- COZY/ Louisville Tin and Stove Co. Inc. INSTALLATION AND OPERATING INSTRUCTIONS DIRECT VENT GAS BASEBOARD HEATER BBT53, BBT54, BBT103, BBT104

ManualsBrandsLouisville Tin and Stove ManualsGas HeaterBBT104

- 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 BY A QUALIFIED INSTALLER,

SERVICE AGENCY OR THE GAS SUPPLIER.

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.

DIRECT VENT GAS

BASEBOARD HEATER

INSTALLATION AND

OPERATING INSTRUCTIONS

P/N 64900 / September 2004

U.S. PATENT #

5253635

CANADIAN PATENT #

2066870

This appliance must be connected to an

electrical ground.

WARNING:

CONNECT TO 115V ELECTRICAL

POWER SUPPLY.

DO NOT CONNECT TO 220V

POWER SUPPLY.

INSTALLER MUST LEAVE THESE INSTRUCTIONS

WITH THE CONSUMER, HAVE THEM COMPLETE,

AND RETURN THE WARRANTY CARD.

MODEL NUMBERS

NAT. GAS L.P. GAS

BBT53 BBT54

BBT103 BBT104

NOTE: Obstruction in the vent exhaust tube or air intake tube due to insects, small animals, debris,

etc. will prevent the heater from operating but DOES NOT constitute a warranty issue.

This unit is not approved for installation in greenhouses, or environments involving dusty, wet,

corrosive, or explosive conditions. Such conditions will invalidate the warranty and may create unsafe

conditions.

WARNING: Operation of this furnace without the properly installed, factory furnished vent system 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.

Summary of content (26 pages)

