DIRECT VENT WALL FURNACE WITH PILOT PRO Installation and Operating Instructions Natural Gas - CDV155DPPD, CDV255DPPD & CDV305DPPD ! 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. CDV255DPPD CDV305DPPD — 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.
CONTENTS READ CAREFULLY BEFORE INSTALLING UNIT Before Installation Standards ............................................ 2 Specifications ...................................... 3 Introduction ......................................... 3 Safety .............................................. 3 - 4 Venting ................................................ 4 Clearances .....................................
SPECIFICATIONS & DIMENSIONS Your Direct Vent Wall Furnace is shipped complete in one carton. This carton contains the furnace, vent cap, vent tube, air inlet tube, template with rough-in dimensions, installation and operating instructions, and the thermostat with thermostat wire. NOTE: There will be two cartons if an optional vent kit or blower is purchased.
SAFETY - Continued 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.
CLEARANCES G H D E A B B Inside Corner Detail B C FIXED D CLOSE OPERA = Vent Terminal F = Air Supply Inlet BLE BLE OPERA FIXED D CLOSE B B A I M K J B = Area where terminal is not permitted REFERENCE LETTER TO DRAWING CANADIAN INSTALLATIONS* U.S.
CLEARANCES - Continued 1. If the wall furnace is installed directly on carpeting, tile or any combustible material other than wood flooring, the wall furnace shall be installed on a metal plate or wood panel secured to the floor, extending the full width and depth of the wall furnace. 2. RESIDENTIAL GARAGE 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 (46cm) above the floor.
INSTALLATION ! WARNING: Failure to follow these instructions carefully could result in poor performance, property damage, personal injury or death. STEP 1. LOCATE VENT OPENING Locate wall studs and center 9” vent opening a minimum of 22” for CDV15 or 24-1/8” for CDV25/30 above the floor. To locate furnace at minimum clearance from floor, remove template from carton and set on floor at location desired. For model CDV15: For model CDV25/30: Position template no closer than 1” from either side wall.
INSTALLATION FOR ALTERNATE WALL DIMENSIONS 9” TO 15" WALLS ( CDV15 / CDV25-D ) For 9" to 15" wall use Vent Kit No. VK1525/9-15-B. Do not attempt to lengthen the exhaust tube, air intake tube, or wall thimble extension provided with furnace or the VK1525/9-15-B Vent Kit. Disconnect the air intake tube, and the exhaust tube from the back of the furnace and discard. See Figure 6. Replace with exhaust tube and air intake tube from Kit No. VK1525/9-15-B.
INSTALLATION FIG. 4 18" CDV15-D CDV25/30-D Cabinet 34-1/2" 9” Dia. Opening 9" Dia. Opening 9" 29-3/4" 31-3/4" Gas Valve Inlet 22" 8" 1/2" 1/2” Min. Center Line Pipe Elbow 1/8” N.P.T. Pressure Tap Shut Off Valve 13-3/8" Gas Valve Inlet 16-5/8" 24-1/8" 13” Floor Floor 4” Shut Off Valve Gas Supply Drip Leg Cabinet Gas Supply Drip Leg 1/2” Black Iron Pipe 1/2" Black Iron Pipe FIG. 5 1” Minimum Both Sides Wall Studs 16” O.C.
INSTALLATION FIG. 7 Wall Stud Inside Wall Wall Thimble Extension Wall Thimble Assembly Vent Terminal Outside Wall Vent Terminal Spacer Plate STEP 3-B. GAS CONNECTION This heater must be connected to a gas supply capable of supplying the full rated capacity. Provide a 1/8 inch N.P.T. plugged tapping, accessible for test gauge connection, immediately upstream of the gas supply connection to the appliance.
INSTALLATION STEP 4. The next few steps will vary depending on the model of CDV you are assembling. For the smaller 155 model: For the larger, 255 / 305 models: CDV155DPPD CDV255DPPD OR CDV305DPPD Continue to page 12. Skip ahead to page 15. NOTE: Pages 12-14 are assembly steps specifically for the CDV155DPPD (this section has a gray background). NOTE: Pages 15-17 are assembly steps specifically for the CDV255DPPD and CDV305DPPD models.
