COZY HEDV403 and User manual

HI-EFFICIENTDIRECT
VENTWALLFURNACE
INSTALLATIONAND
OPERATINGINSTRUCTIONS
P/N 72903 / December 2006
MODEL NUMBERS
NAT. GAS L.P. GAS
HEDV403 HEDV404
- Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
- WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch; do not
use any phone in your building.
Immediately call your gas supplier from a
neighbor’s phone. Follow the gas
supplier’s instructions.
If you cannot reach your gas supplier, call
the fire department.
- Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the
fire department.
- INSTALLATION AND SERVICE MUST BE PER-
FORMED BYA QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING: Operation of this furnace without the properly installed, factory furnished vent system and
vent cap could result in Carbon Monoxide (CO) poisoning and possible death. For your safety, this
furnace and the vent system should be inspected at least annually by a qualified service person.
May be installed in an aftermarket, permanently located, manufactured home (mobile home) where not
prohibited by local codes. See owner’s manual for details. This appliance is not convertible for use
with other gases, unless a certified kit is used.
WARNING: If the information in these instructions are
not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
Thisunitisnotapprovedforinstallationingreenhouses,orenvironmentsinvolvingdusty, wet, corro-
sive,orexplosiveconditions. Suchconditions will invalidate the warranty and maycreateunsafe
conditions.
RR
INSTALLER: Leave thismanualwiththeappliance.
CONSUMER: Retainthismanualforfuture reference.

Page 2
INTRODUCTION
THIS ISAGAS-FIRED DRAFT INDUCED, POWER DEPENDENTDIRECTVENTWALLFURNACE
THAT WILL OPERATE SAFELY AND PROVIDE AN EFFICIENT SOURCE OF HEAT WHEN
INSTALLED,OPERATEDANDMAINTAINEDASRECOMMENDED INTHESEINSTALLATIONAND
OPERATINGINSTRUCTIONS. READTHESEINSTRUCTIONSTHOROUGHLYBEFOREINSTALLING,
SERVICING, OR USING THEAPPLIANCE. IFYOU DO NOT UNDERSTANDANYPART OFTHESE
INSTRUCTIONS CONSULT LOCALAUTHORITIES, OTHER QUALIFIED INSTALLERS, SERVICE
AGENCIES,THE GAS SUPPLIERORTHE MANUFACTURER.
MODEL INPUT GAS TYPE MAX. WALL MIN. WALL
NO. BTU/HR. WIDTH DEPTH HEIGHT CONN. GAS Thickness Thickness
HEDV403 40,000 34-1/2” 9” 30” 1/2” Nat. 32” 5”
HEDV404 40,000 34-1/2” 9” 30” 1/2” L.P. 32” 5”
SPECIFICATIONSAND DIMENSIONS
YourDirectVentWall Furnaceisshippedcomplete inonecarton. Thiscarton containsthefurnace,vent cap,
ventexhausttube,airinlettube,templatewithrough-indimensions,installation andoperatinginstructions,and
thethermostat.
Introduction…………………………….. 2
Specificationsand Dimensions…………. 2
SafetyRules…………………………….. 3
Clearances………………………………. 4/5
Location………………………………… 6
Installation……………………………… 7
LightingInstructions…………………… 10
PilotAdjustment……………………….. 11
BurnerOrifice………………………….. 11
WiringDiagram………………………… 12
RemovingMainBurner………………… 11
ProperBurnerFlame…………………… 11
SequenceofOperation…………………. 13
OptionalKits…………………………… 14
TroubleShooting………………………. 17
PartsDrawing………………………….. 19
PartsList……………………………….. 20
Warranty……………………………….. 22
CONTENTS
The State of Massachusetts requires that installation and service of a gas appliance be
performedbyaplumberor gas fitter licensed intheCommonwealthofMassachusetts.

SAFETY RULES
1. Improper installation, adjustment, alteration, service, or maintenance can cause property damage, bodily
injury, or death.
2. Use in other than a residential application may result in unsatisfactory performance and may void the
warranty.
3. Follow all applicable codes and ordinances. If there are none, follow the latest edition of National Fuel
Gas Code ANSI Z223.1 A copy may be obtained from the CSA International, or the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA. 02269. In Canada, use latest edition of CAN1-B149
installation code.
4. DO NOT INSTALL THIS FURNACE IN A RECREATIONAL VEHICLE OR TRAILER.
5. Do not operate wall furnace unless it is connected to the supplied vent system with vent cap in place.
6. Check the rating label attached to the wall furnace to be sure it is equipped for the type gas you intend to
use.
7. Never use a match, candle, flame or other source of ignition to check for gas leaks. Use only soapy water
or liquid detergent.
8. Have your wall furnace and vent system inspected at least annually by a qualified service technician.
9. Before cleaning or servicing, turn off the gas and allow furnace to cool.
10. Do not operate wall furnace without all components properly installed (top, front, etc.).
11. Due to high temperatures, the wall furnace should be located out of traffic and away from furniture and
drapes.
12. Children and adults should be alerted to the hazard of high surface temperature and should be kept away to
avoid burns or clothing ignition.
13. Young children should be carefully supervised when they are in the same room with the wall furnace.
14. Do not place clothing or other flammable material on or near the furnace.
15. INSTALLATION AND REPAIR SHOULD BE DONE BYA QUALIFIED SERVICE PERSON. THE
WALL FURNACE 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,
burner, and circulating air passageways of the furnace be kept clean.
16. Do not install in a closet, alcove, or small hallway where the furnace could be isolated from the space to
be heated by closing a door.
17. Do not put anything around the furnace or vent cap that will obstruct the flow of combustion and
ventilation air.
18. The appliance, when installed, must be electrically grounded in accordance with local codes or, in the
absence of local codes, with the latest edition of National Electrical Code,ANSI/NFPA 70. In Canada, use
CSA C22.1.
19. Never operate this furnace without the sight glass in place or with the glass broken or missing.
20. If it is suspected that rising water may enter the furnace, turn off the gas immediately.
21. Do not use the 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.
22. It is necessary to replace damaged gaskets or sealing material within the vent or air intake system. Failure
to do so may result in property damage, personal injury or loss of life.
23. Any safety screen or guard removed for servicing must be replaced prior to operating heater.
24. This appliance must not be connected to a chimney flue serving a separate solid fuel burning appliance.
Page 3