PAGE 1
DIRECT VENT GAS BASEBOARD HEATER INSTALLATION AND OPERATING INSTRUCTIONS R P/N 64900 / MODEL NUMBERS NAT. GAS L.P. GAS BBT53 BBT54 BBT103 BBT104 September 2004 R INSTALLER MUST LEAVE THESE INSTRUCTIONS WITH THE CONSUMER, HAVE THEM COMPLETE, AND RETURN THE WARRANTY CARD. 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.
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The State of Massachusetts requires that installation and service of a gas appliance be performed by a plumber or gas fitter licensed in the Commonwealth of Massachusetts. CONTENTS Introduction……………………………..... 2 Specifications and Dimensions………...….. 2 Safety Rules…………………………….. 3 Clearances………………………………. 4, 5 Location………………………………… 5 Installation………………………………. 6 - 10 Lighting Instructions……………………... 11 Gas Conversion......................................... 12 Burner Orifice………………………….....
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SAFETY RULES The Direct Vent Gas Baseboard Heater and its components meet all applicable safety standards when installed as directed in this manual. For safe installation and operation of your Direct Vent Gas Baseboard Heater, read all these instructions before you begin. Failure to follow them exactly will void your warranty and may present a fire hazard. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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CLEARANCES CLEARANCES TO COMBUSTIBLES COMBUSTIBLE CLEARANCE Floor...................................... 0 Inches (0 cm) Right Side.............................. 0 Inches (0 cm) Left Side................................ 0 Inches (0 cm) Back...................................... 0 Inches (0 cm) Front...................................... 16 Inches (41 cm) Ceiling.................................... 36 Inches (91 cm) Draperies................................ 4 Inches (10 cm) Vent...............................
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CLEARANCES - CONT’D. 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 [46 cm] above the floor. Unit should be located or protected so it is not subject to damage by a moving vehicle. Use care in selecting a good location within the garage. DO NOT locate the heater where heated air will be directed onto a nearby parked vehicle.
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OPTIONAL KITS For special installation applications and modifications, the following kits are available from your local dealer. To ensure safe, efficient operation of your Direct Vent Gas Baseboard be sure to use only authorized kits. Table 1: Special adaptation and modification kits available for use with the Direct Vent Baseboard Heaters. MODEL # VWSK5/10 DESCRIPTION Vent Weather Seal Kit CONTENTS 2” diameter PVC pipe, external wall seal, O-ring, 2 PVC straps, PVC glue, instructions.
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INSTALLATION - Cont’d. STEP 2. a) ROUGH IN GAS SUPPLY – (See Figure 3) Select the bottom, rear or right side to bring the factory supplied flexible gas line assembly out of the heater. The valve must be connected only by means of a pipe union of the ground joint type. Mr. Installer, hold gas valve when connecting gas supply line. Install at least a 3/8” gas line. Contact local gas supplier if any questions.
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CUT THE AIR INTAKE 1-1/2” LONGER THAN THE WALL THICKNESS (Do not cut to less than 5-1/2”) 1-1/2” 1” BASEBOARD HEATER Measure Wall Thickness EXHAUST TUBE CUT THE EXHAUST TUBE FROM THE UNTHREADED END, USE THE CUT-OFF SECTION FROM THE AIR INTAKE TUBE AS A GUIDE (Do not cut to less than 7-1/2”) THREADED END AIR INTAKE TUBE EXTERIOR WALL FIGURE 5 FIGURE 6 BASEBOARD HEATER HEATER MUST BE LEVEL USE THE MOUNTING HOLES PROVIDED IN THE CASING BACK TO MOUNT BASEBOARD TO WALL.
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INSTALLATION - Cont’d. STEP 4. a) b) c) d) e) f) g) h) i) INSTALLING THE BASEBOARD HEATER Use only factory supplied parts. Do not modify in any way. Using a measuring tape, measure the thickness of the wall. See Figure 5. Using a tube cutter, cut the air intake pipe 1.5” [3.8 cm] longer than the wall thickness (no less than 5-1/2”). Measuring from the threaded end, cut the vent exhaust pipe 3.0” [7.62 cm] longer than the wall thickness (no less than 7.5” {19.05 cm}).
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INSTALLATION - Cont’d. 24 V. Thermostat Gas Baseboard Gas Baseboard Gas Baseboard When wiring more than one baseboard heater to a single thermostat, the baseboard heaters must be wired in PARALLEL. When wiring more than one baseboard heater to a single 24 VAC thermostat, the baseboard heaters must be hard wired in parallel. Do not use cord sets. Do not cross thermostat connections between heaters. Purple thermostat connection from first heater to purple thermostat on second and third heater.
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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. B. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. • If you cannot reach your gas supplier, call the fire department. C. Use only your hand to push in or turn the gas control knob. Never use tools.
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GAS CONVERSION The gas control valve supplied on this heater is field convertible. CAUTION: A qualified installer or service agency must perform any conversion of this gas control valve. CONVERSION INSTRUCTIONS 1. Remove the converting seal cap. See Figure A. WARNING: Do not remove or tamper with any other valve components. 2. Remove the black rubber gasket from the down side of the converting seal cap and reinstall gasket on opposite side of converting seal cap.
