Kozyheat Chaska Owner Manual

Quality Fireplaces for Life

INSTALLATION

AND

OPERATION MANUAL

INSTALLER: LEAVE THIS MANUAL WITH THE APPLIANCE.

CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.

Shown with Young Pattern Full Door Shroud

DIRECT VENT FIREPLACE INSERT

WARNING

: This product must be installed by a licensed plumber or gas fitter when installed in the Commonwealth of Massachusetts.

IMPORTANT: Installation of a CO detector is required in the fireplace room when installed in the Commonwealth of Massachusetts.

DO

DISC

NO

ARD

T

This appliance may be installed in an aftermarket permanently located, manufactured (mobile) home, where not prohibited by local codes.

A manufactured home (USA only) or mobile home OEM installation must conform with the Manufac-

tured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or when such a standard is not applicable, the Standard for Manufactured Home Installations, ANSI/NCSBCS A225.1, or Standard for Gas Equipped Recreational Vehicles and Mobile Housing, CSA Z240.4

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.

◙

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or

any other appliance.

IF YOU SMELL GAS:

◙ Do not light any appliance.

◙ Do not touch any electrical switch: do not use any phone in your building.

◙ Immediately call gas supplier from a neighbors phone. Follow the gas supplier 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.

This appliance is only for use with the type (s) of gas indicated on the rating plate. A conversion kit is supplied with the appliance. www.kozyheat.com

June - 2009

CSK-31-REV-09

INTRODUCTION

Read this manual before installing or operating this appliance.

Please retain this owner’s manual for future reference.

CONGRATULATIONS!

We welcome you as a new owner of a Kozy Heat gas fireplace. Kozy Heat products are designed with superior components and materials and assembled by trained craftsmen who take pride in their work. The burner and valve assembly are

100% test-fired and the complete fireplace is thoroughly inspected before packaging to ensure that you receive a quality product. Our commitment to quality and customer satisfaction have remained the same for over 30 years. We offer a complete line of gas and wood fireplaces, unique cabinets and stylish accessories to compliment any décor. Adding a fireplace is one of the best ways to increase the value of your home and we are proud to offer a network of dealers throughout the country to help make your experience everything you imagine. We pride ourselves in being dedicated to not only function and reliability, but customer safety as well.

We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your Kozy Heat gas fireplace.

Jim Hussong Dudley Hussong

President Board Chairman

Homeowner Reference Information

We recommend that you record the following information about your fireplace.

Model Name:______________________________ Date purchased/installed:____________

Serial Number:____________________________ Location on fireplace:_______________

Dealership purchased from:__________________ Dealer Phone:_____________________

Notes:_____________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

PAGE 1

TABLE OF CONTENTS

INTRODUCTION

Introduction and Homeowner Reference Information

CONTENTS

Table of Contents

SAFETY INFORMATION

Safety Information

FEATURES

Features

COMMONWEALTH OF MASSACHUSETTS INFORMATION

Commonwealth of Massachusetts Information

SPECIFICATIONS

Fireplace Dimensions

Clearances

Components List

Additional Components Required

Placement Clearance Requirements

EXISTING FIREPLACE SPECIFICATIONS

Existing Fireplace Requirements

PREPARE EXISTING FIREPLACE

Existing Fireplace Minimum Opening Requirements

Prepare Existing Fireplace

FAN DIRECT WIRE INSTALLATION

CSK-31 / CSK-31-RAD Fan Direct Wire Installation

CSK-31-RF Fan Direct Wire Installation

THERMOSTAT / WALL SWITCH / REMOTE - CSK-31

Thermostat / Wall Switch / Remote - CSK-31

GLASS FRAME ASSEMBLY

Glass Frame Assembly Removal

Glass Frame Assembly Installation

INSTALLATION

Approved Venting

Combustion Air Venting Options

Air Duct Removal

Kozy Heat #816-CL Co-Linear Vent System

Run Vent System Through Existing Chimney

Connect Vent System to Air Duct

Position Fireplace Insert

4

5

7

7

7

6

6

8

9

9

1

2

3

10

11

12

13

13

14

14

14

15

16

17

17

GAS LINE CONNECTION

Gas Line Connection

Check Millivolt Board Installation

COMPLETE FAN WIRING INSTALLATION

CSK-31 / CSK-31-RAD Complete Fan Wiring Installation

CSK-31-RF Complete Fan Wiring Installation

3 PIECE SHROUD ASSEMBLY AND INSTALLATION

3 Piece Shroud Assembly and Installation

LOG SET INSTALLATION

Log Set Installation

MILLIVOLT BOARD REMOVAL

Millivolt Board Removal

MILLIVOLT BOARD INSTALLATION

Millivolt Board Installation

CSK-31 OPERATING INSTRUCTIONS

CSK-31 / CSK-31-RAD Valve and Pilot Assembly Components

CSK-31 / CSK-31-RAD Lighting and Shutdown Instructions

CSK-31 / CSK-31-RAD Pressure Testing

CSK-31-RF OPERATING INSTRUCTIONS

CSK-31-RF Valve and Pilot Assembly Components

CSK-31-RF Lighting and Shutdown Instructions

CSK-31-RF Pressure Testing

CSK-31-RF Remote Receiver Functions

FINALIZING THE INSTALLATION

Flame Appearance

To Adjust Venturi

MAINTENANCE

Maintenance

TROUBLESHOOTING (CSK-31)

Troubleshooting (CSK-31 / CSK-31-RAD)

TROUBLESHOOTING (CSK-31-RF)

RF Remote Troubleshooting (CSK-31-RF)

Troubleshooting (CSK-31-RF)

REPLACEMENT PARTS LIST

Replacement Parts List

WARRANTY

Warranty

24

25-27

28

29

30-32

33

34-35

36

36

37

38-40

41

42-43

44

22

23

20

21

18

18

19

19

45-46

PAGE 2

SAFETY INFORMATION

This fireplace has been tested to and complies with ANSI Z21.88a-2007·CSA 2.33a-2007·CSA P.4.1-02 “VENTED GAS FIREPLACE

HEATERS” by OMNI-Test Laboratories, Portland, OR. Installation must conform with local building codes or in the absence of local building codes, with the National Fuel Gas Code, ANSIZ223.1/NFPA 54 - Current Edition, or the Natural or Propane Installation Code,

CSAB149.1

Installation and repair should be done only by a qualified service person. The appliance should be inspected by a qualified service person before use. Annual inspection by a qualified service person is required to maintain warranty. More frequent cleaning may be required due to excessive lint from carpeting, bedding materials, etc. It is imperative that control compartments, burners and circulation air passageways of the appliance be kept clean.

If this appliance is installed directly on carpeting, tile or other combustible material other than wood flooring, the appliance shall be installed on a metal or wood panel extending the full width and depth of the appliance.

Children and adults should be alerted to the hazards of high surface temperatures 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.

Clothing or other flammable material should not be place on or near the appliance.

Adequate accessibility clearances for servicing and proper operation must be maintained.

This appliance must not share or be connected to a chimney flue serving any other appliance.

Keep area around the appliance clear of combustible materials, gasoline and other flammable vapor and liquids.

The flow of combustion and ventilation air must not be obstructed.

Due to high temperatures the appliance should be located out of traffic and away from furniture and draperies.

The glass front or any part removed for servicing the appliance must be replaced prior to operating the appliance. Work should be done by a qualified service technician.

Clean glass only when cool and only with non-abrasive cleansers.

Do not operate this appliance with the glass/frame assembly removed, cracked or broken. The glass assembly, Part #CSK-057T, shall only be replaced as a complete unit, as supplied by Hussong Mfg.

Co., Inc. Replacement of the glass assembly must only be performed by a licensed or qualified service person. DO NOT SUBSTITUTE MATERIALS.

Do not strike or slam glass assembly.

Any safety screen or guard removed for servicing the appliance must be replaced prior to operating the appliance.

Under no circumstances should any solid fuel (wood, coal, paper or cardboard etc.) be used in this appliance.

Keep burner and control compartment clean.

Do not use this fireplace if any part has been under water. Immediately call a qualified service technician to inspect this appliance and to replace any part of the control system and any gas control which has been under water.

PAGE 3

FEATURES

STANDARD FEATURES

High efficiency

High quality lifetime glass

14-1/4” x 29” (362 mm x 737 mm)

Quick latch glass frame assembly

Co-linear vent system - 3” combustion air / 3” exhaust

Innovative vent connection system

Engineer-designed burner system

High - Low regulator

*Modulating valve system w/ fan and flame adjustment, remote control (Kozy Kontrol)

**Automatic fan kit (2) - 75 CFM

Refractory brick lining

(2) hoods / lower grill (black)

Minnesota Energy Code compliant to 50 pascals

*Standard on RF models

**Standard on RF and RAD models

OPTIONAL FEATURES

Red brick refractory

Standard size or custom sized (3 & 4 pc.) shrouds

Surrounds

Flex vent adaptor kit

Remote control* or thermostat remote control

Wall mount thermostat / wireless wall mount thermostat

Decorative full door faces in various styles and finishes

Mission design doors in various finishes

Various cabinet & flush surrounds

Automatic fan kit (RAD model)

*Standard on RF models

SAFETY FEATURES

Each unit factory tested!

Tested by OMNI - Test Laboratories

Sealed combustion chamber with standing pilot ignition

Removable millivolt board with 30-second delay pilot

Automatic pressure relief glass system

Requires no electricity to operate (excluding fan)

Bedroom and mobile home approved

WEIGHT

Fireplace Weight (as packaged for shipment)

127 lbs. (57.61 kg)

PAGE 4

COMMONWEALTH OF MASSACHUSETTS REQUIREMENTS

NOTE: The following requirements reference various Massachusetts and national codes not contained in this manual.

For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

INSTALLATION OF CARBON MONOXIDE DETECTORS

At the time of installation of the side wall horizontally vented gas fueled equipment, the installing plumber or gas-fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gas-fitter shall observe that a battery operated or hard wired carbon monoxide detector is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS

Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

SIGNAGE

A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print no less the one-half inch (1/2”) in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

INSPECTION

The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08 (2) (a) 1 through 4.

