR FURNACE
Learn how to keep your new
Cozy Furnace operating.
CONTENTS
2
2
3
4
5
6
6
6
6
6
7-18
7
9
12
13
14
16
19
20
21
22
24
25
26
27
29
30
32
34
35
7
20
22

4COUNTERFLOW DIRECT VENT GAS WALL HEATER
WARNING: Read these rules and the instructions
carefully. Failure to follow these rules and instructions
could cause a malfunction of the furnace. This could result
in death, serious bodily injury and/or property damage.
INSTALLATION MUST CONFORM TO LOCAL CODES.
IN THE ABSENCE OF LOCAL CODES, INSTALLATION
MUST CONFORM TO THE NATIONAL FUEL GAS CODE,
ANSI Z223.1. THE APPLIANCE, WHEN INSTALLED MUST
BE ELECTRICALLY CONNECTED AND GROUNDED
IN ACCORDANCE WITH LOCAL CODES OR, IN THE
ABSENCE OF LOCAL CODES, WITH THE CURRENT
NATIONAL ELECTRICAL CODE ANSI/NFPA NO. 70.
IN CANADA:
1. Installation must conform to local codes or, in the
absence of local codes, the current CAN/CGA B149
installation code.
2. The appliance, when installed, must be electrically
connected and grounded in accordance with
local codes or, in the absence of local codes, with
the current CSA C22.1 Canadian Electrical code.
3. Reference is made in this manual regarding gas
type as propane gas Be advised that propane gas
is not available in Canada, refer to propane gas.
1. Use only manufacturer’s replacement parts. Use of
any other parts could cause injury or death.
2. DO NOT install the furnace in an alcove.
3. DO NOT install this furnace where it could be
isolated by closing doors to the heated space.
4. DO NOT install this furnace in a travel trailer or
recreational vehicle.
5. MAINTAIN all clearances specified in section “Locating
Wall Furnace and Thermostat” and “Vent Installation.”
6. BE SURE this furnace is for type of gas to be used.
Check the rating plate by the gas valve in the lower
cabinet. Do not change it to use other gases without
the proper manufacturer’s Gas Conversion Kit.
7. For natural gas, the minimum inlet gas supply
pressure for the purpose of input adjustment is 5”
water column. The maximum inlet gas supply
pressure is 7” water column.
For propane gas, the minimum inlet gas supply
pressure for the purpose of input adjustment is 11”
water column.
The maximum inlet gas supply pressure is 13” water
column.
8. Any safety screen, guard or parts removed for servicing
this appliance must be replaced prior to operating
the appliance to avoid property damage, bodily injury
or death.
9. Install the furnace vent directly to the outdoors so that
harmful combustible flue gases will not collect inside
the building. Follow the venting instructions for your
type of installation exactly. Use only the type and size
of vent pipe and fittings specified.
10. BE SURE to provide for adequate combustion and
ventilation air. The flow of this air to the furnace must
not be blocked.
11. NEVER vent flue gases into another room, a fireplace
or any space inside a building. This could cause
property damage, bodily injury or death.
12. Never test for gas teaks with an open flame. Use a
soap solution to check all gas connections. This will
avoid the possibility of fire or explosion.
13. ALLOW the furnace to cool before servicing. Always
shut off electricity and gas to furnace when working
on it. This will prevent any electrical shocks or burns.
14. DUE TO HIGH TEMPERATURES, locate the furnace out
of traffic and away from furniture and draperies.
15. ALERT children and adults to the hazards of high
surface temperatures and warn them to keep away
to avoid burns or clothing ignition.
16. CAREFULLY supervise young children when they are
in the same room with the furnace.
17. DO NOT place clothing or other flammable material
on or near furnace.
18. INSTALLATION and REPAIR must be done by a
qualified 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 and circulating air passages
be kept clean.
19. BEFORE INSTALLING: To avoid electrical shock, tum off
electrical circuits that pass through the wall where you
are going to install the furnace.
20. BE AWARE of good safety practices by wearing
personal protective equipment such as gloves and
safety glasses to avoid being injured by sharp metal
edges in or around furnace and while cutting or
drilling holes in wood and/or sheet metal.
21. CAUTION: Label all wires prior to disconnection when
servicing controls.
WARNING: Do not use this furnace if any part has
been under water. Immediately call a certified service
technician to inspect the furnace and to replace any
part of the control system and any gas control which
has been under water.
WARNING: Do not install any of these furnaces
(natural or propane gas) in mobile homes, trucks or
SAFETY RULES

COUNTERFLOW DIRECT VENT GAS WALL HEATER 5
INTRODUCTION
BASIC DESCRIPTION
The following steps are all needed for proper installation
and safe operation of your furnace. If you have any doubts
as to any requirements, check with local authorities. Obtain
professional help where needed. All of the checks and
adjustments in the “Start-Up Procedures” are vital to the
proper and safe operation of your furnace. Please read our
instructions before you install and use your furnace. This will
help you obtain the full value from this furnace. It could also
help you avoid needless service costs if the answer to the
problem is found within this instruction manual.
Always consult your local heating or plumbing inspector,
building department or gas utility company regarding
regulations, codes or ordinances which apply to the
installation of a counterflow Direct Vented wall furnace.
Check the furnace nameplate, located in the burner
compartment, to make sure the furnace is equipped to
operate on the type of gas available (either natural or propane gas).
DO NOT convert the furnace from natural gas to propane
gas or from propane gas to natural gas without the proper
manufacturer’s gas conversion kit.
Your Counterflow Direct Vent Furnace draws air in at the
top of the furnace by the fan and discharged through the
grille near the floor. It is shipped ready to install on the
surface of a wall or recessed into a wall. Combustion air is
drawn in from the room where the furnace is located and
vented out the top of the furnace through listed vent piping
to a roof Direct Vent. Venting material is not supplied with
this furnace.
This appliance is equipped with a vent safety shutoff
system designed to protect against improper venting of
combustion products. Operation of this wall furnace when
not connected to a properly installed and maintained
venting system or tampering with the vent safety shutoff
system can result in carbon monoxide (CO) poisoning and
possible death.
1) Seal any unused openings in the venting system.
2) Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas
and Propane Installation Code, CSA B149.1 and
these instructions. Determine that there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
3) As far as practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system
are located and other spaces of the building.
4) Close fireplace dampers.
5) Turn on clothes dryers and any appliance not
connected to the venting system. Turn on
any exhaust fans, such as range hoods and
bathroom exhausts, so they are operating at
maximum speed. Do not operate a summer
exhaust fan.
WARNING: CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting system being placed
into operation could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance connected to the venting system being placed into
operation, while all other appliances connected to the venting system are not in operation:
6) Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7) Test for spillage from draft hood equipped appliances
at the draft hood relief opening after 5 minutes
of main burner operation. Use the flame of a match
or candle.
8) If improper venting is observed during any of the
above tests, the venting system must be corrected
in accordance with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane
Installation Code, CSA B149.1.
9) After it has been determined that each appliance
connected to the venting system properly vents
when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other
gas-fired burning appliance to their previous
conditions of use.