PAGE 13
PROPER BURNER FLAME BURNER BOX COVER The burner flame may be observed through the sight glass located in the burner box cover. See Figure 11. 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). There is no primary air adjustment on the burner, and proper flame is assured since the correct manifold pressure and orificing has been done at the factory for elevations up to 2,000 feet.
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WIRING If any of the original wire supplied with heater has to be replaced, it must be replaced with type 105 Degree C 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.
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Thermostat calls for heat â â Spark Ignition Energized â Gas control valve opens gas flow to burner â NO Ignition Proved 15 Sec. â Heating Cycle â SEQUENCE OF OPERATION Thermostat satisfied â Gas control valve closes â Draft inducer off 20 Sec. Post Purge â HEATER IS NOW IN STANDBY MODE. STEP # 1) Thermostat calls for heat. 2) Inducer turns on. 3) Pressure switch closes. 4) Power to ignitor. 5) Gas flow to burner. 6) Burner ignition proven.
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VENT RISER KIT VRK5/10 MOUNTING PLATE NOTE: This kit has been designed and certified for use with a Cozy gas baseboard heater only. Use only factory supplied kit and components. WARNING: DO NOT INSTALL IN WINDOW WELL OR BELOW GRADE WHERE WATER MAY ACCUMULATE. MUST NOT TOUCH THE GROUND! STEP 1. STEP 2. STEP 3. STEP 4. STEP 5. STEP 6. WALL Install Cozy gas baseboard heater per installation instructions.
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SIDE VALVE CONCEALER KIT - SVCK5/10 NOTE: This kit has been designed and certified for use with a Cozy gas baseboard heater only. Use only factory supplied kit and components. STEP 1. STEP 2. STEP 3. STEP 4. STEP 5. With the offset up and out from the wall, place the mounting bracket flush to the right side of the heater cabinet. Align the top of the mounting plate with the top of heater cabinet. Mark the location of the mounting holes. See Figure 1. Drill holes where marked.
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BOTTOM VALVE CONCEALER KIT - BVCK5/10 NOTE: This kit has been designed and certified for use with a Cozy gas baseboard heater only. Use only factory supplied kit and components. STEP 1. Place the mounting plate against the wall and flush with the bottom of the gas baseboard heater. The mounting plate must cover the manual gas shut off valve. See Figure 1. Mark the location of the mounting holes. STEP 2. Drill holes where marked. Depending on wall material, install anchors (not provided) if needed.
PAGE 19
VENT WEATHER SEAL KIT - VWSK5/10 NOTE: This kit has been designed and certified for use with a Cozy gas baseboard heater only. Use only factory supplied kit and components. See Figure 1 for parts list of Vent Weather Seal Kit. STEP 1. Change the location for the vent by following Figure 1 in the installation and operating instructions provided with the Cozy gas baseboard heater. STEP 2. Drill a three (3) inch diameter hole through the wall of the chosen location. STEP 3. Measure the wall thickness.
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VENT WEATHER SEAL KIT - Cont’d.
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TROUBLE SHOOTING CHART SYMPTOM POSSIBLE CAUSES Flame too large 1. Defective operator section of valve. 2. Burner orifice too large. Yellow burner flame CORRECTIVE ACTION 3. If installed above 2,000 ft. 1. Clogged burner ports. 2. Obstruction around vent cap. Gas odor Delayed Ignition 1. Gas leak. 1. Low gas pressure. 2. Igniter not properly located. Failure to ignite 1. Main gas off. 2. Thermostat not set high enough to call for heat. 3. Clogged burner orifice. 4. Incorrect wiring. 5.
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TROUBLE SHOOTING CONTROL BOARD TO IMPROVE DIAGNOSING AND SERVICING, THIS CONTROL MODULE IS EQUIPPED WITH A SELF-DIAGNOSING RED INDICATOR LIGHT. TO INDICATE STAND-BY MODE AND PROPER OPERATION, THIS LIGHT WILL REMAIN OFF. IF THERE SHOULD BE A MALFUNCTION, THE LIGHT WILL FLASH A VARYING NUMBER OF TRIES WITH A PAUSE BETWEEN EACH SERIES OF FLASHES. THE NUMBER OF FLASHES WILL INDICATE WHICH CIRCUIT TO CHECK. # OF FLASHES 1 2 3 REASON FOR INDICATION Air flow fault POSSIBLE CAUSES a.
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MODEL NUMBERS BBT53 / BBT103 - NAT. GAS BBT54 / BBT104 - L.P. GAS DIRECT VENT GAS BASEBOARD HEATER Prices and specifications subject to change without notice. All prices are F.O.B. factory. 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 prices & schematic drawings on current models are shown at www.cozyheaters.com.
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HOW TO PROPERLY ORDER PARTS: 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 located inside the cabinet cover.
PAGE 25
IMPORTANT SAFETY BULLETIN ON YOUR GAS CONTROL AND PILOT LIGHT SYSTEM FOR HEATING EQUIPMENT WHAT YOU DON’T KNOW CAN HURT YOU. Your pilot light system has been designed for safe and reliable operation. Although safety mechanisms are built-in, the potential for hazard exists. This information is intended to help you avoid these hazards.
PAGE 26
LIMITED WARRANTY The Louisville Tin & Stove Co. 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). SELFINSTALLATION IS NOT RECOMMENDED AND MY INVALIDATE YOUR WARRANTY.