EXEMPTIONS

The following equipment is exempt from 248 CMR 5.08 (2) (a) 1 through 4:The equipment listed in Chapter 10 entitled “Equipment Not Required To Be

Vented” in the most current edition of NFPA 54 as adopted by the Board; and Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED

When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

Detailed instructions for the installation of the venting system design or the venting system components; and

A complete parts list for the venting system design or venting system.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED

When the manufacturer of Product Approved side wall horizontally vented gas equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

The referenced “special venting systems” instructions shall be included with the appliance or equipment installation instructions and;

The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

PAGE 5

SPECIFICATIONS

DESCRIPTION Height

FIREPLACE

DIMENSIONS

INCHES

MILLIMETERS

19-1/4

489

FIREPLACE DIMENSIONS

Width Back Width Depth Back Height Back to Elec.

Access

Back to Gas

Line Access

30-7/8

784

23-1/8

587

14-1/2

368

14-5/8

371

9-1/8

232

4-7/8

124

Front to Vent

Center

9-14

235

Back to Vent

Center

5-1/2

140

TOP

23 1

8

"

587mm

14 1

2

"

368mm

5 1

2

"

140mm

30"

762mm

9 1

4

"

235mm

14 1

2

"

368mm

LEFT

19 1

4

"

489mm

30 7

8

"

784mm

FRONT

14 5

8

"

371mm

1 7

8

"

48mm

RIGHT

9 1

8

"

232mm

4 7

8

"

124mm

WARNING: FAILURE TO POSITION THE PARTS IN ACCORDANCE WITH THESE DIAGRAMS OR FAILURE TO USE

ONLY PARTS SPECIFICALLY APPROVED WITH THIS APPLIANCE MAY RESULT IN PROPERTY DAMAGE OR

PERSONAL INJURY.

1. Fireplace insert

2. Spring-loaded latch glass assembly

3. Millivolt board with burner cover

4. Co-linear air duct

5. Log set (see page 21)

6. Refractory panels

Model CSK-31 includes 150 CFM fan with limit switch and speed control.

Model CSK-31-RF includes modulating valve on millivolt board, fan kit and remote control.

MINIMUM CLEARANCES TO COMBUSTIBLES

Insert to sidewall: 10” (254 mm)

Insert top to 10” (254 mm) mantel: 13” (330 mm)

Insert top to 3/4” (20 mm) trim: 8” (203 mm)

Insert bottom to combustible floor in front: 3-1/2” (89 mm)

PAGE 6

SPECIFICATIONS

MODEL #CSK-31 COMPONENTS LIST MODEL #CSK-31-RF COMPONENTS

(#CSK-800) - Millivolt Board Assembly with 18” Flexible

Gas Line attached

(#700-203) - Manual Gas Shut-off Valve

(#CSK-135) - Burner Assembly

(#CSK-G900) - Refractory Set

(#CSK-50A) - Log Package

(#CSK-057T) - Glass Frame Assembly

(#OCK-H52L) - LP Conversion Kit

(#816-CL1) - Co-Linear Air Duct

(#CSK-028) - Fan Kit (2)-75 CFM

(#500-CSK) - Grill Assembly

(#CSK-800-RF) - Millivolt Board Assembly with 18” Flexible

Gas Line attached

(#700-203) - Manual Gas Shut-off Valve

(#CSK-135) - Burner Assembly

(#CSK-G900) - Refractory Set

(#CSK-50A) - Log Package

(#RF-028) - RF Fan Kit

(#CSK-057T) - Glass Frame Assembly

(#OCK-H52L-RF) - LP Conversion Kit

(#700-108) - Remote Control

(#816-CL1) - Co-Linear Air Chute

(#500-CSK) - Grill Assembly

MODEL #CSK-31-RAD COMPONENTS LIST

Refer to Model #CSK-31 list.

All components same with the exception of the fan kit

Model #CSK-31-RAD does not include a fan kit.

ADDITIONAL COMPONENTS REQUIRED

Vent System; Part #816-CL: For use with minimum 6” x 8” I.D. masonry or 7” I.D. Class A metal chimneys - Includes 12 ft. (3.66 m)

compressed, expandable to 35 ft (10.67 m) co-linear 3” x 3” flexible chimney, and termination cap.

Other approved venting: ICC, Selkirk, American Metals, Simpson Dura-Vent

Shrouds - 3 pc & 4 pc.: Standard shrouds are available for this insert and will fit most applications. Custom shrouds may be ordered on a

non-returnable basis. When ordering a custom shroud, please specify the existing fireplace front opening height and

width. An upper hood and lower grill are included with fireplace.

or

Blank Shrouds - 3 & 4 pc.: Blank shrouds are available for on-site custom fit applications and are sized to the opening after the insert has

been installed. The interior perimeter is properly sized to fit onto the insert. The outer perimeter must be cut,

formed and finished (painted). An upper hood and lower grill are included with fireplace.

or

Full Door Shrouds: Full door decorative shrouds are available for this insert and are used in place of a standard or blank shroud. An upper

hood and lower grill are included with fireplace.

PLACEMENT CLEARANCE REQUIREMENTS

This fireplace must be installed on a level surface capable of supporting the fireplace and venting.

Fireplace must be placed directly on wood or non-combustible surface (not linoleum or carpet) extending the entire depth and width of fireplace.

Due to high surface temperatures, fireplace should be located out of traffic and away from furniture and draperies.

This fireplace may be installed in a bedroom.

Please be aware of the large amount of heat this fireplace will produce when determining a location.

PAGE 7

EXISTING FIREPLACE SPECIFICATIONS

THIS INSERT IS APPROVED FOR INSTALLATION IN MASONRY AND FACTORY-BUILT SOLID FUEL BURNING FIREPLACES.

EXISTING FIREPLACE REQUIREMENTS

The existing fireplace & chimney must be clean and in good working order and constructed of non-combustible materials.

A gas line must be able to be installed to the insert.

Provisions made to provide electrical power to operate the insert fan and thermostatic control (if used).

Any chimney clean-outs must fit properly.

Existing Chimney must be comprised of one of the following: Class „A‟ metal chimney: 7” minimum inside diameter.

Masonry Chimney: 6" x 8" minimum inside diameter.

Existing Chimney Height: Minimum: 12 ft. (3.66m)

Maximum: 30 ft.(9.14m)

Determine length of your existing chimney:

1. Remove and discard existing chimney cap.

NOTE: It is helpful to have two people complete the next step in determining chimney height.

2. Measure from fireplace base to the top of chimney.

Subtract 19-1/2” (489 mm) (height of insert).

This is the total length of co-linear flexible aluminum you will require.

MEASUREMENT FROM FIREPLACE BASE TO TOP OF CHIMNEY:__________________

LESS 19-1/2”" (489 mm) (HEIGHT OF INSERT):

TOTAL CHIMNEY LENGTH REQUIRED:

- 19-1/2" (489 mm)

__________________

.

CAUTION: THIS APPLIANCE MUST NOT BE CONNECTED TO A CHIMNEY

FLUE SERVING A SEPARATE SOLID-FUEL BURNING APPLIANCE.

MIN. 12 ft. (3.66 m)

MAX. 30 ft. (10.67 m)

PAGE 8

PREPARE THE EXISTING FIREPLACE

EXISTING FIREPLACE MINIMUM OPENING REQUIREMENTS

(A) Height: 19-1/2" (495 mm)

(B) Front Width : 31" (787 mm)

(C) Depth: 15-1/4" (387 mm)

(D) Back Width : 23-7/8" (606 mm)

All dimensions are minimum requirements

PREPARE THE EXISTING FIREPLACE

WARNING: CUTTING ANY SHEET-METAL PARTS OF THE FIREPLACE, IN WHICH THE GAS FIREPLACE IS TO BE

INSTALLED, IS PROHIBITED.

1. The refractory, glass doors, screen rails, screen mesh and log grates may be removed from existing fireplace before installing this gas fireplace insert.

2. Any smoke shelves, shields and baffles may be removed if attached by mechanical fasteners.

3. If necessary, remove firebrick on sides and back of the existing fireplace to obtain at least the minimum opening requirements listed above.

4. The fireplace flue damper can be fully blocked open or removed for installation of this gas fireplace insert.

5. Remove existing chimney cap.

6. Clean chimney and inside of fireplace to prevent creosote smell from entering the home.

7. Place „THIS UNIT HAS BEEN MODIFIED‟ label in the bottom of existing firebox so it will be visible if this gas fireplace insert is removed.

8. Run electrical wiring if hard wiring to the insert. See „FAN DIRECT WIRE INSTALLATION‟ instructions on following pages.

9. Run any electrical wiring needed if insert is to be run by a thermostat.

PAGE 9

CSK-31 FAN DIRECT WIRE INSTALLATION /

CSK-31-RAD #CSK-028 FAN KIT DIRECT WIRE INSTALLATION

(OPTIONAL)

DIRECT WIRE CONNECTION MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN.

CSK-31:This fireplace insert comes complete with a fan and thermostatic control switch already installed. A speed control, receptacle, and

8 ft. (2.44 m) fan cord have been installed, wired and mounted in a removable electrical box panel on the right side of the fireplace. If wiring to the pre-installed electrical box is desired, the wiring should be run prior to permanently setting the insert in place and connecting the vent system.

CSK-31-RAD: A speed control, receptacle, and 8 ft. (2.44 m) fan cord have been installed, wired and mounted in a removable electrical box panel on the right side of the fireplace. If wiring to the pre-installed electrical box is desired, the wiring should be run prior to permanently setting the insert in place and connecting the vent system.

NOTE: If this fireplace insert is being installed in the minimum opening dimensions, the wiring may need to be completed after the fireplace insert is set in place.

WARNING: This appliance is equipped with a three-prong (grounding) plug for protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug. Do not allow any excess fan cord to touch the fireplace.

NOTE: Code approved line voltage wiring 14 gauge or better must be used when wiring this assembly. Refer to your local electrical codes for specific requirements in your area.

DIRECT WIRE INSTALLATION:

NOTE: The cord must be removed and wiring disassembled.

Insert 110V-120V wiring (with ground) through the romex connector and wire to speed control / receptacle assembly, matching black, white & green

(ground) wires to the corresponding wires on the speed control / receptacle

assembly.

Electrical Box

110V-120V

60Hz

Speed Control / Receptacle Assembly

Temperature Switch:

Magnetically attaches to bottom of firebox.