REFERENCE LETTER TO
DRAWING CANADIAN INSTALLATIONS¹ U.S. INSTALLATIONS²
A= Clearance above grade,
veranda, porch, deck, or
balcony
12 Inches (30 cm) 12 Inches (30 cm)
B= Clearance to window or door
that may be opened 12 Inches (30 cm) 9 Inches (23 cm)
C= Clearance to permanently
closed window 12 Inches (30 cm) 9 Inches (23 cm)
D= Vertical clearance to
ventilated soffit located above
the terminal within a horizontal
distance of 2 Feet (61 cm) from
the center line of the terminal
18 Inches (46 cm) 18 Inches (46 cm)
E= Clearance to unventilated
soffit 18 Inches (46 cm) 18 Inches (46 cm)
F= Clearance to outside corner 12 Inches (30 cm) 12 Inches (30 cm)
G= Clearance to inside corner 12 Inches (30 cm) 12 Inches (30 cm)
H= Clearance to each side of
center line extended above
meter/ regulator assembly
3 Feet (91 cm) within a height
15 Feet (4.5m) above the
meter/regulator assembly
Clearance in accordance with
local installation codes and the
requirements of the gas supplier
I= Clearance to service regulator
vent outlet 3 Feet (91 cm) Clearance in accordance with local installation codes and the
requirements of the gas supplier
J= Clearance to nonmechanical
air supply inlet to building or the
combustion air inlet to any other
appliance
12 Inches (30 cm) 12 Inches (30 cm)
K= Clearance to a mechanical
air supply inlet 6 Feet (1.83 m) 3 Feet (91 cm) above if within 10 Feet (3 m) horizontally
L= Clearance above paved
sidewalk or paved driveway
located on public property
7 Feet (2.13m) A vent shall
not terminate directly above
a sidewalk or paved driveway
that is located between two
single family dwellings and
serves both dwellings.
Clearance in accordance with
local installation codes and the
requirements of the gas
supplier.
M= Clearance under veranda,
porch, deck, or balcony 12 Inches (30 cm) permitted only if veranda, porch, deck,
or balcony is fully open on a
minimum of two sides.
Clearance in accordance with
local installation codes and the
requirements of the gas
supplier.
¹ In accordance with the current CSA-B149.1 Natural Gas and Propane Installation Code
² In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code
VENT TERMINAL CLEARANCES
Page 4
VentTerminal AirSupplyInlet Areawhere terminalisnotpermitted

Page 5
CLEARANCES
1. As you face the heater, the clearance to a side wall on the right side is 0” (Fig. 1), and the left side is 1”
(Fig. 2).
2. The minimum clearance from the top of the heater to the ceiling or any projecting overhang is 10”.
(See Figure 3).
3. The minimum clearance from the bottom of the heater to the floor, or the top surface of carpeting, tile, etc.
is 0”. (See Figure 4).
4. When the furnace is installed directly on carpeting, tile or other combustible material other than wood
flooring, the furnace shall be installed on a metal or wood panel extending the full width and depth of the
furnace.
5. The minimum clearance from the edge of the vent cap to any overhanging obstruction, perpendicular side
wall, or corner of building is 12”. (See Figure 5).
6. Vent cap must be located at least 9” from any opening that would allow combustion products to enter the
building, windows, doors, etc., and 12” above the ground or shrubbery (See Figure 5). Do not install vent
cap in a window well. Provisions must be made to prevent snow accumulation from infringing on vent cap
clearances.
1” (2.54 cm)
SideWall
Ceiling or Overhang
10” (25.4 cm)
FIGURE 1 FIGURE 2 FIGURE 3
FIGURE 5

