GAS-FIRED VENTED
WALL FURNACE
INSTALLATION AND
OPERATING INSTRUCTIONS
P/N 84502
/
REV. 11/04
R
R
NATURAL
GAS
W251F, W351F, W501F
W255F, W355F, W505F
L.P. W252F, W352F, W502F
GAS W256F, W356F, W506F
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 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
PERFORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING: Operation of this furnace when not connected to a properly installed and maintained venting
system can result in Carbon Monoxide (C.O.) poisoning and possible death. For your safety, this furnace and
the venting system should be inspected at least annually by a qualified service person.
This appliance is equipped with a blocked flue switch designed to protect against a blocked flue condition.
The coating selected to provide longer life to the heat exchanger may smoke slightly upon initial firing. Please
provide adequate ventilation if this occurs.
This heater may be installed without recessing into stud space by using optional FSK (Free Standing Kit).
This unit is not approved for installation in mobile homes, greenhouses, or environments involving dusty, wet,
corrosive, or explosive conditions. Such conditions will invalidate the warranty and may create unsafe conditions.
THIS UNIT IS NOT TO BE INSTALLED IN MOBILE HOMES.
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SAFETY RULES
CONTROLS
A)
B)
The wall furnace should be located near the center of
the house for best heat distribution.
Due to high temperatures, the appliance should be
located out of traffic and away from furniture and
draperies.
Children and adults should be alerted to the hazards
of high surface temperature and should stay away to
avoid burns or clothing ignition.
Young children should be carefully supervised when
they are in the same room as the appliance.
Do not place clothing or other flammable material on
or near the appliance. Precautions should be taken
so as not to place furniture, drapes, or other articles
directly in front of grille or lower access door that
would obstruct air openings as proper air flow is
critical to proper operation of unit.
All controls are preassembled at the factory. If
integral snap-bulb type thermostat is used, make sure
that sensing bulb is located on the bottom of gas valve
with clips provided. DO NOT KINK the connecting
tubing. Do not bend the capillary bulb.
The normal manifold pressure should be 3.5”
w.c. on Natural Gas and 10” w.c. on L.P. Gas. The
maximum inlet pressure in the gas supply pipe should
never exceed 14” w.c. on L.P. Gas or 7.0” w.c. on
Natural Gas.
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 ½ psig.
The appliance must be isolated from the gas
supply piping system by closing its individual manual
shutoff valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than ½
psig.
C)
D)
E)
F)
G)
Any safety screen guard or casing front removed for
servicing an appliance must be replaced prior to
operating the appliance.
If the area where the appliance is to be installed
contains carpeting, tile or combustible materials, other
than wood flooring, the appliance shall be installed
on a metal plate, a wood panel or other non-
combustible materials. The use of ceramic or quarry
tile is acceptable and will provide a surface that is
easily cleaned. This material is to extend the full width
and depth of the appliance.
The minimum inlet pressure in the gas supply
pipe should be 5.0” w.c. on Natural Gas or 11” w.c. on
L.P. Gas, “for purpose of input adjustment”.
The appliance is orificed at the factory for
elevations up to 2,000 feet. If installed above 2,000 feet,
the BTU input must be reduced 4% per 1,000 feet. See
the following orifice chart for the proper orifice for a
specific elevation. A blank orifice is shipped in the high
altitude kit which will have to be drilled to correct size
by installer, gas supplier or qualified serviceman.
CLEARANCES
As viewed from front of heater, the minimum clearance
from cabinet to combustible construction: Side Wall – 1”;
Floor – 2”; Ceiling – 11”.
NATURALGAS
In selecting a location for installation it is necessary
to provide adequate accessibility clearances for servicing
and proper operation. This appliance must not be connected
to a chimney flue that serves to vent a solid-fuel burning
(wood or coal) appliance, or a multi-vent system.
Model
No.
W251F
W255F
W351F
W355F
0 to
2,000’
43
43
36
2,000 -
4,000’
44
44
38
38
4,000 -
6,000’
45
45
40
6,000 -
8,000’
47
47
41
8,000 –
10,000’
48
48
43
36
40
41
43
ORDER KIT #49820 45-1 HIGH ALTITUDE KIT
11”
1”
W501F
W505F
43
43
44
44
45
45
47
47
48
48
ORDER KIT #49850 2287-2 HIGH ALTITUDE KIT
L.P. GAS
Model
No.
W252F
W256F
W352F
W356F
0 to
2,000’
1.45mm 54
1.45mm 54
52
52
2,000 -
4,000’
4,000 -
6,000’
54
54
52
6,000 -
8,000’
55
55
53
8,000 –
10,000’
55
55
54
52
52
52
53
54
ORDER KIT #49820 45-1 HIGH ALTITUDE KIT
W502F
W506F
1.45mm
1.45mm
54
54
54
54
55
55
55
55
2”
ORDER KIT #49850 2287-2 HIGH ALTITUDE KIT
Page 3
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COMBUSTION AND VENTILATION AIR
ALL COMBUSTION AIR FROM
ADJACENT INDOOR SPACES
THROUGHINDOORCOMBUSTION
AIROPENINGS
When installed, this gas appliance must be provided with fresh air for combustion,
ventilation, and dilution of hot flue gases. The minimum required volume of the
area where the appliance is installed should be 50 cubic feet per 1,000 btu/hr.
UL Listed Vent Cap
UL Listed Gas Vent
If installed in an area of the home that is considered an unconfined space, the
natural infiltration of air around windows and doors will be adequate. If the area is
considered a confined space (less than 50 cubic feet per 1,000 btu), fresh air can be
supplied by providing two permanent openings into adjoining rooms. Each opening
shall have a minimum free area of one square inch per 1,000 btu per hour of the total
input rating of all gas appliances in the confined space, but not less than 100
square inches. One of the openings shall be within 12 inches of the ceiling and one
within 12 inches of the floor. See Figure A.