DIRECT WIRE INSTALLATION

1. Loosen (but do not remove) screw securing removable access panel (with electrical box & romex connector installed) from the right side of fireplace. Remove access panel.

2. Remove (2) screws securing speed control / receptacle to expose wiring.

3. Remove existing cord and insert 110V-120V wiring (with ground) through romex connector, wiring to speed control / receptacle assembly, matching black (hot), white (neutral), and green (ground) wire to the corresponding wires on speed control / receptacle assembly. NOTE: The (3) wire nuts obtained when removing existing cord may be used for this purpose.

4. Secure speed control / receptacle assembly into the electrical box with (2) screws provided.

Refer to page 19 for instructions on completing fan wiring after insert has been installed.

This appliance, when installed, must be electrically grounded in accordance with local codes, or in the absence of local codes,

with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Codes, CSA C22.1

PAGE 10

CSK-31-RF (only) FAN DIRECT WIRE INSTALLATION


IMPORTANT: A fan assembly is pre-installed and wired to the RF gas valve in

CSK-31-RF models.

A receptacle and 8 ft. (2.44m) fan cord have been installed, wired, and mounted in a removable electrical box panel on the right side of the fireplace. If direct wiring to the pre-installed electrical box is desired, wiring should be completed prior to permanently positioning insert and connecting the vent system.







(ground) wires to corresponding wires on the receptacle.

DIRECT WIRE INSTALLATION Gas Valve (RF)

Wires connect to valve

1. Loosen (but do not remove) screw securing removable access panel (with electrical box & romex connector installed) from the right side of fireplace. Remove access panel.

2. Remove (2) screws securing speed control / receptacle to expose wiring.

3. Remove existing cord and insert 110V-120V wiring

(with ground) through romex connector, wiring to speed control / receptacle assembly, matching black (hot), white (neutral), and green (ground) wire to the corresponding wires on speed control / receptacle assembly.

NOTE: The (3) wire nuts obtained when removing existing cord may be used for this purpose.

Electrical Box w/ Romex connector

4. Secure speed control / receptacle assembly into the electrical

box with (2) screws provided.

Refer to page 19 for instruction on completing fan wiring after insert has been installed.

Wires connect to fan cord

Receptacle & Cover

110V-120V

60Hz

Incoming wiring

110V-120V

This appliance, when installed, must be electrically grounded in accordance with local codes, or in the absence of local codes, with

the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Codes, CSA C22.1

PAGE 11

THERMOSTAT / WALL SWITCH / REMOTE

(CSK-31 / CSK-31-RAD only)

CAUTION: DO NOT CONNECT HIGH

VOLTAGE (115V) WIRE TO THE GAS

VALVE!

If desired, a thermostat (wireless style also available), wall switch, or remote control assembly may be used to turn the fireplace „OFF‟ and „ON‟. Only ONE of these may be installed. Follow instructions included with each assembly.

OPTIONAL:

Disconnect ON/OFF rocker switch wires from the back of gas valve.

NOTE: INSTALLATION OF THERMOSTAT OR WALL

SWITCH SHOULD ONLY BE DONE BY A QUALIFIED

INSTALLER.

Thermostat Wiring Diagram

WALL SWITCH / THERMOSTAT:

Run low-voltage (thermostat) wires from terminals on the gas valve to the desired location of wall switch or thermostat.

Attach the appropriate connectors to wall switch / thermostat wires and connect to the top and bottom terminals marked TH / TPTH on the gas valve.

REMOTE CONTROL:

Follow instructions included with the remote control .

IMPORTANT: The insulated cover included with the remote control must be placed over the remote receiver to prevent overheating.

IMPORTANT: If ON/OFF rocker switch wires are not disconnected, the ON/OFF rocker switch on the millivolt board must be in the „OFF‟ position for proper operation of any of these components.

If rocker switch is „ON‟, the fireplace burner will operate until it is turned „OFF‟ by the rocker switch. A wall switch, thermostat, or remote control will not turn the fireplace „OFF‟ when it has been turned „ON‟ by the rocker switch.

NOTE: The fireplace must be turned „ON‟ and

„OFF‟ by the same method. For example: If fireplace is turned „ON‟ by the remote control, it must be turned „OFF‟ by the remote control.

Remote Control Wiring Diagram

PAGE 12

GLASS FRAME ASSEMBLY

REMOVE GLASS FRAME ASSEMBLY

A. Locate the spring-loaded latches securing glass frame assembly at bottom of firebox.

B. Pull bottom latches out and „down‟ to release glass frame assembly bottom.

C. Lift glass frame assembly up off tabs located at top of firebox.

WARNING: DO NOT OPERATE THIS FIREPLACE WITH THE GLASS REMOVED, CRACKED OR BROKEN. REPLACEMENT OF GLASS FRAME

ASSEMBLY, #CSK-057T SHOULD BE DONE BY A LICENSED OR QUALIFIED SERVICE PERSON.

WARNING: DO NOT REMOVE GLASS ASSEMBLY WHEN HOT!

INSTALL GLASS FRAME ASSEMBLY

A. Align slots at top of glass frame assembly over tabs at top of firebox while lowering bottom of glass frame assembly into position.

B. Pull bottom latches out and „up‟ to secure glass frame assembly bottom.

FIREBOX TABS / GLASS FRAME ASSEMBLY SLOTS

GLASS FRAME ASSEMBLY LATCHES

PAGE 13

INSTALLATION

IMPORTANT: ALL STEPS AS OUTLINED IN „PREPARE THE EXISTING FIREPLACE‟ MUST BE COMPLETED BEFORE

CONTINUING WITH THIS INSTALLATION.

APPROVED VENTING

Kozy Heat #816-CL Co-Linear Vent System. Follow instructions on following pages.

ICC

Selkirk

American Metals

Simpson Dura-Vent

Follow instructions included from vent pipe manufacturer as well as the venting requirements as outlined in this installation manual.

COMBUSTION AIR VENTING OPTIONS

OPTION 1:

OPTION 2:

FULL CONNECTION: The combustion air intake pipe is run the entire chimney length and connected to the

termination cap.

STUB VENTING: A 3” combustion air intake pipe is extended a minimum of 4 ft. (1.22 m) past the damper opening and into existing chimney. It is not connected to the termination cap.

AIR DUCT REMOVAL

Remove the air duct, located at the top of insert, by sliding it back out of the channel. Follow instructions on following pages for vent system attachment to the air duct.

PAGE 14

KOZY HEAT #816-CL CO-LINEAR VENT SYSTEM

The co-linear pipes included in this vent system are designed to extend up to 35 ft. (10.67m)

IMPORTANT: The 3" exhaust pipe can be identified by the red marking. It is imperative for proper operation of this insert that the exhaust and combustion air pipes be connected to the correct collar both on the termination kit and air duct on the insert.

A. Carefully extend the 3” exhaust and combustion air intake pipes to equal the total chimney length required.

NOTE: If using „stub‟ method for the combustion air pipe, extending it is not necessary.

Determine length needed from the air duct on insert (4 ft. (1.22 m) minimum) to above the damper opening in the existing chimney. Remove excess combustion air pipe from end without a collar. Continue with Step B. #2 below.

B. 1. If using „Full Connection‟ method:

Slide 3" intake pipe (end without collar) over collar on termination cap. Secure with 3 self-tapping screws (provided).

2. Place a bead of sealant around inner edge at end of 3" exhaust pipe (without collar / red marking) and slide onto corresponding

collar on termination cap (collar with label). Secure with 3 self-tapping screws (provided). Apply additional sealant around joint

to ensure a proper seal.

INTAKE COLLAR

NOTE: Collar extends through

bottom plate.

SEALANT

SHEET METAL SCREWS (3 TOTAL)

T ERMINATION CAP

EXHAUST COLLAR

NOTE: Collar extends through

middle divider plate

SEALANT

IMPORTANT: THE EXHAUST COLLAR ON FIREPLACE AIR DUCT IS ON THE

RIGHT SIDE. INSTALL TERMINATION CAP WITH EXHAUST

COLLAR ON RIGHT SIDE.

PAGE 15

RUN VENT SYSTEM THROUGH EXISTING CHIMNEY

We strongly suggest wrapping the first 3 ft.(914 mm) of vent system below the termination cap with non-faced fiberglass insulation (secure with wire) before running it through the existing chimney. This will prevent cold air from coming down the existing chimney.

DO NOT USE THIS METHOD IF YOU ARE STUBBING THE 3" COMBUSTION

AIR PIPE FROM BOTTOM OF EXISTING CHIMNEY!

NOTE: If offsets are present in existing chimney, it may be easier to place a weighted rope around the end of each 3" pipe to guide them through it.

DO NOT ATTEMPT TO TIE ONE ROPE AROUND BOTH PIPES.

1. Guide rope, if used, and flexible pipe(s) down existing chimney. See illustration at lower left.

2. To secure chimney termination cap to the existing chimney, apply a liberal bead of sealant (provided) around the top of existing chimney. Set termination cap into position as instructed in installation manual included with chosen vent system .

OPTIONAL: #816-CL kits - Secure the termination cap to existing chimney with 2" self-tapping screws and anchor straps provided through pilot holes located at the sides of termination cap.

3. From inside existing fireplace opening, CAREFULLY pull ropes down until 3" exhaust pipe and 3” combustion air intake (if using „full connection method‟), are into existing fireplace.

STUB VENTING: From inside existing fireplace, insert a minimum of 4ft. (1.22m) of combustion air pipe (end without collar) past the

damper opening and into existing fireplace. See illustration at lower right.

4. We strongly suggested placing non-faced fiberglass insulation between vent pipes and existing chimney to prevent heat loss up the

chimney, being careful not to block end pipe if using stub method.

Minimum 4 ft. (1.22m) section of 3" combustion air flex pipe

DO NOT block pipe end with insulation or any other sealing materials

3" exhaust flex pipe must be connected to collar on fireplace insert and termination cap

Seal area around vent pipes with non-faced fiberglass insulation

PAGE 16

CONNECT VENT SYSTEM TO AIR DUCT

1. Place air duct (previously removed from insert top, page 14) into the existing fireplace opening.

2. Place a bead of sealant (provided) around 3” exhaust pipe

(red marking). Slide exhaust pipe inside 3" collar marked

„Exhaust‟ on the air duct. Secure with (3) ½" self-tapping screws, provided. Apply additional sealant around the joint to ensure an air-tight seal.