INSTALLATION (CDV155DPPD) STEP 5-A. Connecting the PilotPro Wires Find the three connection terminals at the base of the heater IID Valve (34). 34 Find the green, orange and black wires that are together on one end of the Wiring Harness (57). 57 Connect: TH - Green TH wire to TH terminal of the valve. green wire - Black TP wire to the TP terminal of valve. PILOT TP IN - Orange THTP wire to the THTP terminal of the valve.
INSTALLATION (CDV155DPPD) STEP 5-C. Left Side Install Right Side Install ≤10” ≤10” Choose which side of your heater will best accomodate the PilotPro attachment. • It can be installed on your choice of the left OR right side. • Be sure to allow room for future removal of the PilotPro cover. • Do not install the PilotPro more than 10” from the base of the heater. STEP 5-D. The wires from Steps 5-B and 5-C should appear as illustrated here.
INSTALLATION (CDV155DPPD) NOTE IF USING BLOWER KIT DVB3: Attach the wires to the Blower Shield STEP 6. Right Side Install A. Bundle and loop the wires, neatly settling them on the valve bracket. WARNING: Ensure wires do not touch combustion chamber. OR: B. Allow the free ends of the wires to extend to the RIGHT, approximately 16” from the rear of the valve bracket. B A 16” C. Bundle and secure the wires to each end of the valve bracket with two cable ties (64) as illustrated.
INSTALLATION (CDV255DPPD and CDV305DPPD) 34 STEP 5-A. Connecting the PilotPro Wires Find the three connection terminals at the base of the heater IID Valve (34). PILOT Find the green, orange and black wires that are together on one end of the Wiring Harness (57). ADJ IN 57 - Connect Orange THTP wire to the THTP terminal of the valve. - Connect Black TP wire to the TP terminal of valve. - Connect Green TH wire to TH terminal of the valve.
INSTALLATION (CDV255DPPD and CDV305DPPD) STEP 5-C. Left Side Install Right Side Install ≤10” ≤10” Choose which side of your heater will best accommodate the PilotPro attachment. • It can be installed on your choice of the left OR right side. • Be sure to allow room for future removal of the PilotPro cover. • Do not install the PilotPro more than 10” from the base of the heater. STEP 5-D. The wires from Steps 5-A and 5-B should appear as illustrated here.
INSTALLATION (CDV255DPPD and CDV305DPPD) STEP 6. Right Side Install C 6” A WARNING: Ensure wires do not touch combustion chamber. OR: A. Connect the orange sparker wire and black sensor wire to the lower heat shield with a cable tie (64) directly below the burner sight glass. B B. Route the orange and black wires over to the wiring harness (connected to the valve). C. Allow the free ends of the wires extend approximately 6” from the rear of the valve bracket.
INSTALLATION 57 STEP 7. Black Orange Plug main Wiring Harness (57) into the Control Module (50). Gree n Brown NOTE: Plug the wiring harness into place with the clip facing out as illustrated here. Blac Re k d 50 WARNING: Add the wiring sleeves on this step to prevent PilotPro damage during testing. STEP 8. Add the protective Wire Sleeves (63) to both wires that extend from the Battery Pack (49) and slide back the clear insulation on both wires.
INSTALLATION STEP 9. AA. Connect bare brown SWI wire from the control module wiring harness (57) to the white thermostat wire, using a wire nut. BB. Connect the bare brown wire from the control module wiring harness (57) to the red thermostat wire, using a wire nut. B SWI 57 n Bar e Br ow Wi r Bare e A Brow Red Wire (Thermostat) n Wi re SWI White Wire (Thermostat) STEP 10-A. 33 Plug the orange wire (33) from Ignitor (32) into the port labeled “I” on the control module (50).
INSTALLATION STEP 10-B. Plug the black flame sensor wire (47) into the port labeled “S” on the control module (50). Ensure it is firmly seated. 47 S 47 NOTE: Base of the connector terminal may be slightly exposed. 50 STEP 10-C.
INSTALLATION STEP 11. TESTING Turn on all gas and electricity to the appliance. Conduct a gas leakage test of the appliance piping & control system downstream of the shutoff valve in the supply line to the appliance. 62 Adjust thermostat to lowest setting. Place two D Batteries (62) in the Battery pack (49). Initial startup of the pilot pro system may take several minutes due to air in the PILOT gas line. B. After turning up thermostat, the ignitor will begin to spark. After 1 minute, it will stop.
