COZY DVCF402D - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document describes the Direct Vent Counterflow Wall Furnace, a heating appliance designed for residential use. It is approved for aftermarket manufactured home installations, provided local codes do not prohibit it. The furnace is not intended for factory installation in manufactured homes, trailers, or recreational vehicles.

Function Description:

The Counterflow Direct Vent Furnace draws combustion air from outside the dwelling and discharges flue gases directly to the outdoors through a listed vent piping system, typically to a roof direct vent. This sealed combustion system prevents harmful combustible flue gases from accumulating inside the building. Room air is drawn in at the top of the furnace by a fan and discharged through a grille near the floor, providing efficient heat distribution. The appliance is equipped with a vent safety shutoff system to protect against improper venting of combustion products.

Important Technical Specifications:

The furnace is available in various models, supporting both natural gas and propane gas.

Model Numbers (Natural Gas): DVCF402D, DVCF602D (older models: DVCF403C-H, DVCF553C-H, DVCF407C-H, DVCF557C-H)
Model Numbers (Propane Gas): DVCF401D, DVCF601D (older models: DVCF404C-H, DVCF554C-H, DVCF408C-H, DVCF558C-H)
BTU/hr Input: Ranges from 40,000 to 60,000 BTU/hr, depending on the model.
Gas Inlet Size: Typically 1/2 inch.
CFM (Cubic Feet per Minute): Ranges from 320 to 440, depending on the model.
Type Control: 24 Volt.
Blower Speed: Some models (e.g., DVCF60XD series) feature a two-speed fan that operates at low speed and shifts to high speed as the furnace heats up. Other models may have a single-speed blower.
Approx. Shipping Weight: Ranges from 130 lbs to 144 lbs.
Amps: Ranges from 1.95 to 3.35, depending on the model.
Minimum Inlet Gas Supply Pressure: 5” water column for natural gas, 11” water column for propane gas (for input adjustment).
Maximum Inlet Gas Supply Pressure: 7” water column for natural gas, 13” water column for propane gas.
Manifold Pressure: 4 inches water column for natural gas, 10.5 inches water column for propane gas (when burners are operating).
Electrical Connection: 115V, 60Hz, 15 Ampere circuit, electrically grounded with a three-prong (grounding) plug.
Vent System: Uses specific vent tubes and a vent cap assembly. The smaller diameter vent tube (B) must be installed first. The vent cap must be at least 18 inches away from any window or other building opening and at least 18 inches above ground level or from any overhang.
Clearances: Minimum side wall clearance of 4 inches, ceiling clearance of 4 inches, and floor clearance of 0 inches. Specific models and optional kits may have different clearance requirements. For recessed installations, a portion of the furnace recessed up to 10 inches may have zero-inch clearance to combustibles.

Usage Features:

Installation Flexibility: Can be installed flush against a wall or recessed into a wall (up to 10 inches maximum wall thickness).
Gas Type: Designed for use with either natural gas or commercially pure propane gas. Conversion kits are required to switch between gas types.
Ignition: Equipped with a manually operated Piezo spark igniter device to light the pilot gas. Some models (DVCF407C-H, DVCF408C-H, DVCF557C-H, DVCF558C-H) are equipped with an automatic ignition device.
Thermostat Control: Compatible with millivolt thermostats (e.g., Thermostat 78355). For models with two-rate control valves (P321704 or P321705), the rate knob can be set to "LO" for about 70% maximum capacity or "HI" for maximum capacity during cold weather.
Safety Controls: Includes a safety pilot to shut off the gas valve in case of pilot failure, a redundant gas valve, a limit switch to prevent overheating, and a thermal overload protector for the motor. Some models also feature a manual reset auxiliary limit switch.
Optional Accessories:
- Diffuser Grille Kits (6703 & 6704): Route heated air in two-way or one-way directions.
- Side Outlet Grille Kit (6702): Directs heated air from the side of the furnace into the same room.
- Outlet Grille Register (6701): Routes heated air into a second room, mounted on the side wall within 10 inches of the wall furnace.
- Trim Strip Kit (4701): Provides a finished edge at the sides of the wall furnace.
- Hardwire Accessory (9940): Converts the furnace to a hardwired, permanent electrical connection.

Maintenance Features:

Annual Upkeep: Recommended to have a qualified service technician perform checks at the beginning of each heating season, including inspection of the burner, pilot, heat exchanger, and vent system.
Cleaning: The cabinet can be cleaned with a damp rag. Abrasive cleaners should not be used. The burner compartment should be cleaned regularly with a vacuum cleaner to remove lint and dust, especially around the pilot.
Oiling: The fan motor bearings should be oiled every twelve months with SAE 20 oil.
Pilot Adjustment: The pilot flame should surround 3/8 to 1/2 inch of the thermocouple tip. Adjustment is made by turning a screw on the gas valve.
Burner Flame Check: Burner flames should be soft and blue. Abnormal flames require immediate contact with the gas company or a qualified service technician.
Venting System Check: Ensure no parts of the vent air system are blocked or rusted. Clean or replace as needed.
Gas Input and Pressure Check: Verify gas input and manifold pressure according to specifications, especially for installations above 2,000 feet where ratings are reduced. Orifice changes may be required and should be performed by a qualified service technician.
Troubleshooting: The manual provides a comprehensive troubleshooting chart for common issues such as pilot not staying lit, main burner not coming on, burner turning off prematurely, abnormal operation, and incorrect gas input.