6COUNTERFLOW DIRECT VENT GAS WALL HEATER
INTRODUCTION
Basic Tools Needed
Hand drill or properly grounded electric drill
Expansion bit 1/2"to 1-5/8"or 1/2"and 1-1/2"blade bits
1/8"and 3/16"drill bit (metal)
6 ft. folding rule or tape measure
Screwdriver (medium blade)
Screwdriver (Phillips and Flat Head)
Pliers (wire cutting)
Hammer
Stud Locater or small finishing nails
Tin Snips
8"adjustable wrench
12"adjustable wrench
7/8" wrench
3/4"wrench
1"wrench
Gloves and safety glasses
Materials
Pipe and fittings to make connections to furnace (See
page 17).
Caulking compound(silicone rubber with a temperature
rating of 500°F).
DO NOT use caulking compound advertised as paintable or
for bath tub use as most contain fillers and will not withstand
high temperatures.
Pipe Joint Compound resistant to propane gases.
Electrical wiring supplied as needed, see page 26. Minimum
wire size is #14 gauge copper.
Trim Accessory 4701 is recommended or 3/4” quarter round
or other wood trim molding approximately 16’ long.
Oval Vent Kit 9901 is recommended.
Vent Enclosure Kit 9812 or 9824 if furnace is to be surface
mounted is recommended.
1 x 1 wood strips if Optional Side Outlet Grille Register
6701 is used.
Helpful Installation Information
The following booklets will help you in making the installation:
ANSI/NFPA 70 (1990 or current edition) “National Electrical
Code”.
In Canada: CSA C22.1 Canadian Electrical Code. American
National Standard NFPAS4/ANSI Z223.1 1988 or current
edition “National Fuel Gas Code”.
Obtained from: American National Standards Institute, Inc.,
1430 Broadway, New York, N Y 10018.
In Canada: CAN/CGA B149.
Optional Accessories
DIFFUSER GRILLE KITS 6703 & 6704
6703 let’s you route some heated air in a two-way direction.
Kit 6704 for one-way direction.
SIDE OUTLET GRILLE KIT 6702
Allows you to direct heated air from the side of furnace into
the same room.
OUTLET GRILLE REGISTER 6701
Let’s you route some heated air into a second room. Mounts
on the side wall of second room and must be within 10 inches
of wall furnace.
TRIM STRIP KIT 4701
Provides finished edge at sides of wall furnace. Neutral beige
enamel painted steel.
THERMOSTAT 78355
Unpacking Your Furnace
The furnace is shipped in two cartons, one containing the
furnace, installation instruction booklet and hardware bag
and the other containing the vent cap with inlet and vent
tubes.
1. Lay the carton horizontally.
2. The bottom front panel can be removed by grasping
just below the handle and pulling it outward and then
upward. See Figure 1
3. Place these and other parts, as they are removed from
furnace, where they cannot be lost or damaged before
you need them.
NOTE
Check the burner rating plate, located in burner
compartment, to make sure your furnace is equipped
to operate on the type of gas available (either natural or
propane gas).
4. Remove all literature, wire and metal anchors used for
free standing installation.
5. Check the fan blade to be sure it spins freely.
6. Take out the four screws holding fan shroud to the side
flanges of cabinet and remove shroud. See Figure 1
NOTE
The fan blade must be removed in order to remove the
cardboard shipping brace located under motor.
7. Before removing the fan blade, remember its position
by examining the blade nut and the amount of shaft
visible. Scribe or mark the motor shaft in order to
reinstall the fan blade to its original place on the shaft.
8. Loosen the 1/8” “Allen head” set screw holding the fan
blade to motor shaft and remove the fan. Place the fan
blade and fan shroud where they will not be damaged.
9. Remove the cardboard shipping brace located under
the motor mounting brackets.
10. Properly dispose of shipping materials.