CLEARANCES
7. RESIDENTIALGARAGE INSTALLATION: Gas utilization equipment in residential garages
shall be installed so that all burners and burner ignition devices are located not less than 18 inches
(46 cm) above the floor. You must build a platform 18” above floor, the full width and depth of
the heater, including the rear trim kit. HEATER IS NOT DESIGNED TO HANG ON WALL.
Unit should be located or protected so it is not subject to damage by a moving vehicle. Use care
in selecting a good location whith in the grage. DO NOT locate the appliance where heated air
will be directed onto a nearby parked vehicle. Paint may discolor or rubber may harden and
crack. DO NOT allow open or closed containers of paint, gasoline or other liquids having flam-
mable vapors to be stored or used in the same area as the heater.
LOCATION
1. The wall furnace must be installed on an outside wall, unless optional Kit No. HEVK-5 is used.
2. For most efficient performance, locate furnace as centrally as possible in the area to be heated and
where occupants may move about freely without coming into contact with the cabinet, and within
reach of a 115V wall outlet.
3. If the furnace is installed in a basement, a 12” clearance must be maintained between ground level
and the bottom of the vent cap. Do not install furnace where vent cap will terminate in a window
well or any other opening below ground level. Do not allow snow accumulation to build up
within 12” of the vent cap.
OPTIONAL KITS
1. HEVK-5 - To extend vent 5 foot from heater. This will allow vent cap to be installed above grade
from basement or to an outside wall. A total of 3 kits with 2 additional elbows may be used.
Page 6
12” Minimum above grade
without excavation

INSTALLATION
Failure to follow these instructions carefully could result in poor performance, property damage, personal injury, or
death.
STEP 1. LOCATE VENT OPENING (Requires 3-1/2” diameter wall opening)
a) Select area on wall where heater will be installed. Using template (packed with heater) mark shaded area
where hole can be cut and to locate the wall brackets.
b) Locate studs on each side of this area.
c) Mark location for 3-1/2” diameter hole between studs. Hole should be offset to miss studs. (See Figure 6).
d) Check outside wall at this location for proper clearances around vent cap.
e) Cut vent openings into both the inside and outside walls, being sure to maintain level across both openings.
STEP 2. ROUGH-IN GAS SUPPLY (See Figure 7)
a) Install a 1/2” gas supply line. The gas line will enter the heater from the 5” spacing between the heater
back and the wall.
b) Install a drip leg in gas supply line immediately upstream from the gas connection to heater, (see local
codes), and provide a 1/8” N.P.T. plugged tapping, accessible for test gauge connection and a individual
manual shut off valve. The furnace and its individual shut off valve must be disconnected from the gas
supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig
(3.5Pa). The furnace must be isolated from the gas supply piping system by closing its individual manual
shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than 1/2 psig (3.5Pa).
Page 7
Template
Shaded
Area
Wall
Studs
16” O.C.
FIGURE 6
Manual Shut
OffValve
1/8” N.P.T. Plugged Hole
for Pressure Gauge
Ground Joint
Union
3”(76mm)Min.
Gas
Valve
Gas Supply
Inlet
FIGURE7

INSTALLATION - CONTINUED
STEP 3 INSTALLING VENT SYSTEM 5” - 32” WALL THICKNESS (12.7 cm - 81.3 cm)
a) Use only factory supplied parts. Do not attempt to modify in any way. To do so could cause a system
imbalance resulting in poor performance and/or unsafe operating conditions.
b) Slide collection box pipes through cutout and secure collection box to inside wall. Anchors (not supplied)
may be required. (See Figure 8).
c) From outside house, mark collection box pipes and cut off 1/2” beyond outside wall.
d) Slide vent cap pipes onto collection box pipes and push in until flange is flush against house. Secure vent
cap assembly to outside wall with a slight downward slope. This will prevent water from entering and
allow and condensation to drain. Caulk around the edges of the vent cap mounting plate. NOTE: It may
be necessary to build a metal or wood frame to provide a flat surface for the mounting plate to be flush
against or to attain the 5” minimum wall thickness.
Page 8
CollectionBox
Assembly
Vent Cap
Assembly
Vent Cap
Mounting
Plate
FIGURE 9
BRACKETS

STEP 5. INSTALLING REAR TRIM KIT
a) Secure right and left trim kit sides to the wall and trim kit brackets with eight #8 screws provided. See
figure 11. The back of the heater should now be spaced 5” from the wall.
b) Remove the temperature sensing unit from the back of the heater. Save the nylon attachment clip and the
#8 screw.
c) Slide the temperature sensing unit through the 1/2” bushing located on the right trim kit side. Viewed from
the front of the heater.
d) Secure the temperature sensing unit to the outside of the right trim kit side using the nylon clip and #8
screw saved from step B. Engagement hole provided.
e) Secure trim kit top panel to trim kit sides with four #8 screws provided.
f) Plug power supply cord into a 115V grounded electrical outlet.
g) Turn the manual gas supply valve to the “on” position.
HEATER IS NOW INSTALLED, FOLLOW LIGHTING INSTRUCTIONS.
Page 9
STEP 4. INSTALLING HEATER
a) Screw wall brackets to wall. Location marked with template. (See Step 1a)
b) Screw trim kit brackets to back of heater. (See Figure 9).
c) Slide heater to within approximately 5” from wall.
d) Attach air intake hose to collector box outlet and burner box inlet with clamps provided. (See Figure 10).
e) Attach vent exhaust tube to exhaust pipe on collector box and draft inducer outlet on back of heater.
Secure with clamps provided. (See Figure 10).
f) GAS CONNECTION. Make gas connection between manual shut off valve and furnace valve with
approved connectors. Compounds used on threaded joints of gas piping shall be approved for use with
L.P. gas. The gas lines must be checked for leaks by the installer with soapy water or liquid detergent,
never an open flame. If connections are not exposed, a pressure test must be run. Be sure to disconnect
the gas supply line from the appliance valve before pressure testing. The manifold pressure is pre-set at
the factory and should be 3.5” w.c. for Natural Gas and 10” w.c. for L.P. gas. The minimum inlet
pressure for Natural Gas is 4.5” w.c. and 11” w.c. for L.P. Gas, “for purpose of input adjustment”. The
maximum inlet pressure should never exceed 7.0” w.c. on Natural Gas or 14” w.c. on L.P. Gas.
Trim KitTop
TrimKit
Right Side
TrimKit
Bracket(4)
Temperature Sensing Unit
1/2” Bushing
TrimKit
LeftSide
FIGURE 11