Opening
Opening
If the home is of unusually tight construction (new and remodeled homes), free air
must be supplied through opening(s) to the outdoors. This can be accomplished
by providing 2 permanent openings, one commencing within 12 inches of the
ceiling and one within 12 inches of the floor. These openings shall communicate
directly with the outdoors, or spaces that communicate freely with the outdoors,
such as a ventilated attic and crawl space through galvanized or equivalent
corrosion-resistant ducts. Exception: unobstructed stud and joist spaces are
acceptable ducts provided that not more than one fire block is removed. Special
provisions must be taken to insure that these stud and joist spaces cannot be
blocked with insulation or other objects. Each of these openings using vertical
ducts shall have a minimum free area of one square inch per 4,000 btu/hr of total
input rating of all gas appliances. See Figure B and C. If horizontal ducts are used,
the minimum free area shall be one square inch per 2,000 btu/hr of total input rating
of all gas appliances.
FIGURE A
ALL COMBUSTION AIR FROM
OUTDOORS. INLET AIR FROM
VENTILATED CRAWL SPACE AND
OUTLET AIR TO VENTILATED ATTIC.
UL Listed Vent Cap
UL Listed Gas Vent
Ventilation Louvers
(each end of attic)
Fresh make-up air can also be provided through a duct to one permanent opening
commencing within 12 inches of the ceiling. The minimum free area of this opening
shall be one square inch per 3,000 btu/hr of the total input rating of all gas appliances
but not less than the sum of the areas of all vent connectors in the space. See
Figure D.
Outlet Air
Inlet Air
When calculating the amount of fresh air needed you must include make-up air
requirements for the operation of exhaust fans, kitchen ventilation systems, clothes
dryers, and fireplaces.
Ventilation
louvers for unheated
crawl space
Additional information can be found in the latest edition of ANSI Z223.1 (National
Fuel Gas Code).
FIGURE B
ALL COMBUSTION AIR FROM OUTDOORS
ALL COMBUSTION AIR FROM OUTDOORS
THROUGH VENTILATED ATTIC
THROUGHSINGLECOMBUSTIONAIROPENING
UL Listed Vent Cap
UL Listed Vent Cap
UL Listed Gas Vent
Ventilation Louvers
(each end of attic)
UL Listed Gas Vent
Opening
Inlet
Outlet Air
Grille
Alternate
Opening
Location
Inlet Air Duct
(Ends 1 ft. [300mm] above floor)
Inlet
Grille
FIGURE D
FIGURE C
Page 4
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VENTING
USING ADJACENT STUD SPACE
FOR ALL COMBUSTION AIR
FROM OUTSIDE
This appliance must be properly connected to a venting
Consult local ordinances governing venting. Install only
system.
UL listed type BW 4” oval gas vent. When the vent enters the
attic, a listed type B-1 round flue pipe may be used. See Figure
2, Page 7.
HOLES CONNECTING
TO VENTILATED ATTIC
Vent pipe must connect to the wall furnace header plate
with a “B” vent base plate and terminate with a cap at a point at
least 12 foot above the bottom of the wall furnace, two feet
above any obstacle within a 10 foot radius, and at least 3 foot
above the roof.
CEILING
PLATE
Provisions must be made for adequate combustion and
ventilationair.
This appliance is equipped with a manual reset blocked
flue switch designed to protect against a blocked flue condition,
which would cause combustion products to spill back into the
living quarters. NOTE: A partially blocked, inadequate, or
disconnected vent system may not activate the switch.
Discoloration of the grille is an indication of a bad vent. If this
occurs, the vent can be checked by a qualified serviceman using
a draft gauge. After 15 minutes the gauge should read between
-.02 up to -.04 inches w.c. Vent must be checked at the
beginning of each heating season.
AIR
GRILLE
FLOOR
PLATE
The switch when activated on a bulb control burner will
extinguish the pilot flame, on a thermostat controlled burner, the
thermostat circuit will be broken, turning off the main burner
flame. Before the heater can be relit, the reset button must be
activated. See Figure B for location of the manual reset blocked
flue switch. To reset the switch, insert a slender rigid object
(i.e. screwdriver) through the front panel louvers and push the
reset button down. See Figure B-1. However, you may have
to remove the front panel, then reset the switch and reinstall the
front panel to relight heater. If homeowner experiences this
problem, the vent system must be checked and corrected.
NOTE: A pre-existing vent that has worked for years may not
be adequate for todays design because of higher efficiency
requirements that result in lower stack temperatures. See
“Possible Causes and Corrective Action” on Page 16.
HOLES CONNECTING TO
VENTILATED CRAWL
SPACE
BASED ON 4,000 BTU OF TOTAL INPUT
RATING OF ALL GAS APPLIANCES, THE
HEATER ONLY REQUIRES A MINIMUM
FREE AREA OF:
SQUARE
IN.
6.25
8.75
12.50
HOLE
SIZE =
1”
1.5”
2”
SQUARE
IN.
.785
1.76
3.14
BTU
25,000
35,000
50,000
All type “B” vents shall extend in a generally vertical
direction with offsets not exceeding 45 degrees, except that a
vent system having not more than one 60 degree offset may be
allowed.
Any angle greater than 45 degrees from the vertical is
considered horizontal. The total horizontal run of a vent plus
the horizontal vent connector shall be not greater than 75 percent
of the vertical height of the vent.
