Kozyheat #911 Owner Manual

I N S T A L L A T I O N M A N U A L

DIRECT VENT FIREPLACE INSERT

IMPORTANT:

This installation manual is to be used in conjunction with SUPPLEMENTAL

INSTALLATION AND HOMEOWNER INFORMATION MANUAL. Read both manuals before installing and operating appliance.

INSTALLER: Leave this manual with the appliance.

CONSUMER: Retain this manual for future reference.

English and French Installation Manuals

Available Through Your Local Dealer or

Visit Our Website at www.kozyheat.com

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

This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used.

WARNING: If the information in these instructions 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 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.

WARNING

HOT GLASS WILL CAUSE BURNS.

DO NOT TOUCH GLASS UNTIL COOLED.

NEVER ALLOW CHILDREN TO TOUCH GLASS.

Report Number: 216-F-22b-6.5

MAY 2013

911-R20

www.kozyheat.com

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:_______________________________________________________________________________________________

____________________________________________________________________________________________________

____________________________________________________________________________________________________

1

TABLE OF CONTENTS

INTRODUCTION

Introduction and Homeowner Reference Information

TABLE OF CONTENTS

Table of Contents

SAFETY INFORMATION

Safety Information

COMMONWEALTH OF MASSACHUSETTS INFORMATION

Commonwealth of Massachusetts Information

SPECIFICATIONS

Fireplace Insert Dimensions

Clearances

Additional Components Required

Placement Clearance Requirements

EXISTING FIREPLACE SPECIFICATIONS

Existing Fireplace Requirements

Existing Fireplace Minimum Opening Requirements

PREPARE EXISTING FIREPLACE

Prepare Existing Fireplace

GLASS FRAME ASSEMBLY

Remove Glass Frame Assembly

Install Glass Frame Assembly

ELECTRICAL WIRING

Electrical Wiring

GAS LINE CONNECTION

Gas Line Connection

INSTALLATION

Approved Venting

Air Duct Removal

911-MSP Masonry Side Panel Installation (Optional)

Restrictor

VENTING INSTALLATION

Kozy Heat #815-CL Co-Linear Vent System

Kozy Heat #815-CA Co-Axial Vent System

1

2

3

4

5

5

6

6

7

7

7

7

7

7

8

10-11

12-13

9

9

9

9

CONTROL BOARD

Control Board Installation

Control Board Removal

ZC SHROUD ASSEMBLY AND INSTALLATION

ZC Shroud Assembly and Installation

MASONRY SHROUD ASSEMBLY AND INSTALLATION

Masonry Shroud Assembly and Installation

LOG SET INSTALLATION

Log Set Installation

FINALIZING THE INSTALLATION

Flame Appearance

Venturi Adjustment

Restrictor Usage / Troubleshooting / Installation / Modification

Seasonal Heat Dump

MAINTENANCE

Maintenance

WARRANTY

Warranty

14

14

15

16-17

18

19

19

20

21

22

23-24

2

SAFETY INFORMATION

This fireplace has been tested by OMNI-Test Laboratories, Portland, Oregon and complies with:

ANSI Z21.88-2009 “Standard for Vented Gas Fireplace Heaters.”

This installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

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.

This fireplace insert is to be installed into a solid fuel masonry or factory built non-combustible fireplace that has been i n s t a l l e d i n a c c o r d a n c e w i t h t h e N a t i o n a l , P r o v i n c i a l , S t a t e a n d l o c a l b u i l d i n g c o d e s .

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. Toddlers, young children and others may be susceptible to accidental contact burns. A physical barrier is recommended if there are at risk individuals in the house. To restrict access to a fireplace or stove, install an adjustable safety gate to keep toddlers, young children and other at risk individuals out of the room and away from hot surfaces.

Clothing or other flammable material should not be placed 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.

WARNING: DO NOT OPERATE APPLIANCE WITH THE GLASS/FRAME ASSEMBLY REMOVED, CRACKED

OR BROKEN. REPLACEMENT OF THE GLASS SHOULD ONLY BE PERFORMED BY A LICENSED OR

QUALIFIED SERVICE PERSON.

The glass assembly, Part #700-08T, shall only be replaced as a complete unit, as supplied by Hussong Mfg. Co., Inc.

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.

3

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 time of installation of 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 o f the installation.

4

FIREPLACE

DIMENSIONS

DESCRIPTION

INCHES

MILLIMETERS

SPECIFICATIONS

FIREPLACE DIMENSIONS

Height Width Back Width Depth Back Height Back to Vent Center

18

457

31-1/4

794

20-7/8

530

16-1/8

410

19-1/2

495

4-3/4

121

TOP

20

7

8

"

530mm

16

1

8

"

410mm

4

3

4

"

121mm

19

1

2

"

495mm

18"

457mm

29

1

2

"

749mm

14

1

2

"

368mm

2

1

4

"

57mm

Figure 5a

LEFT

31

1

4

"

794mm

FRONT RIGHT

WARNING

Failure to position components in accordance with these diagrams or failure to use only parts specifically approved for use with

911 may result in property damage or personal injury.

1. Fireplace insert

2. Spring-loaded latch glass frame assembly

3. Control board with burner cover

4. Log set (see page 18 )

5. *150 CFM fan kit

6. Co-linear air duct

*Optional accessory for 911-RAD models.

Figure 5b

MINIMUM CLEARANCES TO COMBUSTIBLES

Insert glass to sidewall: 10” (254 mm)

Insert top to combustible 10” (254mm) mantel: 12” (305 mm)

5

SPECIFICATIONS

ADDITIONAL COMPONENTS REQUIRED

Vent System; Part #815-CL: For use with minimum 6” x 8” I.D. masonry or 8” I.D. Class A metal chimneys - Includes 12 ft. (3.66 m)

compressed, expandable to 25 ft (7.62 m) co-linear 3” x 4” flexible chimney, and termination cap.

Part #510: Used in conjunction with #815-CL to extend termination up to a maximum of 30 ft. (9.14 m).

Part #815-CA: For use with minimum 7” I.D. Class ‘A’ metal chimneys - Includes 12 ft. (3.66 m) compressed expandable

to 32 ft. (9.75 m) co-axial 4” x 6” flexible chimney system, co-axial air duct, and termination cap.

Part #716A: Used in conjunction with #815-CA to extend termination up to a maximum of 40ft. (12.19 m).

Other approved venting: Selkirk, ICC, American Metals, Security

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 existing fireplace front opening height and width. Grill set or clean face frame (required) in various finishes purchased separately.

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). Grill set or clean face frame (required) in various finishes purchased separately.

Or

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

PLACEMENT CLEARANCE REQUIREMENTS

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

This fireplace insert is to be installed into a solid fuel masonry or factory built non-combustible fireplace that has been installed in accordance with the National, Provincial, State and local building codes.

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.

EXISTING FIREPLACE SPECIFICATIONS

EXISTING FIREPLACE REQUIREMENTS

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

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 insert.

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

Any chimney clean-outs must fit properly.

Existing Chimney must be comprised of one of the following: Factory built chimney: Co-linear - 8” (203 mm) minimum inside diameter.

Co-axial - 7” (178 mm) minimum inside diameter.

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

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

Maximum: Co-axial venting: 40 ft. (12.19 m)

Co-linear venting: 30 ft. (9.14 m)

DETERMINE LENGTH OF EXISTING CHIMNEY

1.

Remove and discard existing chimney cap.

NOTE It is helpful to have two people complete next step to determine chimney height.

2. Position one person at fireplace and another person at top of chimney.

Measure from fireplace base to top of chimney.

Subtract 24” (610mm) (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 24" (610mm) (HEIGHT OF INSERT): -24" (610mm)____

TOTAL CHIMNEY LENGTH REQUIRED:

_________________

CAUTION

This appliance must not be connected to or joined with any other chimney flue serving another appliance.

6

EXISTING FIREPLACE SPECIFICATIONS

EXISTING FIREPLACE MINIMUM OPENING REQUIREMENTS

A Height 19” (483mm)

B Front Width 31-1/2” (770mm)

C Depth 16-1/4” (413mm)

D Back Width 21” (533mm)

All dimensions are minimum requirements

OPTIONAL

Figure 7a

Masonry panel kit #911-MSP is available and can be installed on this insert when installed in an existing masonry opening

that is larger than the insert. Its purpose is to concentrate flow of heated room air between the firebox and panel walls.

PREPARE EXISTING FIREPLACE

ATTENTION Any removed parts must be capable of reinstallation if this insert is ever removed (removal of rivets or screws is acceptable).

Any removed parts must be capable of reinstallation if this insert is ever removed (removal of rivets or screws is acceptable ).

The refractory, glass doors, screen rails, screen mesh and log grates may be removed from existing fireplace before installing this gas fireplace insert. Any smoke shelves, shields and baffles may be removed if attached by mechanical fasteners. If necessary, remove firebrick to obtain at least minimum opening requirements.

The fireplace flue damper can be fully blocked open or removed for installation of this gas fireplace insert. Remove existing chimney cap.

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

Cutting of any sheet metal parts is prohibited, except the metal floor. If metal floor is removed, the insert must be placed directly on metal base of metal fireplace.

Mechanically attach ‘THIS UNIT HAS BEEN MODIFIED’ label at bottom of existing firebox so it will be visible if this gas fireplace insert is removed.

IMPORTANT

If the factory-built fireplace has no gas access hole(s) provided, an access hole of 1-1/2” (37.5 mm) or less may be drilled through the lower sides or bottom of the firebox in a proper workmanship like manner. The access hole must be plugged with non-combustible insulation after the gas supply line has been installed.

CAUTION Trim panels or surrounds must not seal ventilation openings in existing fireplace that this appliance is installed in.

WARNING

GLASS FRAME ASSEMBLY

DO NOT OPERATE THIS FIREPLACE WITH GLASS REMOVED, CRACKED OR BROKEN. REPLACEMENT OF GLASS ASSEMBLY,

#700-08T SHOULD BE DONE BY A LICENSED OR QUALIFIED SERVICE PERSON.

DO NOT REMOVE GLASS ASSEMBLY WHEN HOT!

REMOVE GLASS FRAME ASSEMBLY

1. Locate spring-loaded handles securing glass frame assembly at bottom of firebox.

2. Pull bottom handles out and down to release glass frame assembly bottom.

3. Pull bottom of glass frame assembly out and lift up off tabs at top of firebox.

INSTALL GLASS FRAME ASSEMBLY

A. P l a c e g l a s s f r a m e a s s e m b l y t o p o v e r t a b s a t t o p o f f i r e b o x .

B. Pull bottom handles out and up to secure glass frame assembly bottom.

Figure 7b

7

ATTENTION

ELECTRICAL WIRING

Electrical wiring must be installed by a licensed electrician.

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

Nation Electric Code, ANSI/NFPA 70-latest edition, or the Canadian Electric Code, CSA C22.1

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 grounding prong from this plug.

Do not allow excess cord to touch fireplace.

GAS LINE CONNECTION

GAS CONVERSION

This fireplace is manufactured for use with Natural Gas. Follow instructions included with conversion kit if converting to LP gas.

ATTENTION

The conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdiction and in accordance with the requirements of the ANSI Z223.1 installation code.

CAUTION

Installation of the gas line must only be done by a qualified person in accordance with local building codes, if any.

If not, follow ANSI 223.1.

Commonwealth of Massachusetts: Installation must be done by a licensed plumber of gas fitter.

NOTE

A listed (and Commonwealth of Massachusetts approved) 1/2” (13mm) T-handle manual shut-off valve and flexible gas connector (included) are connected to the 1/2” (13mm) control valve inlet. If substituting for these components, please consult local codes for compliance.

This fireplace is equipped with a 3/8”(10mm) x 18” (457mm) long flexible gas connector and manual shut-off valve. The gas line should be run to the point of connection where the shut-off valve and flexible gas line will connect.

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 (3.5 kPa).

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).

For high altitude installations, consult the local gas distributor or the authority having jurisdiction for proper rating methods.

IMPORTANT

The efficiency rating of this appliance is a product of thermal efficiency rating determined under continuous operating

conditions and was determined independently of any installed system.

NOTE

If installing this insert into minimum opening dimensions, the gas line may need to be run after placement 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.

IMPORTANT Do not run gas line in a manner that would obstruct fan operation.