3. Apply a liberal bead of sealant (provided) around 3” collar on the air duct. Slide 3” combustion intake pipe over the collar. Secure with (3) ½" self-tapping screws, provided. To ensure an air-tight seal, apply additional sealant around the joint.

Sheet metal screws

(3 total)

POSITION FIREPLACE INSERT

1. Slide insert into fireplace opening.

Sealant

2. Position air duct into channels located at top of insert. Slide air duct forward until seated.

Shown without venting attached for clarity purposes only

3. Secure air duct to insert front with (2) 1/2” sheet metal screws (included in components packet).

4. If necessary, level insert by threading leveling bolts (included in components packet) into nuts mounted in the bottom of insert behind lower air passage - 2 each side.

Secure with sheet metal screws

PAGE 17

Leveling legs (2 per side)

GAS LINE CONNECTION

#CSK-31-RAD owners: If installing optional fan kit #CSK-028 please do so now before connecting gas line.

IMPORTANT:

DO NOT RUN GAS LINE IN A MANNER THAT WOULD OBSTRUCT THE OPERATION OF THE FAN OR FAN COMPONENTS.

Run gas line into the fireplace, preferably through the left or right gas line holes provided. A gas line knock-out is also located in the outer bottom of insert if running the gas line through the bottom is the only option.

NOTE: If installing this insert into minimum opening dimensions, the gas line may need to be run after the insert is in place due to space limitations.

If installing this gas fireplace insert into a factory-built fireplace and the factory-built fireplace has no access hole provided, an access hole of

1 ½"(38 mm) or less may be drilled through the lower sides or bottom of the firebox in a proper workmanship like manner. This access hole must be plugged with non-combustible insulation after the gas supply line has been installed.

1-3/8” (35 mm) from bottom to gas line WARNING LABEL

MINIMUM INLET GAS PRESSURE

MAXIMUM INLET GAS PRESSURE

MANIFOLD PRESSURE (HI)

MANIFOLD PRESSURE (LO)

ORIFICE SIZE

INPUT BTU/hr.

MINIMUM INPUT BTU/hr.

EFFICIENCY

AFUE

P-4 AFE

CHECK MILLIVOLT BOARD INSTALLATION

NATURAL GAS

CSK-31 / CSK-31-RF

5.0 inches W.C. (7.0 W.C. recommended)

10.5 inches W.C.

LP GAS

11.0 inches W.C. (recommended)

13.0 inches W.C.

3.5 inches W.C 10.0 inches W.C.

1.7 inches W.C.

#37

27,500

19,000

72%

71%

58%

6.3 inches W.C

#52

28,000

20,400

72%

72%

60%

NOTE: Refer to page 23 for complete millivolt board

installation procedures.

1. Ensure that all (6) nuts are attached to the mounting studs, securing the millivolt board in position.

2. Verify burner venturi is properly positioned over burner orifice and the burner assembly is secured to burner heat shield.

3. Check all gas connection for leaks, whether field or factory made.

PAGE 18

COMPLETE FAN WIRING INSTALLATION

#CSK-31

#CSK-31-RAD OPTIONAL FAN KIT #CSK-028

#CSK-31-RAD with optional fan kit #CSK-028

1. If not previously done, turn gas valve an d manual shut off valve to „OFF‟. Disconnect gas line from manual shut off valve.

2. Remove glass frame assembly. Refer to page 13.

3. Slide left, then right fan through the lower grill opening (right side of gas valve), positioning onto their corresponding mounting studs on the floor of fireplace. Secure each fan with (2) nuts included.

4. Connect the flexible gas line to the manual shut off valve. Turn the manual shut off valve to „ON‟.

CAUTION: CHECK CONNECTION FOR LEAKS.

#CSK-31 & #CSK-31-RAD

1. Secure electrical access panel to side of fireplace.

2. Place thermostatic control switch on bottom of firebox.

3. Plug power cord into electrical box receptacle.

4. Turn speed control counter-clockwise until it „clicks‟. This is the „OFF‟ position.

5. Turn speed control „ON‟ by turning the knob clockwise past the „click‟ - this is the highest setting.

NOTE: This appliance must be electrically grounded and connected in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 Current Edition, or the Canadian Electrical Code CSA C22.1.

NOTE: This fan will not operate unless the speed control has been turned „ON‟ and sufficient heat has been applied to the temperature control switch. The fan will turn „ON‟ and „OFF‟ automatically as the fireplace heats and cools. Adjust fan to desired speed while it is running.

TEMPERATURE CONTROL SWITCH POSITION

Before adjusting the temperature control switch, unplug the 3-prong plug on the fan cord from the receptacle. Adjust position of the temperature control switch to a warmer location under the firebox to turn fan „ON‟ sooner or move it to a cooler location under firebox to turn the fan „ON‟ later. The fan will turn on when the sensor in the temperature control switch reaches 110° F and will turn „OFF‟ when the sensor reaches 90° F. After adjustment, plug the 3-prong plug on fan cord into the receptacle.

Temperature Control Switch (looking through lower grill opening).

#CSK-31-RF (only)

1. Secure electrical access panel to side of fireplace.

2. Plug power cord into electrical box receptacle .

NOTE: This appliance must be electrically grounded and connected in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 Current Edition, or the Canadian Electrical Code CSA C22.1.

3. Upon complete installation of this fireplace, follow Lighting & Shutdown instructions as outlined in this manual as well as the instructions included with the remote transmitter for complete fan operation guidelines.

PAGE 19

3 PIECE SHROUD ASSEMBLY AND INSTALLATION

NOTE: If installing a Full Door Shroud, follow instructions included with that component.

Shroud assembly includes: (1) Shroud top

(1) Shroud left side

(1) Shroud right side

(2) 10-24 x 1" RH Philips Mch Screw (#300388)

(6) 8 x 3/8" Phillips PH-Type B Blk Zinc SMS (#300121)

(4) 10-24 x 1/2" PH Phillips Truss head Screw BZ (300338-1)

You will also need the flanged upper hood and lower grill which are included with fireplace.

1. Remove glass assembly from fireplace.

2. Lay shroud sections face down on a protective surface to assemble. Note the orientation of leg sections in Figure 1. Attach leg sections to top section by aligning holes (2 ea. side) in top section with holes in leg sections. Secure with black phillips head sheet metal screws (2 ea. side).

3. Partially thread remaining (2) black phillips head sheet metal screws into holes located along the bottom flange of top section (1 ea. side). Do not tighten at this time. Figure 1.

Figure 1.

Partially threaded screw. (1) ea. side.

4. Attach shroud to fireplace by aligning the (2) holes in each leg section to the corresponding mounting nuts in mounting brackets on either side of fireplace opening. Secure with phillips truss head screws (2 ea. side).

Refer to Figure 2.

5. Install the upper hood with a flange on each end (included with fireplace)

(Figure 3) by aligning slots in hood to the partially threaded screws in shroud top, slide hood back and tighten screws. Figure 4.

Figure 3.

6. Attach lower grill by threading 1” phillips head screws through mounting nuts

(1 ea. side) on grill and into corresponding holes located at the bottom of shroud leg sections (1 ea. side) Refer to Figure 5. Tighten screws.

Note: When completed, the grill may be adjusted slightly from side to side if necessary.

Figure 5.

PAGE 20

Figure 2.

Figure 4.

LOG SET INSTALLATION

ATTENTION: If converting to LP (propane) gas, do so now before installing log set. Follow instructions included with conversion kit.

NOTE: Log numbers are located on the bottom of each log. Refer to following instructions and illustrations for proper placement.

CAUTION: Do not place logs directly over burner port holes. Improper log placement may affect flame appearance and cause excessive soot to build up on logs and glass.

C1

C2 C3

C12

C13

Align holes in bottom of base logs C1,C2, & C3 to mounting pins on burner. Push logs down onto pins to seat.

Position ember logs C12 & C13 in front of burner as shown above.

Install C4 - C8 logs, aligning with notches in base logs.

C5

C8

C6

C4 C7

Use a steel or stiff bristle nylon brush to distribute Rock Wool Embers onto logs and burner.

PAGE 21

MILLIVOLT BOARD REMOVAL

CAUTION: If the burner and/or pilot have been burning, use the appropriate protection to avoid burns or damage to personal property before removing any components.

1. Turn gas control knob to the „OFF‟ position.

2. Shut off gas supply at the manual shut-off valve.

3. Disconnect gas line flex tube from the manual shut-off valve.

4. Model CSK-31 / CSK-31-RAD:

Disconnect any wall switch, remote control, or thermostat wires from „TH‟ / „THTP‟ terminals on the gas valve.

Model CSK-31-RF:

Unplug fan cord from receptacle, disconnect the (2) wires from fan cord. (Wires will remain connected to the back of gas valve).

5. Remove glass assembly. Page 13.

NOTE: It is not necessary to remove the shroud or full door shroud to remove millivolt board.

6. Remove logs.

7. Remove screws securing burner assembly. Remove burner assembly from firebox.

8. Remove burner heat shield from firebox.

9. Remove (6) nuts securing millivolt board. Lift board up and out of firebox.

Burner Assembly

Remove nuts

Heat shield

PAGE 22

MILLIVOLT BOARD INSTALLATION

WARNING: DO NOT OPERATE THIS FIREPLACE WITHOUT SEALING GASKET (LOCATED UNDER THE MILLIVOLT BOARD) IN PLACE.

IF GASKETING IS DAMAGED, IT MUST BE REPLACED.

1. Place millivolt board in firebox, aligning holes in the millivolt board with mounting studs in the firebox bottom. MAKE SURE SEALING GAS-

KET IS IN PLACE ON FIREBOX BOTTOM! Secure millivolt board to firebox bottom with the (6) nuts previously removed.

2. Re-install burner heat shield, positioning cut-outs over pilot assembly and burner orifice, centering from side to side and as far back as possible.

3. Re-install burner assembly, making sure burner tube is positioned over burner orifice, and alignment slots are placed over mounting studs in burner heat shield. Secure with nuts previously removed.

4. Reinstall log set. Page 21.

5. Reconnect gas line to manual shut-off valve.

6. Model CSK-31 /CSK-31-RAD:

Reconnect any wall switch, remote control or thermostat wires to terminals on the gas valve marked „TH‟ / „THTP‟.