Any offsets used should be as far above the
drafthood as possible to allow a venting action to begin
before any restriction is encountered.
Page 5
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ROUGH-IN INSTRUCTIONS
NOTE: Maximum wall thickness for a dual
wall (W501, W502, W505, W506) installation
is 5-3/8”.
WARNING: Do not bypass the blocked flue
switch. To do so could expose the consumer to
property damage, personal injury or possible death.
STEP 1.
Attach the base plate (purchased
Height above any
More than 10’
with the vent pipe) to the header plate
using two No. 8 sheet-metal screws
through the pre-punched holes. The
heater may not vent properly without a
base plate to anchor and seal the vent
system. See Figure C.
roof surface
10’
within 10’
horizontally
FIGURE A
2’ Min.
Ridge
3’ Min.
10’ or Less
2’ Min.
Chimney
Ridge
Installation of B-W Gas
3’ Min.
Vent for one story buildings
or for first floor of multi-
story buildings
Ceiling plate spacers to
center B-W gas vent in
stud space - nail securely
at both ends
Chimney
Plate cut away for full
width of stud space to
provide ventilation
Studs on 16 inch centers
Man. Reset
Blocked
Flue Switch
Sheet metal screw base plate
to header
Use manufacturer’s method of
fastening pipe to base plate
Reset
Button
Draft
Diverter
Relief
Header plate of vented wall furnace
(also acts as firestop)
Switch/
Gas
Control
Wire
Opening
FIGURE C
Combustion
Chamber
STEP 2.
Cut out an opening between the
studs of 14-3/8” x 66-1/2” above the floor
plate. Embed the rear flange of the channel
on top of header into either the drywall or
the plastered wall. This provides part of
the required fire stop. Square up and nail
the header in place with the top front of
header located 65-3/4” above floor plate.
(See arrow on right side of header and
Figure 1, 5A and 5B on Page 7).
FIGURE B
FIGURE B-1
STEP 3.
Rough in ½” gas supply on center
line of left stud either 4” above top of floor
plate or 4” to right of left stud through floor
plate. See Figure 1 located on Page 7.
Page 6
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STEP 4.Remove double ceiling plate between studs.
Install one ceiling plate spacer across the cut out
in ceiling plate. Install vent pipe into position,
be sure to lock bottom of vent pipe into the base
plate. Nail second ceiling plate spacer in place.
(See Figure C, Page 6).
ROUGH-IN INSTRUCTIONS
FIGURE 1
ROUGH-IN
DIMENSION
STEP 5.If the vent continues through additional stories
within the 2x4-stud space, then fire-stop-spacers
must be installed at the second and subsequent
ceiling levels. See Figure D.
*65-3/4”
* This
14-1/4”
Min.
14-1/2” Max.
measurement
must be
taken from
top of
Firestop spacers
Installation of B-W gas
supplied by
vent for each subsequent
manufacturer of
ceiling or floor level
B-W gas vent
floor
plate
of multi-story
buildings
Plate cut away to
provide passage of
B-W gas vent
4”
4”
Nail firestop
spacer securely
NOTE: For proper combustion, make sure units are
level, front to back and side to side.
FIGURE D
Dry-Wall
VENT INSTALLATION
LISTED
VENT TOP
B-W Type Vent
2 FT. MIN.
Screw
STORM COLLAR
ROOF
FLASHING
Front
Panel
OVAL TO
ROUND ADAPTER
CEILING PLATE
SPACERS
Plaster
Ground
LISTED “BW”
VENT PIPE
12 FT.
FIGURE 5A - DRY WALL
BASE PLATE
CEILING
MIN.
PLATE
HEADER PLATE
SPACER
LANCES
Plaster
B-W Type Vent
2 X 4 WALL
STUDS
Screw
Front
Panel
Plaster
Ground
FIGURE 2 - VENT INSTALLATION
FIGURE 5B - PLASTER WALL
Page 7
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INSTALLATION
STEP 6.
To place furnace into position, grasp
furnace and lift so furnace flue vent and header
plate vent opening engage. Do not use burner or
gas control to lift heater. Lift furnace upward and
swing bottom into wall opening until legs rest on
floorplateandareflushtofinishedwall. Forproper
combustion, level heater front to back and side to
side. Nail legs to studs. DO NOT BEND LEGS
as this will put the entire unit into a bind and cause
expansion noises (See Figure 3).
B-W VENT
STEP 7.
A drip leg and a manual valve equipped
with a 1/8 N.P.T. plugged tapping accessible for
test gauge connection should be installed
immediatelyupstreamofthegassupplyconnection
to the appliance. Some codes and ordinances
require that the manual valve be located outside
the appliance.
FIGURE 3
STEP 8.
Make gas connection using connector the
same size as gas connection of furnace. CHECK
ALL CONNECTIONS FOR GAS LEAKS
WITH LEAK DETECTOR SOLUTION. DO
NOT USE OPEN FLAME.
STEP 9.
For wall thermostat units, see “Wiring”
section for thermostat connections. Make sure
all connections are correct and connector stems
are not touching.
BURNER
SHELF
STEP 10. To fasten front panel to furnace, be sure exposed
portion of header is free of debris and plaster.
Place outer panel over furnace with top of panel
about one inch above header and centered in
opening. Keep front panel flush to finished wall
and slide down until rear flange of top outer panel
is wedged tight with header and flush with wall.
Open bottom door of front panel and place sheet
metal screw into locking latch. Secure top of front
panel to header plate with screw provided. This
will hold front panel securely to wall. See Figures
5A, 5B, (See Page 7), and 5C.
