Empire Comfort Systems DV-55SPP Quick start guide

INSTALLATION INSTRUCTIONS
AND
OWNER'S MANUAL
R-1628 Page 1
FAN TYPE
DIRECT VENT
WALL FURNACE
MODEL
DV-55SPP
EFFECTIVE DATE
AUGUST, 2000
WARNING: If the information in this
manual 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 vi-
cinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
•Do not try to light any appliance.
•Donottouchanyelectricalswitch;do
not use any phone in your building.
•Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
•Ifyoucannotreachyourgassupplier,
call the fire department.
— Installation and service must be per-
formed by a qualified installer, service
agency or the gas supplier.
WARNING: If not installed, operated and
maintained in accordance with the manu-
facturer's instructions, this product could
exposeyoutosubstances infuel orfromfuel
combustion which can cause death or seri-
ous illness.
This appliance may be installed in an after-
marketpermanentlylocated,manufactured
(mobile)home,wherenotprohibitedbystate
or local codes.
Thisapplianceisonlyforusewiththetypeof
gas indicated on the rating plate. This appli-
ance is not convertible for use with other
gases, unless a certified kit is used.

ventilate the room in which the unit is installed.
Installation on Rugs and Tile
If this appliance is installed directly on carpeting, tile or other
combustible material other than wood flooring the appliance
shall be installed on a metal or wood panel extending the full
width and depth of the appliance.
The base referred to above does not mean the fire-proof base
as used on wood stoves. The protection is for rugs that are
extremely thick and light colored tile.
Installation in Residential Garages
Gas utilization equipment in residential garages shall be in-
stalled so that all burners and burner ignition devices are
located not less than 18" above the floor.
Such equipment shall be located, or protected, so it is not
subject to physical damage by a moving vehicle.
Specifications
Model DV-55SPP
Input BTU/HR 55,000
Height 82 3/8"
Width 16"
Depth 11 1/2"
Gas Inlet 1/2" Pipe
CFM 400
Accessories
SOR-1 Register, Side Outlet
SOK-1 Side Outlet Kit, 10" Boot Assembly with Register
DV-822 Vinyl Siding Vent Kit
Introduction
Always consult your local Building Department regarding
regulations, codes or ordinances which apply to the installa-
tion of a direct vent wall furnace.
Instructions to Installer
1. Installer must leave instruction manual with owner after
installation.
2. Installer must have owner fill out and mail warranty card
supplied with furnace.
3. Installer should show owner how to start and operate
furnace and thermostat.
Warning:
Any change to this furnace or its control can be dan-
gerous. Thisisaheatingapplianceandanypanel,door
or guard removed for servicing an appliance must be
replaced prior to operating the appliance.
General Information
This furnace is design certified in accordance with American
National Standard/CSA Standard Z21.86b-1998 and CSA
2.32b-M98 by the American Gas Association and Canadian
Gas Association, as a fan type direct vent wall furnace to be
installed according to these instructions.
Any alteration of the original design, installed other than
as shown in these instructions or use with a type of gas not
shownontherating plateistheresponsibilityoftheperson
and company making the change.
Important
All correspondence should refer to complete Model No.,
Serial No. and type of gas.
Notice: Duringinitial firing ofthisunit, its paint willbake out
and smoke will occur. To prevent triggering of smoke alarms,
R-1628Page 2
THIS IS A HEATING APPLIANCE
DO NOT OPERATE THIS APPLIANCE WITHOUT FRONT PANELS INSTALLED.
•Due to high temperatures the appliance should be lo-
catedoutoftrafficandawayfromfurnitureanddraper-
ies.
• Children and adults should be alerted to the hazards of
highsurfacetemperaturesandshouldstayawaytoavoid
burns or clothing ignition.
• Young children should be carefully supervised when
they are in the same room as the appliance.
• Clothing or other flammable material should not be
placed on or near the appliance.
• Any safety screen or guard removed for servicing an
appliancemust be replacedpriortooperating theappli-
ance.
• Keep burner and control compartment clean.
• Vent cap hot while furnace is in operation.
• Installation and repair should be done by a QUALI-
FIED SERVICE PERSON. The appliance should be
inspected before use and at least annually by a
qualified service person. More frequent cleaning
may be required due to excessive lint from carpeting,
bedding materials, etc. It is imperative that control
compartments,burners andcirculatingairpassageways
of the appliance be kept clean.
• DO NOT put anything around the furnace that will
obstruct the flow of combustion and ventilation air.
• DOkeeptheapplianceareaclearandfreefromcombus-
tiblematerial,gasoline and other flammable vapors and
liquids.
• DO examine venting system periodically and replace
damaged parts.
• DO make a periodic visual check of pilot and burners.
Clean and replace damaged parts.
• CAUTION: Pilot hole cover must be kept tightly closed
during operation.