MINIMUM INLET GAS PRESSURE

MAXIMUM INLET GAS PRESSURE

NATURAL GAS

5” WC (1.25 kPa) (7” WC (1.74 kPa) (recommended)

10.5” WC (2.62 kPa)

LP GAS

11” WC (2.74 kPa) (recommended)

13” WC (3.24 kPa)

8

INSTALLATION

ATTENTION All steps as outlined in ‘PREPARE EXISTING FIREPLACE’ must be completed before continuing with this installation.

APPROVED VENTING

Kozy Heat #815-CL Co-Linear Vent System. Follow instructions on pages 10-11.

Kozy Heat #815-CA Co-Axial Vent System. Follow instructions on pages 12-13.

Selkirk, ICC, American Metals, Security. Follow instructions included from vent pipe manufacturer as well as venting requirements as outlined in this installation manual.

AIR DUCT REMOVAL

Remove air duct by lifting up and off top of insert. Follow instructions below and on following pages for vent system attachment to air duct.

Air Duct

Figure 9a

#911-MSP MASONRY SIDE PANEL INSTALLATION (OPTIONAL)

IMPORTANT

For use when insert is installed in an existing masonry opening. This kit must be attached to air duct (manifold) prior to vent system connection.

This kit includes: (1) Right side panel

(1) Left side panel

(12) Sheet metal screws

NOTE

If air duct and masonry side panels are not placed outside flanges at insert bottom, a rattling noise may occur when fan is in operation.

1. If air duct on insert is not positioned outside flange at bottom, remove and reposition.

2. Position each side panel outside the flanges on insert bottom, aligning (2) holes in top and (2) holes in back of masonry side panels with corresponding holes in air duct. Secure with screws included.

This installation will be continued at a later point.

RESTRICTOR INSTALLATION

Figure 9b

Masonry side panels and air duct positioned outside flange at bottom of insert.

IMPORTANT Do not install if venting configuration is at minimum requirements.

Each installation is unique and affected by various factors including venting configuration, altitude and climate. Therefore, after fireplace insert installation is complete, a restrictor may be required or may need to be removed or modified.

Page 20 has information on restrictor recommendations depending on burner flame appearance and instructions on installation after venting is completed.

Large Restrictor

Figure 9c

Remove tab (s) to create small restrictor

Bend tabs to approx. 80 degree angles to create tension to hold itself in place whe n i nstalled.

9

Slide restrictor into exhaust pipe on top of fireplace with tabs pointing towards you prior to attaching venting.

VENTING INSTALLATION

KOZY HEAT #815-CL CO-LINEAR VENT SYSTEM

NOTE

The co-linear pipe included with this vent system is designed to extend up to 25 ft. (7.62 m). If additional length is required, Part

#510 is available to extend venting to a maximum of 30 ft . (9.14 m).

If using ‘stub’ method for combustion air pipe, extending it is not necessary. Determine length needed from insert air duct

(4 ft. (1.22 m) minimum) to above damper opening in existing chimney. Remove excess combustion air pipe from end without collar. Continue with Step B. #2 below.

A. Carefully extend 3” combustion intake and 4” exhaust pipes (and extension kit if used) to equal total chimney length required.

Full Connection method:

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

B. Place bead of sealant around inner edge of exhaust pipe (end without collar) and slide onto corresponding collar on termination cap. Secure with 3 self-tapping screws

(provided). Apply additional sealant around joint to ensure a seal.

C. If an extension kit is being used, it must be connected as follows:

Exhaust extension:

Apply a liberal bead of sealant around exhaust adaptor (male) extension pipe and slide into female connector on end of 4” exhaust pipe already attached to the chimney termination plates. Secure with 3 self-tapping screws, (provided). To ensure an air-tight seal, additional sealant should be applied at the point of connection.

Combustion intake extension:

Apply a liberal bead of sealant (provided) around male end of extension kit and slide in to female en d o f 3 ” comb u stion in take pip e attach ed to ch imn ey termination plates. Secure with 3 self-tapping screws (provided). To ensure an air-tight seal, additional sealant should be applied at point of connection.

Figure 10a

#815-CL Termination Kit

Vent Extension Kit

Male

Female

RUN VENTING THROUGH EXISTING CHIMNEY

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

DO NOT USE THIS METHOD IF YOU ARE STUBBING COMBUSTION AIR

PIPE FROM BOTTOM OF EXISTING CHIMNEY.

NOTE

If offsets are present in existing chimney, place a weighted rope around pipe ends to guide them through chimney.

DO NOT ATTEMPT TO TIE ONE ROPE AROUND BOTH PIPES.

Figure 10b

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

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

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

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

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

damper opening and into existing fireplace. See illustration on following page.

4. We strongly suggested placing non-faced fiberglass insulation between vent pipes and existing chimney to prevent heat loss up chimney, being careful not to block pipe end if using stub method.

ILLUSTRATION ON FOLLOWING PAGE.

10


KOZY HEAT #815-CL CO-LINEAR VENT SYSTEM

(cont.)

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

Minimum 4ft. (1.22m) section of 3" combustion air flex pipe DO NOT block pipe end with insulation or any other sealing materials

Seal area around vent pipes with non-faced fiberglass insulation

Figure 11a

CONNECT #815-CL VENT SYSTEM TO AIR DUCT

1. Place air duct (previously removed from insert top, page 9) into existing fireplace opening.

2. Place a bead of sealant (provided) around 4” exhaust pipe. Slide exhaust pipe inside

4" collar air duct. Secure with (3) ½" self-tapping screws, provided. Apply additional sealant around 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 joint.

ATTACH AIR DUCT TO INSERT

1. Slide insert into fireplace opening.

2. If necessary, level insert by threading leveling bolts (included in components packet) into nuts mounted inside lower air passage.

3. Attach air duct to insert by aligning two holes in insert top to studs on each side of 4" exhaust duct, and four holes at back of insert to mounting studs at lower end of air duct.

NOTE

To prevent rattling noises that may occur during fan operation, position air duct back and sides on the OUTSIDE of insert bottom flanges.

Leveling legs (2 per side)

IMPORTANT Before completing steps 4 & 5, ensure air duct gasket is properly seated.

4. Locate baffle with seasonal heat dump inside firebox, noting (2)access holes on each side of heat dump. Secure air duct to insert through access holes with (2) 1/4" nuts.

5. Using a 7/16” wrench, secure lower end of air duct to insert firebox with (4) 1/4" nuts.

If installing optional #911-MSP:

Align (4) holes in insert face to corresponding holes in masonry side panels. Secure with remaining screws included with kit.

Position air duct back and sides outside insert bottom flanges

Figure 11b

11


KOZY HEAT #815-CA CO-AXIAL VENT SYSTEM

NOTE

The co-axial pipe included with this vent system is designed for chimneys up to 32 ft. ( 9.75 m). If additional length is required,

Part #716-A is available to extend the venting to a maximum of 40 ft. (12.19 m).

The 4" exhaust flex pipe and 6" combustion air flex pipe are coiled and packaged separately.

Carefully extend 4” and 6” flex pipes and extension kit (if used) to equal total chimney length required.

If an extension kit is used, it must be connected to 4" exhaust and 6" combustion air intake pipe included with #815-CA Vent Kit.

EXHAUST CONNECTION:

Apply liberal bead of sealant (provided) around 4” exhaust adaptor (with external notches) on extension kit and slide into female connector on end of 4” exhaust pipe. Secure with 3 self-tapping screws, (provided). To ensure an air-tight seal, apply additional sealant at point of connection.

COMBUSTION INTAKE CONNECTION:

Slide extended 6" combustion intake pipe included with 815-CA kit over extended 4" exhaust pipe included with 815-CA kit. Apply liberal bead of sealant (provided) around 6” combustion intake adaptor (with external notches) on extension kit and slide it over extended 4" exhaust pipe extension and into female end of 6” combustion intake pipe. Secure with 3 self-tapping screws (provided). To ensure an air-tight seal, apply additional sealant at point of connection. The 4" exhaust pipe is now inside 6" intake pipe.

A. Apply liberal bead of sealant (provided) around inside edge of 4” exhaust pipe, (end without collar) and slide it onto 4" collar on vent cap. Secure with 3 equally spaced self-tapping screws through both sections. Apply additional sealant around joint to ensure an air-tight seal.

B. Apply liberal bead of sealant (provided) around inside edge of 6” combustion intake pipe, (end without collar) and slide it onto 6” collar on vent cap. Secure with 3 equally spaced self-tapping screws through both sections. Apply additional sealant around joint to ensure an air-tight seal. The 4" exhaust pipe will be inside the 6" combustion intake pipe.

Figure 12a

RUN VENTING THROUGH EXISTING CHIMNEY

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

NOTE

If offsets are present in existing chimney, it may be easier to place a weighted rope around end of each pipe to guide them through it. DO NOT ATTEMPT TO TIE ONE

ROPE AROUND BOTH PIPES.

A. Guide ropes, if used, and flexible pipes down existing chimney.

B. To secure chimney termination cap to existing chimney, apply liberal bead of sealant around top of existing chimney, set termination cap into position. Secure with (4) 1-1/2” self-drilling screws (provided).

12

Figure 12b


CONNECT #815-CA CO-AXIAL VENT SYSTEM TO AIR DUCT

A. Place air duct into existing fireplace opening.

B. Place bead of sealant (provided) around 4” flex pipe and slide into 4” collar on air duct.

Secure with (2) self-tapping screws (provided).

Apply additional sealant around joint to ensure an air-tight seal.

C. Apply bead of sealant around 6” collar on flex pipe and slide into 6” collar on air duct.

Secure with (1) self-tapping screw (provided) through center front of this connection. Apply additional sealant around joint to ensure an air-tight seal.

ATTACH AIR DUCT TO INSERT

1. Slide insert into fireplace opening.

2. If necessary, level insert by threading leveling bolts (included in components packet) into nuts mounted inside lower air passage.

3. Attach air duct to insert by aligning two holes in insert top to studs on each side of 4" exhaust duct, and four holes at back of insert to mounting studs at lower end of air duct.

NOTE

To prevent ra ttling noises tha t ma y o ccur during f a n opera tio n, position air duct back and side flanges on OUTSIDE of insert bottom flanges.

Leveling legs (2 per side)

IMPORTANT Before completing steps 4 & 5, ensure air duct gasket is properly seated.

4. Locate baffle with seasonal heat dump inside firebox, noting (2) access holes (A) on each side of heat dump. Secure air duct to insert through access holes with (2) 1/4" nuts.

5. Using a 7/16” wrench, secure lower end of air duct to insert firebox with (4) 1/4" nuts.

If installing optional #911-MSP:

Align (4) holes in insert face to corresponding holes in masonry side panels.

Secure with remaining screws included with kit.

Position air duct back and sides outside insert bottom flanges

Figure 13a

13

CONTROL BOARD REMOVAL / INSTALLATION

CAUTION

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

NOTE Your components may look slightly different than ones shown.

CONTROL BOARD REMOVAL

1. Turn fireplace off.

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

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

4. Disconnect any wall switch, remote control, or thermostat wires from TH / THTP terminals on gas valve, or unplug all components from electrical outlet, disconnect all wiring harnesses attached to gas valve.

5. Remove glass assembly and logs.

6. Remove burner assembly and burner heat shield.

7. Remove (8) nuts securing control board. Lift board up and out of firebox.

CONTROL BOARD INSTALLATION

WARNING

DO NOT OPERATE THIS FIREPLACE WITHOUT SEALING GASKET IN PLACE

(LOCATED UNDER CONTROL BOARD).

IF GASKETING IS DAMAGED, IT MUST BE REPLACED.

1. Place control board in firebox, aligning holes in control board with mounting studs in firebox bottom. Ensure sealing gasket in in place on firebox bottom!

Secure control board to firebox bottom with (8) 1/4” nuts. Place burner heat shield over control board (flanges facing down).

CAUTION

Before securing, check that all wires are clear and unobstructed. Do not allow any wires or gas flex line to come in contact with fan terminals.

2. Install burner assembly; burner tube is positioned over burner orifice and sides are inside control board flanges.

3. Install pilot shield around pilot assembly.

4. Connect gas line to manual shut-off valve.

5. Re-onnect any wall switch, remote control or thermostat wires to terminals on valve marked TH / THTP, or reconnect all wiring harnesses to gas valve. Plug components into electrical outlet.

6. Install log set.

7.

8. Install glass frame assembly.

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

Figure 14a

CAUTION CHECK ALL CONNECTIONS FOR LEAKS WITH SOAPY WATER, WHETHER FIELD OR FACTORY MADE.