Model CSK-31-RF:

Re-connect the (2) wires to fan cord. Plug fan cord into receptacle.

7. Reinstall glass frame assembly. Page 13.

8. Turn gas on.

9. Verify proper log placement, operation of fireplace, and any electrical components.

Heat shield

Burner Assembly

Secure nuts

CAUTION: CHECK ALL CONNECTIONS FOR LEAKS, WHETHER

FIELD OR FACTORY MADE.

PAGE 23

CSK-31 / CSK-31-RAD VALVE & PILOT ASSEMBLY COMPONENTS

THERMOCOUPLE

ELECTRODE

PILOT HOOD

THERMOPILE

HI /LO FLAME ADJUSTMENT KNOB

GAS CONTROL KNOB PIEZO IGNITOR

VALVE TERMINALS

PAGE 24

ON/OFF ROCKER SWITCH

CSK-31 / CSK-31-RAD LIGHTING AND SHUTDOWN

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.

DUE TO HIGH SURFACE TEMPERATURES, KEEP CHILDREN, CLOTHING AND FURNITURE AWAY.

This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

1. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.

2. BEFORE LIGHTING, smell all around the appliance for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

3. 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, do not try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion, and loss of warranty.

4. 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 which has been under water.

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 touch any electrical switches

Do not try to light any appliance

Do not use the 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

WARNING: CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE TEMPERATURES

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. CLOTHING OR OTHER FLAMMABLE MATE-

RIAL MUST NOT BE PLACED ON OR NEAR THE APPLIANCE.

NOTE: A PAINT SMELL WILL OCCUR DURING THE FIRST FEW HOURS OF BURNING. IT IS RECOMMENDED TO

LEAVE THE FAN OFF DURING THIS PERIOD TO HELP SPEED THE PAINT CURING PROCESS.

NOTE: THIS FIREPLACE MAY PRODUCE NOISES OF VARYING DEGREE AS IT HEATS AND COOLS DUE TO METAL

EXPANSION AND CONTRACTION. THIS IS NORMAL AND DOES NOT AFFECT THE PERFORMANCE OR LONGEVITY

OF THE FIREPLACE.

PAGE 25


(cont.)

LIGHTING

1. Set thermostat to the lowest setting, if installed.

2. Turn off all electrical power to the appliance. (Fan).

3. Open lower grill to access the gas valve & controls.

A

A. Push gas control knob in slightly and turn clockwise to “OFF”. Wait five (5) minutes to allow any gas that may have accumulated inside the firebox to escape. If you then smell gas, STOP! Follow the safety information on the front cover and on the previous page of this installation manual. If you don‟t smell gas, go to the next step.

NOTE: Gas control knob cannot be turned from “PILOT” to

“OFF” unless knob is pushed in slightly. Do not force.

B

B. Locate pilot - follow metal tube from gas control. The pilot is located inside the combustion chamber.

C. Push gas control knob on the gas valve in slightly and turn counterclockwise to „PILOT‟. Push valve knob in and hold while repeatedly pressing the piezo igniter button until the pilot is lit while continuing to hold in the gas control knob.

D. Hold gas control knob in for one (1) minute after pilot is lit. Release the gas control knob. If the pilot goes out, repeat steps C-D. When the pilot is lit, proceed to step E.

C

CAUTION: If knob does not pop up when released, stop and

immediately call your service technician or the 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 the gas supplier.

E. Push gas control knob in slightly and turn counterclockwise to „ON‟. The burner can now be turned „ON‟ by depressing the ON/OFF rocker switch located beside the valve, or wall switch, OR by setting the thermostat or remote control to the desired setting.

F. Turn on all electric power to the appliance (if applicable).

NOTE: When the fireplace is initially lit, condensation will appear on the glass; this is normal in all gas fireplaces and will disappear after several minutes.

PAGE 26

D

E

5 MINUTES

PILOT

PILOT TUBE

1 MINUTE


(cont.)

G

TURN BURNER OFF

G. To turn the burner „OFF‟, depress the ON/OFF rocker switch to „OFF‟, flip „off‟ wall switch or adjust setting on the thermostat or remote control.

NOTE: The pilot will stay lit.

TURN PILOT OFF

H. Turn the pilot off by pushing in and turning the gas control knob to the

„OFF‟ position. DO NOT FORCE.

NOTE: This control valve has an interlock device. If pilot has been turned off, it cannot be relit until the thermocou-

ple has cooled, (approximately 60 seconds).

H

ADJUSTING FLAME HEIGHT

The gas control valve has a HI /LO flame adjustment knob designed to allow you to tailor the look and heat output of your fireplace. Adjust by turning the middle knob on the gas control valve.

PAGE 27

CSK-31 / CSK-31-RAD PRESSURE TESTING

IMPORTANT NOTICE: Pressure check taps for the manifold (outgoing) and inlet (incoming) pressure have been incorporated into the valve. The pressure tap marked „OUT‟ measures outgoing pressure and the pressure tap marked „IN‟ measures incoming pressure. Follow instructions below for proper testing procedures.

NOTE: The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at pressures in excess of ½ psi.

NOTE: The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any

pressure testing of the gas line at test pressures equal to or less than ½ psi (3.5 kPa).

INLET PRESSURE TEST:

1. Loosen inlet („IN‟) pressure tap screw (counter-clockwise).

2. Attach manometer using a 5/16” I.D. hose.

3. Light pilot.

4. Turn gas control knob to „ON‟ (burner should not light). Note manometer reading.

5. Press rocker switch to „ON‟. Check pressure to ensure that it stays near the maximum inlet pressure.

6. Press rocker switch to „OFF‟.

7. Turn gas control knob to „OFF‟.

8. Disconnect hose and tighten screw (clockwise). Screw should be snug, do not over tighten.

9. Relight pilot and turn gas control knob to „ON‟. Reattach manometer to inlet pressure tap to verify that it is completely sealed. Manometer should read no pressure.

NOTE: If inlet pressure reading is too high or too low, contact the gas company. Only a qualified gas service technician should adjust the

incoming gas pressure.

MANIFOLD PRESSURE TEST:

1. Light pilot.

2. Loosen manifold („OUT‟) pressure tap screw (counter-clockwise).

3. Attach manometer to pressure tap using a 5/16” I.D. hose.

4. Turn gas control knob to „ON‟.

CAUTION: A LOW PRESSURE READING CAN

CAUSE DELAYED IGNITION

5. Press rocker switch to „ON‟ and note manometer reading.

6. Press rocker switch to „OFF‟.

7. Disconnect manometer hose and tighten screw (clockwise). Screw should be snug, do not over tighten.

8. Attach manometer to manifold pressure tap to verify that it is completely sealed. Manometer should read no pressure when the rocker switch is pressed to „ON‟.

MANIFOLD INLET

PAGE 28

CSK-31-RF VALVE & PILOT ASSEMBLY COMPONENTS

INLET

PRESSURE

TAP

OUTLET

PRESSURE

TAP

MOTOR

GAS CONTROL

KNOB

PIEZO

PILOT

ADJUSTMENT

SCREW

MOTOR

COVER

LED

RF VALVE (bottom view)

WIRING

TERMINALS

THERMOPIL E

ELECTRODE

ANTENNA

PILOT

WHITE

FUEL CONVERSION

PLUG

THERMOPILE

FAN

TERMINALS

WHITE

DOTS

RED

PAGE 29

CSK-31-RF LIGHTING AND SHUTDOWN

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.

DUE TO HIGH SURFACE TEMPERATURES, KEEP CHILDREN, CLOTHING AND FURNITURE AWAY.

This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

1. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.

2. BEFORE LIGHTING, smell all around the appliance for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

3. 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, do not try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion, and loss of warranty.

4. 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 which has been under water.

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 touch any electrical switches

Do not try to light any appliance

Do not use the 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

WARNING: CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE TEMPERATURES

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. CLOTHING OR OTHER FLAMMABLE MATE-

RIAL MUST NOT BE PLACED ON OR NEAR THE APPLIANCE.

NOTE: A PAINT SMELL WILL OCCUR DURING THE FIRST FEW HOURS OF BURNING. IT IS RECOMMENDED TO

LEAVE THE FAN OFF DURING THIS PERIOD TO HELP SPEED THE PAINT CURING PROCESS.

NOTE: THIS FIREPLACE MAY PRODUCE NOISES OF VARYING DEGREE AS IT HEATS AND COOLS DUE TO METAL

EXPANSION AND CONTRACTION. THIS IS NORMAL AND DOES NOT AFFECT THE PERFORMANCE OR LONGEVITY

OF THE FIREPLACE.

PAGE 30

CSK-31-RF LIGHTING AND SHUTDOWN (cont.)

LIGHTING

1. Turn off all electrical power to the appliance. (Fan).


5 MINUTES

A. Push control knob in slightly and turn clockwise to the

OFF position. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow the safety information on the previous page and on the front cover of this installation manual. If you don‟t smell gas, go to the next step.

A.

B. Locate pilot. The pilot is located inside the combustion chamber.

B.

C. Push the control knob on the gas valve in slightly and turn counterclockwise to PILOT. Push the control knob all the way in and hold. Push the plunger on the piezo ignitor until the pilot is lit. The pilot will generally light within two or three pushes on the piezo ignitor. Hold the knob for about one (1) minute after the pilot is lit. Release knob and it will pop back out. Pilot should remain lit. If it goes out, repeat steps A-C.

CAUTION: If knob does not pop up when released, stop and immedi-

ately call your service technician or the 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 the gas supplier.

C.

NOTE: Gas control knob cannot be turned from “PILOT” to “OFF”

unless knob is pushed in slightly. Do not force.

D. Push the control knob on the gas valve in slightly and turn counterclockwise to the ON position.

NOTE: If the manual switch is in the LOCAL position, the main burner will turn on immediately .

NOTE: When the fireplace is initially lit, condensation will appear on the glass; this is normal in all gas fireplaces and will disappear after several minutes.

PAGE 31

D.

1 MINUTE

CSK-31-RF LIGHTING AND SHUTDOWN (cont.)

INITIAL USE OF TRANSMITTER

IMPORTANT:

On the initial use of the transmitter, a recognition operation is required between the receiver / valve and the transmitter.