• DONOTusethisheaterifanyparthasbeenunderwater.
Immediatelycallaqualifiedservicetechniciantoinspect
the heater and to replace any part of the control system
and any gas control which has been under water.

Some people cannot smell well. Some people cannot smell
the odor of the chemical stench put into the gas. You must
findoutifyoucansmelltheodorantinpropane. Smokingcan
decrease your ability to smell. Being around an odor for a time
can affect your sensitivity or ability to detect that odor. Some-
times other odors in the area mask the gas odor. People may not
smell the gas odor or their minds are on something else. Think-
ing about smelling a gas odor can make it easier to smell.
The odorant in LP-gas is colorless, and it can fade under
some circumstances. For example, if there is an underground
leak,themovement ofthegasthroughsoilcanfilter theodorant.
Odorants in LP-Gas also are subject to oxidation. This fading
by point with the members of your household. Someday
whentheremaynotbeaminutetolose,everyone'ssafetywill
depend on knowing exactly what to do. If, after reading the
followinginformation,youfeelyoustill need more informa-
tion, please contact your gas supplier.
Propane (LP-Gas) is a flammable gas which can cause fires
and explosions. In its natural state, propane is odorless and
colorless. Youmaynotknowallthefollowingsafetyprecau-
tions which can protect both you and your family from an
accident. Read them carefully now, then review them point
can occur if there is rust inside the storage tank or in iron gas
pipes.
The odorant in escaped gas can adsorb or absorb onto or into
walls, masonry and other materials and fabrics in a room. That
will take some of the odorant out of the gas, reducing its odor
intensity.
LP-Gasmaystratifyinaclosedarea,andtheodorintensitycould
varyatdifferent levels. Since it is heavier than air, there maybe
more odor at lower levels. Always be sensitive to the slightest
gas odor. If you detect any odor, treat it as a serious leak.
Immediately go into action as instructed earlier.
•LearntorecognizetheodorofLP-gas. YourlocalLP-Gas
Dealer can give you a "Scratch and Sniff" pamphlet. Use it
to find out what the propane odor smells like. If you suspect
thatyour LP-Gashas aweak orabnormal odor,call yourLP-
Gas Dealer.
• If you are not qualified, do not light pilot lights, perform
service, or make adjustments to appliances on the LP-Gas
system. Ifyouarequalified,consciouslythinkabouttheodor
ofLP-Gas prior to andwhilelighting pilot lights orperform-
ing service or making adjustments.
• Sometimes a basement or a closed-up house has a musty
smell that can cover up the LP-Gas odor. Do not try to light
pilot lights, perform service, or make adjustments in an area
where the conditions are such that you may not detect the
odor if there has been a leak of LP-Gas.
• Odor fade, due to oxidation by rust or adsorption on walls of
new cylinders and tanks, is possible. Therefore, people
should be particularly alert and careful when new tanks or
cylinders are placed in service. Odor fade can occur in new
tanks, or reinstalled old tanks, if they are filled and allowed
to set too long before refilling. Cylinders and tanks which
have been out of service for a time may develop internal rust
whichwillcause odor fade. If such conditions are suspected
to exist, a periodic sniff test of the gas is advisable. If you
have any question about the gas odor, call your LP-gas
dealer. Aperiodicsnifftestof the LP-gas is a good safety
measure under any condition.
• If, at any time, you do not smell the LP-Gas odorant and you
think you should, assume you have a leak. Then take the
sameimmediateactionrecommendedabovefortheoccasion
when you do detect the odorized LP-Gas.
• If you experience a complete "gas out," (the container is
under no vapor pressure), turn the tank valve off immedi-
ately. Ifthecontainervalveislefton,thecontainermaydraw
in some air through openings such as pilot light orifices. If
this occurs, some new internal rusting could occur. If the
valve is left open, then treat the container as a new tank.
Always be sure your container is under vapor pressure by
turningitoffatthecontainerbeforeitgoescompletelyempty
or having it refilled before it is completely empty.
SAFETY INFORMATION FOR USERS OF LP-GAS
• Do not operate electric switches, light matches, use your
phone. Do not do anything that could ignite the gas.
• Geteveryoneoutofthebuilding,vehicle,trailer,orarea. Do
that IMMEDIATELY.
• Close all gas tank or cylinder supply valves.
• LP-Gas is heavier than air and may settle in low areas such
as basements. When you have reason to suspect a gas leak,
keep out of basements and other low areas. Stay out until
firefighters declare them to be safe.
• Useyourneighbor'sphoneandcallatrainedLP-Gasservice
person and the fire department. Even though you may not
continue to smell gas, do not turn on the gas again. Do not
re-enter the building, vehicle, trailer, or area.
•Finally, let the service man and firefighters check for
escaped gas. Have them air out the area before you return.
Properly trained LP-Gas service people should repair the
leak, then check and relight the gas appliance for you.