FIGURE 4
“Z Bracket
Front Panel
Casing
Front
Panel
Door
FIGURE 5C
Page 8
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CAUTION: Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
Manual Reset
Blocked Flue Switch
Thermo-
couple
WIRING INSTRUCTIONS –
GRAVITY WALL FURNACE
WARNING: Failure to locate the thermostat properly or to
wire the furnace correctly may result in continuous operation,
control damage or failure to operate. This can cause property
damage, personal injury, or loss of life.
Gas
Valve
BULB MODELS
NAT.
L.P.
W251F W252F
W351F W352F
W501F W502F
Follow the instructions included with the thermostat. Locate the
thermostat approximately five (5) feet above the floor and four
feet (4’) from appliance. Always mount the thermostat on an
inside wall where it won’t be affected by heat or cold sources such
as direct sunlight, televisions, fireplaces, hidden hot or cold water
pipes, drafts, etc. The thermostat must never be installed in an
adjoining room where a door can be closed between the thermostat
and wall furnace. This wall furnace is equipped with a self
generating control system. Never connect to a 24 volt transformer
or to the household electrical system. Do not use more thermostat
wire than is included with the wall furnace. Do not run thermostat
wire in same stud space with vent. Conceal wire inside wall or
secure to wall with insulated staples that are included .
E.C.O.
Fitting
FIGURE 1
Thermostat
Manual
Reset
Blocked
Flue Switch
Pilot
Generator
Wire
Nut
WALL
THERMOSTAT
MODELS
YOUR FURNACE MAY BE EQUIPPED WITH EITHER A
WALL THERMOSTAT (Figure 2) OR SNAP-BULB, BUILT-
IN THERMOSTAT (Figure 1) CONTROL. CHECK THE
CONTROL ASSEMBLY TO DETERMINE WHICH
WIRING EXAMPLE TO USE.
NAT.
L.P.
W255F W256F
W355F W356F
W505F W506F
Gas Valve
FIGURE 2
SPECIAL INSTRUCTIONS FOR REAR REGISTER KIT APPLICATION
(Figures 6 and 7 line drawings of rear register opening)
STEP 1.Cut hole in the back wall 8-1/4” high by 12-5/8” wide. The lower edge of the hole to be 45-3/4” above the floor plate
as shown in Figure 6.
STEP 2.Install frame for rear register in hole and nail frame to stud as shown in Figure 7.
STEP 3.Install rough-in header and follow instructions for installation of regular furnace.
NOTE: See Supplement No. 84504 packaged with Rear Register Kit.
14-1/8
Plaster
Plaster
12-5/8”
8-1/4”
Hole for back
register
Stud
Nail to stud
Opening 7/8” from
each stud
Stud
Plaster
Stud
45-3/4”
Stud
Plaster
Plate
Plaster
Plate
Plaster
FIG. 7 - PLACING FRAME FOR REAR REGISTER
FIG. 6 - ROUGH-IN DIMENSION FOR REAR REGISTER
Page 9
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LIGHTING INSTRUCTIONS
MODELS: W255F, W256F / W355F, W356F / W505F, W506F
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.
B.
This appliance has a pilot which must be lighted
by hand. When lighting the pilot, follow these in-
structions exactly.
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.
•
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. 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.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electric 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.
D.
Do not use this 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.
•
•
•
LIGHTING INSTRUCTIONS
1.
2.
3.
4.
STOP! Read the information on the safety label.
Set thermostat to it’s lowest setting.
Open cabinet door.
Depress and turn gas control knob clockwise
to “OFF”.
Gas Control Knob
Pilot is
located
on side
of burner
Manifold
Pressure Tap
8.
Push gas control knob and hold in. Immediately
light the pilot with a match. Continue to hold the
gas control knob in for about one (1) minute after
the pilot is lit. Release gas control knob and it will
pop back up. Pilot should remain lit. If pilot goes
out, repeat steps 4 through 8.
Pilot Adjustment
Screw Cap
Internal Manifold
Pressure Regulator
NOTE: Knob cannot be turned from “PILOT” to “OFF” unless
knob is pushed in slightly. Do not force.
5.
Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow “B” in the information on the
safety label. If you don’t smell gas, go to the next
step.
•
•
If knob does not pop up when released, STOP and
immediately call your service technician 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.
6.
7.
Locate the pilot. (Follow metal pilot tube from gas
control).
Turn gas control knob counterclockwise
“PILOT”.
9.
Turn gas control knob counterclockwise
“ON”.
to
to
10.
11.
Close the cabinet door.
Set thermostat to desired setting.
TO TURN OFF GAS TO APPLIANCE
1.
2.
Set the thermostat to it’s lowest setting.
Open cabinet door.
3.
Push in gas control knob slightly and turn clockwise
to “OFF”. Do not force.
4.
Close cabinet door.
Page 10
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LIGHTING INSTRUCTIONS
MODEL: W251F, W252F / W351F, W352F / W501F, W502F
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.
•
If you cannot reach your gas supplier, call the fire
department.
A.
B.
This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these instruc-
tions exactly.
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.
C.
Use only your hand to push in or turn the gas control
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
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electric 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.
•
•
•
LIGHTING INSTRUCTIONS
1.
2.
3.
4.
STOP! Read the information on the safety label.
Open cabinet door.
Turn temperature control knob to “LO”.
Depress and turn gas control knob clockwise
to “OFF”.
Pilot is
located
on side
of burner
Temp. Control Knob
8.
Depress gas control knob and hold in. Immediately
light the pilot with a match. Continue to hold the
gas control knob in for about one (1) minute after
the pilot is lit. Release gas control knob and it will
pop back up. Pilot should remain lit. If pilot goes
out, repeat steps 4 through 8.