2 SECONDS

1. Turn gas control knob to the PILOT position. Move LOCAL / REMOTE switch to the LOCAL position for at least two (2) seconds, then move switch to the REMOTE position.

2. Press FAN or FLAME button on the transmitter within thirty (30) seconds of the switch change.

1.

WITHIN

30 SECONDS

2.

PRESS

3. Turn gas control knob to the ON position.

OR

3.

The LED will blink, indicating that the transmitter will now work with the receiver / valve. If the switch stays in the REMOTE position, the TR8220A Transmitter will control the main valve, flame modulation level and fan control.

If the LOCAL / REMOTE switch is in the LOCAL position, the receiver / valve will be at the highest setting.

TURN THE BURNER OFF

LOCAL SETTING: Turn control knob clockwise to the PILOT position.

REMOTE SETTING: The TR8220A transmitter can shut off the main burner and fan. However, the control is still „ON‟ and a command from the transmitter can turn on the main burner and fan.

TURN THE SYSTEM OFF


2. Turn gas control knob clockwise to the OFF position. This closes the main gas and safety valves.

The transmitter cannot turn on the main burner or the fan.

NOTE: If the manual switch is in the LOCAL position,

the main burner will turn on immediately.

NOTE: This control valve has an interlock device. If pilot has been turned off, it cannot be relit until the

thermocouple has cooled, (approximately 60 seconds).

PAGE 32

PRESSURE TESTING (CSK-31-RF)

IMPORTANT NOTICE: Pressure check taps for the manifold (outgoing) and inlet (incoming) pressure have been incorporated into the valve. The pressure tap marked „OUT‟ measures outgoing pressure and the pressure tap marked „IN‟ measures incoming pressure. Follow instructions below for proper testing procedures.

NOTE: The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at pressures in excess of ½ psi.

NOTE: The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during

any pressure testing of the gas line at test pressures equal to or less than ½ psi (3.5 kPa).

INLET PRESSURE TEST:

1. Loosen inlet („IN‟) pressure tap screw (counter-clockwise).

2. Attach manometer using a 1/4” I.D. hose.

3. Light pilot.

4. Turn gas control knob to „ON‟. Note manometer reading.

5. Turn gas control knob to „OFF‟.

6. Disconnect hose and tighten screw (clockwise). Screw should be snug, do not over tighten.

9. Relight pilot and turn gas control knob to „ON‟. Reattach manometer to inlet pressure tap to verify that it is completely sealed.

NOTE: If inlet pressure reading is too high or too low, contact the gas company. Only a qualified gas service technician should adjust

the incoming gas pressure.

MANIFOLD PRESSURE TEST:

1. Light pilot.

2. Loosen manifold („OUT‟) pressure tap screw (counter-clockwise).

3. Attach manometer to pressure tap using a 1/4” I.D. hose.

CAUTION: A LOW PRESSURE

READING CAN CAUSE DELAYED

IGNITION

4. Turn gas control knob to „ON‟. Note manometer reading.

5. Disconnect manometer hose and tighten screw (clockwise). Screw should be snug, do not over tighten.

6. Attach manometer to manifold pressure tap to verify that it is completely sealed. Manometer should read no pressure.

PAGE 33

CSK-31-RF REMOTE RECEIVER FUNCTIONS

IMPORTANT: PLEASE REVIEW AND RETAIN INSTRUCTIONS INCLUDED WITH THE RF TRANSMITTER. IT PROVIDES ADDITIONAL

INFORMATION AND DETAILS CONCERNING OPERATIONAL PROCEDURES AND FUNCTIONS FOR THE RF REMOTE CONTROL.

FUNCTIONS:

Flame powered system.

Flame powered flame modulation.

Electronics integrated into valve to provide thermostat, flame, and fan functions with RF commands.

Temperature compensated RF receiver.

Main burner runs on „HIGH‟ when manual switch is set to „LOCAL‟.

TRANSMITTER SIGNAL:

When transmitter is in Auto mode, a signal is sent every 10 minutes if there is a change in room temperature.

When transmitter is in „ON‟ or „OFF‟ modes, a signal is sent every 10 minutes with the „ON‟ or „OFF‟ status condition.

Make sure antennae is not touching metal.

RECEIVER SHUTDOWN OF BURNER:

In the remote „AUTO‟ mode, the valve shuts off if it does not receive a signal within 3 hours from the transmitter.

In the „LOCAL‟ mode, the valve does not shut off.

In the remote „MANUAL‟ mode, the valve shuts off if it does not receive a signal within 6 hours from the transmitter.

THERMOPILES:

The negative leads (white) must be connected to the terminals marked with white dots.

LED TROUBLESHOOTING:

In normal operation, LED blinks once every two seconds; also, LED will be on for one second after every valid command received by the RV83110D; these are not error codes.

Failure codes (see table) can occur anytime after the pilot burner is lit. Failure code timing is 1/4 second on, 1/2 second off.

Sequence is failure code followed by LED not blinking for four seconds.

In the event of multiple failure codes, the next failure code follows the previous code failure by approximately three seconds.

3

2

1

Code Service Action

8 Replace valve

7 Confirm stepper motor connection exists

4 Fuel conversion plug missing or has poor connection (RV8310E only)

Replace thermopile with Q313

Device too hot. Check application

None required. This is normal operation and indicates the control is powered

MODE:

AUTO

ON

OFF

COUNTDOWN

TIMER

FAN

RT8220A TRANSMITTER

DISPLAY:

Room Temperature

Set Temperature

Flame Height Level

Fan Speed Level

Countdown Timer

Low Battery

FLAME

UP:

Increases Flame height,

Fan Speed, Timer, or Set

Point

DOWN:

Decrease Flame Height,

Fan Speed, Timer, or Set

Point

PAGE 34

CSK-31-RF REMOTE RECEIVER FUNCTIONS (cont.)

FIRST USE OF TRANSMITTER:

STATUS

Begin communication between transmitter and receiver / valve.

Transmit unique code.

Confirm recognition between transmitter and receiver valve.

Chose REMOTE or LOCAL operation.

ACTION

Move LOCAL/REMOTE Switch to LOCAL position for at least two seconds; then move switch to the REMOTE position.

Press Fan or Flame key within 30 seconds.

Observe LED turns on for one second.

Move LOCAL/REMOTE switch to LOCAL or leave in REMOTE.

OPERATION IN THE REMOTE POSITION:

AUTO Mode

With the control in the AUTO mode, the flame in the main burner will turn on, off, or change height based on the heat needed to maintain the set temperature.

STATUS

Set to AUTO.

ACTION

Press MODE button until mode is AUTO.

Change set temperature. Press UP or DOWN key to change temperature.

Flame.

Fan.

To set Delay Timer.

Automatically changes.

Automatically changes.

Press TIME key followed by either UP or DOWN arrow key.

CAUTION: PROPERTY DAMAGE HAZARD. Excessive heat can cause property damage. In AUTO Mode, the main burner will cycle indefinitely to maintain the set temperature. Keep the transmitter in a heated living space to make sure the main burner is not on continuously.

ON Mode

With the control in the ON mode, the flame and fan levels and the delay timer are changed with the UP and DOWN arrow keys.

STATUS ACTION

Set to ON. Press MODE button until mode is ON.

Flame. Press FLAME button and press UP or DOWN arrow keys to change flame height.

Fan. Press FAN button and press UP or DOWN arrow keys to change fan speed.

Delay Time. Press DELAY TIMER button and press UP or DOWN key to change timer.

Press MODE until mode is OFF. OFF Mode

The flame in the main burner will turn off and the room temperature will be displayed in the remote window.

Operation in the LOCAL Mode. NOTE: Remote/Local switch on the receiver/valve must be in the LOCAL position.

FAN

Flame height and fan speed both go to the highest position.

In LOCAL mode, to turn fan ON/OFF, rotate manual knob from ON to PILOT position.

OTHER FUNCTIONS:

Change between Fahrenheit and Celsius temperature units.

Fan override during AUTO Mode.

Press UP and DOWN arrow keys at the same time and hold for at least three seconds.

Press FAN button, and press UP or DOWN arrow key to change the fan speed.

Disable/enable thermostat function in the AUTO

Mode.

Press the TIME, DOWN and FLAME arrow keys at the same time and hold for at least three seconds.

PAGE 35

FINALIZING THE INSTALLATION

FLAME APPEARANCE:

Flame appearance is affected by several factors including altitude, venting configuration and fuel quality. Although the venturi setting has been factory set, adjustments may be necessary for optimal performance and visual aesthetics.

When fireplace is first lit, the flames will be blue. The flames will gradually turn yellowish-orange during the first 15 minutes of operation. If the flames remain blue or the flames become dark orange with evidence of sooting (black tips), the burner tube venturi may need to be adjusted.

WARNING: BURNER TUBE ADJUSTABLE VENTURI POSITIONING SHOULD ONLY BE PERFORMED BY A

QUALIFIED PROFESSIONAL SERVICE TECHNICIAN.

WARNING: TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY, ALLOW FIREPLACE AMPLE TIME TO

COOL BEFORE MAKING ANY ADJUSTMENTS.

FACTORY SET BURNER TUBE VENTURI SETTINGS

(ADJUST AS NECESSARY FOR YOUR INSTALLATION)

NATURAL GAS

1/8” (3 mm) OPEN

LP (PROPANE) GAS

1/2” (13 mm) OPEN

BURNER TUBE VENTURI ADJUSTMENT GUIDELINES

VENTURI POSITION

Closed too far

Open too far

FLAME COLOR

Dark orange flame with black tips

Blue flames

VENTURI ADJUSTMENT

Open venturi setting slightly

Close venturi setting slightly

NOTE: IF SOOT IS PRESENT, CHECK LOG POSITIONING BEFORE ADJUSTING BURNER VENTURI. LOGS

MUST NOT BLOCK BURNER PORTS.

IMPORTANT: SLIGHT ADJUSTMENTS TO THE BURNER VENTURI OPENING CREATE DRAMATIC RESULTS.

ADJUST AT SLIGHT INCREMENTS UNTIL DESIRED LOOK IS ACHIEVED. ALWAYS BURN FIREPLACE FOR

AT LEAST 15 MINUTES AND ALLOW TIME TO COOL BEFORE MAKING ANY FURTHER ADJUSTMENTS.