SOME POINTS TO REMEMBER
NO ODOR DETECTED - ODOR FADE
LP-GAS WARNING ODOR
If a gas leak happens, you should be able to smell the gas because of the odorant put in the LP-Gas.
That's your signal to go into immediate action!
R-1628 Page 3

Installing Optional Side Outlets
Side outlet register, SOR-1 may be installed on one or both
sides of the furnace at the required clearances of 18 inches to
adjacent wall or combustible material as shown in Figure 1.
1. Locate and cut the 5 1/2" square opening in the cabinet
side using the template from the kit, exposing the inner
liner knock-out.
2. Remove the knock-out.
3. Place the register on the 5 1/2" opening with the louvers
set for the desired direction and mark the mounting
holes using the register as a template.
4. Drill (2) 1/8" diameter holes in cabinet side and fasten
the register in place with (2) #10 x 1" screws provided.
Side outlet kit, 10" boot assembly with register, SOK-1 for
warmair discharge into anadjoiningroom may be installedon
either side of the furnace at the required clearance of 4 inches
to adjacent wall as shown in Figure 3A.
1. Locate and cut the 5 1/2" square opening in the cabinet
side using the template from the kit, exposing the inner
liner knock-out.
2. Remove the knock-out.
3. Using the inner and outer boots as hole templates, mark
and drill (8) 1/8" diameter holes in the inner liner and
cabinet side.
4. Using Figure 3A locate and cut a 6 3/4" square opening
through walls.
5. Preparewallopening for the vent-airintakesystem (see
Locating Wall Opening).
6. With furnace in place, after checking alignment of side
outlet opening in wall and furnace, place the 9 3/8" x 9 3/8"
side outlet wall plate over outer boot, pass the outer
bootthrough the wall andattach side outletwallplate to
furnace side of wall with (2) #10 x 1" screws provided.
7. Fasten outer boot to the cabinet side with (4) #8 x 1/4"
screws provided.
8. Position and attach inner boot to inner liner with (4) #8
x 1/4" screws provided.
9. Locate the register with its louvers positioned for the
desired air discharge direction and mark the mounting
holes using the register as a template.
10. Drill (2) 1/8" diameter holes in the wall and fasten the
register in place with (2) #10 x 1" screws provided.
Figure 1
R-1628Page 4
Qualified Installing Agency
Installation and replacement of gas piping, gas utilization
equipment or accessories and repair and servicing of equip-
mentshallbe performed only by a qualified agency. The term
"qualified agency" means any individual, firm, corporation or
company which either in person or through a representative is
engaged in and is responsible for (a) the installation or re-
placement of gas piping or (b) the connection, installation,
repair or servicing of equipment, who is experienced in such
work, familiar with all precautions required and has complied
with all the requirements of the authority having jurisdiction.
The installation must conform with local codes or, in the
absenceof local codes, withtheNational Fuel Gas CodeANSI
Z223.1*/Canadian Installation Code, CAN/CGA B149.
*Available from the American National Standards Institute, Inc., 11
West 42nd St., New York, N.Y. 10036.
Clearances
1. In selecting a location for installation, it is necessary to
provide adequate accessibility clearances for servicing
and proper installation.
2. The DV-55 minimum wall depth is 4 1/2 inches and
maximum wall depth is 13 inches. The use of tubes not
supplied by the manufacturer results in unsatisfactory
performance.
3. TheDV-55can be attached tothewall or recessed into the
wall up to 4 inches in depth but the minimum 4 1/2 inches
vent/air intake system wall depth must be maintained.
Example: If furnace is recessed into the wall at a depth of
4 inches, the minimum wall depth must be 8 1/2 inches.
4. The wall in which the furnace is recessed has (0) zero
clearance to the furnace sides and top.
5. When using side discharge registers, SOR-1 or SOK-1,
the furnace cannot be recessed into the wall.
6. Clearance to sidewall or combustible material is 4 inches.
7. Ceiling clearance is 4 inches.
8. Floor and rear wall clearance is (0) zero inches.
9. Clearance of 18 inches is required to sidewall or combus-
tible material when flush mounted SOR-1, side outlet
register is used.
10. The minimum distance from the center of the vent cap to
the nearest outside corner or obstruction is 24 inches.
The vent terminal of a direct vent appliance with an input over
50,000 BTU per hour shall be located at least 12 inches from
any opening through which flue gases could enter a building.
The bottom of the vent terminal and the air intake shall be
located at least 12 inches above grade.
WARNING: The nearest point of the vent cap should
be a minimum horizontal distant of six (6) feet from
any pressure regulator. In case of regulator malfunc-
tion, the six (6) feet distance will reduce the chance of
gas entering the vent cap.
Locating Wall Opening
The furnace is to be located on an outside wall. Locate wall
studs so that wall opening will be located between wall studs.