FOR YOUR SAFETY READ BEFORE OPERATING
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 does not have a pilot. It is • If you cannot reach your gas supplier, call
equipped with an ignition device which the fire department.
automatically lights the burner. Do not try
to light the burner by hand. C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
B. BEFORE OPERATING smell all around the not push in or turn by hand, don’t try to repair
appliance area for gas. Be sure to smell next it, call a qualified service technician. Force or
to the floor because some gas is heavier than attempted repair may result in a fire or explosion.
air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS: D. Do not use this appliance if any part has been
• Do not try to light any appliance. under water. Immediately call a qualified service
• Do not touch any electric switch; do not technician to inspect the appliance and to
use any phone in your building. replace any part of the control system and any
• Immediately call your gas supplier from a gas control which has been under water.
neighbor’s phone. Follow the gas supplier’s
instructions.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on 5. Remove frontpanel.
this label. 6. Pull the gas control lever DOWN clockwise 6
2. Set the thermostat to lowest setting. to “OFF”. Do not force.
3. Turn off all electric power to the appliance. 7. Wait five (5) minutes to clear out any gas. Then
4. This appliance does not have a pilot. It is smell for gas, including near the floor. If you
equipped with an ignition device which auto- smell gas, STOP! Follow “B” in the safety
matically lights the burner. Do not try to information above on this label. If you don’t
light the burner by hand. smell gas, go to the next step.
8. Push gas control lever UP counterclockwise 7
to “ON”.
9. Replace front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance”
and call your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting. 4. Pull the gas control lever DOWN clockwise 6
2. Turn off all electric power to the appliance to “OFF”. Do not force.
if service is to be performed. 5. Replace front panel.
3. Remove front panel.
Page 10
Gas
Inlet
Gas control
knob shown
in“OFF”
position

MODEL 0 to 2,000’ 4,000’ 6,000’ 8,000’ -
NO. 2,000’ 4,000’ 6,000’ 8,000’ 10,000’
NATURAL GAS
HEDV403 45 47 48 49 50
L.P. GAS
HEDV404 55 55 56 56 57
PROPER BURNER FLAME
The burner flame may be observed by raising the sight
glass cover. A proper flame will have a dark blue inner
mantle, with a lighter blue outer mantle that extends from
the burner into the heat exchanger tube, (see Figure 12).
Thereis noprimary airadjustmenton theburner, andproper
flame is assured since the correct manifold pressure and
orificing has been done at the factory.
TO REMOVE MAIN BURNER FOR INSPEC-
TION AND CLEANING
1. Turn off all electrical supply to heater.
2. Turn off gas supply.
3. Remove front panel.
4. Unplug wire to ignitor and sensor. (See Fig. 13.)
5. Disconnect vacuum hose from burner box.
6. Remove screws holding burner box top to burner
box. (See Figure 13.)
7. Remove burner plate and burner box top. Take
care not to contact, or strain ignitor in any way
as it is extremely fragile. (See Figure 13.)
8. Remove 2 nuts holding burner bracket. (See
Figure 13).
9. Slide burners toward heat exchanger and lift up
from rear and back. (See Figure 13).
10. Clean or replace as needed.
11. Reinstall by reversing Steps 9 - 1.
BURNER ORIFICE
This appliance is orificed at the factory for elevations up to
2,000 ft. If installed above 2,000 ft., the BTU input must
be reduced 4% per 1,000 ft. See the following orifice chart
for the proper orifice for a specific elevation.
SPECIFIC ELEVATIONS
Page 11
NOTE: THE FURNACE AND ALL COMPO-
NENTS MUST BE INSPECTED AT LEAST
ANNUALLYBYAQUALIFIEDSERVICE PER-
SON. THIS SHOULD INCLUDE THE
BURNER, HEAT EXCHANGER, AND VENT
SYSTEM. BE SURE THAT THE FLOW OF
COMBUSTIONANDVENTILATIONAIRARE
NOT OBSTRUCTED AND THAT ALL HOSES
ARE UNDAMAGED,AND ALLCLAMPS ARE
SECURELY TIGHTENTED.
Primary Flame
Burner
Secondary Flame
Heat Exchanger Tube
FIGURE 12
Valve
Burner
Box
Top
Mani-
fold
Burner
Burner
Box
Plate
Sensor Nut
Burner Bracket
Ignitor Vacuum
Hose
FIGURE 13
NOTE: Ifthisheater isinstalledabove anelevationof8,000 feet,thefactory installedpressureswitch maynot
functionproperly. Ifyou experienceaproblemwiththepressureswitch,contactaqualified serviceagencyto
replacethefactory installed pressureswitchwitha high altitudepressureswitchP/N 72521. To order seeyour
localCozydealeror contact thefactory.