Internal Outlet
Pressure Regulator
Gas Control Knob
NOTE: Knob can not be turned from “PILOT” to “OFF”
unless knob is pushed in slightly. Do not force.
•
•
If knob does not pop up when released, STOP and
immediately call your service technician 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.
5.
Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow “B” in the information on the
safety label. If you don’t smell gas, go to the next
step.
Locate the pilot. (Follow metal pilot tube from gas
control).
Turn gas control knob counterclockwise
to “PILOT”.
9.
Turn gas control knob counterclockwise
to “ON”.
Turn temperature control knob to desired setting,
usually a setting of 5 or 6 is satisfactory.
Close the cabinet door.
6.
7.
10.
11.
TO TURN OFF GAS TO APPLIANCE
1.
2.
Open the cabinet door.
Turn temperature control knob clockwise
to “LO”.
3.
Push in gas control knob slightly and turn clockwise
to “OFF”. Do not force.
Close cabinet door.
4.
Page 11
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PILOT ADJUSTMENT
MAINTENANCE INSTRUCTIONS
Locate the pilot adjustment screw on the valve. The pilot
flame should surround at least the top 3/8” of the powerpile
(pilot generator) or thermocouple (see below). The pilot is
unregulated so it will be operating at inlet line pressure (Max.
7” w.c. for natural gas and 11” w.c. for propane). To decrease
the pilot flame, turn the screw clockwise (approximately seven
to nine full turns to bottom of pilot light channel) until you
produce sufficient flame at the minimum noise level.
1.
Installation and repair should be done by a qualified
service person. The appliance 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, burners, pilot
burners, circulating air passageways and venting systems
of the appliance be kept clean.
2.
3.
If the appliance has been equipped with the optional
WFF81-C fan kit assembly, the bearings of the motor
should be oiled every six months with approximately 2
drops of S.A.E. 20 oil.
PILOT FLAME ADJUSTMENT
3/8 TO 1/2 INCH
The appliance area must be kept clear and free of any
combustible materials, gasoline and other flammable
vapors and liquids.
4.
5.
It is essential that the flow of combustion and ventilation
air not be obstructed.
Periodic examination of the entire ventilation system as
a routine part of the safety performance check is
recommended on an annual basis.
PILOT FLAME SHOULD ENVELOP 3/8 TO 1/2 INCH
OF THE TIP OF THE GENERATOR.
BURNER FLAME ADJUSTMENT - STAINLESS STEEL BURNER
2
1
3
Air
Shutter
1. FLAME TOO SOFT- Yellow
Flame. Open air shutters until
yellow tipping disappears.
2. FLAME TOO HARD - Deep Blue
Coloration. Closing air shutters
to a point where yellow tipping
begins, re-open slightly to
3. NORMALFLAMES
eliminate yellow tipping. Air
shutter adjustment is now correct.
NOTE: It is advised that the burner flames be checked at least twice during the heating season for any changes in burner
characteristics. Vacuum burner compartment at start of heating season or as often as needed.
Page 12
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MODEL WFF81-C OPTIONAL FAN KIT
INSTALLATION INSTRUCTIONS
NOTE: This fan kit is to be installed after installation of wall furnace and with the wall furnace front panel in
place.
STEP 1.
STEP 2.
STEP 3.
This appliance, when installed, must be electrically grounded in accordance with local codes, or in
the absence of local codes, with the latest edition of the National Electric Code, ANSI/NFPA
No. 70. In Canada, see the current Canadian Electrical Code CSA C22.1.
Set fan kit on top of the wall furnace front panel. Using the back top edge of the fan kit cabinet
as a guide, mark a horizontal line across the wall. Mark a small vertical line which aligns with the
slot located toward the rear of the fan kit casing.
Using the four one inch screws provided, secure the wall mounting bracket to wall 1/8” below the
horizontal line. Fan attachment bracket must be up and threaded nut sert aligned with the small
vertical line. Note: Anchors (not provided) may be required.
STEP 4.
Remove junction box and connect 115v power supply in accordance with the wiring diagram.
Replace junction box.
STEP 5.
Set fan kit on top of wall furnace front panel. Slot should align with the nut sert. Secure fan kit
to wall mounting bracket with thumb screw provided.
Thumb
Screw
Wiring
Threaded Nut
Diagram
Slot
Sert
Fan Attachment
Bracket
Wall Mounting
Bracket
One Inch
Screw (4)
Junction
Box
Fan
Kit
Wall Furnace
Front Panel
Page 13
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WFF81-C WIRING SCHEMATIC
Ground
L1 Black
115 VAC
L2 White
115 VAC
WHITE
BLACK
BLACK
FAN SWITCH
BLACK
BLACK
BLACK
WHITE
MOTOR
GREEN GROUND WIRE
115 VAC 60 HZ - Less than 12 Amps. If any of the original wire as
supplied with this appliance must be replaced, it must be replaced with
type thermoplastic 105 degree C wire or its equivalent.
L2
White
L1
Black
Page 14
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TROUBLE SHOOTING CHART for qualified serviceman - MAIN BURNER
SYMPTOM
POSSIBLE CAUSES
CORRECTIVE ACTION
Flame too large
1. Defective operator section of gas valve.
2. Burner orifice too large.
1. Replace complete valve.
2. Check with local gas company for proper
orifice size and replace.
3. If installed above 2,000 ft.
1. Too much primary air.
1. Too much primary air.
2. Noisy pilot.
3. Refer to orifice chart, Page 3.
1. Adjust air shutter. (See Page 12).
1. Adjust air shutter. (See Page 12).
2. Reduce pilot gas with adjusting screw on
combination gas control valve.