The furnace is 16 inches in width and normal 16 inches on
center studs will not allow the furnace to be recessed into the
wall unless a stud is repositioned. The wall opening required
as shown in Figure 2 is a diameter of 7 1/2 inches.
A template is provided in furnace carton for positioning
furnace on the wall. Also, refer to Figure 2 for positioning the
furnace on wall and for locating gas line connection.

Figure 4
Locating Gas Supply
The gas line can enter the furnace either through the floor or
outsidewall. Thegaslineopening shouldbemadeatthis time.
Location of the opening will be determined by the position of
floor joists and the valve and union used for servicing.
Locating Electric Supply
A 7/8" diameter knockout is provided at the bottom of the left
and right side panels. A three-prong (grounding) plug assem-
bly is located within the control compartment (bottom) of the
furnace. Please remove 7/8" knockout from appropriate side
panel when routing plug assembly to an electrical outlet.
Installation of Three-prong (Grounding) Plug Assembly
1. Disconnect nylon cap on 3' plug assembly from nylon plug
on wiring harness. Remove 3' plug assembly from control
compartment (bottom) of the furnace.
2. Remove 7/8" knockout from appropriate side panel.
3. Insertnyloncap on3'plug assemblyintothe7/8"holeinthe
side panel.
4. Connect nylon cap on 3' plug assembly to nylon plug on the
wiring harness.
5. Place 7/8" strain relief bushing around the cord of the 3'
plug assembly. Insert 7/8" strain relief bushing into the 7/
8" hole in the side panel.
Attention! The 7/8" strain relief bushing is located within the
same yellow envelope as the Installation Instructions and
Owner's Manual.
Attaching Furnace to Wall
Refer to Figure 2 for the location of the 7 1/2" diameter wall
opening for the furnace. After the wall opening has been
locatedandcut,positionflueoutletonfurnaceincenterofwall
opening. When attaching furnace to the wall remove that
portion of baseboard and molding on the wall which is behind
the furnace. Attach furnace to wall, at the outer casing top,
with (2) toggle bolts provided and to floor, at the outer casing
bottom, with (2) #10 x 1 1/2" screws provided.
Attention! The screw holes on the outer casing bottom are
off-setabovethefloorapproximately3/8". Donotover-tighten
screws and distort the off-set on the outer casing bottom.
Distortion of the outer casing bottom will not allow the lower
front panel to be attached to the furnace.
R-1628 Page 5
Figure 2
Figure 3 Figure 3A

Page 6 R-1628
Cutting Vent Tubes
This is the most important part of the installation. With the
furnace installed on wall the 6" diameter air inlet tube and the 4"
diameter flue outlet tube are to be marked and cut using the
following procedure.
1. Attach 6" diameter air inlet tube onto the collar of air drop
assembly. Be sure 6" diameter air inlet tube is placed as far
aspossibleontothecollaroftheair dropassembly. Markthe
6" diameter air inlet tube 1/2" beyond the outside wall.
Remove 6" diameter air inlet tube from collar of air drop
assembly.
2. Attach 4" diameter flue outlet tube onto flue outlet collar on
combustion chamber. Be sure 4" diameter flue outlet tube is
placed as far as possible onto the collar of flue outlet. Mark
the 4" diameter flue outlet tube 2 1/4" beyond the outside
wall. Remove4"diameterflueoutlettubefromcollarofflue
outlet on combustion chamber.
3. Markorwraptapecompletelyaroundthetubesatthemarked
points to help in making a true cut. Do not crimp or enlarge
tubes.
Installing Vent Assembly
1. Place provided caulking beneath the edge of the outside
mounting plate. Use additional caulking to correct uneven
wall surface, such as clapboard.
2. Attach 6" diameter air inlet tube onto the collar of air drop
assembly. Attachcaulked,outsidemountingplateintothe6"
diameter air inlet tube. Position the outside mounting plate
sothat 6"diameterair inlettube has aslight downwardslope
to the outside. The downward slope is necessary to
prevent the entry of rainwater. Attach outside mounting
plate to exterior wall with (4) #10 x 1 1/2" screws provided.
3. Apply furnace cement to 4" diameter flue outlet collar on
combustion chamber and to 4" diameter collar on vent cap.
Attach 4" diameter flue outlet tube onto flue outlet collar on
combustion chamber. Attach vent cap into the 4" diameter
flue outlet tube. Attach vent cap to outside mounting plate
with (3) #10 x 1/2" screws provided.
4. Installation is completed.
Reassembly And Resealing Vent-Air Intake System
Whenvent-airintakesystemisremovedforservicingthefurnace,
the following steps will assure proper reassembly and resealing
of the vent-air intake assembly.
1. Removeoldcaulking beneaththeedgeofthe outsidemount-
ing plate. Apply new caulking beneath the edge of the
outside mounting plate. Use additional caulking to correct
uneven wall surface, such as clapboard.