TO ADJUST VENTURI:

1. Remove glass frame assembly. Refer to page 13.

2. Remove log set.

3. Remove burner assembly.

4. Loosen screw on burner venturi and adjust as necessary. Tighten screw.

5. Reinstall all components previously removed.

6. Light fireplace and wait 15 minutes before determining if any further adjustments are needed.

BURNER VENTURI

PAGE 36

MAINTENANCE

The appliance is required to be inspected at least once a year by a professional service person.

The compartment below the firebox (behind the lower grill) must be cleaned at least once a year, more frequent cleaning may be required due to excessive lint from carpeting, bedding materials, or other fibrous materials. It is imperative that the burner be cleaned once a year.

NOTE: INSTALLATION AND REPAIR SHOULD BE DONE ONLY BY A

QUALIFIED SERVICE PERSON. THE APPLIANCE SHOULD BE INSPECTED

BEFORE USE AND ANNUALLY BY A QUALIFIED SERVICE PERSON. MORE

FREQUENT CLEANING MAY BE REQUIRED DUE TO EXCESSIVE LINT

FROM CARPETING, BEDDING MATERIALS, ETC. IT IS IMPERATIVE THAT

CONTROL COMPARTMENTS, BURNERS AND CIRCULATION AIR

PASSAGEWAYS OF THE APPLIANCE BE KEPT CLEAN.

MILLIVOLT BOARD SYSTEM

Annual cleaning of the burner system is required.

The burner assembly may be removed for easier access. Refer to pages 22-23 in this installation manual for complete instruction on removing & reinstalling the burner assembly.

Visually check for blocked port holes, especially near the pilot. Blocked port holes may cause delayed ignition.

Reinstall the burner assembly following instructions on page 23 of this installation manual.

Visually check pilot light and burner when in operation. The flames should be steady, not lifting or floating.

Burner Ports

CSK-31-RF Pilot CSK-31 / CSK-31-RAD Pilot Burner Orifice

FAN

The fan should be disconnected from electrical current, and cleaned

(vacuumed) every six months. The bearings are sealed and require no oiling.

VENT SYSTEM

Annual examination of the venting system by a qualified agency is required.

IF THE VENT-AIR INTAKE SYSTEM IS DISASSEMBLED FOR ANY

REASON, RE-INSTALL PER THE INSTRUCTIONS PROVIDED WITH

THE INITIAL INSTALLATION.

The flow of combustion and ventilation air must not be obstructed.

IMPORTANT: ANY SAFETY SCREEN OR GUARD REMOVED FOR SERVICING

MUST BE REPLACED PRIOR TO OPERATING THE APPLIANCE.

CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING

CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS

OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

CAUTION: KEEP THE APPLIANCE AREA CLEAR OF COMBUSTIBLE MATERI-

ALS, SUCH AS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.

GLASS CLEANING & REPLACEMENT

Clean glass only when cool and only with nonabrasive cleansers.

Do not operate this fireplace with the glass/frame assembly removed, cracked or broken.

The glass assembly, part #CSK-057T, shall only be replaced as a complete unit, as supplied by

Hussong Mfg. Co., Inc.

Replacement of the glass & frame assembly, part #CSK-057T, must only be performed by a licensed or qualified service person.

DO NOT SUBSTITUTE MATERIALS.

Do not strike or slam glass door assembly.

PAGE 37

TROUBLESHOOTING (CSK-31 / CSK-31-RAD only)

CAUTION: THE FOLLOWING MUST BE PERFORMED BY A QUALIFIED TECHNICIAN.

NO SPARK FROM ELECTRODE TO PILOT WHEN PIEZO BUTTON IS TRIGGERED.

A. Check wiring at back of piezo for proper connection.

B. Check wiring at electrode for proper connection.

C. Check position of electrode (1/8” (3 mm) between electrode and pilot). Readjust if necessary.

D. Look for arc below electrode and along electrode wire. Direct metal contact may cause an arc below electrode.

SPARK IGNITOR WILL NOT LIGHT AFTER REPEATED TRIGGERING OF PIEZO BUTTON.

A. No gas or low gas pressure.

♦ Check remote shut off valves from fireplace. Usually there is a valve near the main. There may be more than (1) valve between

the fireplace and the main.

♦ Low gas pressure can be caused by several situations such as a bent line, too narrow diameter pipe, or low line pressure. Consult

with plumber or gas supplier.

B. No LP in tank.

♦ Check LP (propane) tank. Refill if necessary .

PILOT WILL NOT STAY LIT AFTER CAREFULLY FOLLOWING LIGHTING INSTRUCTIONS.

A. Check that pilot flame impinges on thermocouple. Clean and / or adjust pilot for maximum flame impingement.

B. Ensure the thermocouple connection at gas valve is fully inserted and tight (hand tight plus 1/4 turn).

C. Thermocouple reading below 15 millivolts.

♦ Disconnect thermocouple from valve, place one millivolt meter lead wire on the end of the thermocouple and the other millivolt

meter lead wire on the thermocouple‟s copper wire. Start pilot while holding valve knob in. If the millivolt reading is less than 15

millivolts, replace the thermocouple.

.

D. Thermopile not generating sufficient millivolts.

♦ Pilot flame must be enveloping thermopile. Adjust pilot flame if necessary.

♦ Check thermopile wire connections at valve. Tighten if necessary.

♦ Check thermopile with millivolt meter. Turn remote / thermostat / wall switch or ON/OFF switch to OFF. Turn valve knob to

PILOT position (pilot should remain lit). Take reading at THTP & TP terminals on gas valve. Reading should be 350 millivolts

minimum. Replace thermopile if reading falls below specified minimum.

PAGE 38


BURNER WILL NOT LIGHT

A. Gas control knob not turned to „ON‟.

B. „ON‟/„OFF‟ switch not turned on.

C. Remote, wall switch or thermostat not turned „ON‟.

D. Plugged main burner orifice.

E. Remote, wall switch ,thermostat or „ON/ OFF‟ switch wires defective.

♦ Check wires for proper connections. Place jumper wires across terminal at switch. If burner lights, replace defective switch.

♦ If switch checks ok, place jumper wires across switch wires on gas valve. If burner lights, wires are faulty or connections are

bad.

FREQUENT PILOT OUTAGES

A. Pilot shield not installed.

B. Pilot flame too high or too low, causing pilot safety to drop out.

♦ Clean and adjust flame for maximum flame impingement on thermopile.

BURNER WON‟T STAY LIT

A. Thermopile wires loose at valve terminals.

♦ Tighten if necessary.

B. Thermopile wires ground out due to pinched wires.

♦ Free pinched wires if necessary.

C Refractory panel placement (if installed).

♦ Refractory panels must be tight against firebox walls. It may be necessary to secure panels with high-temp sealant, especially

around the intake duct.

PAGE 39


PILOT AND BURNER EXTINGUISH WHILE IN OPERATION

A. No LP (propane) in tank.

♦ Check tank and refill if necessary.

B. Glass frame assembly not installed correctly.

♦ Refer to page13 in this manual for proper glass frame assembly installment instructions.

C. Defective thermopile or thermocouple.

♦ Check thermopile and thermocouple for proper millivolts.

D. Improper pitch on horizontal vent.

♦ 1/4” (6 mm) rise per foot is required on horizontal venting.

E. Inner vent pipe leaking exhaust gases back into firebox.

♦ Check for leaks. Repair if necessary.

F. Improper vent cap installation.

♦ Check for proper vent cap installation. Maximum downward slope of horizontal vent cap is 1/4” (6 mm). Adjust if necessary.

♦ Check vent cap for blockage. Remove debris if necessary.

G. Excessive draft.

GLASS SOOTING

A. Improper log placement.

♦ Refer to log placement instructions on page 21 of this installation manual.

B. Improper venturi setting.

♦ Venturi may need to be opened slightly to allow more air into the gas mix.

C. Improper pitch on horizontal venting.


FLAME BURNS BLUE AND LIFTS OFF BURNER

A. Improper Venturi setting.

♦ Venturi may need to be closed slightly.

B. Improper vent cap installation.

♦ Check for proper vent cap installation.

C. Blockage or vent system leaks.

PAGE 40

RF REMOTE TROUBLESHOOTING (CSK-31-RF only)

AUTO PATH

If the manual switch is set to

REMOTE, press the Mode button to display AUTO on the transmitter, Does the transmitter display the room and temperature setting?

Yes

If the setting is above room temperature on the transmitter, does the main valve and fan turn on?

Yes

No

Move switch from LOCAL to

REMOTE. Press any key within 30 seconds.

If the setting is below room temperature on the transmitter, does the main valve and fan turn off?

Yes

Turn pilotstat knob to OFF to turn valve completely off.

Yes

No

Set manual switch to

LOCAL or REMOTE

Yes

Light pilot burner.

Yes

Five minute wait period.

Did the LED stop blinking?

Yes

Yes Review LED failure analysis.

Release pilotstat knob.

Yes

Turn pilotstat knob from PILOT to ON.

Yes

Cycle switch once and leave in remote. Press any key on transmitter for recognition operation.

Yes

Choose LOCAL or REMOTE path. Set switch to LOCAL or

REMOTE.

REMOTE PATH


REMOTE, set the Mode button to display “ON”. Does the transmitter control the main burner and fan ?

Yes

Does transmitter change levels of flame height, fan speed and set temperature?

Yes

Set levels of flame height and fan to “0” to shut off main burner and fan.

No

Move switch from

MANUAL to RE-

MOTE. Press any key on transmitter.


LOCAL PATH


LOCAL, did the main burner light?

Yes

Does the transmitter control fan.

Yes

Turn pilotstat knob to PILOT to turn off main burner.

No

Move switch from

LOCAL to REMOTE.

Press any key on transmitter. Move switch back to LOCAL.


PAGE 41

TROUBLESHOOTING (CSK-31-RF only)

CAUTION: THE FOLLOWING MUST BE PERFORMED BY A QUALIFIED TECHNICIAN.

NO SPARK FROM ELECTRODE TO PILOT WHEN PIEZO BUTTON IS TRIGGERED.