COUNTERFLOW DIRECT VENT GAS WALL HEATER 7
INSTALLING YOUR FURNACE
FIGURE 1
TOP FRONT PANEL
BOTTOM FRONT PANEL
HANDLE
CABINET
THUMB SCREW
FAN SHIELD
SCREWS
FAN BLADE
The following steps are needed for proper installation and
safe operation of your furnace. If you have any doubts as
to any requirements, always consult your local Heating or
Plumbing lnspector, Building Department or Gas Utility
Company regarding regulations, codes, or ordinances
which apply to the installation of a vented wall furnace.
Obtain professional help where needed.
The CHECK AND ADJUSTMENTS on page 22 are vital
to the proper and safe operation of the furnace. Be sure
they are done.
IMPORTANT
For satisfactory and trouble-free operation, be sure to:
1. Locate the furnace properly within the space to
be heated.
2. Install the furnace in accordance with local codes or
ordinances and instructions provided. In the absence of
local codes or ordinances, install the furnace to conform
with the current edition of the National Fuel Gas Code,
NFPA 54, ANSI Z223.1/Canadian Installation Code, CAN/CGA B149.
3. Maintain minimum clearance: Floor 0 inches or ceiling
4 inches, side wall 4 inches. For exception to minimum
side wall clearance, as shown on Page 8, Figure 3.
4.Provide enough combustion and ventilation air.
Locating Your Wall Furnace &
Thermostat
Consider the following points before attempting to install
the furnace:
1. This is a direct-vent wall furnace. It must be installed
on an OUTSIDE WALL for proper venting of flue gases
(Figure 2).
a. Ideally, the wall should be on the least windy side of
the dwelling, as strong gusts may extinguish the pilot.
b. Furnace may be installed flush against a wall or
recessed up to 10” maximum. Wall thickness
from back surface of furnace to outside of wall can be
3/4” minimum to 9” maximum. See Page 8, Figure 3
With standard furnace discharge outlet, do not install
closer than 4” to intersecting wall. See Page 8, Figure 4
Studs must be spaced on 16-inch centers or stud
space will have to be framed in. See Page 9 and 10,
Recessed Mounting.
2. The top of the furnace must be at least 4-inches from
the ceiling.
3. Check the clearances needed from the furnace and
vent (Page 8, Figure 2 and Page 8, Figure 4). You
must place the furnace where you will have no less
than the clearances shown. See Page 8-9, Figure 5, 6 & 7
4. When using optional kits 6703 or 6704, maintain the
clearances as shown on Page 8-9, Figure 5, 6 & 7
5. When using optional kit 6701, maintain clearance as
shown on Page 8, Figure. 4. Use only optional outlet
and grille kits available from manufacturer.
6. The outside vent cap must be at least 18-inches away
from any window or other building opening (Figure 2).
7. The furnace will not work if anything stops free entry
of fresh air into the vent, or free flow of flue gases from
it. Be sure the center of the vent cap is at least 18
inches above ground level or shrubs are as shown
in Figure 2. Make sure shrubs are kept trimmed. It
must also be at least 18 inches from any overhang.
8. Try to place the furnace near the center of the space
to be heated for good air circulation. Do not put it
behind a door or draperies. Do not put in a closet,
alcove, hallway or other confined space.
9. Be sure that gas piping and electrical wiring can be
brought to the furnace. See sections on gas piping
and electrical wiring for your type of furnace mounting.
10. The bottom of the furnace must rest directly on a
wood or concrete floor. If the floor is other than wood
or concrete, such as carpet or sheet vinyl flooring,
there must be a piece of wood or sheet metal under
the furnace that is at least the same size as the
bottom of the furnace.
WARNING: If vinyl siding is used on exterior wall
surface, heat from the vent cap could cause distortion/
discoloration. Shield to protect the siding. Check with
manufacturer for additional options.

8COUNTERFLOW DIRECT VENT GAS WALL HEATER
INSTALLING YOUR FURNACE
FIGURE 2  MINIMUM CLEARANCES
11. Be sure to provide adequate clearance and service
access. The front of the furnace must face the
open room.
12. Choose a location for the thermostat (optional) about
5-feet above the floor on an inside wall. The
thermostat wire supplied with your furnace is 20-feet
long, which should be enough to run up through the
attic of a single-story home, so the thermostat can be a
maximum of 16-feet from the furnace measure in a
straight line, or about 8-feet from the furnace if the wire
is run under the floor. Use heavier wire size if more than
20-feet of wire is required. The thermostat should be
sensing average room temperature.
AVOID THE FOLLOWING:
HOT SPOTS COLDSPOTS:
Concealed pipes or ducts Concealed pipes or ducts
Fireplaces Stairwells – drafts
Registers Doors – drafts
TV sets Unheated rooms
Radios on the other side of the wall
Lamps DEAD SPOTS
Direct sunlight Behind doors
Kitchen Corners and alcoves
13. After picking a location that meets the requirements,
inspect the wall, floor and outside areas. Make sure
there are no pipes, wiring, or anything else that would
interfere with furnace, vent, or thermostat installation.
If required, move them or pick a new location.
RECESSED INSTALLATION CLEARANCE NOTE: A
portion of the furnace that is recessed into a wall up to
10” maximum recess may have (0) zero inch clearance
to combustibles. (See Figure 3). All other clearances for
the unrecessed portion must be observed. 3/4-inch to
5-inch outer wall will require thin wall collar accessory
FIGURE 3  RECESSED INSTALLATION CLEARANCE
FIGURE 4 VENT CAP
FIGURE 5
FIGURE 6 VENT CAP

COUNTERFLOW DIRECT VENT GAS WALL HEATER 9
FIGURE 7
Recessed Mount Installation
FIND THE STUDS
Use a stud locator or small finishing nails. Repeatedly drive
and remove a nail into the wall in the area of the stud until
you find it. Then find one side. Leave the nail there. Drive
another nail just on the other side of the same stud.
Inside edge of the other stud should be about 14½-inches
from the one found. Drive finishing nail on inside edge of
this stud.
NOTE: If studs are not on 16-inch centers, see section
“Close off Stud Space”, below.
CUT WALL OPENING
1. Lay out the required opening to be cut in inside wall
(Figure 8). Mark center of the vent hole on wall. Using
a window, door or wall corner for reference, measure to
find where vent will be on outside wall. Check to
be sure clearances (Page 8, Figure 2, and Figures 4, 5,
6 and 7 on page 9) will be right.
2. Drill a ¼-inch hole through vent hole center to the
outside wall to mark vent location.
3. Make the required cutout in inside wall. (Figure 8).
4. Using the hole drilled through to the outside wall
as the center, cut a 9¼-inch diameter hole for the vent.
It may be better to work from outside, especially when
breaking through brick, stone or tile. (See Figure 8).
5. In new stud wall construction, install blocks as shown
in Figure 7 and install plaster grounds around inside of
wall opening.
6. The vertical height of the opening shown is 3-inches
greater than height of furnace to allow space for
connection of wiring after furnace is installed.
NOTE: Vertical measurements are from finished floor.
(Figure 7)
CLOSE OFF STUD SPACE (If Required)
If studs are not on 16-inch centers, cut the hole for the
furnace next to an existing stud and frame in the other
side using a 2”x 4” and spacer blocks as required. As shown
on Page 9, Figure 9.
If the distance from the top of the cutout to the ceiling
wall plate is more than 18-inches, it is recommended that
it be closed off.
Nail a 2”x 4” long enough to go between the studs at the
top of the opening to close off the stud space.
FIGURE 8  WALL OPENING FOR RECESSED MOUNT
FIGURE 9  CLOSE OFF STUD SPACE
DVCF40XD
DVCF60XD