14

ZC SHROUD ASSEMBLY AND INSTALLATION

Shroud assembly includes: (1) Shroud top

(1) Shroud left side

(8) Phillips head screws

(2) Shroud extensions

(1) Shroud right side with on/off rocker switch mounting hole

You will also require a grill set or a clean face frame (sold separately).

911 / 911-RAD : You will need the following items from insert components packet: Rocker Switch Wires and On/Off Rocker Switch.

Grill option: Remove nuts from upper grill. Place grill rods through holes in shroud top section. Secure with nuts. If necessary, recess

upper grill by re-positioning in one of three mounting holes.

Clean Face frame option: Follow instructions included with clean face frame.

1. Secure right and left shroud sections to top section by aligning (2) holes in side sections to holes in top section. Secure with phillips head screws (2 ea. side).

OPTIONAL Attach shroud extensions by aligning slots in shroud with desired hole in shroud extension. Secure with phillips head screws.

Grill attachment holes

Phillips head screws

Attach shroud extensions by aligning slot in shroud with desired hole in shroud extension.

Secure with phillips head screws.

Figure 15a

911 / 911-RAD: Snap rocker switch into place on shroud. Slide one connector on each rocker switch wire to the rocker switch.

2. Attach shroud to insert by placing tabs on left and right shroud pieces into slots in insert. The shroud will set into place.

911 / 911-RAD: Slide remaining connectors on rocker switch wires to terminals on gas valve marked TH / THTP.

Grill option: Remove nuts from lower grill, insert grill bolts through lower hinges on insert. Attach and tighten nuts.

Tabs

Figure 15b

Holes

15

MASONRY SHROUD ASSEMBLY & INSTALLATION

Shroud assembly includes: (1) Shroud top (8) Phillips head screws

(1) Shroud left side (1) Set ‘inside fit’ brackets

(1) Shroud right side with on/off rocker switch mounting hole

You will also need upper grill from grill set or a clean face frame (sold separately).

911 / 911-RAD: You will need the following items from insert components packet: Rocker switch wires and On/Off Rocker Switch

Grill option: Remove nuts from upper grill. Place grill rods through holes in shroud top section. Secure with nuts.

Clean Face frame option: Follow instructions included with clean face frame.

1. Secure right and left shroud sections to top section by aligning (2) holes in side sections to holes in top section. Secure with phillips head screws (2 ea. side).

911 / 911-RAD: Snap rocker switch into place on shroud. Slide one connector on each rocker switch wire to the rocker switch.

2. Attach shroud to insert by inserting tabs (A) on left and right shroud sections to holes (B) in insert face. The shroud will set down into place.

Screws secured from bottom.

Snap On/Off rocker switch into mounting hole as shown.

Figure 16a

OUTSIDE FIT APPLICATIONS:

911 / 911-RAD: Slide remaining connectors on rocker switch wires to terminals on gas valve marked TH / THTP.

Grill option: Remove nuts from lower grill, insert grill bolts through lower hinges on insert. Attach and tighten nuts.

Tabs

Figure 16b

Holes

INSIDE FIT APPLICATIONS:

(You will require ‘inside fit’ brackets included with shroud assembly).

1. Remove glass frame assembly.

2. Referring to illustration at right, use tin snips to remove lower end of (4) mounting tabs on shroud side sections.

Figure 16c

16

MASONRY SHROUD ASSEMBLY & INSTALLATION cont.

IMPORTANT

IMPORTANT- MOUNTING BRACKET ORIENTATION. Figure 17a.

Right mounting bracket is notched out at the bottom.

Flanges on both mounting brackets face the inside of insert.

1. Align holes in mounting brackets to corresponding holes in insert face, making sure brackets are positioned as shown in Figure 17a.

Secure with screws provided (Figure 17b).

2. Position tabs (lower end previously removed) on shroud into slots in insert face, aligning oblong holes on inside flange of shroud side sections to holes in mounting brackets. Secure with (4) screws (C), 2 each side. Figure 17c.

911 / 911-RAD: Slide remaining connectors on rocker switch wires to terminals on gas

valve marked TH / THTP.

Figure 17a

Grill option: Remove nuts from lower grill, insert grill bolts through lower hinges on

insert.

OPTIONAL MASONRY PANEL INSTALLATIONS:

1. Remove screws (A) (2 ea. side) securing masonry panels. Figure 17b.

2. Align holes in mounting brackets to corresponding holes in insert face & masonry panels, making sure brackets are positioned as shown in Figure 17b. Secure with screws removed in step1and included in shroud components packet.

3. Position tabs (lower end previously removed) on shroud into slots in insert face, aligning oblong holes on inside flange of shroud side sections to holes in mounting brackets. Secure with (4) screws (C), 2 each side. Figure 17c.

911 / 911-RAD: Slide remaining connectors on rocker switch wires to terminals on gas

valve marked TH / THTP.

Grill option: Remove nuts from lower grill, insert grill bolts through lower hinges on

insert. Attach and tighten nuts. Figure 17d.

A B

Figure 17b

C

Figure 17d

Figure 17c

17

#932-500A 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 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.

AD

AG

BI

AJ

HB

Figure 18a

Align notches on bottom of BI log with brackets in burner cover. Set down into position.

Position AD, AG, HB & AJ logs onto burner cover, pressing down onto pins.

C

M

M

Figure 18b

Align hole in bottom of right M log to knob on HB log.

Position remaining M log and C log as shown above.

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

18

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. Flames will gradually turn yellowish-orange during first 15 minutes of operation. If flames remain blue, or become dark orange with evidence of sooting (black tips), the burner tube venturi may need adjustment.

Lazy yellow flames - ideal

Short blue flames

venturi open too far

Figure 19a

Correct pilot flame

Figure 19b

Dark orange flames / black tips

Venturi closed too far

Excessive burner media

Lifting (ghosting) flames

Improper Venting

Gas pressure too high

FACTORY SET BURNER TUBE VENTURI SETTINGS

(ADJUST AS NECESSARY FOR YOUR INSTALLATION)

NATURAL GAS

3/16” (5mm) open

LP (PROPANE) GAS

5/8” (16mm)

VENTURI POSITION

Closed too far

Open too far

BURNER TUBE VENTURI ADJUSTMENT GUIDELINES

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 ADJUSTM ENTS TO BURNER VENTURI OP ENING 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:


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.

19

BURNER VENTURI

Figure 19c


RESTRICTOR USAGE:

Turn fireplace on and allow to burn for 15 minutes.

If flames indicate there is excessive draft (flickering, short flames), a restrictor may be necessary.

If flames indicate insufficient draft (lifting or ghosting flames), a previously installed restrictor may need to be modified or removed.

WARNING

TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY, ALLOW FIREPLACE AMPLE TIME TO COOL BEFORE MAKING ANY

ADJUSTMENTS AND / OR INSTALLATIONS.

FLAME APPEARANCE

RESTRICTOR TROUBLESHOOTING

DRAFT PROBLEM RESTRICTOR SOLUTION

Short, flickering

Lifting or ghosting*

Excessive draft - not enough restriction

Insufficient draft - too much restriction

Add restrictor

Remove inner ring (s) on restrictor or remove restrictor

* Improper venting installation may cause flames to lift or “ghost” - a dangerous situation. Inspect flames after installation to ensure proper performance. If determined that venting is correct, and the restrictor has been removed, yet flames are still lifting or ghosting, shut off gas supply to fireplace and call a qualified service technician.

RESTRICTOR INSTALLATION / MODIFICATION

(after termination completion)

:

If it is determined that a restrictor is needed or restrictor modification is required after termination is installed, access can be reached through insert baffle. Please remove logs and refractory to avoid damaging these components.

1. Remove (2) nuts securing baffle. Remove baffle to expose venting.

2. Depending on your specific needs, determined by the chart above along with other factors, make necessary modifications.

3. If installation of a restrictor (included in components packet) is necessary, bend tabs on restrictor to approx. 80 degree angles to create tension when inserted into the exhaust pipe on fireplace insert. Insert restrictor into 4” exhaust pipe with tabs pointing towards you.

4. If modification is necessary, remove restrictor by pulling it down and out of 4” exhaust pipe.

5. Reinstall baffle, secure with (2) nuts previously removed.

6. Reinstall refractory and log set.

7. Attach glass frame assembly and light fireplace. Wait 15 minutes before determining if any further modifications are necessary.

Figure 20a

Remove baffle to expose venting. Large Restrictor Remove tab (s) to create small restrictor

Bend tabs to approx. 80 degree angles to create tension to hold itself in place when installed.

20


SEASONAL HEAT DUMP

This fireplace insert has been manufactured with a heat dump damper located at the inside top of firebox. This allows infinite control over the amount of heat emitted into the living area without affecting flame height.

INSTALLER: Please install this fireplace insert with the heat dump in the closed position.

HOMEOWNER: This fireplace insert has been installed with the heat dump in the closed position and will operate at its peak efficiency at this setting. The heat dump may be opened as much as necessary to maintain desired heat level.

CAUTION

Do not attempt to adjust heat dump opening if fireplace has been in operation. Allow ample time to cool or use appropriate protection to avoid serious burns and / or property damage.

Remove glass frame assembly. Open or close heat dump as desired. Re-install glass frame assembly.

Figure 21a

Shown in closed position Shown in partial open position

21

MAINTENANCE

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

The compartment below firebox 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. Use a vacuum to clean all components at least once a year.

NOTE

INSTALLATION AND REPAIR SHOULD BE DONE ONLY BY 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

.

CONTROL BOARD SYSTEM

Annual cleaning of burner system is required. Vacuum all components thoroughly.

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

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

Figure 22a

911 Pilot

911-RAD Pilot

911-MV Pilot

911-IPI Pilot

Burner Orifice

Burner Ports

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 venting system by a qualified agency is required.

IF VENT-AIR INTAKE SYSTEM IS DISASSEMBLED FOR ANY REASON, RE-INSTALL PER INSTRUCTIONS PROVIDED WITH INITIAL

INSTALLATION.


GLASS CLEANING & REPLACEMENT


WARNING: DO NOT OPERATE APPLIANCE WITH GLASS/FRAME ASSEMBLY REMOVED, CRACKED OR BROKEN. REPLACEMENT OF THE

GLASS SHOULD ONLY BE PERFORMED BY A LICENSED OR QUALIFIED SERVICE PERSON.

Use protective gloves to handle any broken or damaged glass assembly components.

The glass assembly, part #700-08T, shall only be replaced as a complete unit, as supplied by Hussong Mfg. Co., Inc.

Replacement of glass assembly, part #700-08T, must only be performed by a licensed or qualified service person.


Do not strike or slam glass door assembly.

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.

KEEP APPLIANCE AREA CLEAR OF COMBUSTIBLE MATERIALS, SUCH AS GASOLINE AND OTHER FLAMMABLE VAPORS AND

LIQUIDS.

22

LIMITED WARRANTY

KOZY HEAT LIMITED 10 YEAR WARRANTY

This limited 10 Year Warranty will not become effective until the Warranty Registration Form has been completed and mailed to

Hussong Manufacturing Co., Inc., P.O. Box 577, Lakefield, MN 56150. This registration form must be received within 30 days of installation. Failure to do so may result in delayed warranty coverage and submission of proof of purchase will be required.

Hussong Manufacturing Co., Inc. warranties to the original purchaser of this Kozy Heat Fireplace, that it is free of defects in materials and workmanship at the time of manufacture.

Subject to the following conditions & requirements, Hussong Manufacturing Co., Inc. extends the following limited warranty under normal use and service, with respect to the Kozy Heat line of gas burning fireplaces.

YEAR 1: Subject to the conditions & requirements listed below, within the first year from date of purchase, Hussong Manufacturing Co.,

Inc. shall, at its discretion, replace or repair any such defect in material or workmanship, at Hussong Manufacturing Co., Inc.’s expense, including reasonable labor costs to repair or replace the defective component, if a factory pre-authorization is given for the repair.

YEARS 2-10: Subject to the conditions & requirements listed below, beginning with the first day of the second year and continuing through the tenth year, Hussong Manufacturing Co., Inc., will at its discretion, provide repair or replacement parts at current list prices for any defect in material or workmanship of components, including optional components and accessories (if available). Husson g

Manufacturing Co., Inc. shall not be responsible for any installation, labor, transportation of other indirect costs.