2. Remove old furnace cement from flue outlet collar on com-
bustionchamber andcollarofventcap. Removeoldfurnace
cement from both ends of 4" diameter flue outlet tube.
3. Attach 6" diameter air inlet tube onto the collar of air drop
assembly. Attachcaulked,outsidemountingplateintothe6"
diameter air inlet tube. Position the outside mounting plate
sothat 6"diameterair inlettube has aslight downwardslope
to the outside. The downward slope is necessary to
prevent the entry of rainwater. Attach outside mounting
plate to exterior wall with (4) #10 x 1" screws provided.
4. Apply furnace cement to 4" diameter flue outlet collar on
combustion chamber and to 4" diameter collar on vent cap.
Attach 4" diameter flue outlet tube onto flue outlet collar on
combustion chamber. Attach vent cap into the 4" diameter
flueoutlettube. Attachventcaptooutsidemountingplate
with (3) #10 x 1/2" screws provided.
5. Reassembly and resealing vent-air intake system is completed.
Installing a Vent Near a Window Ledge,
Other Type of Projection or on Vinyl Siding
Direct vent furnaces are designed to be installed on a uniform
outsidewall.When the wind comes from any angle (up,down or
from either side), it must hit the vent cap equally over both the
air inlet and the flue outlet portions of the vent. Any wall
projection, such as a door or window casing, which disturbs the
windononesideoftheairinletsectionwillresultinbackpressure
on the flue section smothering the flame and eventual pilot
outage.
When the vent cap is to be installed on vinyl siding or it appears
thataprojectionwithin6"of anysideoftheairinletsectioncould
shield the air inlet section, the entire vent should be supported
away from the wall at least the distance of the projection. 2" x 4"
framingwhose outsidedimensions match theoverall dimensions
of the mounting plate is recommended. The 2" x 4" framing
protectsvinylsiding frompossible warpageordiscoloration. All
joints can then be sealed and painted. The wall depth plus the
additional depth of the 2" x 4" framing should not exceed a total
depth of 13" for DV-55. (See Figure 5)
Vinylsidingventkit,DV-822, isavailablefromEmpireComfort
Systems, Inc. The depth is 3", which enables the vent cap to be
extended away from vinyl siding or projections. The wall depth
plustheadditional3"depth ofthe vinylsiding ventcapextension
shouldnotexceedatotaldepthof13"forDV-55. (SeeFigure5a)
Warning: Whenvinylsiding vent kit, DV-822 or2"x4"
framing is added to an existing installation (furnace is
installed)donotattempttoaddsectionsofpipetotheflue
outlet tube or air inlet tube. An air tight seal is required
forbothtubes. RefertoPartsList,page11toordertubes.
Figure 5 Figure 5a
Gas Supply
Check all local codes for requirements, especially for the size
and type of gas supply line required. On Natural gas lines less
than 15' long, use 1/2" pipe; on longer runs, use 3/4" iron pipe
or equal. On LP gas lines please consult LP gas supplier.
Installing a New Main Gas Cock
Each appliance should have its own manual gas cock.
Amanualmaingascockshouldbelocatedinthevicinityofthe
unit. Where none exists, or where its size or location is not
adequate, contact your local authorized installer for installa-
tion or relocation.

Compounds used on threaded joints of gas piping shall be
resistant to the action of liquefied petroleum gases. The gas
lines must be checked for leaks by the installer. This should
be done with a soap solution watching for bubbles on all
exposed connections, and if unexposed, a pressure test should
be made.
Never use an exposed flame to check for leaks. Appliance
must be disconnected from piping at inlet of control valve
and pipe capped or plugged for pressure test. Never
pressure test with appliance connected; control valve will
sustain damage!
A gas valve and ground joint union should be installed in the
gas line upstream of the gas control to aid in servicing. It is
required by the National Fuel Gas Code that a drip line be
installed near the gas inlet. This should consist of a vertical
length of pipe tee connected into the gas line that is capped on
the bottom in which condensation and foreign particles may
collect.
Figure 6
Method of Installing a Tee Fitting Sediment Trap
The use of the following gas connectors is recommended:
— ANS Z21.24 Appliance Connectors of Corrugated Metal
Tubing and Fittings
— ANS Z21.45 Assembled Flexible Appliance Connectors
of Other Than All-Metal Construction
Theaboveconnectorsmaybe usedif acceptablebytheauthor-
ity having jurisdiction.
Pressure Testing of the Gas Supply System
1. To check the inlet pressure to the gas valve, a 1/8" N.P.T.
pluggedtapping,accessiblefortestgaugeconnection, must
be placed immediately upstream of the gas supply connec-
tion to the appliance.
2. The appliance and its individual shutoff valve must be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess of
1/2 psig (3.5 kPa).