WIRING
This appliance is equipped with a three prong grounding
plug. For your protection against shock hazard, this ap-
plianceshouldbe pluggeddirectly intoa properlygrounded
three-prong receptacle. Do not cut or remove the ground-
ing prong from this plug.
NOTE: If any of the original wire supplied with this ap-
pliance has to be replaced, it must be replaced with type
105EC wire or its equivalent.
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper and
dangerous operation.
Verify proper operation after servicing.
WARNING
THIS IS A GAS-FIRED APPLIANCE. KEEP THE
AREA CLEAR OF GASOLINE AND OTHER FLAM-
MABLE VAPORS AND LIQUIDS. ALL COMBUS-
TIBLE MATERIALMUST BE KEPTCLEAR OF THIS
AREA TO AVOID FIRE OR EXPLOSION.
Page 12
Gas Valve
Pressure
Switch
Circulating
Blower
XFMR
L 1
EAC/LSPD
Heat
Hum
M 1
M 2
Black
White
Draft
Inducer
White White
Neutrals
Flame
Sensor
Brown
White
Black
24VAC
Transformer
Yellow
Yellow
Thermostat
Yellow
Yellow
White
Red
Black
Black
W
C
R
Y
MODEL HEDV 403, 404
Ignitor
Blue
Blue
High
Limit
Red
Red
Black
White
Green
Thermostat Limit Pressure Gas
Switch Switch Valve
Circulating
Blower
Draft
Inducer
Ignitor
Flame
Sensor 115 VAC
Primary
Transformer
Secondary
24 VAC
3 Amp
Fuse

STEP # STEP #
1) Thermostat calls for heat. 8) Continued...
2) Combustion fan turns on. return to Step 2. If after 3 attempts
3) Pressure switch closes. malfunction still occurs, furnace will
4) Power to Ignitor. go into lockout mode for one hour.
5) Ignitor warm up period. This one hour mode can be bypassed
6) Gas flow to burner. by resetting thermostat.
7) Burner ignition proven. 9) Thermostat satisfied.
8) Circulating blower on. 10) Gas valve closes.
NOTE: If there is a mal- 11) Combustion fan off.
function in any of the 12) Blower off.
above steps, the sequence
will stop at that point and HEATER NOW IN STAND-BY MODE.
Page 13
SEQUENCE OF OPERATION - HEDV403/4
Lockout
t=10 sec.
IGNITION
PROVED? YES
t=50 sec.
NO
Blower
On
@t=X
Thermostat
is satisfied
t=x sec.
Burners
Off
t=X+15 sec.
Combust.
Fan Off
Blower
Off
@t=0
THERMOSTAT
CALLS FOR
HEAT
Power to
Combust.
Fan
10 SEC
PURGE
Three
Attempts
Made?
NO YES
Fan
Proved YES
NO
Power to
Ignitor
NO
Three
Attempts
Made?
YES
Gas
Flow
10 SEC
PURGE
t=X+120 sec.
t=15 sec. t=20 sec.

HEVK-5 5’ VENT EXHAUST KIT
INSTALLATIONINSTRUCTIONS
WARNING: Use only Louisville Tin & Stove Company factory supplied parts and kits. Failure to do so could result in
loss of life, personal injury, property damage, or unsatisfactory performance.
CONTENTS OF KIT
1 only P/N 72532 2”x3” Steel Coupling 1 only P/N 41520 Center Bracket
1 only P/N 72575 2”x5’ Black Flocked Tube 8 only P/N 72593 2” Hose Clamps
1 only P/N 72612 2”x6’ Black Flex Tubing 1 only P/N 72578 2”x3” Black Silicone
2 only P/N 41515 Support Brackets Wrapped Coupling
STEP 1 - LOCATE VENT OPENING
a) Select location on outside wall that vent will exit through.
b) Check outside for proper clearances around vent cap. See installation instructions.
c) Mark and cut 3-1/2” hole through both inside and outside walls, being sure to maintain level across both openings.
d) Measure wall thickness. Mark and cut off both intake and exhaust pipes to 1/2” beyond outside wall.
e) Secure collection box to wall. Wall anchors, not provided, may be required.
STEP 2 - INSTALL HEATER
a) Select location on wall where heater will be installed.
b) Using wall template supplied with heater, mark location for trim kit wall brackets.
c) Attach brackets to wall (wall anchors, not provided may be required) and back of heater. Using screws provided on
back of heater.
d) Slide heater into position and secure brackets togehter. This should position back of heater 5” off wall.
e) Select direction vent will exit trim kit, left, right, or straight up.
f) Before installing trim kit remove knockout on this side.
STEP 3 - INSTALL VENT
a) Remove and discard P/N 72611 2”x24” black flex tubing from air inlet. (Save hose clamp).
b) Attach P/N 72612 2”x6’ black flex tubing to air inlet. Secure with P/N 72593 2” hose clamp.
c) Slide P/N 72575 2”x5’ flocked tube through trim kit opening (knockout) and attach to P/N 72610 orange silicone
90Eelbow supplied with heater. Secure with 2” hose clamp.
d) Attach P/N 41515 support brackets to wall. Wall anchors, not provided, may be required. Postion support brackets
within 8” from side of trim kit and end of pipe. Secure flex tubing and flocked tube to brackets using 2” hose
clamps.
e) Attach P/N 41520 center bracket 2-1/2’ from pipe end and insert flex tube through bracket. This will prevent the
flex tube from touching the black flocked exhaust tube.
f) Connect flex air intake tube and flocked exhaust tube to collection box.
g) Complete gas connection and attach trim kit to brackets.
h) Follow lighting instructions.
SPECIAL NOTES
a) You may use up to three HEVK-5 Kits for a total of 15’ vent extension with two additional elbows. DO NOT
EXTEND VENT BEYOND 15’ OR USE MORE THAN THREE TOTAL ELBOWS (one elbow is attached to
heater outlet).
b) To connect two vent kits together use P/N 72532 2”x3” steel coupling. Secure with 2” hose clamps.
c) If you are using one, two, or three kits, after installation is complete you will discard 2 P/N 72593 hose clamps and
one P/N 72532 steel coupling.
d) If you need to make a 90Eoffset you will need to order P/N HEEL-1 90EElbow Kit. Two offsets require two kits.
e) If complete vent extension is horizontal, pipes may be sloped down slightly to allow any condensate to
drain through the exhaust pipe to the outside. DO NOT ALLOW TO DRAIN ONTO WALKWAY. If any part of
vent extension is vertical or local codes do not allow draining of condensate to outside you must add P/N HECK-1
Condensate Kit.
f) For cosmetic purposes, the addition of the HEVK-5 Kit can be enclosed by adding a HEVE-5 Vent Enclosure Kit.
To completely enclose the HEVK-5 Kit one HEVE-5 will be needed for each HEVK-5 used.
Page 14
P/N 72612
2”x6’ Black
Flex Tubing P/N 72532
Use only if connecting
flex tubing of 2 or
more ktis
P/N 72575 2”x5’
Black Flocked Tube P/N 72593
2” Hose Clamps
P/N 41515
Support
Brackets (2)
P/N 72578 2”x3”
Black Silicone
Wrapped Coupling
P/N 41520
Center Bracket