LIMITATION OF LIABILITY

To make a claim under this warranty, the purchaser must first contact the dealer/installer from whom the fireplace was purchased.

This limited warranty will be void if the fireplace is not installed by a qualified installer and according to the installation instructions.

Use of unauthorized components will make this warranty null and void.

This limited warranty also is void if the fireplace is not operated, at all times, according to the operating instructions furnished.

This warranty is limited to defects in material and workmanship. It does not apply to any product that has been subject to negligence, misapplication, improper installation.

No person is authorized to extend the time of this warranty or to accept on Hussong Manufacturing Co., Inc.’s behalf any additional obligation of liability connected with the unit.

It is expressly agreed and understood that this warranty is Hussong Manufacturing Co., Inc.’s sole obligation and purchaser’s exclusive remedy for defective fireplace equipment. Hussong Manufacturing Co., Inc. shall not be liable for any consequential, incidental or contingent damages whatsoever. The foregoing warranty is exclusive and in lieu of all other expressed warranties. Hussong

Manufacturing Co., Inc. shall not be held to implied warranties or merchantability and fitness for a particular purpose. This warranty replaces all previous warranty policies.

Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

Hussong Manufacturing Co., Inc. reserves the right to make changes at any time, without notice, in design, material, specifications and prices. Hussong Manufacturing Co., Inc. reserves the right to discontinue models and products.

WARRANTY CONDITIONS & REQUIREMENTS:

1. You are the original purchaser. This warranty is not transferable.

2. Installation of the fireplace is performed by a qualified installer.

3. Installation and operation must comply with installation and operation instructions.

4. Paint and glass gaskets are covered for 30 days from date of purchase.

5. Remote controls and all optional accessories are covered for 1 year from date of purchase.

6. This warranty does not offer coverage for Light Bulbs or Batteries (whether factory, dealer or installer supplied). This includes any damage stemming from either component’s nonuse.

7. Components broken, (including glass panels), during shipping, careless handling of components, or defects resulting from improper installation, misuse of the fireplace and components are not covered under this warranty.

8. This warranty does not cover any part of the fireplace or any components which have been exposed to or submerged under water.

9. Hussong Manufacturing Co., Inc. must be notified by the dealer the fireplace was purchased from or a qualified installer/service technician of the defect.

10. Annual service of the fireplace as required in the installation manual, is performed by a qualified installer/service technician.

(Copies of such service records may be required to claim a warranty).

11. All previous warranty/service has been performed by a qualified installer or service technician.

Effective September 01, 2011

23

LIFETIME WARRANTY

LIFETIME WARRANTY

THIS LIFETIME WARRANTY COVERAGE WILL BE EXTENDED AS DESCRIBED BELOW PROVIDED ALL WARRANTY

CONDITIONS AND REQUIREMENTS ARE MET AS OUTLINED IN THE 10 YEAR LIMITED WARRANTY POLICY.

LIFETIME WARRANTY COVERAGE

LIFETIME WARRANTY IS EXTENDED AS FOLLOWS: Hussong Manufacturing Co., Inc. warranties to the original purchaser that the firebox, heat exchanger, fiber logs, burner tube and glass panel of this Kozy Heat Fireplace will not be defective in materia l or workmanship under normal use and service for as long as you own this product. If any of these components fail due to defects in material and workmanship under normal use and service, Hussong Manufacturing, Co., Inc. will, at its sole discretion, repair or replace the defective component. This LIFETIME WARRANTY does not cover any installation, labor, transportation or other indirect cost arising from defective components.

LIMITATION OF LIABILITY

This Lifetime Warranty will be void if the fireplace is not installed by a qualified installer and according to the installation instructions.

Use of unauthorized components will make this warranty null and void. This Lifetime Warranty also is void if the fireplace is not operated, at all times, according to the operating instructions furnished. This warranty is limited to defects in material and workmans hip of components specified. It does not apply to any product that has been subject to negligence, misapplication, improper installa tion.

No person is authorized to extend the time of this Lifetime Warranty or to accept on Hussong Manufacturing Co., Inc.’s behalf any additional obligation of liability connected with the unit.

Hussong Manufacturing Co., Inc. may fully discharge all obligations with respect to this Lifetime Warranty by refunding the wholesale price of the defective component(s).

It is expressly agreed and understood that this Lifetime Warranty is Hussong Manufacturing Co., Inc.’s sole obligation and original purchaser’s exclusive remedy for defective fireplace equipment. Hussong Manufacturing Co., Inc. shall not be liable for any consequential, incidental or contingent damages whatsoever other than those incurred by Hussong Manufacturing Co., Inc. to repair or replace the defective component. The foregoing warranty is exclusive and in lieu of all other expressed warranties. Hussong Manufacturing

Co., Inc. shall not be held to implied warranties, including but not limited to the implied warranties or merchantability and fitness for a particular purpose. This lifetime warranty replace all previous lifetime warranty policies.

Hussong Manufacturing Co., Inc. reserves the right to make changes at any time, without notice, in design, material, specifications and prices. Hussong Manufacturing Co., Inc. reserves the right to discontinue models and products.

To activate this Lifetime Warranty coverage, this registration card must be completed and mailed with your completed 10 Year

Limited Warranty form within 30 days of installation to the following address:

Hussong Manufacturing Co., Inc.

P.O. Box 577

204 Industrial Park Drive

Lakefield, MN 56150-0577

Sept. 2011

CUT ALONG DOTTED LINE

PURCHASER NAME:

ADDRESS:

TELEPHONE:

INSTALLER NAME:

ADDRESS:

TELEPHONE:

INSTALLATION DATE:

MODEL #:

SERIAL #:

24

Supplemental Installation and Homeowner

I n f o r m a t i o n M a n u a l f o r 9 1 1 M o d e l :

DIRECT VENT GAS FIREPLACE

IMPORTANT:

This supplemental installation and homeowner manual is to be used in conjunction with 911 INSTALLATION MANUAL. Read both manuals before installing and operating appliance.






WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to fireplace installation manual and this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier.


—

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

of this or any other 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.




WARNING




Report No. 216-F-22b-6.5

MAY 2013

911-SUP-REV-02


SAFETY INFORMATION

Safety Information

SPECIFICATIONS

Components List

Gas Pressure Requirements / BTU’s

THERMOSTAT / WALL SWITCH / REMOTE

Thermostat / Wall Switch / Remote

OPERATING INSTRUCTIONS

Valve and Pilot Assembly Components

Lighting and Shutdown Instructions

Pressure Testing

TROUBLESHOOTING

Troubleshooting

CONVERSION KIT INSTRUCTIONS

Conversion Kit Instructions

MAINTENANCE

Maintenance

REPLACEMENT PARTS

Replacement Parts


2

13-15

16

5

6-8

9

3

3

4

10-12

17

1





























2

SPECIFICATIONS

#911 COMPONENTS

911-770

700-203

911-135

911-G900

932-500A

700-08T

815-CL1

911-028

900-085

Millivolt Control Board Assembly

Manual Gas Shut-off Valve

Burner Assembly

Refractory Set

Log Package

Glass Assembly

Co-Linear Air Chute

Fan Kit (2)-75 CFM

4” Restrictor Plate



MANIFOLD PRESSURE (HI)

MANIFOLD PRESSURE (LO)

ORIFICE SIZE

INPUT BTU/hr. (kW)

MINIMUM INPUT BTU/hr. (kW)

NATURAL GAS


911

LP GAS


10.5” WC (2.62 kPa)

3.5” WC (.87 kPa)

1.6” WC (.40 kPa)

#32

36,500 BTU/hr (10.7 kW)

27,500 BTU/hr (8.06 kW)

13” WC (3.24 kPa)

10” WC (2.49 kPa)

6.4” WC (1.59 kPa)

#50

32,000 BTU/hr (9.38 kW)

23,500 BTU/hr (6.89kW)

3

THERMOSTAT / WALL SWITCH / REMOTE

If desired, a thermostat (wireless style also available), wall switch, or remote control assembly may be used to turn fireplace OFF and ON.

Only ONE of these may be installed. Follow instructions included with chosen assembly.

NOTE

INSTALLATION OF THERMOSTAT OR WALL SWITCH SHOULD ONLY BE PERFORMED BY A QUALIFIED INSTALLER.

CAUTION

DO NOT CONNECT HIGH VOLTAGE (115V) WIRE TO THE GAS VALVE!

Remote Control Wiring Diagram

Thermostat Wiring Diagram

OPTIONAL

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

Figure 4a

WALL SWITCH / THERMOSTAT:

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

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

REMOTE CONTROL:

Follow instructions included with remote control

.

IMPORTANT

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

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

NOTE

Fireplace must be turned ON and OFF by same method. For example: If fireplace is turned ON by remote control, it must be turned OFF by remote control.

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

4

VALVE & PILOT ASSEMBLY COMPONENTS

THERMOPILE

PILOT HOOD

ELECTRODE

THERMOCOUPLE

PIEZO IGNITOR

GAS CONTROL KNOB

HI /LO FLAME ADJUSTMENT KNOB

VALVE TERMINALS

Figure 5a

5

ON/OFF ROCKER SWITCH

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.

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

B. 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.

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.

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, 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.

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 which has been under water.

WARNING

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS

OR ANY OTHER APPLIANCE.

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

MATERIAL 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

T H E F A N O F F D U R I N G T H I S P E R I O D T O H E L P S P E E D T H E P A I N T C U R I N G P R O C E S S .

THIS FIREPLACE MAY PRODUCE NOISES OF VARYING DEGREES 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.

6

LIGHTING AND SHUTDOWN (cont.)

LIGHTING INSTRUCTIONS

5 MINUTES

1. Set thermostat to lowest setting, if installed.

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

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

4. Push gas control knob in slightly and turn clockwise to OFF.

5. Wait five (5) minutes to clear out any gas. Then smell gas, including near the floor. If you then smell gas, STOP!

Follow WHAT TO DO IF YOU SMELL GAS safety information below. If you don’t smell gas, go to next step.

PILOT


Do not try to light any appliance.

Do not touch any electric switch; 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.

PILOT

TUBE

NOTE

Gas control knob cannot be turned from PILOT to OFF unless knob is pushed in slightly.

Do not force.

6. Locate pilot - follow metal tube from gas control. (Located inside combustion chamber).

7. Push gas control knob on gas valve in slightly and turn counterclockwise to PILOT.

8. Push valve knob in and hold while repeatedly pressing piezo igniter button until pilot is lit while continuing to hold in gas control knob.

9. Hold gas control knob in for one (1) minute after pilot is lit.

Release gas control knob. If pilot goes out, repeat steps 4-8.

When pilot is lit, proceed to step 10.

1 MINUTE

CAUTION

If knob does not pop up when released, stop and immediately call your service technician or the

gas supplier. If pilot will not stay lit after

several tries, turn gas control knob to OFF and call your service technician or gas supplier.

10. Push gas control knob in slightly and turn counterclockwise to ON. The burner can now be turned ON by depressing

ON/OFF rocker switch located beside valve, or wall switch,

OR by setting thermostat or remote control to desired setting.

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

NOTE

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

Figure 7a

7


TO TURN OFF GAS TO APPLIANCE

TURN BURNER OFF

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

NOTE The pilot will stay lit.

TURN PILOT OFF

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

DO NOT FORCE.

NOTE

This control valve has an interlock device. If pilot has been turned off, it cannot be relit until thermocouple has cooled,

(approximately 60 seconds).

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 middle knob on gas control valve.

Figure 8a

Figure 8b

Figure 8c

8

PRESSURE TESTING

IMPORTANT

Pressure check taps for manifold (outgoing) and inlet (incoming) pressure have been incorporated into the valve. The pressure tap marked OUT measures outgoing pressure and 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 gas supply piping system during any pressure testing of that system at pressures in excess of ½ psi (3.5 kPa).

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 it stays near 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 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.

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


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 it is completely sealed. Manometer should read no pressure when rocker switch is pressed to ON.

CAUTION A LOW PRESSURE READING CAN CAUSE DELAYED IGNITION.

MANIFOLD

INLET

Figure 9a

9

CAUTION

TROUBLESHOOTING

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” (3mm) 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 IGNITER 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 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 end of thermocouple and other millivolt meter lead

wire on thermocouple’s copper wire. Start pilot while holding valve knob in. If millivolt reading is less than 15 millivolts, replace

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.

10

TROUBLESHOOTING

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 intake duct.