Flame pops back
Noisy Flame
3. Burr in orifice (if it whistles or resonates). 3. Remove burr or replace orifice (Do not enlarge orifices).
4. Excessibe gas input.
1. Too little primary air.
2. Clogged main burner ports.
3. Clogged draft hood.
4. Linted up air shutter.
4. See “Flame Too Large” above.
1. Adjust air shutter. (See Page 12).
2. Clean main burner ports. (Do not enlarge ports).
3. Clean draft hood.
4. Check for dust or lint at air mixer opening and
around the shutter. Clean as necessary.
1. Clean flue passageways to remove blockage.
2. Adjust air shutter to increase primary air supply.
(See Page 12).
Yellow tip flame
(some yellow tipping
on L.P. gas is
permissible)
Floating Flame
Gas Odor
1. Blocked venting.
2. Insufficient primary air.
1. Gas leak.
1. Shut off gas service immediately. Check
piping. Call gas company. (See Page 1).
2. Clean flue.
2. Chimney or flue obstruction.
3. Drafts around appliance.
1. Pilot flame too small.
3. Eliminate drafts.
Delayed Ignition
1. Check pilot orifice, increase pilot gas flow
if necessary by adjusting inlet pressure.
2. Clean burner ports (Do not enlarge ports).
3. Check gas supply pressure.
2. Burner ports clogged near pilot.
3. Low gas pressure.
4. Pilot decreases in size when main burners
come on.
5. Air shutter open too far.
4. Supply piping is inadequately sized. Consult local
gas utility or competent installer.
5. Close air shutter to proper setting as outlined in these
instructions (slight yellow tipping is allowable on
L.P. Gas). (See Page 12).
6. Drafts around appliance.
7. Bad venting.
6. Eliminate drafts.
7. See “Venting”.
Failure to Ignite
1. Main gas off.
1. Open all manual gas valves.
2. Defective gas valve.
1. Improper venting.
2. Replace gas valve.
1. See “Venting”.
Condensation of
water vapor
Burner won’t
turn off
1. Defective or sticking automatic valve.
2. Excessive gas pressure (The supply gas
pressure must not exceed 1/2 psi or 14”
water column).
1. Clean or replace valve.
2. To correct this situation contact the utility
supplying the gas.
Incorrect gas input
Not enough heat
1. Gas input not checked.
2. Clogged orifice.
1. Re-check gas input.
2. Check orifice for clogging. If clogged,
clean out the hole carefully with a smooth wood toothpick.
(Do not in any way enlarge or distort it).
1. This is especially true when a dwelling or room is
enlarged. Have the heat loss calculated and compare
to the appliance output (70% of input). Your gas
company or installer can supply you with this
information. If appliance is undersized, replace with
correct size unit.
1. Appliance undersized.
2. Temperature dial set too low. (Bulb
type valves).
3. Incorrect supply pressure.
1. Temperature dial set too high.
2. Raise setting of Temperature Dial. See
“Lighting and Shutting Down Instructions”.
3. Check supply pressure as outlined above.
1. Lower setting of temperature dial. See “Lighting
and Shutting Down Instructions”.
Too much heat
2. Combination control valve sticks open.
2. Replace combination control valve.
Page 15
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TROUBLE SHOOTING CHART - AUTOMATIC PILOT & VALVE
SYMPTOM
POSSIBLE CAUSES
CORRECTIVE ACTION
Burner won’t
turn on
1. Pilot flame too large or too small.
2. Dirt in pilot orifice.
1. Re-adjust pilot flame using adjustment on
combination control valve.
2. Clean pilot orifice with air or solvent, do
not ream.
3. Defective automatic pilot section in
combination control valve.
3. Replace entire combination control valve.
4. Defective thermocouple.
4. Replace thermocouple.
5. Replace valve.
6. Reset switch, see Page 6 and blocked flue
section below.
5. Defective combination control valve.
6. Wall thermostat models - manual reset
blocked flue switch tripped.
TROUBLE SHOOTING CHART - BLOCKED FLUE SWITCH (FOR USE BY A QUALIFIED SERVICEMAN)
POSSIBLE CAUSES
1. Blockage in
vent pipe
CORRECTIVE ACTION
A. Check vent pipe for blockage, such as bird nest, wasp nest, twigs, leaves, etc.
B. Check inside the bottom of the vent pipe to make sure the top of the draft diverter did not
rip the inner liner causing it to block part of the vent opening.
C. Check that no insulation from the header plate got caught on top of the draft diverter when
the heater was inserted into the wall.
D. Check that the vent cap is properly installed, not shoved too far down on the vent pipe.
A. Check the manifold pressure.
B. Check the rate, NOTE: This appliance was orificed for elevations up to 2,000 feet. When
installed at higher elevations refer to orifice chart in controls section of instructions for
proper orifice size and re-orifice accordingly.
2. Burner is
overfiring
3. Improper vent
system
3. Correct vent system.
A. Vent too short
A. The vent should terminate a minimum of 12 feet above the floor. See Figure 2. Also, the
top of the vent must be at least 2 foot above any obstacle within a 10 foot radius, including
the roof. See Figure A.
B. Restriction in
vent system
caused by offsets
B. All type “B” vents shall extend in a generally vertical direction with offsets not exceeding 45
degrees, except that a vent system having not more than one 60 degree offset may be allowed.
Any angle greater than 45 degrees from the vertical is considered horizontal. The total
horizontal run of a vent plus the horizontal vent connector shall be not greater than 75 percent
of the vertical height of the vent.
Any offsets used should be as far above the drafthood as possible to allow a venting action to
begin before any restriction is encountered.