3. The appliance must be isolated from the gas supply piping
system by closing its individual manual shutoff valve dur-
ing any pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 psig (3.5 kPa).
Attention! If one of the above procedures results in pressures
in excess of 1/2 psig (14" w.c.) (3.5 kPa) on the appliance gas
valve, it will result in a hazardous condition.
R-1628 Page 7
Figure 7
Checking Manifold Pressure
Both Propane and Natural gas valves have a built-in pressure
regulator in the gas valve. Natural gas models will have a
manifold pressure of approximately 4.0" w.c. at the valve outlet
with the inlet pressure to the valve from a minimum of 6.0" w.c.
for the purpose of input adjustment to a maximum of 7.0" w.c.
Propanegasmodelswillhaveamanifoldpressureapproximately
10.0" w.c. at the valve outlet with the inlet pressure to the valve
fromaminimumof11.0"w.c.forthepurposeofinputadjustment
to a maximum of 13.0" w.c.
A 1/8" N.P.T. plugged tapping, accessible for test gauge connec-
tion, is located on the outlet side of the gas control.
The built-in regulator comes on at approximately 1/4th pressure
and full on in 10 seconds.
High Altitudes
For altitudes/elevations above 2,000 feet, input ratings should be
reducedattherateof4percentforeach1,000feetabovesealevel.
Canadian High Altitudes for locations having an elevation
above mean sea level between 2,000 feet (610m) and 4,500 feet
(1370m), the manifold pressure is to be decreased from 4.0" w.c.
to 3.2" w.c. for Natural Gas and from 10.0" w.c. to 8.0" w.c. for
Propane Gas.
Piezo Pilot Ignitor Instructions
Depressing the red button completely causes a spark to occur at
the pilot. This is a substitute for a match which requires opening
the pilot hole cover.
Tolightthepilot,itisimportantthattheelectrodebe1/8"fromthe
thermocouple. Thesparkmustoccuratthepointtheburnerflame
hits the thermocouple. The end of the electrode will be red hot
with the pilot on.
On a new installation with air in the gas line, it is suggested that
a match be used. The match will light the pilot faster than the
piezo under this condition.
Proper Pilot Flame
Thecorrect pilotflame (Figure 8)will beblue, extending pastthe
thermocouple. The flame will surround the thermocouple just
below the tip.
Naturalgaspilots require adjusting when the inletgaspressure is
above 5" w.c. Remove the pilot cover screw on the control valve
(Figure 7), and turn the adjustment screw clockwise to reduce
flame. Replace pilot cover screw to eliminate gas leaking at that
control valve opening.
LP gas (propane) will not require adjustment.
After use, cleaning may be required for the proper flame.

PROPER FLAME ADJUSTMENT
Figure 8
Proper Main Burner Flame
The correct flame will be a short blue inner flame with a much
larger light blue outer flame. The main burner (Figure 9)
shows the approximate height of each part of the flame for
each gas. The burner does not have a primary air adjustment.
Theflame willbecorrectifthefactory-setpressure andorifice
opening are used. After the furnace has been operating, the
burner ports may be blocked by foreign matter carried in by
combustion air. Therefore, cleaning of the burner may be
needed for proper flame.
To clean burner port disconnect the gas supply to the valve,
and remove the eight screws fastening the burner door. After
removing the burner door from the combustion chamber,
remove rear burner, pilot burner and front burner. With front
and rear burners removed from furnace, force water into the
ribbon ports and dry with air pressure.
Figure 9
Replacing Fan and Oiling the Motor
The fan motor should be cleaned and oiled once each heating
season. To reach the motor, withdraw the metal shroud
surrounding the fan blade by removing the screws on each
side. Oil holes are located on the top at each end of the motor.
Useafewdrops of #10 motor oil. To clean the motor, blow air
through its ventilation openings with a vacuum cleaner or low
pressure air source.
If fan motor is replaced, the silicone rubber gaskets, see Page
11,IndexNo.4,PartNo.712059,shouldalsobereplaced. The
gaskets must be stretched to fit the motor bolts into the gasket
holes and then the motor and gaskets installed on the motor
mounting bars.
Wiring
The appliance, when installed, must be electrically grounded in
accordancewithlocal codesor,in theabsenceof localcodes,with
the National Electrical Code, ANSI/NFPA 70 or Canadian Elec-
tricalCode, CSAC22.1, ifan externalelectrical sourceis utilized.
This appliance is equipped with a three-prong [grounding]
plug for your protection against shock hazard and should be
pluggeddirectlyintoaproperly groundedthree-prongrecep-
tacle. Do not cut or remove the grounding prong from this
plug. For an ungrounded receptacle, an adapter, which has two
prongs and a wire for grounding, can be purchased, plugged into
theungroundedreceptacleanditswireconnectedtothereceptacle
mounting screw. With this wire completing the ground, the
appliance cord plug can be plugged into the adapter and be
electrically grounded. A 7/8" hole is provided in the junction box
for use with a conduit connector if local codes require this type of
protection.