MORE TROUBLESHOOTING ON FOLLOWING PAGE

11

TROUBLESHOOTING

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 installation 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” (6mm) 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” (6mm). 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 in fireplace installation manual.

B. Improper venturi setting.

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

12

CONVERSION KIT INSTRUCTIONS

#OCK-S32A NAT GAS CONVERSION KIT / #OCK-S50A LP GAS CONVERSION KIT

WARNING

This conversion kit shall be installed by a qualified service agency in accordance with the manufacturers instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fire, explosion or productions of carbon monoxide may result, causing property damage, personal injury or loss of life. The qualified service agency is responsible for proper installation of this kit. The installation is not proper and complete until operation of the converted appliance is checked as specified in the manufacturer’s instructions supplied with the kit. Refer to appliance owner’s manual or product data plate for proper inlet and manifold pressure adjustments and orifice sizing.

IMPORTANT

THE CONVERSION SHALL BE CARRIED OUT BY A MANUFACTURER’S AUTHORIZED REPRESENTATIVE, IN

ACCORDANCE WITH THE REQUIREMENTS OF THE MANUFACTURER, PROVINCIAL OR TERRRITORIAL

AUTHORITIES HAVING JURISDICTION AND IN ACCORDANCE WITH THE REQUIREMENTS OF THE

CAN/CGA-B149.1 OR CAN/CGA-B149.2 INSTALLATION CODES.

Kit includes:

(1) Burner Orifice: NAT #32 / LP #50 (1) Pilot Orifice: NAT #BL22N / LP #BL14LP (1) Gas Label

(1) Valve and Pilot Assembly Conversion Instructions (1) Gas Conversion Label

CAUTION

WARNING

THE GAS SUPPLY SHALL BE SHUT OFF PRIOR TO DISCONNECTING THE ELECTRICAL POWER, BEFORE PROCEEDING WITH

THE CONVERSION.

SHUT OFF GAS SUPPLY AND ELECTRIC POWER TO FIREPLACE.

SHUT OFF GAS SUPPLY BEFORE DISCONNECTING ELECTRIC POWER.

IMPORTANT

For high altitude installations: Above 2000ft. (610m) US / 4500ft. (1372m) Canada, consult the local gas distributor or

authority having jurisdiction for proper de-rating methods.

PREPARE THE FIREPLACE:

1. Turn fireplace off by pushing in and turning gas control knob clockwise to OFF position.

2. Remove glass frame assembly, logs, and burner assembly from fireplace insert.

Burner Orifice

REPLACE BURNER ORIFICES:

Remove existing orifice cap. Install orifice cap included with kit. Tighten cap securely.

(Number stamped on burner orifice).

NAT #32

LP #50

Figure 13a

NAT LP

Figure 13b

PILOT ORIFICE

CONVERT PILOT ASSEMBLY:

1. Using a 7/16” wrench, loosen and remove pilot hood by turning counter-clockwise.

2. Remove pilot orifice located inside pilot housing. Install pilot orifice included with kit.

NAT #BL22N / LP #BL14LP (Number stamped on pilot orifice).

3. Re-attach pilot hood. Tighten with wrench, making sure hood is centered between thermopile and thermocouple.

CONVERT HI/LO REGULATOR ON GAS VALVE:

Follow instructions included with kit to convert gas valve.

13


COMPLETE THE CONVERSION:

1. Adjust burner tube venturi to correct setting by loosening screws adjusting cap and retightening screw.

CORRECT SETTINGS: NAT: 3/16” (5mm) open / L.P: 5/8” (16mm) open

2. Re-install burner into fireplace, making sure orifice is properly seated inside burner venturi and pilot hood is above burner assembly.

3. Re-install pilot shield.

4. Re-install logs.

5. Turn on gas and electrical supplies. Check for leaks at all connections with soapy water, whether field or factory made.

6. Test inlet pressure. Visually check pilot flame. Flame should envelope top of flame sensor and extend onto burner far enough for proper ignition. To Adjust pilot: Turn pilot adjustment screw clockwise to decrease or counter-clockwise to increase pilot flame.


8. Affix gas type sticker to label.

9. Re-install glass frame.

10. Verify proper ignition and operation of fireplace.

11.

Complete and affix ‘Gas Conversion’ label to outer wrap close to gas valve.

BURNER VENTURI

Figure 14a

PROPER BURNER / PILOT ORIENTATION

(Your pilot may look slightly different than one shown)

Figure 14b

GAS CONVERSION LABEL

(included with conversion kit)

Figure 14c

NATURAL GAS LP GAS

MINIMUM INLET GAS PRESSURE 5” WC (1.25 kPa) (7” WC (1.74 kPa) recommended) 11” WC (2.74 kPa) (recommended)

MAXIMUM INLET GAS PRESSURE 10.5” WC (2.62 kPa)



3.5” WC (.87 kPa)

1.6” WC (.40 kPa)

13” WC (3.24 kPa)

10” WC (2.49 kPa)

6.4” WC (1.59 kPa)

14








Figure 15a


Figure 15b





Improper Venting


WARNING Burner tube adjustable venturi positioning should only be performed by a qualified professional service technician.



NATURAL GAS LP (PROPANE) GAS

3/16” (5mm) OPEN 5/8” (16mm) OPEN


Closed too far

Open too far


FLAME COLOR VENTURI ADJUSTMENT


Blue flames



IMPORTANT






2. Remove log set.


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



Figure 15c

BURNER VENTURI

15

MAINTENANCE



NOTE





.





Figure 16a

911 Pilot

Burner Orifice Burner Ports

FAN


VENT SYSTEM



INSTALLATION.











IMPORTANT


CAUTION




LIQUIDS.

16

BI

M

C

AJ

911-770

911-771

700-023

700-086A

700-087A

700-064

700-064-1

700-090

700-060

911-035

911-35

REPLACEMENT PARTS LIST

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

932-500A

AD

AG

HB

900-REMB

911 Control Board - Nat Gas

911 Control Board - LP Gas

On/Off Rocker Switch

S.I.T. Valve - Natural Gas

S.I.T. Valve - LP Gas

Pilot Assembly - Nat Gas

Pilot Assembly - LP Gas

Piezo Igniter w/ Nut (no wire)

Flexible Pilot Tubing (Valve to Pilot)

Burner Tube

Burner Plate

911 CONTROL BOARD AND PARTS

700-094 Natural Gas Pilot Orifice

700-095

700-092

700-059

700-203

700-213-B

700-225-F

700-232

700-250

OCK-S32A

OCK-S50A

LP Gas Pilot Orifice

Millivolt Generator

Thermocouple

Manual Shut-off Valve

18” Flexible Gas Line-Black

Flexible Gas Line-Valve to Burner Connection

Natural Gas Orifice #32

LP Gas Orifice #50

Natural Gas Conversion Kit

LP Gas Conversion Kit

LOG SET

8 pc. Log Set

AD Log

AG Log

HB Log

BI Log

M Log

C Log

AJ Log

Rock Wool Embers

911-G900

REFRACTORY PANELS

(Sandstone)

Back / Sides Refractory Panels - 3pc.

911-G900B Back Refractory Panel (only)

911-G900S Side Refractory Panel (1side only)

GLASS & GLASS GASKET

Replacement Valance - only 911-005

900-006

700-08T

911-028

1-1/8” Glass Gasket w/ Adhesive

12” x 27” Glass with Gasket

FAN ASSEMBLY

Fan Kit


P.O. Box 577


Lakefield, MN 56150-0577

USA

911

www.kozyheat.com

17




IMPORTANT:









—







instructions.




WARNING





MAY 2013

911-IPI-SUP-REV-02


SAFETY INFORMATION

Safety Information

SPECIFICATIONS

Components List


WIRING SCHEMATICS

Wiring Schematics


Control System Components

System Operations

Lighting and Shutdown

Pressure Testing

TROUBLESHOOTING

Troubleshooting



MAINTENANCE

Maintenance

REPLACEMENT PARTS

Replacement Parts


4

5-6

7-10

11-12

13

2

3

3

14-15

16-18

19

20

1




























2

SPECIFICATIONS

911-IPI COMPONENTS LIST

PART NUMBER

911-100

700-203

911-135

911-G900

932-500A

700-08T

815-CL1

911-IPI-028

700-308

900-085

DESCRIPTION

Control Board Assembly


Burner Assembly

Firebrick Refractory Set

Log Package

Glass Assembly

Co-Linear Air Chute

Fan Kit

Remote Control






ORIFICE SIZE



NATURAL GAS


911-IPI

LP GAS


10.5” WC (2.62 kPa)

3.5” WC (.87 kPa)

1.6” WC (.40 kPa)

#32

36,500 BTU/hr (10.7 kW)

27,500 BTU/hr (8.06 kW)

13” WC (3.24 kPa)

10” WC (2.49 kPa)

6.4” WC (1.59 kPa)

#50

32,000 BTU/hr (9.03 kW)

23,500 BTU/hr (6.89kW)

3

WIRING SCHEMATICS

IMPORTANT

THIS SYSTEM REQUIRES ELECTRICITY (120V) AND / OR BATTERIES TO OPERATE.

USING BATTERY BACK UP WILL OPERATE BURNER ONLY. FAN AND LIGHT COMPONENTS WILL NOT FUNCTION ON BATTERY

BACK-UP POWER.

Pilot Assembly

To Fan

To Lights

Green

Orange

Green / yellow

Figure 4a

Not used

4

CONTROL SYSTEM COMPONENTS

REMOTE CONTROL

Figure 5a

GAS VALVE

Stepper motor

Main valve connection (green)

Outlet pressure tap

Pilot connection (orange)

Figure 5b

Inlet pressure tap

Pilot flame adjustment

PILOT ASSEMBLY

Flame Sensor

Figure 5c

5

Igniter

Pilot

RECEIVER


Figure 6a

FAN CONTROL MODULE

Figure 6b

DFC CONTROL BOARD

Figure 6c

6

SYSTEM OPERATION

INITIALIZING THE SYSTEM FOR THE FIRST TIME

1. Move slider switch on receiver to OFF position.

2. Install 4 AA batteries (included in components packet) into receiver battery bay.

3. Using the end of a paper clip, or other similar object, press button through hole marked PRG on receiver front cover. Receiver will ‘beep’ three (3) times to indicate it is ready to synchronize with a transmitter.

4. Install 3 AAA batteries (included in components packet) into transmitter battery bay (located on base of transmitter). Push the ON button. The receiver will beep four (4) times to indicate the transmitter’s command is accepted and set to the particular code of that transmitter.

5. Push OFF button on transmitter. The receiver will ‘beep’ two (2) times to indicate the transmitter’s command is again accepted.

6. Move slider switch to REMOTE position.

7. Turn On fan control module, switching to ON ( | ) position.

8. The system is now initialized.

Figure 7a

NOTE This procedure must be performed every time batteries are replaced in Receiver or Transmitter.

TEMPERATURE DISPLAY

With the system in OFF position, press Thermostat Key and Mode Key at the same time to change from degrees F to C. Look at transmitter LCD screen to verify that C or F is visible on right side of Room Temperature display.

Figure 7b

TURN ON THE APPLIANCE

Press ON/OFF key on transmitter. The display will show all active icons on the screen. A single ‘beep’ from receiver will confirm reception of the command.

TURN OFF THE APPLIANCE

Press ON/OFF key on transmitter. The display will show only room temperature and icon on the screen. A single ‘beep’ from receiver will confirm reception of the command.

7


REMOTE FLAME CONTROL

The remote control has six (6) flame levels. With system ON and flame level at maximum, press Down Arrow Key once to reduce flame height by one step until flame is turned off. The Up Arrow Key will increase flame height on step each time it is pressed. If Up Arrow Key is pressed while system is on but flame is off, the flame will come on in High position. A single ‘beep’ will confirm reception of the command.

Figure 8a

ROOM THERMOSTAT (Transmitter Operation)

The remote control can operate as a room thermostat. The thermostat can be set to desired temperature to control a rooms comfort level.

To activate this function, press the Thermostat Key. The LCD display will change to show the room thermostat is ON and set temperature is now displayed. To adjust set temperature, press Up or Down arrow keys until desired set temperature is display on LCD screen.

Figure 8b

SMART THERMOSTAT (Transmitter Operation)

The Smart Thermostat function adjusts flame height based on set temperature and actual room temperature. As room temperature gets closer to set point the Smart Function will automatically adjust flame down.