C. Incorrect vent pipe C. Use listed BW type vent pipe. Do not use tansite or any other type of ceramic pipe for venting.
Do not use single wall pipe. When venting into a masonry chimney the chimney must be
properly lined and sized for this gas furnace. The use of type B or flexible chimney liner is
recommended.
4. Incorrect header
plate location
4. The header plate must be 65-3/4” above the floor plate. See rough-in instructions.
5. Vent pipe not down 5. Use a base plate (obtained from the vent pipe manufacturer) on top of our header plate.
on the header plate
securely
This will lock the vent pipe down and prevent the draft diverter from shoving it up.
6. Loose connections
on the vent safety
wiring harness
6. Check the connection on both the switch and the gas valve. Tighten if necessary.
DO NOT BYPASS THE BLOCKED FLUE SWITCH
To do so could expose the consumer to property damage, personal injury or possible death.
Page 16
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Prices and specifications subject
to change without notice. All
prices are F.O.B. factory.
GRAVITY WALL FURNACE
LIST PRICES - - JUNE 2004
SINGLE WALL FURNACE
Model Numbers
DUAL WALL FURNACE
Model Numbers
Nat. L.P.
1
12
12
N
W
W
W
W
W501F W502F
W505F W506F
7
10
47
10
9
7A
1
11
47
4
46
9
2
4
8
3
8
11
3
2
38
29
13
49
21
17
29
29A
43
28
20
44
36
16
15
35
38
48
19
44
36
14
35
32
30
31
18
WFF81-C FAN KIT Used on
Single and Dual Wall models
34
34
32
42 39
57
58
33
BURNER ASSEMBLY /
SINGLE WALL FURNACE
42 39
BURNER ASSEMBLY /
DUAL WALL FURNACE
27
60
55
59
24
56
40
FSK-A
FREESTANDING
KIT
25
26
22
23
THERMOSTAT
REAR REGISTER KIT - Used
NOTICE: When ordering any component in the Burner Assembly, specify
on Single Wall models only
either Honeywell or Robertshaw components.
REV. 08/02
Page 17
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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 that is attached to heater.
FRONT PANEL, DOOR & BODY ASSEMBLY
WFF81-C FAN KIT
FOR MODELS
W25F
PART
NO.
W35F
PART
NO.
40025 $121.80
40032
40033
W50F
PART
NO.
(Fits all Models)
REF.
NO.
1
2
3
LIST
PRICE
LIST
PRICE
LIST
PRICE
REF.
NO.
13
PART
NO.
40304
LIST
PRICE
$33.30
PART DESCRIPTION
Front Panel Assembly
Lower Door
Handle Assembly
Body Assembly
PART DESCRIPTION
40025 $121.80
40032
40033
*40025 $121.80 Fan Cabinet
*40032
*40033
$9.60
$4.40
$9.60
$4.40
$9.60 Junction Box
$4.40 Motor Mounting Brk.
14
15
16
17
18
19
40315
40313
85110
85115
84155
84170
$6.80
$4.10
$56.20
$8.10
$1.10
$5.60
4
39805 $157.50
39805 $157.50
40103 $181.70 Motor
Draft Diverter Assembly
Draft Diverter Assembly
Heat Exchanger
7
7A
8
40042
N/A
40260 $129.20
$37.20
N/A
40045
N/A
40265 $127.10
$37.10
N/A
40141
40140
$34.20 Fan Blade
$34.80 Heyco Strain Relief
*40260 $129.20 Fan Switch
Upper Shield
9
40068
40055
40065
78050
84166
84134
84133
84095
$2.90
$25.90
$13.10
$1.10
$8.90
$8.90
$8.90
$6.00
40068
40055
40065
78050
84166
84134
84133
84095
$2.90
$25.90
$13.10
$1.10
$8.90
$8.90
$8.90
$6.00
*40068
40150
*40065
78050
84166
84134
84133
84095
W501/ 502F
W505/ 506F
PART
NO.
40212
$2.90 Wiring Diagram (label) 20
91147 N/C
Header Assembly
Lower Front Shield
Gasket Flue Pipe
Blocked Flue Sw. 350 Deg.
Wiring Harness/Bulb
Wiring Harness/Wall
E.C.O. Fitting/Bulb
BURNER ASSY. PARTS
FOR MODELS:
10
11
12
46
47
47
34
$35.00 Fan Housing
$13.10 Fan Switch Wire
$1.10 Wall Mtg. Bracket
$8.90 Installation Manual
$8.90
21
48
49
40311
*84171
40317
$17.90
$1.60
$6.10
N/A
84511 N/C
$8.90
$6.00
W251/ 252/ 255 / 256F
W351/ 352 / 355 / 356F
40542-A REAR REGISTER
(W25/35E & F SERIES ONLY)
REF.
REF.
NO.
28
PART
NO.
N/A
84070
LIST
PRICE
N/A
LIST
PART
NO.
40375
LIST
PRICE
$2.40
PART DESCRIPTION
Burner, Support Assy.
Burner, Steel
Burner, Steel WITH
Carry Over Tapping
Burner Restrictor Plate
for W502F and W506F#
Orifice Coupling
Elbow 3/8 90 Degree
Orifices
PRICE
$17.20 Damper
PART DESCRIPTION
NO.