INSTALLATION STEP 13. TESTING Determine that the pilot is igniting and burning properly and that main burner ignition is satisfactory by turning the thermostat off and back on. Make this determination with the appliance burner both cold and hot. Perform this step as many times as is necessary to satisfy yourself that the automatic intermittent pilot system is operating properly. - Sequence the appliance through at least three (3) operating cycles.
INSTALLATION STEP 15. Check the inside of the housing for safety labels. Try to avoid drilling through any pertinent safety information during this step. A B Use the base of the PilotPro as a template for the following steps. Mount as directed or the wire harness will not reach. 10” 1. PLEASE NOTE A OF THIS STEP. Align the PilotPro very close to the back edge of the housing. WALL WALL Right Side of Heater WALL WALL Left Side of Heater 2. PLEASE NOTE B OF THIS STEP.
INSTALLATION STEP 16. 55 With a phillips-head screwdriver, attach the mounting plate (51) to the side of the heater cabinet (2) using: 55 2 55 - x3 Screws #8-32 x 3/4” (55) - x3 Nuts #8 (56) DO NOT USE A POWERED DRILL FOR THIS STEP, IT COULD CRACK THE MOUNTING PLATE. 51 USE A SCREWDRIVER AND HAND-TIGHTEN ONLY. 56 56 56 Right Side STEP 17. Place cabinet on the furnace. NOTE: Loop the loose wiring around the back edge of the cabinet, near the Pilot Pro.
INSTALLATION STEP 18. 33 57 Re-connect the PilotPro wiring to the Control Module (50). 47 - (33) Ignitor Wire - (47) Flame Sensor Wire - (57) IID Wiring Harness 50 STEP 19. 47 49 Ensure a protective Electrical Wire Sleeve (63) is on the red wire that extends from the Battery Pack (49). Connect the red wire from the Battery Pack (49) and the red wire from the Wiring Harness (47).
INSTALLATION STEP 20. 49 57 Ensure a protective Electrical Wire Sleeve (63) is on the black wire that extends from the Battery Pack (49). Connect the black wire from the Battery Pack (49) to the black wire from the Wiring Harness (57). Black Wire Black Wire Black Wire Slide the protective Electrical Wire Sleeve (63) over the wire connection. Ensure the sleeve is centered on the connectors and secure in place with two cable ties (64). 63 Black Wire Trim excess off the ends of the cable ties (64).
INSTALLATION STEP 21. Redirect any excess length of wire between the cabinet and wall, tucking them out of sight and neatly into the heater. STEP 22. 54 Slide the PilotPro Cover (52) in place as illustrated, and secure with the two remaining bolts (54). 52 NOTE: Tighten in place by hand, no tools necessary.
LIGHTING INSTRUCTIONS - ( IID PILOT ) MODELS: CDV155DPPD / CDV255DPPD / CDV305DPPD Page 28 1019068-C
MAINTENANCE WARNING: This is a gas-fired appliance. Keep the area clear of gasoline and other flammable vapors and liquids. All combustible material must be kept clear of this area to avoid fire or explosion. ! 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 compartment and under heater.
MAINTENANCE 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. Orifice change must be completed by a qualified installer or service technician. Fig 11: Specific Elevations Model No. 0 to 2,000’ NATURAL GAS CDV155D CDV255D CDV305D 48 2.
MAINTENANCE ! CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. NOTE: The furnace and all components must be inspected at least annually by a qualified service technician. This should include the burner, heat exchanger, and vent system. Be sure that the flow of combustion and ventilation air are not obstructed. FIG.
TROUBLESHOOTING CHART ( FOR QUALIFIED SERVICE TECHNICIAN ) SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Flame Too Large 1. Defective operator section of valve. 2. Burner orifice too large. 3. If installed above 2,000 ft. 1. Replace valve. 2. Check with local gas company for proper orifice size and replace. 3. See burner orifice section, Page 30. Yellow Burner Flame 1. Clogged burner ports. 2. Obstruction around vent cap. 1. Remove main burner and check for obstructions in throat, ports, and orifices.
KITS AND PART LIST CDV155DPPD, CDV255DPPD & CDV305DPPD Cozy Heating Systems, LLC | cozyheaters.