HEVE-5
VENT ENCLOSURE KIT
INSTALLATIONINSTRUCTIONS
STEP 1)Position end of Part No. 41610 enclosure body to
heater trim kit where pipes exit trim kit, centering
pipes inside body and attach to wall. Wall anchors,
not provided, may be required. Collector box may
be behind HEVE-5 Kit.
STEP 2)Cut to fit enclosure panel 1” beyond end of vent
run. Insert Part No. 41620 End Cap and attach
using three #8 screws provided.
SPECIAL INSTRUCTIONS
STEP 3)If more than one HEVE-5 Kit is used, attach Part
No. 72604 Trim Kit where ends meet.
STEP 4)If making a 90Eturn, measure 1” beyond outside
turn and cut off enclosure panel. Notch panel on
surface of direction turn is being made to allow
pipes to pass through into next HEVE-5 Kit.
Attach second panel to wall and attach Part No.
72604 Trim Kit where two bodies meet. Install
end cap Part No. 41620.
HECK-1
CONDENSATE KIT
INSTRUCTIONS
STEP 1)Attach condensate trap to back of heater using 2 #8
screws provided, as shown below. End of trap
should extend through back of heater and into
bottom of condensate pan.
STEP 2)Remove and discard cap from bottom of draft
inducer drain tube.
STEP 3)Connect 1/4” plastic line from draft inducer drain
tube to condensate trap. Secure with 2 1/4” hose
clamps, provided.
STEP 4)Fill condensate pan with water.
WARNING: Keep condensate pan filled with water.
The water provides a seal to prevent combustion products
from being pushed through the drain into the house.
HEEL-1
90EE
EE
EELBOW KIT
Contains 1 only P/N 72613 90//
//
/Elbow 2”
Page 15
BACK OF HEATER
Exhaust
1/4” Clear Tubing
Condensate
Trap
Drain Tube
FromDraft
Inducer
Condensate trap empties through back
of heater into a condensate pan below
heat exchanger.

MAINTENANCE INSTRUCTIONS
For proper and safe operation keep furnace and furnace area clean. At regular intervals turn control valve to off, let
cool and clean inside control and heat exchanger compartment. To clean front panel use only a damp cloth, do not
use any kind of solvent or cleaning fluid that could leave a residue to burn or give off fumes when furnace is turned
on.
Remove the blower filter from back of heater and clean as needed. Filter can be cleaned with garden hose, in bathtub,
sink, etc. Use only water or air to clean. DO NOT USE ANY CLEANING SOLUTION AS THEY COULD BE
FLAMMABLE AND COULD CAUSE ODORS. Dry thoroughly and re-install. Do not operate heater without filter
in place.
Have the furnace checked, cleaned, and repaired by a qualified service person. Check venting system, and burner
operation prior to use each year.
Follow a regular service and maintenance schedule for safe and efficient operation.
Do not obstruct combustion and ventilation air. Examine the venting system as a routine part of the safety perfor-
mance check on an annual basis.
If the heat exchanger is removed, check the heat exchanger intake gasket and draft inducer gasket and replace if there
is any sign of damage. Be sure all gaskets are in place when the heat exchanger is replaced.
Failure to replace any gasket that has been damaged may result in property damage, personal injury or loss of life.
Oil the bearings of the fan motor every 6 months with S.A.E. 20 oil.
SERVICE RECORD
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Page 16