Thermostat Installation
The thermostat should be installed in the same room as the
furnace4'to5'abovethefloorandawayfromanotherheat source
(cooking stove, hot water heater, etc.) including walls and
doorwayswithaheatsourceinanadjoiningroom.DoNotInstall
Thermostat on Outside Wall.
Page 8 R-1628
Figure 10

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. Whenlightingthe pilot, followtheseinstructions
exactly.
B. BEFORE LIGHTING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your building.
• Immediately call your gas supplier from a neigh-
bor'sphone. Followthegassupplier'sinstructions.
• Ifyoucannotreachyourgassupplier,callthefire
department.
C. Useonlyyourhandtopushinorturnthegascontrol
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 techni-
cianto inspect theapplianceandto replace anypart
of the control system and any gas control which has
been under water.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to appliance if service is
to be performed .
3. Remove control access panel (lower front panel).
4. Push in gas control knob slightly and turn clock-
wise to "OFF." Do not force.
5. Replace control access panel (lower front panel).
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. Remove control access panel (lower front panel).
5. Turngas control knob clockwise to"OFF."
6. Wait ten (10) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information
above. If you don't smell gas, go to the next step.
7. Remove the pilot access cover located on the com-
bustion chamber.
8. Find pilot - follow metal tube
from gas control. The pilot is
located between the two burner
tubes behind the pilot access cover.
9. Turn gas control knob counterclockwise
to "PILOT."
10. Pushand holdredresetbutton downcompletelyand
repeatedly push the ignitor button until the pilot
burner is lit. Pilot may also be lit with a match.
Continuetoholdtheredresetbuttondownforabout
one (1) minute after the pilot is lit. Release button
and it will pop back up. Pilot should remain lit. If it
goes out, repeat steps 5 through 10.
• If button does not pop up when released, stop
and immediately call a qualified service tech-
nician or gas supplier.
• If the pilot will not stay lit after several tries,
turn the gas control knob to "OFF" and call
your service technician or gas supplier.
11. Replace pilot access cover.
12. Turngascontrolknobcounterclockwise to
"ON."
13. Replace control access panel (lower front panel).
14. Turn on all electric power to the appliance.
15. Set thermostat to desired setting.
R-1628 Page 9

SERVICE AND MAINTENANCE SUGGESTIONS
CALL SERVICEMAN
GENERAL : All furnaces have been fire-tested to check for
proper operation. This includes, main burner flame, pilot
flame, fan operation, fan control, limit control and automatic
valve operation. If the furnace fails to function on initial
installation, it is advisable to re-check the following:
1. 115 volts to the junction box.
2. Inlet gas pressure.
3. The 24 volt system.
4. Type of gas being used and that shown on the rating
label.
TheServiceDepartmentatEmpireComfortSystems,Inc.may
be contacted to assist in servicing furnace.
Servicing the Pilot and Main Burners, Pilot Orifice, Ther-
mocouple, and Main Burner Orifices: Disconnect the gas
supplyattheinlettothecontrolvalve. Thenremovetheburner
door to which the above components are attached.
Servicing The Fan Motor: The upper front panel, the shroud
surroundingthe fan blade and fanblademust be removed. See
"Oiling the Motor" paragraph on page 8.
Spark Igniter Does Not Light Pilot: With air in the gas line,
such as when the furnace is first installed or was off all
summer, the pilot flame may be too lean to ignite on the first
few trials. Turn the control valve knob to pilot position and
depresstheredresetbutton. Holdingthebuttondowncontinu-
ally to bleed the line;
1. Use lighter rod to light pilot with a match.
2. Use the piezo ignitor at 30 second intervals until it
lights.
If Electrode Does Not Produce Spark:
1. Check wire connections.
2. Check gap for pilot burner to the electrode tip. Should
be between 1/8" and 3/16". Electrode wire and tip must
be more than 1/4" away from all other metal compo-
nents.
If Pilot Does Not Light By Any Means:
1. Check valve knob for being in the "Pilot" position.
2. Check pilot adjustment for being full open (counter-
clockwise to open).
3. If gas is available in the supply tubing, the pilot orifice
and/or pilot burner is probably restricted by a spider
web. Clean pilot assembly and relight.
If Pilot Does Not Remain On After Releasing Knob:
1. Follow instructions and hold button down longer and
harder.
2. Determine if pilot flame extends past thermocouple; if
not, adjust input or clean pilot burner.
3. Replace thermocouple if millivolts read less than 15
millivolts.
Pilot Outage During Normal Operation:
1. Check air inlet tube for a good tight fit at both ends (6"
diameter tube).