10 COUNTERFLOW DIRECT VENT GAS WALL HEATER
INSTALLING YOUR FURNACE
GAS AND ELECTRICAL SUPPLY OPENINGS
Holes must be drilled for the gas line and electrical supply.
Holes must be located from each side of furnace as shown
in Figure 10.
Decide whether the gas line will come through the floor
or wall.
Drill a 1½ -inch hole in wall or floor as needed.
Gas line can be run at this time or done after furnace is
mounted, see section GAS SUPPLY AND PIPING,
on Page 16.
The electrical supply opening should be at the lower
portion of the furnace, to match openings shown in Figure
10. Mark ceiling wall plate and drill holes. If not practical
to run wiring from the attic, drill holes through wall stud
and run wires up through adjoining stud space from crawl
space or basement.
Run the electrical supply with the ground wire and
thermostat cable to the openings. Leave enough length to
connect in the junction box after the furnace is installed.
See section “Electrical Wiring,” on page 15.
CAUTION: Do not run wire in any location where it
might be damaged. Avoid splicing thermostat wire
unless the spliced wires are properly cleaned, soldered,
and taped.
OFFSET WALL INSTALLATION
To mount the wall furnace on an offset wall, the area
behind the furnace must be made flush or flat.
Use lumber (2"x 4"s, 2"x 6"s etc.) to make the surface flush
with other portion of wall.
Use sheet rock or paneling etc. to finish area.
Follow procedures under Surface Mount Installation.
SURFACE MOUNT INSTALLATION - FIND THE STUDS
1. Find two studs at spot where furnace is to be placed.
Use a stud indicator or small finishing nails. Repeatedly
drive and remove a nail into the wall in the area of the
stud until you find it. Then find one side. Leave the nail
there. Drive another nail just on the other side of the
same stud.
2. Inside edge of the other stud should be about 14½-inches
from the one found. Drive finishing nail on inside
edge of this stud.
CUT VENT OPENINGS
1. Lay out and mark the center of the hole to be cut
through the wall for the vent (Page 9, Figure 8). Using
a window, door, or wall corner for reference, measure to
find where vent will be on outside wall. Check to be sure
clearances are correct. (See Pages 7-9, Figures 2, 4, 5, 6 &
7) .
FIGURE 10  GAS AND ELECTRICAL OPENINGS
2. Drill a ¼-inch hole through vent hole center to the
outside. Cut the 9¼-inch diameter hole through inside
wall. Using the ¼-inch hole as the center, cut a
matching hole in outside wall. It may be better to
work from the outside, especially when breaking
through brick, stone or tile.
GAS AND ELECTRICAL SUPPLY OPENINGS
Holes must be drilled for the gas line and electrical supply.
Holes must be located from each side of furnace as shown
on Page 10, Figure 10.
Drill a 1½-inch hole in floor or wall for gas line.
Gas line can be run at this time or done after furnace is
mounted, see section: Gas Supply and Piping, Page 16.
Mark ceiling or wall to match wall furnace openings and
drill a 1-inch hole for the power supply and a ½-inch hole
for the thermostat cable. Run the electrical supply and
ground wires to the opening. Leave enough length to
connect in the junction box after the furnace is installed.
See section “Electrical Wiring,” Page 15.
DVCF40XD
DVCF60XD

COUNTERFLOW DIRECT VENT GAS WALL HEATER 11
ROUGH-IN OPTIONAL SIDE OUTLET NO. 6701
Install plaster ground as shown in Figures. 12 & 13. Flanges
of plaster ground extend the thickness of normal plaster. If
“dry-wall” or other thin material, flanges must be trimmed
off flush with wall surface.
Follow measurements given carefully, and note that when
a side outlet is used, the furnace casing must be exactly
4 inches from surface of adjacent wall except minimum
clearance may be ¾-inch when optional 1-way Diffusing
Grille Kit 6704 is used.
FIGURE 11  WALL OPENING SURFACE MOUNT
FIGURE 12  PLASTER GROUND INSTALLATION
FIGURE 13  PLASTER GROUND INSTALLATION
MOUNTING OPTIONAL SIDE OUTLET GRILLE
KIT NO. 6701 Refer to Figure 14.
1. Before setting furnace into position, cut 5”x 7” rectan
gular opening in furnace outer casing where marked.
See Page 10, Figure 10.
2. Place the outer boot against casing with inner flanges
exactly on edges of cut hole, mark screw location, re
move boot and drill #33 holes for the sheet metal screws.
3. Remove the knockout plate and knockouts for screws
from the inner liner.
4. Secure 1”x 1” wood strip (not included with this kit) to
the wall next to the side outlet as a backup for metal
filler strips.
5. Fasten metal filler strips to the side of the furnace
casing with the front surface exactly opposite the front
of wood backup strip.
6. After the furnace is placed in position, place the outer
boot through the plaster ground tight against the
furnace casing. Then mark and cut off the outer end
flush with the wall surface.
7. Press the inner boot against liner, mark and cut it off
flush with the wall surface. Install the outer boot first,
then the inner boot, fastening through all holes with
the screws provided.
FIGURE 14  MOUNTING GRILLE KIT 6701
DVCF40XD
DVCF60XD