TROUBLE SHOOTING CHART
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
Flame too large 1. Defective operator section of valve. 1. Replace valve.
2. Burner orifice too large. 2. Check with local gas company for proper
orifice - size and replace.
3. If installed above 2,000 ft. 3. See burner orifice section, Page 11.
Yellow burner flame 1. Clogged burner ports. 1. Remove burners and check for obstruc-
tions in throats, ports, and orifices. Clean -
but do not enlarge ports or orifices.
2. Obstruction around vent cap. 2. Make sure area around vent cap is clear, be
sure vent system is sealed.
Gas odor 1. Gas leak. 1. See Page 1.
Delayed Ignition 1. Low gas pressure. 1. Check gas supply pressure.
2. Igniter not peroperly located. 2. Check ignitor location and correct if
necessary.
Failure to ignite 1. Main gas off. 1. Open all manual gas valves.
2. Temperature dial or thermostat not set high 2. Set temperature dial or thermostat to
enough to call for heat. higher temperature.
3. Cloggedburner orifice. 3. Clean burner orifices (do not enlarge).
4. Incorrect wiring. 4. Checkwiring diagram.
5. Defective valve. 5. Replace valve.
6. No power to unit. 6. Plug in power supply cord. Check 115 V.
wall outlet.
Burner won’t 1. Defective or damaged thermostat wire, 1. Can be checked by removing wire from con-
turn off or thermostat. trol board terminal. If burner goes off, replace
thermostat.
2. Thermostat sensor location on back of heater. 2.Thermostat sensor attached to back of heater
to re-locate out of drafts, hot, or cold spots.
3. Defective or sticking valve. 3. Replacevalve.
4. Excessive gas pressure. 4. Contact utility supplying gas.
5. Defective or damaged sensor. 5. Replace thermostat.
Incorrect gas 1. Gas input not checked. 1. Re-check gas input.
input 2. Clogged orifices. 2. Clean orifices with a smooth wood toothpick,
do not enlarge.
Not enough heat 1. Furnace undersized. 1. This is especially true when a dwelling or
room is enlarged. Have the heat loss
calculated and compare to furnace output.
Your gas company can supply you with this
information. If furnace is undersized,
replace with correct size unit.
2. Temperature dial set too low. 2. Raise temperature setting.
3. Incorrect supply pressure. 3. Check supply pressure.
Too much heat 1. Temperature dial set too high. 1. Lower temperature setting.
2. Combination control valve stuck open. 2. Replace combinationcontrol valve.
Main burner 1. Defective flame sensor. 1. Check voltage and replace if low.
goes out 2. Input too high. 2. Check input rate.
during normal 3. Cover around pilot lighter hole not air 3. Tighten wing nuts securing cover and sight
operation tight. glass. Check and replace gasket if needed.
4. Vent tubes not properly installed or 4. Follow instructions. Check both exhaust and
sealed. air intake tubes, and vent cap. Be sure all
gaskets are in place and properly sealed. Use
only tubes and vent cap supplied. Do not
alter vent tubes or cap.
5. Limit switch opens. 5. Clean air filter.
6. Exhaust or Air Intake tubes blocked. 6. Remove obstruction. Check for snow
accumulation around vent cap.
Page 17

TROUBLE SHOOTING CONTROL BOARD
To improve diagnosing and servicing, this control board is equipped with a self diagnosing
green status light (see wiring diagram). To indicate stand by mode and proper operation
this light will remain on. If there should be a malfunction, the light will flash a varying
number of times with a pause between each series of flashes. The number of flashes will
indicate the circuit to check.
# of Reason for Indication Possible Causes Corrective Action
Flashes
1 Failed ignition attempts Hot Surface Ignitor: Hot Surface Ignitor:
(3 times) a) Broken a) Replace
This puts heater into one hour b) Loose or damaged wire. b) Connect or replace wire
lockout mode. This one hour
lockout can be bypassed by No Gas to Burner: No Gas to Burner:
resetting the thermostat. a) Valve in “OFF” position. a) Turn to “ON”
b) Gas supply turned OFF. b) Open gas supply valve.
c) Loose or damaged wire to valve. c) Connect or replace wire.
d) Defective or dirty flame sensor. d) Replace or clean sensor.
2 Pressure switch stuck closed Defective switch. Replace switch.
3 Pressure switch failed to close a) Vacuum hose disconnected or damged. a) Reconnect or replace vacuum hose.
b) Defective switch. b) Replace switch.
c) Wire disconnected or damaged. c) Connect or replace wire.
d) Obstruction in vent pipe. d) Remove obstruction.
4 Limit switch circuit open a) Defective limit switch. a) Replace limit switch.
b) Disconnected or damaged wire. b) Replace or connect wire.
5 Gas valve energized with no a) Defective gas valve. a) Replace gas valve.
call for heat b) Sensor defective. b) Replace sensor.
c) Short in sensor wire. c) Replace sensor wire.
6 Polarity reversal a) Hot and neutral electrical supply a) Unplug supply cord from wall
very wire reversed in junction box. socket. Open junction box and
rapid switch the hot and neutral wires.
Page 18

HI-EFFICIENT DIRECT VENT
WALL FURNACE
Prices and specifications subject
to change without notice.
All prices are F.O.B. factory.
Page 19
MODEL NUMBERS
HEDV403 - NAT. GAS
HEDV404 - L.P. GAS
46
52
48
33
34 37 36
35
43
41
40
39
38
42
31
47
27
26
50 25
24
23
22
21
20
49
30 53
29
28
32
8
9
10
11
12 13
14
15 16
17 18
54 19
5
51
44
45
6
5
4
3
7
2
1
Mr. Contractor, we only sell parts through our wholesalers, but the prices listed are for your convenience. For prompt parts
service, contact the wholesaler from which you purchased your Cozy heater. NOTE: Parts & schematic drawings on current
models are shown atwww.cozyheaters.com.