DVB-3 BLOWER KIT INSTALLATION - ( OPTIONAL ) This kit must be installed by a qualified installer or service technician only. Compatable with CDV15-D / CDV25-D / CDV30-D Series. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. STEP 1. Remove outer casing. STEP 2. Remove floor shield from bottom of heater and disconnect piezo wire. STEP 3. Remove and discard cover shield.
DVB-3 BLOWER KIT INSTALLATION - ( OPTIONAL ) This kit must be installed by a qualified installer or service technician only. Compatable with CDV15-D / CDV25-D / CDV30-D Series. FIG. 15-A L1 PART NO.
BBSK INSTALLATION INSTRUCTIONS - ( OPTIONAL ) This kit must be installed by a qualified installer or service technician only. FIG. 16-A STEP 1. Find the drilling location at the rear of the cabinet, near the top. See Figure 16-A. STEP 2. Drill a ½” hole. STEP 3. Straighten the capillary tube. See Figure 16-B. DO NOT KINK THE CAPILLARY TUBE OR THE SENSING BULB. STEP 4.
BBSK-CDV LIGHTING INSTRUCTIONS - ( OPTIONAL ) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS: • DO NOT try to light any appliance. • DO NOT touch any electric switch.
PARTS LIST - ( CDV155DPPD ) 14 3 18 17 13 4 1 9 21 10 14 = 6-3/4” Dia. 17 = 4-3/16” Dia.
PARTS LIST - ( CDV155DPPD ) ATTN: Contractors and Qualified Service Technicians: We only sell parts through our wholesalers. For prompt parts service, contact the wholesaler from which you purchased your Cozy heater. PART DESCRIPTION PART NO. REF. # 1 2 3 4 Combustion Chamber Asm. Cabinet Asm. Gasket, Flue Outlet; 5-3/8” Circle Wrapper Asm. w/ Comb. Air Pan 43101 42585-80 70062 43051 7 8 9 Front Heat Shield Bottom Heat Shield Asm.
PARTS LIST - ( CDV255DPPD et CDV305DPPD ) 14 13 44 45 21 9 3 17 6 5 10 10 = 6-3/4” Dia. 18 14 = 4-3/16” Dia. Ref No. 44 & 45 Not Illustrated.
PARTS LIST - ( CDV255DPPD et CDV305DPPD ) ATTN: Contractors and Qualified Service Technicians: We only sell parts through our wholesalers. For prompt parts service, contact the wholesaler from which you purchased your Cozy heater. REF. # Model Numbers �������������������������������� CDV255D CDV305D PART DESCRIPTION PART NO. PART NO. REF. # 43503 43503 43420-80 70062 43495 43494 43420-80 70062 43495 43494 1 Combustion Chamber Asm - Wrapper - Right And Left Leg (Ref. #s 5 & 6) - Comb.
DIRECT VENT WALL FURNACE PARTS LIST : PILOT PRO CDV155DPPD, CDV255DPPD and CDV305DPPD 56 Direct Vent IID: 55 56 50 56 51 55 52 56 56 54 55 55 53 53 55 IID Pilot Assembly: 49 54 32 31 57 PILOT 47 43 67 34 33 46 58 65 NOTE: Parts & schematic drawings on current models are shown at: cozyheaters.com | Specifications subject to change without notice.
DIRECT VENT WALL FURNACE PARTS LIST : PILOT PRO CDV155DPPD, CDV255DPPD and CDV305DPPD ATTN: Contractors and Qualified Service Technicians: We only sell parts through our wholesalers. For prompt parts service, contact the wholesaler from which you purchased your Cozy heater. PART DESCRIPTION PART NO.
LIMITED WARRANTY Cozy Heating Systems LLC warrants to the original user the accompanying product for the period specified herein, provided said product is installed, operated, maintained, serviced, and used according to the instructions and specifications accompanying the product. AS OUTLINED IN OUR INSTRUCTIONS, ANY WARRANTY CONSIDERATIONS ARE CONTINGENT ON INSTALLATION BY A QUALIFIED INSTALLER (CONTRACTOR). SELF-INSTALLATION IS PROHIBITED AND WILL INVALIDATE YOUR WARRANTY.