12 COUNTERFLOW DIRECT VENT GAS WALL HEATER
INSTALLING YOUR FURNACE
OPTIONAL 2-WAY DIFFUSING GRILLE KIT NO. 6703
Refer to Figure 15.
CAUTION: For use only in conjunction with a front
outlet when the furnace is spaced at least 12-inches
from an intersecting wall (see Page 8, Figure 5).
Metal clips on backside of the optional grille snap into the
side louvers of the front warm air outlet. Adjust clips with
pliers if necessary. Grille may also be attached with sheet
metal screws.
1-WAY FRONT DIFFUSING GRILLE KIT NO. 6704
Follow instructions for 2-WAY FRONT DIFFUSING GRILLE
6703 ABOVE, except furnace clearance to an adjacent wall
must be ¾-inch minimum.
CAUTION: Use only optional kits available from the
manufacturer.
FIGURE 15  TWOWAY DIFFUSING GRILLE 6703
Thermostat Installation
1. Thermostat 78355 or any millivolt thermostat.
2. If an old thermostat is being replaced and is in a
satisfactory location and the wiring appears to be
in good condition, use existing wiring. If in doubt, use
new wire.
3. If a new location is chosen or if this is a new
installation, thermostat cable must first be run to the
location selected. All wiring must agree with local
codes and ordinances. These instructions cover
bringing the wire down from the attic but it can be
run from a basement or crawl space using similar methods.
4. Before drilling a hole in the wall at selected location,
drive a small finishing nail through the ceiling in the
corner of the wall and ceiling above the thermostat
location. Pull the nail out and push a small stiff wire
through the hole so it can be found in the attic. Drill a
½-inch hole through the ceiling wall plate.
5. Probe for obstructions in the partition. Then drill a
½-inch hole through wall at the selected location for
thermostat.
6. From the attic, feed the thermostat cable or a stiff wire
through wall until even with thermostat location.
7. Snag thermostat cable through the hole and pull the
cable through the hole in wall so that 6-inches of
cable protrudes.
8. Route cable to wall furnace.
MOUNTING THE THERMOSTAT
1. To remove thermostat cover, squeeze both sides
and lift. Carefully remove and discard the packing tab
protecting the switch contacts. See Fig 17.
2. Connect the thermostat wires to the terminal screws
on the thermostat base. Make sure the wiring
does not interfere with thermostat operation.
3. Push any excess wire back through the hole in the
wall and plug the hole with insulation to prevent
drafts from affecting thermostat operation.
4. Being sure to level the thermostat for best
appearance, fasten the thermostat base to the wall
through the mounting holes with the screws provided.
5. Replace the thermostat cover.
FIGURE 16  ROUTE THERMOSTAT CABLE
FIGURE 17  THERMOSTAT
SQUEEZE FIRMLY
BOTH SIDES AND
LIFT TO REMOVE
COVER

COUNTERFLOW DIRECT VENT GAS WALL HEATER 13
Vent Installation
WARNING: DANGER OF PROPERY DAMAGE,
BODILY INJURY OR DEATH.
Proper vent installation is critical to the safe operation
of the furnace. Therefore, carefully read and follow all
the instructions given in this section.
The following instructions are for either surface or recess
mounted wall furnace.
USE ONLY THE VENT ASSEMBLY SUPPLIED.
IMPORTANT: All joints in the inlet and vent tubes and
all gaskets must be tight. Installation in any other
manner voids the C.S.A. design certification and will
affect the warranty.
Refer to Page 14, Figure 19 for the name and location of
the vent parts.
DETERMINE PROPER LENGTHS
IMPORTANT: To prevent harmful flue gases from
entering the house, make sure NOT to trim air or vent
tubes shorter than specified below.
Air inlet air tube ‘A’ and vent tube ‘B’ are supplied in
lengths to handle wall thickness up to 8½-inches.
To find the correct vent and air tube length, measure
exact distance ‘X’ between surface on which back of
cabinet will rest (inside of recessed cavity or face of wall
when freestanding and the outside wall surface).
See Page 13, Figure 18 & Page 15, Figure 19.
Inlet air tube ‘A’ Add ⅞-inch to dimension ‘X’. Mark on
tube starting from end with collar and holes. Cut off
evenly. File off any burrs resulting.
Vent tube ‘B’ - Add 2⅛-inches to dimension ‘X’. Mark
on tube starting from end with collar and holes. Cut off
evenly. File off any burrs resulting.
CUT ONLY THE PLAIN END (WITHOUT THE FLANGE)
OF THE TUBES. MAKE A SQUARE CUT TO THE EXACT
LENGTH.
HELPFUL CUTTING HINT
To make a straight cut, measure from the end and mark
tube in several places. Align a piece of tape with the marks
and wrap it around the tube. Use the edge of the tape as a
guide to help keep the cut straight.
ATTACHING TUBE TO FURNACE
The smaller diameter vent tube (Page 14, Figure 19 ”B”)
must be installed first. The easiest way to install the vent
tubes and get the gaskets positioned properly is to have
the furnace lying front down on a flat surface.
IMPORTANT: To prevent harmful flue gases from
entering the house, make sure NOT to trim air or vent
tubes shorter than specified below.
1. Attach vent tube (Page 14, Figure 19 ”B”) and gasket
to the back of the furnace heat exchanger with
(8) #8 x ⅜-inch sheet metal screws provided.
2. Attach air tube (Page 14, Figure 19 ”A”) and gasket to
the back of the furnace casting with (8) #8 x ⅜-inch
sheet metal screws provided.
FIGURE 18  WALL THICKNESS
SURFACE
MOUNT
RECESSE
MOUNT
WALL WITH
SIDING
BRICK
VENEER
WALL
NOTE: Each tube must overlap the collars of the vent cap
a minimum of 1¼-inches, which is obtained when tubes
are cut correctly as previously described.

14 COUNTERFLOW DIRECT VENT GAS WALL HEATER
INSTALLING YOUR FURNACE
FIGURE 19  VENT INSTALLATION
Trim
To conceal the space between the furnace and wall, use
4701 Trip Strip Package (not furnished with furnace),
¾-inch round or other wood trim.
TRIM COVER
Place the trim cover on top of the furnace. See Page 14,
Figure 20. Drill through the top casing flange and fasten
each side with a sheet metal screw. This plate covers the
space between the top of the furnace and wall opening
after electrical connections are made.
MOUNT FURNACE THROUGH WALL
Mount the furnace through the wall using surface or
recessed mounting instructions. See Pages 11 - 15.
Refer to Figure 19 for the following steps.
1. Check to see that the air tube protrudes through wall
7/8-inch min. to 1-inch max. for proper seal in vent cap.
2. Check to see that the vent tube protrudes past the air
tube 1/8 inch min. to ¼- inch max. for proper seal in
vent cap.
3. Apply a single strip of mastic (“E” provided in the vent
cap carton) continuously around the outer edge of the
vent cap mounting plate.
4. Holding the vent cap in an upright position (embossed
“top” on the mounting plate towards the top of the
furnace), push it into place until the stops
are contacted. If the stops prevent the mounting plate
from reaching the wall, refer back to “DETERMINE
PROPER LENGTHS” Page 13.
NOTE: The smaller tube in the vent cap must slide over
the vent “B”.
5. Fasten the vent cap mounting plate to the wall with
(4) 1½-inch wood screws “D’’ provided.
6. On masonry construction, drill into the wall and use
plugs or anchors. Additional sealant (silicone) may be
required if the mounting surface is uneven.
FIGURE 20  FURNACE TRIM STRIPS
Mounting Your Furnace
To obtain adequate clearance for fastening the furnace or
to install gas supply fittings, it may be necessary to remove
the burner and control assembly as follows:
CAUTION: Be careful not to damage burner pan
gasket when removing burner and control assembly.
1. Lay the furnace on its back for the following steps.
Remove burner compartment door by pulling the
door top out and up.
TOP VIEW OF FURNACE
TWO STRIPS ON EACH SIDE
TRIM STRIPS (2)
DVCF60XD DVCF40XD