1. Press Thermostat key until the word SMART appears on right side of temperature bulb graphic.

2. To adjust set temperature, press Up/Down arrow keys until desired set temperature is displayed on LCD screen.

Figure 8c

8


FAN SPEED CONTROL

Fan speed can be adjusted through six (6) speeds. To activate this function use Mode Key to index to fan control icon. Use Up/Down Arrow

Keys to turn on, off or adjust fan speed. A single ‘beep’ will confirm reception of the command.

Figure 9a

ACCENT LIGHT KIT (not available in all fireplace models)

The auxiliary function controls the AUX power outlet on the Fan control module which in turn controls the light kit.

1. Use MODE key to guide you to AUX icon.

2. Press Up Arrow Key to turn light kit on, press Down Arrow Key to turn light kit off. A single ‘beep’ will confirm reception of the command.

3. Use the installed dimmer switch to adjust brightness of lights.

Figure 9b

KEY LOCK

This function locks the keys to avoid unsupervised operation.

To Activate: Press MODE and UP keys at same time.

To De-activate: Press MODE and UP keys at same time.

Figure 9c

9


LOW BATTERY DETECTION

TRANSMITTER: Remote control battery lifespan depends on various factors including battery quality, number of ignitions, changes to room thermostat set point, etc.

When transmitter batteries are low, a Battery Icon will appear on the LCD display before all battery power is lost. When batteries are replaced this icon will disappear.

RECEIVER: Receiver battery lifespan depends on various factors including battery quality, number of ignitions, changes to room thermostat set point, etc.

When receiver batteries are low, no ‘beep’ will be emitted from Receiver when it receives an ON/OFF command from the Transmitter. This is an alert for a low battery condition for the Receiver. When the batteries are replaced the ‘beep’ will be emitted from the Receiver when

ON/OFF Key is pressed.

Figure 10a

MANUAL BYPASS OF REMOTE SYSTEM

If batteries of the Receiver or Transmitter are low or depleted, the appliance can be turned on by sliding the three position slider switch on the Receiver to the ON position. This will bypass the remote control feature of the system and the appliance main burner will come on if gas valve is in the ON position.

CONTINUOUS PILOT OPTION

This system has the option of a continuous (standing) pilot feature. This allows you to change from a spark-to-pilot system to a standing pilot system during cold weather conditions. By having the pilot on continuously, the firebox will remain warm and a draft is established in the vent, allowing the main burner to turn on with less air-flow disruption.

When continuous pilot mode is activated and fireplace is turned ON, the pilot will spark and light. When fireplace is turned OFF, the pilot will remain lit when main burner has been turned OFF.

DIRECT FIREPLACE OPERATION

The fireplace may be directly operated from the receiver.

ON: Fireplace burner turns on (regardless of transmitter settings).

OFF: Fireplace burner turns off (regardless of transmitter settings).

REMOTE: Fireplace is controlled by remote control (transmitter).

NOTE

When receiver switch is turned to ON or Off, mode settings (Accent Lights, Fan, Flame Height, Smart Thermostat) will remain in same state as before switch was moved. If you wish to adjust mode settings use transmitter mode button to adjust settings.

The thermostat and burner ON/OFF operating functions will not work on the transmitter.

10


FOR YOUR SAFETY - READ BEFORE OPERATING

WARNING

IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT,

CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

1. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand.

2. BEFORE OPERATING, 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.


* 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.

3. 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.

WARNING



SUPERVISED WHEN THEY ARE IN THE SAME ROOM AS THE APPLIANCE.

CLOTHING OR OTHER FLAMMABLE MATERIAL MUST NOT BE PLACED ON OR NEAR THE APPLIANCE.



NOTE


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

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





11


OPERATING INSTRUCTIONS

STOP!

Read safety information on previous page and front c o v e r o f t h i s m a n u a l b e f o r e c o n t i n u i n g .

1. Turn off all electric power to the appliance.

ATTENTION

This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand.

2. Press hand held remote OFF button.

3. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow ‘WHAT

TO DO IF YOU SMELL GAS’ below. If you don’t smell gas, go to next step.



Do not touch any electric switch; do not use any phone in your building.




1

3

5 MINUTES

4

Power OFF

2

OFF

5

Power ON

4. Turn ON all electric power to the appliance.

5. Press hand held remote ON button.

CAUTION

If fireplace will not operate, follow instructions

TO T U RN GA S O FF TO AP PLI AN CE a n d ca ll y o u r s e r v i c e t e c h n i c i a n o r t h e g a s s u p p l i e r .

Figure 12a

ON

NOTE


TO TURN GAS OFF TO APPLIANCE

1. Press hand held remote OFF button.

2. Turn OFF all electric power to appliance if service is to be performed.

3. Manual shut-off valve located behind lower grill. Turn manual shut-off valve to OFF.

1

OFF

3

2

Power OFF

12

Figure 12b


IMPORTANT

Pressure check taps for 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. Refer to page 17 for proper NAT and LP manifold pressures.

NOTE

The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa). The appliance must be isolated from the gas supply piping system by closing its equipment shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less that 1/2 psi (3.5 kPa).




3. Set IPI/CPI switch to CPI setting.

4. Light pilot. Note manometer reading.

5. Move receiver slider switch to ON. Burner should light. Check pressure to ensure it stays between the min. and max. recommended pressure settings.

6. Set IPI/CPI switch to IPI setting . Move receiver slider switch to OFF. Pilot and burner should go out.


8. Relight pilot. Reattach manometer to inlet pressure tap to verify that it is completely sealed. Manometer should read no pressure.

NOTE


incoming gas pressure.

CAUTION

A LOW PRESSURE READING CAN CAUSE DELAYED IGNITION.


1. Light pilot.



4. Set IPI/CPI switch to CPI setting.

5. Move receiver slider switch to ON. Burner should light. Note manometer reading.

6. Set IPI/CPI switch to IPI setting. Move receiver slider switch to OFF.


8. Attach manometer to manifold pressure tap to verify it is completely sealed. Manometer should read no pressure when receiver slider switch is moved to ON.

Outlet (Manifold) Pressure Screw

Figure 13a

Inlet Pressure Screw

13

TROUBLESHOOTING

ATTENTION TROUBLESHOOTING MUST BE PERFORMED BY A QUALIFIED TECHNICIAN.

Before proceeding with the steps in the following troubleshooting guide, verify the power supply (AC/DC adapter or Fan Control Module) is present and receiver batteries and/or battery pack are fresh and installed with correct polarity.

Make sure all connections between wire harnesses and system components are proper and positive.

Make sure communication link between transmitter and receiver is established.

Verify inlet pressure meets the recommended inlet pressure. If necessary adjust line pressure regulator.

PILOT WILL NOT LIGHT / STAY LIT

Electrical power interrupted or disconnected. Restore electrical power to fireplace or use battery back-up. Ensure batteries are fully charged if using battery back-up as power source.

Verify gas supply is turned on. 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. 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.

No LP in tank. Check LP (propane) tank. Refill if necessary.

Wiring disconnection. Use wiring schematic in this manual to determine that all wiring connections are secure and correct.

Pilot flame not making contact with flame rectification sensor on pilot assembly. This valve is equipped with a pilot flame adjustment screw. Adjust as necessary.

Pilot adjustment screw not sealed. Seal pilot adjustment screw. Do not over tighten.

PILOT FLAME ALWAYS ON / WILL NOT EXTINGUISH

CPI/IPI switch set to CPI position (down). Set switch to IPI position (up).

MAIN FLAME WILL NOT LIGHT

Remote not working properly. Replace batteries.

Remote set to thermostat mode and there is no call for heat. Adjust heat setting.

Thermostat disconnected or set too high. Set thermostat to lower temperature setting.

Ensure pilot flame will ignite. If not, see pilot flame troubleshooting above.

Ensure pilot flame is properly located to ignite main flame.

Plugged main burner orifice.

Wiring disconnection / improper wiring. Check for faulty or incorrect wiring.

Verify gas supply is turned on.


14

TROUBLESHOOTING


No LP in tank. Check and refill if necessary.

Glass frame assembly not installed correctly. Refer to corresponding instructions in this manual.

Improper vent cap installation. Adjust if necessary.

Vent cap blockage. Remove debris if necessary.

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

Inner vent pipe leaking exhaust gases back into firebox. Check for leaks and repair if necessary.

Excessive draft.

GLASS SOOTING

Improper log placement. Refer to corresponding pages in this installation manual.

Improper venturi setting. Venturi may need to be opened slightly to allow more air into the gas mix.

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


Improper venturi setting. Venturi may need to be closed slightly.

Improper vent cap installation. Check for proper vent cap installation.

Blockage or vent system leaks.

NO REACTION TO COMMAND

Receiver or transmitter batteries low. Replace batteries.

No communication between remote control and receiver. Reprogram transmitter to receiver. Follow INITIALIZING THE SYSTEM

FOR THE FIRST TIME as outlined in this manual.

A maximum number of failed ignitions or flame restorations have been reached. Reset DFC control board.

1. Turn system off by pressing ON/OFF button on transmitter.

2. After approximately 2 seconds press ON/OFF button on transmitter again.

3. In manual flame mode, use down arrow button to reduce flame to off, indicated by the word OFF displayed on transmitter LCD screen.

4. Wait approximately 2 seconds and press up arrow button, the ignition sequence will start.

5. With the transmitter off, move slider switch on receiver to OFF position.

6. Wait approximately 2 seconds and move receiver switch to ON position.

15


#NCK-911-S NAT GAS CONVERSION KIT / #LCK-911-S LP GAS CONVERSION KIT

WARNING


IMPORTANT





Kit includes:

(1) Gas Conversion Label (1) Pilot Injector NAT #62 / LP #35 (1) Gas Label

(1) Burner Orifice: NAT #32 / LP #50 (1) Step Motor Pressure Regulator

CAUTION

WARNING


THE CONVERSION.



IMPORTANT






Burner Orifice




NAT #32 LP #50

Figure 16a

Figure 16b


1. Remove pilot hood by pulling it directly up from pilot bracket.

2. Insert 5/32” (4mm) hex key into hexagon key-way of injector, turn counter clockwise to remove from injector journal.

3. Place hex key into end of injector included with kit, install into injector journal, turning clockwise to a recommended torque of 9 lb-in.

(1.0 Nm) is achieved. (LP injectors have groove around top, Nat injectors do not. Numbers are stamped on pilot injectors).

NAT: #62 / LP: #35

4. Align tab on base of pilot hood with slot in side of pilot journal. Push hood down, directly into pilot bracket. Hood must sit squarely for proper operation.

16


CONVERT THE GAS CONTROL VALVE:

Follow stepper motor pressure regulator instruction sheet included with conversion kit to convert gas valve. (LP or NAT marked on stepper motor pressure regulator).





3. Re-install logs.







10.




Figure 17a



Figure 17b




MANIFOLD PRESSURE (HI) 3.5” WC (.87 kPa)

MANIFOLD PRESSURE (LO) 1.6” WC (.40 kPa)

13” WC (3.24 kPa)

10” WC (2.49 kPa)

6.4” WC (1.59 kPa)

17








Figure 18a


Figure 18b





Improper Venting




NATURAL GAS

3/16” (5mm) open

LP (PROPANE) GAS

5/8” (16mm)


Closed too far

Open too far


FLAME COLOR


Blue flames

VENTURI ADJUSTMENT




IMPORTANT






2. Remove log set.


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



18

BURNER VENTURI

Figure 18c

MAINTENANCE



NOTE





.





Figure 19a

911-IPI Pilot

Burner Orifice

Burner Ports

FAN


VENT SYSTEM



INSTALLATION.











IMPORTANT


CAUTION




LIQUIDS.