2. Check burner door and pilot hole cover for tight seal.
3. Check input by manifold pressure gauge or gas meter.
Main Gas Valve Does Not Open When Thermostat Is
Turned To On:
1. Check for 24 volts to valve by removing one wire and
touching to the SAME TERMINAL it was on. Termi-
nal should have a light spark. DO NOT SHORT
ACROSSTERMINALS, ASITWILL BURNOUT
THE WALL THERMOSTAT.
2. Thermostat wires at the wall may be shorted, so check
for a faulty thermostat.
3. To check for line voltage to furnace, remove lower front
panelandswitch compartment cover and short acrosstwo-
terminal fan control to allow fan to operate. (Figure 10)
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper and
dangeros operation. Verify proper operation after servicing.
Page 10 R-1628

PLEASE NOTE: When ordering parts, it is very important that part number and description of part coincide.
R-1628 Page 11
How To Order Repair Parts...
Partscanbe orderedonlythrough yourservicepersonordealer. Forbestresults,the servicepersonordealershouldorderpartsthrough
the distributor. Parts can be shipped directly to the service person/dealer.
All parts listed in the Parts List have a Part Number. When ordering parts, first obtain the Model Number from the name plate on your
equipment. Then determine the Part Number (not the Index Number) and the Description of each part from the following appropriate
illustration and list. Be sure to give all this information . . .
Furnace Model Number Part Description
Furnace Serial Number Kind of Gas (Propane or Natural)
Part Number
Do not order bolts, screws, washers or nuts. They are standard hardware items and can be purchased at any local hardware store.
Shipments contingent upon strikes, fires and all causes beyond our control.
Index Part
No. Number Description Index Part No. Number Description
USE ONLY MANUFACTURER'S REPLACEMENT PARTS. USE OF ANY OTHER PARTS COULD CAUSE INJURY OR DEATH.
31 DV-687 Manifold and Plate Assembly
32 712045 Manifold Gasket
33 712098 Gasket for Observation
Hole Cover
34 DV-781 Lighting Hole Cover w/Mica
35 DV-064 Cover Plate for Observation Hole
36 DV-775 Seal Bracket
37 712059 Gasket Tubing Seal
38 DV-622 Burner Door Natural Gas
38 DV-973 Burner Door LP Gas
39 DV-779 Gasket for Burner Door
40 722040 Manifold Union
41 R-5655 Gas Valve VR8200C LP Gas
41 R-2148 Gas Valve VR8200C Natural Gas
42 UH-810 Transformer Mounting Bracket
43 R-1995 Transformer
44 UH-451 Junction Box Cover
45 DV-657 Outer Casing Bottom
46 8720148 Bushing
47 R-2708 Piezo Ignitor
48 DV-571 Control Compartment Divider
49 DV-671 Manifold Support
50 DV-765 Gasket for Chamber Air Inlet
(Top & Bottom) (Two Required)
51 DV-764 Gasket for Chamber Air Inlet
(Sides) (Two Required)
52 872053 Cord Set
53 8720140 Bushing
54 DV-614 Left Inner Shield
55 DV-566 Side Panel
Not Shown R-1196-D Fan and Limit Wire
Not Shown 662024 24 Volt Wall Thermostat
Not Shown 862060 Lighter Rod
Not Shown 742265 Pilot Orifice LP Gas
Not Shown 742159 Pilot Orifice Natural Gas
1 DV-573 Outer Casing Top
2 632024 Motor Mount (Four Required)
3 DV-574 Motor Mounting Bar
(Two Required)
4 712059 Gasket (Two Required)
5 R-619-G Motor
6 642017 Fan Blade
7 DV-759 Fan Housing
8 DV-559 Upper Front Panel
9 DV-566 Side Panel
10 DV-613 Right Inner Shield
11 DV-725 Vent Cap
12 DV-131 Outside Mounting Plate
13 DV-548 Air Inlet Tube
14 DV-524 Flue Outlet Tube
15 DV-600 Vent Kit Complete
(Nos. 11, 12, 13, 14)
16 DV-567 Air Drop
17 712036 Gasket for Flue Outlet Flange
18 DV-579-C Combustion Chamber
19 8720130 Bushing
20 DV-916 Switch Compartment Assembly
21 912073 Limit Control
22 R-1941 Fan Control
23 DV-832 Switch Compartment Cover
24 DV-562 Lower Front Panel
25 DV-826 Rear Burner
26 672046 Thermocouple
27 762214 Pilot with Orifice LP Gas
27 762111 Pilot with Orifice Natural Gas
28 DV-808 Pilot Tubing
29 DV-824 Front Burner
30 P-88-42B Main Burner Orifice Natural Gas
(Two Required)
30 742223 Main Burner Orifice LP Gas
(Two Required)

Empire Comfort Systems, Inc. Nine Eighteen Freeburg Ave. Belleville, Illinois 62222-0529
R-1628
Page 12