COUNTERFLOW DIRECT VENT GAS WALL HEATER 15
MODELS: DVCF40XD, DVCF60XD
a. Remove the manual spark igniter and bracket by
removing the (2) screws and disconnecting the wire at
the back of the igniter.
b. Disconnect the two (2) slip-on connectors (24 volt
wires) from the gas valve.
c. Remove the (3) screws ‘A’ holding burner pan to the
upper heating element support (Page 15, Figure 22).
Rotate the burner toward the front until the (3) pins ‘B’
disengage from the upper heating element support slots.
d. Remove the burner and control assembly from furnace.
NOTE: Attach vent tubes BEFORE mounting the furnace.
See Pages 13 & 14
2.
If furnace is recessed in the wall, clear the recess of all debris.
3. Be sure the gas is shut off at the meter.
4. Before placing the furnace in position, remove the gas
piping stub if necessary to locate the furnace.
5. After installing the vent tubes, carefully move the
furnace into position, being sure not to bend the
vent tubes.
FASTEN FURNACE BOTTOM
(SURFACE AND RECESSED MOUNT)
NOTE: Fasteners are not furnished because of different
requirements of various types of wall construction.
Fasten the furnace to the floor through the holes provided
in the furnace bottom. If you have concrete flooring, use
an alternate fastening method. See Page 15, Figure 21
If the burner and control assembly were removed, replace
them by reversing steps 1a through 1d.
IMPORTANT: When replacing the burner and control
assembly, be sure that pins “B” all enter the slots in the
upper heating element support. To prevent dam-
age to wiring, be careful not to pinch them between
furnace components and route them away from the
burner pan surface.
FASTEN FURNACE TOP (SURFACE MOUNTING)
Fasten the furnace top to wall using two (2) metal anchors
(packed in plastic bag with thermostat) by placing them
over the back flange of the furnace top and screwing
them to the wall. Refer to Figure 21.
FASTEN FURNACE TOP (RECESSED MOUNTING)
Fasten the furnace top by drilling two (2) holes through
the side flanges of the furnace top and securing it with
two (2) screws or nails into the wall studs. Refer to Figure 21.
FIGURE 21  FURNACE MOUNTING
FIGURE 22  BURNER PAN
FIGURE 23  IGNITION CONTROL
CAUTION: Be careful not to damage furnace components
or wiring when drilling holes.

16 COUNTERFLOW DIRECT VENT GAS WALL HEATER
INSTALLING YOUR FURNACE
Gas Supply and Piping
Gas control valve, within the furnace, is shipped with a seal
over the gas inlet tapping. Do not remove seal until ready
to connect piping.
WARNING: Danger of property damage, bodily
injury or death. Make sure the furnace is equipped
to operate on the type of gas available. Models
designated as natural gas are to be used with
natural gas only. Furnace designated for use with
liquefied petroleum propane gas rate orifices sized for
commercially pure propane gas. They cannot be used
with butane or a mixture of butane and propane.
GAS SUPPLY
For Natural gas, the minimum inlet gas supply pressure for
the purpose of input adjustment is 5" water column. The
Maximum inlet gas supply pressure is 7" water column.
For propane gas, the minimum inlet gas supply pressure
for the purpose of input adjustment is 11" water column. The
maximum inlet gas supply pressure is 13" water column.
Gas pressure and input to the burners must not exceed
the rated input and pressure shown on the rating plate.
On Natural Gas the manifold pressure should be 4 inches
water column. The manifold pressure should be 10.5
inches water column for propaned gas. See page 19 for
operation above 2,000 feet altitude. Orifice change may
be required to suit gas supplied. Check with your local
gas supplier.
ORIFICE SIZES
Furnace Technical Information, page 23, shows the correct
orifice sizes for the different input ratings when using
Natural or propane gas.
GAS PIPING
The gas supply line must be of adequate size to handle
the BTU/hr. requirements and length of the run for the
unit being installed.
Determine the minimum pipe size from Page 16, Figure
24, basing the length of the run from the gas meter or
source to the unit.
All piping must comply with local codes and ordinances or
with the National Fuel Gas Code (ANSI Z223.1), whichever
applies. In Canada: Follow CAN 1(B149 Installation Code.
Refer to Page 15, Figure 21, for the general layout at the
unit. It shows the basic fittings needed.
FIGURE 24  LEFT SIDE GAS INLET
FIGURE 25  PROPER PIPING PRACTICE
PROPER PIPE
THREADING
INCORRECT
THREADING
2 THREADS EXPOSED
SEALANT THIN
ENOUGH TO SHOW
THREADS
OVERTHREADED
SEALANT
TOO THICK
SEALANT
PAST TIP
DAMAGED
THREADS