19



911-100

911-101

Control Board - Nat Gas

Control Board - LP Gas

700-557 SIT IPI Valve - Natural

700-557-1 SIT IPI Valve - LP

700-552

700-553

Proflame DFC Board

DFC Wire Harness Assembly

700-551 Pilot Assembly - Natural Gas

700-551-1 Pilot Assembly - LP Gas

700-308R Receiver

700-558 GTMFS Wire Harness

700-130

700-308

700-166

Fan Control Module

Transmitter

#62 Natural Gas Pilot Orifice

700-168 #35 LP Gas Pilot Orifice

FAN ASSEMBLY

911-IPI-028 Fan Assembly

911-G900


(Sandstone)




911-005

900-006

700-08T


Replacement Valance - only



LOG SET

932-500A

AD

AG

HB

8 pc. Log Set

AD Log

AG Log

HB Log

BI

M

C

AJ

BI Log

M Log

C Log

AJ Log

900-REMB Rock Wool Embers

CONTROL BOARD AND PARTS

700-503 Valve Step Motor - Natural Gas

700-503-1

700-203

700-213B

700-226

700-232

700-250

NCK-911-S

LCK-911-S

911-35

911-035

700-992

700-993

Valve Step Motor - LP Gas





LP Gas Orifice #50



Burner Plate

Burner Tube

Pilot Igniter (with wire)

Pilot Flame Sensor (with wire)


P.O. Box 577


Lakefield, MN 56150-0577

USA

911-IPI

www.kozyheat.com

20




IMPORTANT:









—







instructions.




WARNING





MAY 2013

911-MV-SUP-REV-02


SAFETY INFORMATION

Safety Information

SPECIFICATIONS

Components List


WIRING SCHEMATICS

Wiring Schematics


Control System Components

System Operations


Pressure Testing

TROUBLESHOOTING

Troubleshooting



MAINTENANCE

Maintenance

REPLACEMENT PARTS

Replacement Parts


5-6

7-9

10-12

13

14-15

16-18

19

2

3

3

4

20

1





























2

SPECIFICATIONS

#911-MV COMPONENTS

911-700

700-203

911-135

911-G900

932-500A

700-08T

815-CL1

900-085

911-IPI-028

700-308

Control Board Assembly


Burner Assembly

Refractory Set

Log Package

Glass Assembly

Co-Linear Air Chute


IPI Fan Kit

Remote Control





ORIFICE SIZE



NATURAL GAS


911-MV

LP GAS


10.5” WC (2.62 kPa)

3.5” WC (.87 kPa)

1.6” WC (.40 kPa)

#32

36,500 BTU/hr (10.7 kW)

27,500 BTU/hr (8.06 kW)

13” WC (3.24 kPa)

10” WC (2.49 kPa)

6.4” WC (1.59 kPa)

#50

32,000 BTU/hr (9.38 kW)

23,500 BTU/hr (6.89kW)

3

WIRING SCHEMATICS

IMPORTANT

THIS SYSTEM REQUIRES ELECTRICITY (120V) AND / OR BATTERIES TO OPERATE.

USING BATTERY BACK UP WILL OPERATE BURNER ONLY. FAN AND LIGHT COMPONENTS WILL NOT FUNCTION ON BATTERY

BACK-UP POWER.

Pilot Assembly

To Fan

To Lights

Millivolt Operator

(top view)

Figure 4a

Not used

Gas Valve

4


REMOTE CONTROL

Figure 5a

GAS VALVE

Step Motor

Valve Terminals

Figure 5b

PILOT ASSEMBLY

Thermopile

Pilot Hood

Electrode

Thermocouple

Figure 5c

5

Manifold Pressure Tab

Inlet Pressure Tab

Gas Control Knob

RECEIVER


Figure 6a

FAN CONTROL MODULE

Figure 6b


INITIALIZING THE SYSTEM FOR THE FIRST TIME

1. Move slider switch on receiver to OFF position.

2. Install 4 AA batteries (included in components packet) into receiver battery bay.

3. Move slider switch to REMOTE position.

4. Using the end of a paper clip, or other similar object, press button through hole marked PRG on receiver front cover. Receiver will ‘beep’ three (3) times to indicate it is ready to synchronize with a transmitter.

5. Install 3 AAA batteries (included in components packet) into transmitter battery bay (located on base of transmitter). Push the ON button. The receiver will beep four (4) times to indicate the transmitter’s command is accepted and set to the particular code of that transmitter.

6. Turn On fan control module, switching to ON ( | ) position.

7. The system is now initialized.

Figure 6c

NOTE This procedure must be performed every time batteries are replaced in Receiver or Transmitter.

6


TEMPERATURE DISPLAY

With the system in OFF position, press Thermostat Key and Mode Key at the same time to change from degrees F to C. Look at transmitter LCD screen to verify that C or F is visible on right side of Room Temperature display.

Figure 7a

REMOTE FLAME CONTROL

The remote control has six (6) flame levels. With system ON and flame level at maximum, press Down Arrow Key once to reduce flame height by one step until flame is turned off. The Up Arrow Key will increase flame height on step each time it is pressed. If Up Arrow Key is pressed while system is on but flame is off, the flame will come on in High position. A single ‘beep’ will confirm reception of the command.

Figure 7b

ROOM THERMOSTAT (Transmitter Operation)

The remote control can operate as a room thermostat. The thermostat can be set to desired temperature to control a rooms comfort level.

To activate this function, press the Thermostat Key. The LCD display will change to show the room thermostat is ON and set temperature is now displayed. To adjust set temperature, press Up or Down arrow keys until desired set temperature is display on LCD screen.

Figure 7c

7


SMART THERMOSTAT (Transmitter Operation)

The Smart Thermostat function adjusts flame height based on set temperature and actual room temperature. As room temperature gets closer to set point the Smart Function will automatically adjust flame down.

1. Press Thermostat key until the word SMART appears on right side of temperature bulb graphic.

2. To adjust set temperature, press Up/Down arrow keys until desired set temperature is displayed on LCD screen.

Figure 8a

FAN SPEED CONTROL

Fan speed can be adjusted through six (6) speeds. To activate this function use Mode Key to index to fan control icon. Use Up/Down Arrow

Keys to turn on, off or adjust fan speed. A single ‘beep’ will confirm reception of the command.

Figure 8b

ACCENT LIGHT KIT (not available in all fireplace models)

The auxiliary function controls the AUX power outlet on the Fan control module which in turn controls the light kit.

1. Use MODE key to guide you to AUX icon.

2. Press Up Arrow Key to turn light kit on, press Down Arrow Key to turn light kit off. A single ‘beep’ will confirm reception of the command.

3. Use the installed dimmer switch to adjust brightness of lights.

Figure 8c

8


KEY LOCK

This function locks the keys to avoid unsupervised operation.

To Activate: Press MODE and UP keys at same time.

To De-activate: Press MODE and UP keys at same time.

Figure 9a

LOW BATTERY DETECTION

TRANSMITTER: Remote control battery lifespan depends on various factors including battery quality, number of ignitions, changes to room thermostat set point, etc.

When transmitter batteries are low, a Battery Icon will appear on the LCD display before all battery power is lost. When batteries are replaced this icon will disappear.

RECEIVER: Receiver battery lifespan depends on various factors including battery quality, number of ignitions, changes to room thermostat set point, etc.

When receiver batteries are low, no ‘beep’ will be emitted from Receiver when it receives an ON/OFF command from the Transmitter. This is an alert for a low battery condition for the Receiver. When the batteries are replaced the ‘beep’ will be emitted from the Receiver when

ON/OFF Key is pressed.

Figure 9b

MANUAL BYPASS OF REMOTE SYSTEM

If batteries of the Receiver or Transmitter are low or depleted, the appliance can be turned on by sliding the three position slider switch on the Receiver to the ON position. This will bypass the remote control feature of the system and the appliance main burner will come on if gas valve is in the ON position.

TURN ON THE APPLIANCE

Follow instructions as outlined in Lighting and Shutdown. Pages 11-12.

Press ON/OFF key on transmitter. The display will show all active icons on the screen. A single ‘beep’ from receiver will confirm reception of the command.

TURN OFF THE APPLIANCE

Follow instructions as outlined in Lighting and Shutdown. Pages 11-12.

Press ON/OFF key on transmitter. The display will show only room temperature and icon on the screen. A single ‘beep’ from receiver will confirm reception of the command.

9



WARNING












C.


D.


WARNING



WARNING





NOTE






10



5 MINUTES

1. Turn off all electrical power to appliance.





PILOT







PILOT

TUBE

NOTE

CAUTION


Do not force.










9. Turn on all electric power to appliance.

10. Push gas control knob in slightly and turn counterclockwise to ON.

11. Move receiver switch to REMOTE position.

12. Press hand held remote ON button.

NOTE


Figure 11a

1 MINUTE

11



TURN BURNER OFF

To turn burner OFF, press hand held remote OFF button.


TURN PILOT OFF


DO NOT FORCE.

NOTE



Figure 12a

12


IMPORTANT

Pressure check taps for 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. Refer to page 17 for proper NAT and LP manifold pressures.

NOTE

The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa). The appliance must be isolated from the gas supply piping system by closing its equipment shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less that 1/2 psi (3.5 kPa).




3. Light pilot.


5. Press hand held remote ON button. Check pressure to ensure it stays near maximum inlet pressure.

6. Press hand held remote OFF button.





NOTE




1. Light pilot.




5. Press hand held remote ON button and note manometer reading.

6. Press hand held remote OFF button.


8. Attach manometer to manifold pressure tap to verify it is completely sealed. Manometer should read no pressure when burner is turned on.


MANIFOLD

INLET

Figure 13a

13

TROUBLESHOOTING

ATTENTION TROUBLESHOOTING MUST BE PERFORMED BY A QUALIFIED TECHNICIAN.

Before proceeding with the steps in the following troubleshooting guide, verify the power supply (AC/DC adapter or Fan Control Module) is present and receiver batteries and/or battery pack are fresh and installed with correct polarity.

Make sure all connections between wire harnesses and system components are proper and positive.

Make sure communication link between transmitter and receiver is established.

Verify inlet pressure meets the recommended inlet pressure. If necessary adjust line pressure regulator.

PILOT WILL NOT LIGHT / STAY LIT

Electrical power interrupted or disconnected. Restore electrical power to fireplace or use battery back-up. Ensure batteries are fully charged if using battery back-up as power source.

Verify gas supply is turned on. 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.


No LP in tank. Check LP (propane) tank. Refill if necessary.

Wiring disconnection. Use wiring schematic in this manual to determine that all wiring connections are secure and correct.

Pilot flame not making contact with flame rectification sensor on pilot assembly. This valve is equipped with a pilot flame adjustment screw. Adjust as necessary.

Pilot adjustment screw not sealed. Seal pilot adjustment screw. Do not over tighten.

PILOT FLAME ALWAYS ON / WILL NOT EXTINGUISH

CPI/IPI switch set to CPI position (down). Set switch to IPI position (up).

MAIN FLAME WILL NOT LIGHT

Remote not working properly. Replace batteries.

Remote set to thermostat mode and there is no call for heat. Adjust heat setting.

Thermostat disconnected or set too high. Set thermostat to lower temperature setting.

Ensure pilot flame will ignite. If not, see pilot flame troubleshooting above.

Ensure pilot flame is properly located to ignite main flame.

Plugged main burner orifice.

Wiring disconnection / improper wiring. Check for faulty or incorrect wiring.

Verify gas supply is turned on.


14

TROUBLESHOOTING


No LP in tank. Check and refill if necessary.

Glass frame assembly not installed correctly. Refer to corresponding instructions in this manual.

Improper vent cap installation. Adjust if necessary.

Vent cap blockage. Remove debris if necessary.

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

Inner vent pipe leaking exhaust gases back into firebox. Check for leaks and repair if necessary.

Excessive draft.

GLASS SOOTING

Improper log placement. Refer to corresponding pages in this installation manual.

Improper venturi setting. Venturi may need to be opened slightly to allow more air into the gas mix.

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


Improper venturi setting. Venturi may need to be closed slightly.

Improper vent cap installation. Check for proper vent cap installation.

Blockage or vent system leaks.

NO REACTION TO COMMAND

Receiver or transmitter batteries low. Replace batteries.

No communication between remote control and receiver. Reprogram transmitter to receiver. Follow INITIALIZING THE SYSTEM

FOR THE FIRST TIME as outlined in this manual.

15


#NCK-911MV-SH NAT GAS CONVERSION KIT / #LCK-911MV-SH LP GAS CONVERSION KIT

WARNING


IMPORTANT





Kit includes:

(1) Gas Conversion Label (1) Pilot Orifice NAT #BL22N / LP #BL14LP (1) Gas Label

(1) Burner Orifice NAT #32 / LP #50 (1) Step Motor Pressure Regulator

CAUTION

WARNING


THE CONVERSION.



IMPORTANT






Burner Orifice




NAT #32

LP #50

Figure 16a

LP

NAT

Figure 16b

PILOT ORIFICE








16


CONVERT THE GAS CONTROL VALVE:

Follow stepper motor pressure regulator instruction sheet included with conversion kit to convert gas valve. (LP or NAT marked on stepper motor pressure regulator).





