You might have a slight odor of gas when the burner first ignites. Some gas does escape before it completely ignites. It shouldn't smell after 2 years of use. If you can see the pilot flame burning from the top of the heater, the heater pilot assembly is pushed over too far. The pilot fumes could be escaping in the room and cause a smell.
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I would be inclined to look seriously at the gas valve as the source of your problem. First I would check all wiring connections and make sure there is no breakage in the insulation. It's is really hard to say with something that acts differently like that but I would make sure that your pilot flame was good and strong and the thermocouple is as centered in the flames as you can get it. I would also clean burners and pilot light . When burner is on try tapping gently on the valve and main gas line to burners,when you do this the flame shoul burn more orange or yellow and then settle back down. Sometimes you can get tiny particles broke loose and burned on out.
You can bypass the turn over switch but I would only do this for test purposes. Hope this help. Thank you.
There will be a web or bug or debris in the pllot asssembly /rail that blocks the path of the transition to main burner or ignition of pilot assembly itself, when it does ignite, theres too much gas built up in the pilot ignitor area and it explodes, clean the orifices in the pilot asssemblt / and or the pilot rail or main burners orifices at the pilot area.
If you have already changed out the thermocouple and the pilot goes out when the burner goes out, it leads to reason that the gas valve has a weak magnet or that the pilot is dirty. The cheapest thing would be to remove the pilot assembly and clean out the orifice. If it still drops out, you will need to replace the gas valve.
The pilot light is normally located over the just burner box and will have a small door or removable panel to help get to it. The easiest way to find it it to first locate the gas valve. This will be an aluminum block with a few pipes connected to it. It will also have a knob with Off, On, and Pilot written on it. Once you have found the gas valve, look for two small diameter pipes about 1/4" and 1/8" in diameter. Follow these pipes inside the burner area. It will lead to the pilot assembly. Follow the directions on the heater to start your pilot.
The thermocouple needs to get red hot. If the pilot flame is too low or too high or if it is not pointed on the thermocouple well, it won't stay hot enough. If the pilot flame is too low, a draft caused by opening a door could blow it out. If correcting this doesn't fix it, it could be a bad thermocouple or control. The factory assembly on these heaters is not the best.
I'm assuming your heater is the little Cozy direct vent wall furnace, your room calculations are correct, and at 57 degrees your main burner is constantly on. If so, it sounds as if you have too low a flame which can be caused by a main burner jet with an undersized orifice (like a propane one that got in the wrong assembly line) or obstructed by dirt, inadequate gas pressure, or a main gas valve that is not fully opening.
Open the pilot light inspection door and look at the main burner flame height. If it is less than 2 inches or so, check out the three possibilities above. If the flame is very yellow and wandering around lazily, check the air intake on your vent cap for obstruction.
The "wire" you broke is probably the tube for the pilot assembly. It supplies gas to the pilot which in turn fires the burners thru a gas valve. The other option is you broke the thermocouple which causes the gas valve to open (its a safety feature incorporated to keep gas explosions from happening). You will need to replace the broken part before using this unit--period. It is not worth the danger involved trying to bypass these safety measures. BE SAFE!!!
Cozy cheapened their heaters awhile back doing away with the air shutter. Without the shutter, a little gas can seep out into the room before it ignites and cause an odor. As for the curing odor, can you see the pilot flame looking down from the top of the heater? The pilot should be well inside the exchanger out of view. If you can see it, fumes from the pilot are getting into the room causing an odor. I had to remove the plate that holds the pilot assembly and drill a new hole shifting the plate over where it belongs. It was poorly assembled at the factory. Hope this helps.