22
29
$39.30
84070
$39.30 Damper Spring
Frame Assembly
23
24
40377
40365
40379
85003
40355
84504
$1.90
$11.60
$1.30
$1.10
$18.50
N/C
29A
N/A
N/A
N/A
N/A
N/A
84071
#40220
$51.40 Register Chain
$2.10 Bell, Pull
25
26
Register Assembly
N/A Installation Manual
27
N/A
30
31
32
84631
84124
$4.50
$2.00
N/A
N/A
N/A
FSK-A
FREE STANDING KIT (W25/W35 only)
SEE ORIFICES
Manifold
Pipe Nipple
Pilot Tubing w/Fittings
Air Shutter
Valves
33
N/A
44
35
36
N/A
84123
74452
84078
N/A
$1.70
$6.70
$2.10
84072
N/A
74452
$25.80 Floor Plate Assembly
N/A Right Side Assembly
$6.70 Upper Left Side
$2.10 Upper Right Side
55
56
57
58
59
60
40405
40410
40415
40416
40418
40422
$19.00
$29.20
$10.80
$10.80
$18.30
$28.20
*84078
SEE VALVES
Upper Front
Left Side Assembly
Pilots
38
SEE PILOTS
Pilot Generator
Thermostat
Wire, Thermostat
Thermocouple
Carry Over Shield
Installation Instructions
Lighting Instr., Bulb
Lighting Instr., Wall
39
40
41
42
70098
74592
74518
70096
N/A
84502
91263
91253
$30.80
$19.00
$1.20
$11.30
N/A
N/C
N/C
N/C
70098
74592
74518
70096
40209
84502
91263
91253
$30.80
$19.00
$1.20
$11.30
$9.00
N/C
43
N/A
N/A
N/A
N/C
N/C
PILOTS
(Ref. No.38)
ORIFICES
(Ref. No. 32)
VALVES (Ref. No. 36)
PART DESCRIPTION
ROBERTSHAW
7000SRLC Nat.
7000SRLC L.P.
7000MVRLC Nat.
7000MVRLC-L.P.
7000SRLC Nat.
7000SRLC L.P.
7000MVRLC Nat.
7000MVRLC-L.P.
7000SRLC Nat.
7000SRLC L.P.
PART
NO.
Part Desc.
DEXEN
PART
NO.
LIST
PRICE
MODEL
NUMBER
PART
NO.
LIST
PRICE
PART
NO.
LIST
PARTS DESCRIPTION
PRICE
$3.20
$3.20
$3.20
$3.20
$3.20
$3.20
$3.20
$3.20
$3.20
$3.20
$3.20
$3.20
70092 6003H Nat.
70093 6003H L.P.
70090 6003 Nat.
70091 6003 L.P.
70092 6003H Nat.
70093 6003H L.P.
70090 6003 Nat.
70091 6003 L.P.
70092 6003H Nat.
70093 6003H L.P.
70090 6003 Nat.
70091 6003 L.P.
84087
84088
84085
84086
84087
84088
84085
84086
84087
84088
84085
84086
$134.40 W251F
$143.90 W252F
$129.20 W255F
$137.60 W256F
$134.40 W351F
$143.90 W352F
$129.20 W355F
$137.60 W356F
$134.40 W501F
$143.90 W502F
$129.20 W505F
$137.60 W506F
84128
84127
84128
84127
84128
84127
84128
84127
84128
84127
84128
84127
$9.30 Q350A1545 NAT.
$9.30 Q350A1867 L.P.
$9.30 Q350A1545 NAT.
$9.30 Q358A1867 L.P.
$9.30 Q350A1545 NAT.
$9.30 Q350A1867 L.P.
$9.30 Q350A1545 NAT.
$9.30 Q350A1867 L.P.
$9.30 Q350A1545 NAT.
$9.30 Q350A1867 L.P.
$9.30 Q350A1545 NAT.
$9.30 Q350A1867 L.P.
84639
84634
84639
84634
84642
84644
84642
84644
*95274
*84648
*95274
*84648
7000MVRLC Nat.
7000MVRLC-L.P.
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 at www.cozyheaters.com.
AUGUST2004
REVISED11/22/04
*TWO REQUIRED
Page 18
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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.
YOUR GAS CONTROL AND PILOT LIGHT
WHAT TO DO IF YOU SMELL GAS . . .
SYSTEM
•
•
Do not try to light any appliance.
Do not touch any electrical switch; do not use
any phone in your building.
Your gas control and pilot light system has a safety
device whose purpose is to shut-off the gas supply to
the appliance if the pilot light goes out. If you have
trouble lighting the pilot or keeping it lit, it may mean
that this safety device is warning you that there is a
problem with your system. Inspection and repairs or
replacement must be made by a trained gas service
technician.
•
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 performed by a
qualified installer, service agency or the gas
supplier.
TAMPERING IS DANGEROUS
The pilot safety system may also not work if you do
not follow the lighting instructions carefully or if you
tamper with the gas control that you use to light the
pilot. Tampering with the gas control, particularly
with tools, can damage the safety mechanism in the
control and can allow gas to leak. This can result in a
fire or explosion causing property damage, personal
injury or death.
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
CRITICAL SAFETY POINTS TO REMEMBER . . .
•
•
Your gas has been odorized so that you can smell it.
Always smell around for gas before lighting your
appliance.
Sniff for L.P.-gas at floor level. LP-gas is heavier than
air and may temporarily exist at floor level.
IF YOU SMELL GAS, DON’T LIGHT IT
•
•
If you smell gas, do not attempt to light the pilot. Do
not cause a spark by turning on or off electrical
switches or appliances or by using the phone. Turn off
the gas to the appliances and call your gas supplier
from another location.
If your gas control has gotten wet as the result of
flooding or other wetting, it must be replaced
immediately by a trained gas service technician.
Water can lead to damage of the internal safety
mechanism in the gas control and can create a
hazardous condition.
IF YOU CAN’T LIGHT IT,
DON’T FIGHT IT!
THIS IS NOT AN ADVERTISEMENT
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