3. Re-install logs.







10.




Figure 17a



Figure 17b

* REFER TO FIREPLACE INSTALLATION MANUAL IF NECESSARY.




MANIFOLD PRESSURE (HI) 3.5” WC (.87 kPa)

MANIFOLD PRESSURE (LO) 1.6” WC (.40 kPa)

13” WC (3.24 kPa)

10” WC (2.49 kPa)

6.4” WC (1.59 kPa)

17








Figure 18a


Figure 18b





Improper Venting






3/16” (5mm) open 5/8” (16mm) open


Closed too far

Open too far




Blue flames




IMPORTANT





1. Remove glass frame assembly, log set and burner assembly

2. Loosen burner venturi screw, make adjustment, retighten screw.

3. Reinstall burner, making sure venturi is positioned over burner orifice.

4. Reinstall log set and glass frame assembly.


18

BURNER VENTURI

Figure 18c

MAINTENANCE



NOTE





.





Figure 19a

911-RAD Pilot


FAN


VENT SYSTEM



INSTALLATION.











IMPORTANT


CAUTION




LIQUIDS.

19



911-700

911-701

700-084

700-085

Control Board - Nat Gas

Control Board - LP Gas

SIT MV Valve - Natural

SIT MV Valve - LP

700-064

700-064-1

700-308R

700-558

700-130

700-308

Pilot Assembly - Natural Gas


Receiver

GTMFS Wire Harness

Fan Control Module

Transmitter

700-403S Valve Step Motor - Natural Gas

700-403S-1 Valve Step Motor - LP Gas

700-094 Natural Gas Pilot Orifice

FAN ASSEMBLY

911-IPI-028 Fan Assembly

911-G900





911-005

900-006

700-08T


Replacement Valance - only



CONTROL BOARD AND PARTS

700-095 LP Gas Pilot Orifice

700-203

700-213B

700-226




700-232

700-250


LP Gas Orifice #50

NCK-911MV-SH Natural Gas Conversion Kit

LCK-911MV-SH LP Gas Conversion Kit

911-35 Burner Plate

911-035 Burner Tube

700-993

700-992

Pilot Flame Sensor (with wire)

Pilot Igniter (with wire)

(Sandstone)

BI

M

C

AJ

932-500A

AD

AG

HB

900-REMB

LOG SET

8 pc. Log Set

AD Log

AG Log

HB Log

BI Log

M Log

C Log

AJ Log

Rock Wool Embers


P.O. Box 577


Lakefield, MN 56150-0577

USA

911-MV

www.kozyheat.com

20



DIRECT VENT GAS FIREPLACE INSERT

IMPORTANT:









—







instructions.




WARNING





MAY 2013

911-RAD-SUP-REV-02


SAFETY INFORMATION

Safety Information

SPECIFICATIONS

Components List


FAN INSTALLATION

Fan Installation

THERMOSTAT / WALL SWITCH / REMOTE

Thermostat / Wall Switch / Remote


Valve and Pilot Assembly Components


Pressure Testing

TROUBLESHOOTING

Troubleshooting



MAINTENANCE

Maintenance

REPLACEMENT PARTS

Replacement Parts


2

14-16

17

6

7-9

10

4

3

3

5

11-13

18

1





























2

SPECIFICATIONS

#911-RAD COMPONENTS

911-770 Millivolt Control Board Assembly

700-203

911-135

911-G900

932-500A

7-00-08T

815-CL1

900-085


Burner Assembly

Refractory Set

Log Package

Glass Assembly

Co-Linear Air Chute






ORIFICE SIZE



NATURAL GAS


911-RAD

LP GAS


10.5” WC (2.62 kPa)

3.5” WC (.87 kPa)

1.6” WC (.40 kPa)

#32

36,500 BTU/hr (10.7 kW)

27,500 BTU/hr (8.06 kW)

13” WC (3.24 kPa)

10” WC (2.49 kPa)

6.4” WC (1.59 kPa)

#50

32,000 BTU/hr (9.38 kW)

23,500 BTU/hr (6.89kW)

3

OPTIONAL FAN INSTALLATION

INSTALLATION OF THIS FAN SHOULD BE DONE ONLY BY A QUALIFIED INSTALLER

WARNING

MAKE SURE HOUSEHOLD BREAKER IS SHUT OFF PRIOR TO WORKING ON ANY ELECTRICAL LINES.

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

GROUNDING PRONG FROM THIS PLUG.

IMPORTANT

If installing a fan, it is easier to complete prior to connecting millivolt board to gas supply. Wiring must be done before enclosing fireplace sides.

An electrical box and romex connector are pre-installed on a removable panel on right side of fireplace. A receptacle / speed control assembly and

(3) wire nuts must be purchased separately. See you dealer for details

NOTE

Code approved line voltage wiring 14 gauge or better must be used when wiring this assembly.

Refer local electrical codes for specific requirements.

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.

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

Optional fan kit #911-028 includes: (2) 75 CFM fan with temperature control switch and 4ft. (1219mm) fan cord

(4) 1/4” nuts (#

600-083C Speed Control / Receptacle assy. w/ power cord may be purchased separately)

1. If not previously done, turn gas valve and manual shut off valve to OFF. Disconnect gas line from manual shut off valve.


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

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

5. From inside lower right grill opening, loosen screw securing removable access panel (with electrical box & romex connector installed).

Remove panel.

6. Insert 115V wiring (with ground) through romex connector and wire to speed control / receptacle assembly matching black (hot), white (neutral), and green (ground) wires to corresponding wires on speed control / receptacle assembly.

7. Secure speed control / receptacle assembly (purchased separately) to electrical box with (2) screws provided.

8. Re-install electrical access panel. Tighten screw.

9. Place thermostatic control switch on bottom of firebox.

10. Plug power cord into electrical box receptacle.

11. Turn speed control counter-clockwise until it ‘clicks’. This is the OFF position.

12. Turn speed control ON by turning knob clockwise past the ‘click’ - this is the highest setting.

13. Re-install glass frame assembly.

Temperature Switch

Electrical Box

Incoming wiring-

60Hz

110V-120V

TEMPERATURE CONTROL SWITCH POSITION

Before adjusting temperature control switch, unplug 3-prong plug on fan cord from receptacle. Adjust position of temperature control switch to a warmer location under firebox to turn fan ON sooner or move it to a cooler location under firebox to turn fan

ON later. The fan will turn on when sensor in temperature control switch reaches 110° F and will turn OFF when sensor reaches 90°

F. After adjustment, insert fan cord 3-prong plug into receptacle.

Speed Control

Receptacle Assembly

Figure 4a

4

THERMOSTAT / WALL SWITCH / REMOTE

If desired, a thermostat (wireless style also available), wall switch, or remote control assembly may be used to turn fireplace OFF and ON.

Only ONE of these may be installed. Follow instructions included with chosen assembly.

NOTE

INSTALLATION OF THERMOSTAT OR WALL SWITCH SHOULD ONLY BE PERFORMED BY A QUALIFIED INSTALLER.

CAUTION

DO NOT CONNECT HIGH VOLTAGE (115V) WIRE TO THE GAS VALVE!

Remote Control Wiring Diagram

Thermostat Wiring Diagram

OPTIONAL

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

Figure 5a

WALL SWITCH / THERMOSTAT:

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

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

REMOTE CONTROL:

Follow instructions included with remote control

.

IMPORTANT

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

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

NOTE

Fireplace must be turned ON and OFF by same method. For example: If fireplace is turned ON by remote control, it must be turned OFF by remote control.

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

5

VALVE & PILOT ASSEMBLY COMPONENTS

THERMOPILE

PILOT HOOD

ELECTRODE

THERMOCOUPLE

PIEZO IGNITOR

GAS CONTROL KNOB

HI /LO FLAME ADJUSTMENT KNOB

VALVE TERMINALS

Figure 6a

6

ON/OFF ROCKER SWITCH



WARNING












C.


D.


WARNING



WARNING





NOTE






7



5 MINUTES

1. Set thermostat to lowest setting, if installed.

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





PILOT







PILOT

TUBE

NOTE


Do not force.







1 MINUTE

CAUTION




10. Push gas control knob in slightly and turn counterclockwise to ON. The burner can now be turned ON by depressing

ON/OFF rocker switch located beside valve, or wall switch,

OR by setting thermostat or remote control to desired setting.

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

NOTE


Figure 8a

8



TURN BURNER OFF

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


TURN PILOT OFF


DO NOT FORCE.

NOTE



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 middle knob on gas control valve.

Figure 9a

Figure 9b

Figure 9c

9


IMPORTANT

Pressure check taps for manifold (outgoing) and inlet (incoming) pressure have been incorporated into the valve. The pressure tap marked OUT measures outgoing pressure and 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 gas supply piping system during any pressure testing of that system at pressures in excess of ½ psi (3.5 kPa).

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).




3. Light pilot.


5. Press rocker switch to ON. Check pressure to ensure it stays near maximum inlet pressure.






NOTE




1. Light pilot.




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



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


MANIFOLD

INLET

Figure 10a

10

CAUTION

TROUBLESHOOTING

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” (3mm) 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 IGNITER 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 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 end of thermocouple and other millivolt meter lead

wire on thermocouple’s copper wire. Start pilot while holding valve knob in. If millivolt reading is less than 15 millivolts, replace

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.

11

TROUBLESHOOTING

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 intake duct.

MORE TROUBLESHOOTING ON FOLLOWING PAGE

12

TROUBLESHOOTING


A. No LP (propane) in tank.

♦ Check tank and refill if necessary.

B. Glass frame assembly not installed correctly.

♦ Refer to installation 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.


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” (6mm). 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 in fireplace installation manual.

B. Improper venturi setting.

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

C. Improper pitch on horizontal venting.



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.

13


#OCK-S32A NAT GAS CONVERSION KIT / #OCK-S50A LP GAS CONVERSION KIT

WARNING


IMPORTANT





Kit includes:

(1) Burner Orifice: NAT #32 / LP #50 (1) Pilot Orifice: NAT #BL22N / LP #BL14LP (1) Gas Label

(1) Valve and Pilot Assembly Conversion Instructions (1) Gas Conversion Label

CAUTION

WARNING


THE CONVERSION.



IMPORTANT






Burner Orifice




NAT #32

LP #50

Figure 14a

LP

NAT

Figure 14b

PILOT ORIFICE








14






3. Re-install pilot shield.

4. Re-install logs.







11.


BURNER VENTURI

Figure 15a



Figure 15b



Figure 15c






3.5” WC (.87 kPa)

1.6” WC (.40 kPa)

13” WC (3.24 kPa)

10” WC (2.49 kPa)

6.4” WC (1.59 kPa)

15








Figure 16a


Figure 16b





Improper Venting






3/16” (5mm) OPEN 5/8” (16mm) OPEN


Closed too far

Open too far




Blue flames



IMPORTANT






2. Remove log set.


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



Figure 16c

BURNER VENTURI

16

MAINTENANCE



NOTE





.





Figure 17a

911-RAD Pilot


FAN


VENT SYSTEM



INSTALLATION.











IMPORTANT


CAUTION




LIQUIDS.

17

BI

M

C

AJ

911-770

911-771

700-023

700-086A

700-087A

700-064

700-064-1

700-090

700-060

911-035

700-094



932-500A

AD

AG

HB

911 Control Board - Nat Gas

911-RAD CONTROL BOARD AND PARTS

700-095 LP Gas Pilot Orifice

911 Control Board - LP Gas

On/Off Rocker Switch

S.I.T. Valve - Natural Gas

S.I.T. Valve - LP Gas

Pilot Assembly - Nat Gas


Piezo Igniter w/ Nut (no wire)

Flexible Pilot Tubing (Valve to Pilot)

Burner Tube

Natural Gas Pilot Orifice

700-092

700-059

700-203

700-213-B

700-225-F

700-232

700-250

OCK-S32A

OCK-S50A

Millivolt Generator

Thermocouple





LP Gas Orifice #50



8 pc. Log Set

AD Log

AG Log

HB Log

BI Log

M Log

C Log

AJ Log

LOG SET

911-G900


(Sandstone)





Replacement Valance - only 911-005

900-006

700-08T



900-REMB Rock Wool Embers


P.O. Box 577


Lakefield, MN 56150-0577

USA

911-RAD

www.kozyheat.com

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