COUNTERFLOW DIRECT VENT GAS WALL HEATER 17
Electrical Wiring
WARNING: Danger of property damage, bodily
injury or death. Turn off electric power at the fuse
box or service panel before making any electrical
connections. Insulate where necessary. All line voltage
and ground connections must be completed before
electrical power is restored.
All electrical work must conform to your local codes and
ordinances or in their absence, with National Electrical
Code, ANSI/NFPA 70. If you are not familiar with wiring
codes, in general, have a competent electrician do this job.
In Canada: Follow C22.1, Canadian Electrical Code.
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after
servicing.
CAUTION: Do not connect 115V service line to the gas
control valve or wall thermostat.
ELECTRICAL CONNECTION
Refer to paragraph covering GAS AND ELECTRICAL
SUPPLY OPENINGS, Page 10. Follow Wiring Diagrams,
Pages 26.
If you have any doubt regarding the electrical hookup, or
compliance with code or ordinance, consult your electrical
inspector or a licensed electrician.
FIGURE 26  GAS PIPE SIZES
PIPE CAPACITY  BTUhr. WITH FITTINGS
NATURAL GAS PIPE CAPACITY BTUhr.
LENGTH
OF PIPE
FEET
PIPE SIZE INCLUDES FITTINGS
1/2”
3/4” 1”
20
40
60
92,000
63,000
50,000
190,000
130,000
105,000
350,000
245,000
195,000
PROPANE PIPE CAPACITY BTUhr.
LENGTH
OF PIPE
FEET
PIPE SIZE INCLUDES FITTINGS
1/2”
3/4” 1”
20
40
60
189,000
129,000
103,000
393,000
267,000
217,000
732,000
504,000
409,000
The following rules apply:
1. Use new, properly reamed pipe free from metal chips
and debris such as steel or black iron pipe. Use fittings
approved by local codes.
2. Do not thread pipe too far. Valve distortion or mal
function may result from excess pipe within
control. Apply moderate amount of good quality
dope to pipe only, leaving 2 end threads bare. If
propane gas installation, use compound resistant to
action of liquefied petroleum gases.
3. Use ground joint unions.
4. Install a drip leg to trap dirt and moisture before it
can enter the gas valve. Drip leg must be a minimum
of 3 inches long.
5. Install a manual shut-off valve.
6. Provide a 1/8” NPT test gauge connection immediately
before the gas supply connection to the furnace.
GAS CONNECTION
If installation is for propane gas, have propane gas installer
use two-stage regulation and make all connections from
storage tank to furnace. Use two pipe wrenches when
making the connection to the valve to prevent turning or
damage to gas valve.
Connections between the manual shutoff valve and
burner control assembly can be made with an A.G.A./
C.G.A. design certified flexible connector if allowed by local
codes. Drip leg and ground joint unions are still required.
Tighten all joints securely.
CHECKING THE GAS PIPING
Test all piping for leaks. When checking gas piping to
the furnace with gas pressure less than 1/2 PSI, shut off
manual gas valve to the furnace. If gas piping is to be
checked with the pressure at or above 1/2 PSI, the furnace
and manual shut off valve must be disconnected during
testing. (SEE WARNING.) Apply soap solution to each joint.
Bubbles forming indicate a leak. Correct even the slightest
leak at once.
WARNING: Danger of property damage, bodily
injury or loss of life. Never use a match or open flame
to test for leaks. Never exceed specified pressures for
testing. High pressures may damage the gas valve and
cause over-firing which may result in heat exchanger
failure. Liquid petroleum (propane gas) is heavier
than air and it will settle in any low area, including
open depressions and it will remain there unless area
is ventilated. Never attempt startup of unit before
thoroughly ventilating area.

18 COUNTERFLOW DIRECT VENT GAS WALL HEATER
INSTALLING YOUR FURNACE
HELPFUL HINT
After wire nuts are screwed to wires, a small strip of
electrical tape can be applied over wire nut at its base and
onto wires to make a very solid connection.
GROUNDING
The appliance when installed must be electrically
grounded in accordance with local codes and ordinances
or in their absence, with National Electrical Code (ANSI/
NFPA 70) or Canadian Electrical Code (CSA C22.1) if an
external electrical source is utilized. This appliance is
equipped with three-prong (grounding) plug for your
protection against shock hazard and should be plugged
directly into a properly grounded three-prong receptacle.
Do not cut or remove the grounding prong from this plug.
A ground lug is installed for the ground connection. Use
a copper conductor (#AWG) from the unit to a grounded
connection in the electric service panel or a properly
driven and electrically grounded ground rod.
ELECTRICAL POWER SUPPLY
Remove three-prong (grounding) service cord from the
envelope parts package to be installed in the furnace.
Remove 7/8 inch diameter (22mm) knockout at the left or
right bottom side panel to route the three-prong service
cord to an electrical outlet.
1. Insert the nylon cap attached to the end of the three-
prong service cord thru the 7/8-inch diameter
knockout into the burner control assembly area and
insert it into the nylon plug attached to the outer
casing bottom. If desired, you may route the
thermostat wire alongside of the service cord and thru
the same opening or choose another entry into the
burner control assembly area.
2. Attach 7/8-inch diameter strain relief around the three-
prong service cord and thermostat wire (if thermostat
wire is routed thru the knockout). Insert the 7/8-inch
strain relief into the 7/8-inch hole in the side panel
of furnace.
REPLACEMENT PART LISTING:
DESCRIPTION PART NUMBER
Service cord P323335
WARNING: Do not insert the three-prong
(grounding) service cord inside the burner control
assembly area more than 10 inches (245mm). This
could cause damage to the electrical cord resulting in
electrical shock hazard and/or fire.
A branch circuit including this furnace must not exceed 15
Amperes. Run a separate 115V, 60Hz. 15 Ampere circuit from
a separate circuit breaker or fuse in your service panel.
WALL THERMOSTAT WIRING
Run thermostat wire to the furnace. Connect thermostat
to the two wires marked “Thermostat” extending from
top of furnace, using two wire nuts provided. See Wiring
Diagrams on Pages 26. Refer to Page 12, Figure 16 also.
Replace the fan to the original position on the motor shaft,
and tighten securely. Replace the fan shroud, making sure
it is centered vertically on the fan.
Tighten the screws securely.
Replace the top front panel and secure with thumbscrew.
COMPLETE WIRING DIAGRAMS ON PAGES 26.