Page 20 MARCH 2009
HOWTOPROPERLYORDERPARTS: In addition to part description and part number, please give model number, serial
number, and type of gas used. This information can be found on the rating plate that is attached to heater.
MODEL NUMBER REF. LIST LIST
PART DESCRIPTION NO. PART NO. PRICE PART NO. PRICE
Bottom Louver Panel 1 72690 41.80$ 72690 41.80$
Center FrontPanel 2 41080 40.70$ 41080 40.70$
Upper FrontPanel 3 72691 41.80$ 72691 41.80$
LeftSide Panel Insulation 4 72665 2.10$ 72665 2.10$
CabinetSide Panel 5 41085 25.70$ 41085 25.70$
Circulating Blower Assembl
y
6 72500 255.20$ 72500 255.20$
LimitSwitch 7 80091 10.40$ 80091 10.40$
Front Heat Shield Assy. 8 41165 28.90$ 41165 28.90$
Heat Exchanger Assembl
y
9 72530 141.10$ 72530 141.10$
CabinetBase Assembl
y
10 41100 66.80$ 41100 66.80$
Leg Leveler (4 per unit) 11 80009 1.70$ 80009 1.70$
DraftInducerGasket 12 72602 13.00$ 72602 13.00$
Draft Inducer Assembl
y
13 72505 151.10$ 72505 151.10$
SightGlass Frame 14 41215 1.80$ 41215 1.80$
SightGlass 15 70150 1.40$ 70150 1.40$
Flame Sensor 16 72570 11.80$ 72570 11.80$
SightGlass Gasket 17 72600 2.30$ 72600 2.30$
Ignitor 18 72550 23.50$ 72550 23.50$
Burner Orifice (2 per unit) 19 72156 3.80$ 72139 3.80$
Manifold 20 72640 20.90$ 72640 20.90$
Burner Bo
x
21 41185 34.30$ 41185 34.30$
Burner BoxTop Gasket 22 72606 6.60$ 72606 6.60$
Burner BoxTop 23 41210 5.60$ 41210 5.60$
Gas Valve 24 72540 86.10$ 72541 86.10$
Gas Valve Bracket 25 41220 5.60$ 41220 5.60$
Burner BoxMounting Gasket 26 72605 6.60$ 72605 6.60$
Transformer 27 78069 26.20$ 78069 26.20$
Control Board 28 72510 130.10$ 72510 130.10$
Wiring Harness 29 72685 20.90$ 72685 20.90$
Pressure Switch 30 72520 31.30$ 72520 31.30$
Casing Back Assy. 31 41120 54.00$ 41120 54.00$
Thermostat 32 72523 80.90$ 72523 80.90$
Control Knob 33 72633 4.90$ 72633 4.90$
Fresh Air Intake Hose 34 72611 10.90$ 72611 10.90$
2" Hose Clamp (4 per unit) 35 72593 1.90$ 72593 1.90$
VentCap Assembl
y
36 41300 67.00$ 41300 67.00$
VentCap Gasket 37 72608 2.10$ 72608 2.10$
CollectorBoxAssembl
y
38 41230 266.40$ 41230 266.40$
Collector BoxGasket 39 72607 1.40$ 72607 1.40$
Collector BoxCap 40 72587 1.70$ 72587 1.70$
Exhaust Tube 41 72610 192.70$ 72610 192.70$
Trim KitBracket(4 per unit) 42 41275 8.40$ 41275 8.40$
Wall Mounting Bracket(4 per unit) 43 41270 2.20$ 41270 2.20$
Casing Top Assy. 44 41050 117.20$ 41050 117.20$
Trim KitLeftSide Panel 45 41262 25.20$ 41262 25.20$
Trim KitTop 46 41255 30.20$ 41255 30.20$
Trim KitRightSide Panel 47 41260 25.20$ 41260 25.20$
Air Filte
r
48 72615 28.70$ 72615 28.70$
Burner (2 per unit) 49 72533 10.30$ 72533 10.30$
Burner Mounting Bracket 50 72534 6.60$ 72534 6.60$
End Cap,LeftSide 51 72692 18.20$ 72692 18.20$
End Cap,RightSide 52 72693 18.20$ 72693 18.20$
Wire Bracket,HEDV 53 41217 2.90$ 41217 2.90$
Ignitor Bracket, HEDV 54 41212 2.80
$
41212 2.80
$
HEDV403 HEDV404
Mr. Contractor,we onlysell parts through our wholesalers,butthe prices listed above are for your
convenience. For prompt parts service, contact the wholesaler from which you purchased your Cozyheater.
NOTE: Parts & schematic drawings on currentmodels are shown atwww.cozyheaters.com.