A. Check piezo wiring for proper connection.

B. Check position of electrode (1/8” (3 mm) between electrode and pilot). Readjust if necessary.

C. Look for arc below electrode and along electrode wire. Direct metal contact may cause an arc below electrode.

SPARK IGNITOR WILL NOT LIGHT AFTER REPEATED TRIGGERING OF PIEZO BUTTON.

A . No gas or low gas pressure.

♦ Check remote shut off valves from fireplace. Usually there is a valve near the main. There may be more than (1) valve between the

fireplace and the main.

♦ Low gas pressure can be caused by several situations such as a bent line, too narrow diameter pipe, or low line pressure. Consult

with plumber or gas supplier.

B. No LP in tank.

♦ Check LP (propane) tank. Refill if necessary.

PILOT WILL NOT STAY LIT AFTER CAREFULLY FOLLOWING LIGHTING INSTRUCTIONS.

A. Check that pilot flame impinges on thermopiles. Clean and / or adjust pilot for maximum flame impingement.

B. Ensure the thermopile connections at gas valve are properly connected. The negative leads ( white) must be connected

to the terminals with the one white dot next to them.

BURNER WILL NOT LIGHT

A. Gas control knob not turned to „ON‟.

B. Plugged main burner orifice.

FREQUENT PILOT OUTAGES

A. Pilot shield not installed.

B. Pilot flame too high or too low, causing pilot safety to drop out.

♦ Clean and adjust flame for maximum flame impingement on thermopiles .

FLAME BURNS BLUE AND LIFTS OFF BURNER

A. Improper Venturi setting.

♦ Venturi may need to be closed slightly.

B. Improper vent cap installation.

♦ Check for proper vent cap installation.

C. Blockage or vent system leaks.

PAGE 42

TROUBLESHOOTING (CSK-31-RF only)

BURNER WON‟T STAY LIT

A. Thermopile wires loose at valve terminals.

♦ Adjust if necessary.

B. Thermopile wires ground out due to pinched wires.

♦ Free pinched wires if necessary.

C Refractory panel placement (if installed).

♦ Refractory panels must be tight against firebox walls. It may be necessary to secure panels with high-temp sealant, especially

around the intake duct .

PILOT AND BURNER EXTINGUISH WHILE IN OPERATION

A. No LP (propane) in tank.

♦ Check tank and refill if necessary.

B. Glass frame assembly not installed correctly.

♦ Refer to page 13 in this manual for proper glass frame assembly installment instructions.

C. Improper pitch on horizontal vent.


D. Inner vent pipe leaking exhaust gases back into firebox.

♦ Check for leaks. Repair if necessary.

E. Improper vent cap installation.

♦ Check for proper vent cap installation. Maximum downward slope of horizontal vent cap is 1/4” (6 mm). Adjust if necessary.

♦ Check vent cap for blockage. Remove debris if necessary.

F. Excessive draft.

GLASS SOOTING

A. Improper log placement.

♦ Refer to log placement instructions on page 21 of this installation manual.

B. Improper venturi setting.

♦ Venturi may need to be opened slightly to allow more air into the gas mix.

C. Improper pitch on horizontal venting.


PAGE 43

REPLACEMENT PARTS LIST

Replacement parts are available through your local dealer. Contact them for availability and pricing.

CSK-31 / CSK-31-RAD MILLIVOLT BOARD AND PARTS

CSK-770A

CSK-771A

Millivolt Board - Nat Gas

Millivolt Board - LP Gas

700-023 On/Off Rocker Switch

700-086A Valve - Natural Gas

700-087A Valve - LP Gas

700-063 Pilot Assembly - Nat Gas

700-063-1 Pilot Assembly - LP Gas

700-090

700-060

700-092

700-093

Piezo Igniter w/ Nut (no wire)

Flexible Pilot Tubing (Valve to Pilot)

Millivolt Generator

Thermocouple

700-094

700-095

700-098

700-203

700-213-B

700-226F

700-237

700-252

OCK-S37A

OCK-S52A

CSK-135

Pilot Orifice - Natural Gas

Pilot Orifice - LP Gas

Pilot Hood

Manual Shut-off Valve

18” Flexible Gas Line-Black

Flexible Gas Line-Valve to Burner Connection

Natural Gas Orifice #37

LP Gas Orifice #52

Natural Gas Conversion Kit

LP Gas Conversion Kit

Burner Assembly

CSK-31 - RF MILLIVOLT BOARD AND PARTS

CSK-800RF RF Millivolt Board - Natural Gas

700-107 Honeywell RF Valve - Natural Gas

700-083

700-203

Honeywell Piezo Sparker (only)


700-108 Remote Control - RF Valve

700-109 Honeywell RF Pilot Assembly-NAT

700-109-1 Honeywell RF Pilot Assembly-LP

700-060 Flexible Pilot Tubing (Valve to Pilot)

700-092RF Millivolt Generator

700-203

700-213B

700-213

700-098


18” Flexible Gas Line - Black

6” Flexible Gas Line-Valve to Burner Connection

Pilot Hood

700-226F Flexible Gas Line-Valve to Burner Connection

700-237

700-252

Natural Gas Orifice #37

LP Gas Orifice #52

OCK-H37N-RF Natural Gas Conversion Kit

OCK-H52L-RF LP Gas Conversion Kit

CSK-135

700-108

Burner Assembly

Remote Control

CSK-200

CSK-200F

CSK-201

GRILL REPLACEMENT

Upper Hood (For 3 & 4 pc. Shrouds)

Upper Hood (For Full Door Shrouds)

Lower Grill

REFRACTORY PANELS

(Sandstone)

CSK-G900 (4 pc.) Refractory Panel Set

CSK-900B Back Refractory Panel

CSK-G900L Left Side Refractory

CSK-900R Right Side Refractory

CSK-G902 Top Refractory Panel

RF-028

CSK-028

FAN ASSEMBLIES

Fan Assembly (CSK-31-RF only)

Fan Assembly (CSK-31 only)

GLASS & GLASS GASKET

CSK-005 Replacement Valance

900-006 1-1/8” Glass Gasket w/ Adhesive

CSK-057T Valance with 14-1/4” x 29” glass

*Consult your dealer for information on optional accessories available for this fireplace.

This appliance tested & certified by:

OMNI - Test Laboratories, Inc.

13327 NE Airport Way

Portland, Oregon 97230

Model #CSK-31 Chaska

Model #CSK-31-RF Chaska-RF

May 2009-REV09 www.kozyheat.com

PAGE 44

CSK-50A

CSK-1

CSK-2

CSK-3

CSK-4

CSK-5

CSK-6

CSK-7

CSK-8

CSK-12

CSK-13

900-REMB

LOG SET

11 pc. Log Set

#C1 Log

#C2 Log

#C3 Log

#C4 Log

#C5 Log

#C6 Log

#C7 Log

#C8 Log

#C12 Log

#C13 Log

Rock Wool Embers

Manufactured by:

Hussong Mfg. Co., Inc.

204 Industrial Park Drive

Lakefield, Minnesota 56150

507-662-6641

CSK-31-RAD FAN INSTALLATION (optional)


This kit includes: Right and left fan assemblies with temperature control switch

Speed control receptacle assembly

(4) nuts







(ground) wires to the corresponding wires on the speed control / receptacle

assembly.

110V-120V

60Hz

Electrical Box

Speed Control / Receptacle Assembly

Temperature Switch:

Magnetically attaches to bottom of firebox.

1. Remove lower grill and glass frame assembly.

2. Slide fans through lower grill opening, positioning over mounting studs located at back of stove. Secure with nuts. Make sure that all fan components are free and clear of any millivolt board components.

3. Place temperature control switch on the bottom of firebox.

4. Plug fan cord into receptacle on speed control / receptacle assembly.

This appliance, when installed, must be electrically grounded in accordance with local codes, or in the absence of local codes,

with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Codes, CSA C22.1

PAGE 45

PAGE 46

PAGE 47

Kozyheat Chaska Owner Manual

Quality Fireplaces for Life

INSTALLATION

AND

OPERATION MANUAL

DIRECT VENT FIREPLACE INSERT

WARNING

WARNING:

◙

IF YOU SMELL GAS:

Read this manual before installing or operating this appliance.

Please retain this owner’s manual for future reference.

CONGRATULATIONS!

We welcome you as a new owner of a Kozy Heat gas fireplace. Kozy Heat products are designed with superior components and materials and assembled by trained craftsmen who take pride in their work. The burner and valve assembly are

We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your Kozy Heat gas fireplace.

STANDARD FEATURES

OPTIONAL FEATURES

SAFETY FEATURES

WEIGHT

COMMONWEALTH OF MASSACHUSETTS REQUIREMENTS

FIREPLACE DIMENSIONS

MODEL #CSK-31 COMPONENTS LIST MODEL #CSK-31-RF COMPONENTS

MODEL #CSK-31-RAD COMPONENTS LIST

ADDITIONAL COMPONENTS REQUIRED

or

or

PLACEMENT CLEARANCE REQUIREMENTS

THERMOSTAT / WALL SWITCH / REMOTE

WALL SWITCH / THERMOSTAT:

REMOTE CONTROL:

CSK-31 / CSK-31-RF

CSK-31 / CSK-31-RAD VALVE & PILOT ASSEMBLY COMPONENTS

FOR YOUR SAFETY - READ BEFORE LIGHTING

LIGHTING

TURN BURNER OFF

TURN PILOT OFF

ADJUSTING FLAME HEIGHT

INLET PRESSURE TEST:

MANIFOLD PRESSURE TEST:

RF VALVE (bottom view)

FOR YOUR SAFETY - READ BEFORE LIGHTING

LIGHTING

INITIAL USE OF TRANSMITTER

TURN THE BURNER OFF

TURN THE SYSTEM OFF

INLET PRESSURE TEST:

MANIFOLD PRESSURE TEST:

FUNCTIONS:

TRANSMITTER SIGNAL:

RECEIVER SHUTDOWN OF BURNER:

THERMOPILES:

LED TROUBLESHOOTING:

FLAME APPEARANCE:

TO ADJUST VENTURI:

CSK-31 / CSK-31-RAD MILLIVOLT BOARD AND PARTS

CSK-31 - RF MILLIVOLT BOARD AND PARTS

GRILL REPLACEMENT

REFRACTORY PANELS

FAN ASSEMBLIES

GLASS & GLASS GASKET

LOG SET

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