COUNTERFLOW DIRECT VENT GAS WALL HEATER 19
STARTUP PROCEDURE
Start the furnace using the procedures in the section
“OPERATING YOUR FURNACE”.
WARNING: Danger of bodily injury or death.
Liquefied petroleum gas (L.P. Gas) is heavier than
air and it will settle in any low area, including open
depressions and it will remain there unless the area is
ventilated. Never attempt to start-up the unit before
thoroughly ventilating area.
Check the furnace operation as outlined in the following
instructions. If any sparking, odors or unusual noises are
encountered, shut off electric power immediately. Recheck
for wiring errors or obstructions in or near fan motor.
CHECK GAS INPUT AND PRESSURES
For furnaces located at elevations between sea level and
2,000 feet, the measured input must not be greater than
the input shown on the rating plate of the furnace. For
elevations above 2,000 feet, the measured input must not
exceed the input on the rating plate reduced by 4 percent
for each 1,000 feet that the furnace is above sea level.
The gas supply pressure and manifold pressure with the
burners operating is specified on the rating plate.
Rated input will be obtained on a heating value of 2,500
BTU/hr. for propane at 10-inches manifold pressure with
factory-sized orifices. If L.P. Gas having a different heating
value is supplied, orifices must be changed by a qualified
service technician before the furnace is operated.
CHECK THERMOSTAT
Check thermostat operation. When set above room
temperature shown on the thermostat, the main burner
should light. Make certain the thermostat turns off the
furnace when the room temperature reaches the selected
setting and starts the furnace when room temperature
falls a few degrees.
ADJUST PILOT BURNER
PiIot fIame should surround 5/8-inch to 1/2-inch of
the thermocouple tip. To adjust, remove the cap from
the pilot adjustment screw on gas valve. Turn screw
counterclockwise to increase the flame, clockwise to
decrease. Replace cap. Refer to Page 23, Figure 30.
CHECK THE MANIFOLD GAS PRESSURE
A tapped opening is provided in the gas valve to facilitate
measuring the manifold gas pressure. A “U Tube”
manometer having a scale range from 0 to 12-inches of
water should be used for this measurement. The manifold
pressure must be measured with the burner and pilot
operating. Any major changes in flow must be made by
changing the size of the burner orifice.
Check with your local gas supplier for proper orifice sizing.
CHECK THE GAS INPUT (NATURAL GAS ONLY)
WARNING: Natural gas heating value (Btu per
cubic foot) can vary significantly. Therefore, it is the
installer’s responsibility to see that Btu/hr. input to the
furnace is adjusted properly. Failure to do so could
cause combustion chamber failure, asphyxiation, fire or
explosion resulting in damage, bodily injury or death.
Refer to the National Fuel Gas Code (NFPA 54) to be
sure the furnace is burning fuel at the proper rate.
Under firing could cause inadequate heat, excessive
condensation or ignition problems. Over firing could
cause sooting, flame impingement or overheating of the
heat exchanger.
Before starting natural gas input check, obtain heating
value of gas (BTU per cubic foot) at standard conditions
from your local supplier. This factor is used in “Check the
Gas Input” section and procedure.
To measure the input, using the gas meter, proceed as follows:
1. Turn off gas supply to all other appliances except
the furnace.
2. With the furnace operating, time the smallest dial on
the meter for one complete revolution. If this is a
2-cubic-foot dial, divide the seconds by 2. If it is a
1-cubic-foot dial, use the time in seconds as is. This
gives the seconds per cubic foot of gas being delivered
to the furnace.
3. Assuming natural gas with a heating value of 1,000
BTUper cubic foot and 34-seconds per cubic foot used
as determined by step (2), then:
Seconds per hour = 3,600
Input = 1,000 x 3,600 / 34 = 106,000 Btu/hr.
This measured input must not be greater than the
input indicated on the nameplate of the furnace.
4. Relight all other appliances turned off in Step 1 above.
Be sure all pilots are operating.
FIGURE 27  THERMOSTAT
INDICATOR LOWEST SETTIG
TYPE OF GAS MANIFOLD PRESSURE, IN. W.C.
NATURAL 4.0
PROPANE 10.0

20 COUNTERFLOW DIRECT VENT GAS WALL HEATER
OPERATING YOUR FURNACE
WARNING: Danger of bodily injury or death.
Liquefied petroleum L.P. Gas is heavier than air and it
will settle in any low area, including open depressions
and it will remain there unless the area is ventilated.
NOTE:
For models equipped with Cozy gas valve P322041 or
P322042 refer to this pages 20-21 for “SAFETY & LIGHTING
INSTRUCTION” and “TURN GAS OFF TO APPLIANCE.”
For models equipped with Cozy gas valve P321704 or
P321705 refer to this page and Page 23 for “SAFETY &
LIGHTING INSTRUCTIONS” and “TURN GAS OFF TO
APPLIANCE.’’
These furnaces are equipped with a manually operated
Piezo spark igniter device to ignite the pilot gas. Follow the
steps under “Lighting Instructions” (see Page 21) and use
the manual spark igniter to light the pilot in Step 10. Press
spark igniter button vigorously and repeatedly.
On new installations, the gas lines will be filled with air and
it may take several minutes to establish the pilot flame.
Keep all access doors and panels in place except for
inspection and maintenance.
WARNING: The surface of the furnace is hot
during operation. Keep children, clothing, furniture,
and flammable material away from it. Do not store or
use gasoline or other flammable liquids or vapors near
the furnace.
SAFETY CONTROLS
These furnace are protected against unsafe operation by
four automatic safety controls: (1) A safety pilot acts to shut
OFF the gas valve in case of pilot failure; (2) A redundant
gas valve; (3) A limit switch shuts down the main burner to
prevent overheating the furnace cabinet; this limit switch
wilt reset when furnace cools; and (4) A thermal overload
protects the motor against burnout caused by current
surges or if anything should block the flow of air through
the furnace. This switch will reset itself when the motor
cools down and it cannot be adjusted.
WARNING: Danger of bodily injury or death.
Do not operate the furnace with a broken or missing
pilot observation door.
FOR MODELS EQUIPPED WITH COZY GAS VALVE
P321704 OR P321705.
Models are equipped with a two-rate control valve.
The rate knob on the gas valve is marked “LO” and “HI.”
Turn the rate knob to the “LO” position and the room
thermostat will operate the main burner at about 70% of
maximum capacity. Turn the rate knob to the “HI” position
only when a fast heat-up is desired during extremely cold
weather. High operation develops maximum capacity of
the furnace.
A TWOSPEED FAN IS USED WITH MODELS DVCF60XD.
Blower will operate at low speed then shift to high speed
as the furnace heats up.
WARNING: Danger of property damage. Bodily
injury or death. If the furnace overheats or fails to shut
off, turn off the manual gas valve to the furnace before
turning off the electric power.
For your SAFETY,
read before lighting
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these
Instructions exactly.
B. BEFORE LIGHTING smell 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 or strike a match.
• 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.