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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
VENTING INSTALLATION
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
VENTING INSTALLATION
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
VENTING INSTALLATION
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:
1. Remove glass frame assembly.
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
FINALIZING THE INSTALLATION
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
FINALIZING THE INSTALLATION
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.
The flow of combustion and ventilation air must not be obstructed.
GLASS CLEANING & REPLACEMENT
Clean glass only when cool and only with non-abrasive cleansers.
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 SUBSTITUTE MATERIALS.
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.
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
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.
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 No. 216-F-22b-6.5
MAY 2013
911-SUP-REV-02
www.kozyheat.com
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
TABLE OF CONTENTS
2
13-15
16
5
6-8
9
3
3
4
10-12
17
1
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.
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
MINIMUM INLET GAS PRESSURE
MAXIMUM INLET GAS PRESSURE
MANIFOLD PRESSURE (HI)
MANIFOLD PRESSURE (LO)
ORIFICE SIZE
INPUT BTU/hr. (kW)
MINIMUM INPUT BTU/hr. (kW)
NATURAL GAS
5” WC (1.25 kPa) (7” WC (1.74 kPa) (recommended)
911
LP GAS
11” WC (2.74 kPa) (recommended)
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
WHAT TO DO IF YOU SMELL GAS:
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
LIGHTING AND SHUTDOWN (cont.)
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.
6. Press rocker switch to OFF.
7. Disconnect manometer hose and tighten screw (clockwise). Screw should be snug, do not over tighten.
8. Attach manometer to manifold pressure tap to verify 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.
♦ 1/4” (6mm) rise per foot is required 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
CONVERSION KIT INSTRUCTIONS
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.
7. Turn fireplace off.
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)
MANIFOLD PRESSURE (HI)
MANIFOLD PRESSURE (LO)
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
CONVERSION KIT INSTRUCTIONS
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 15a
Correct pilot flame
Figure 15b
Dark orange flames / black tips
Venturi closed too far
Excessive burner media
Lifting (ghosting) flames
Improper Venting
Gas pressure too high
WARNING Burner tube adjustable venturi positioning should only be performed by a qualified professional service technician.
FACTORY SET BURNER TUBE VENTURI SETTINGS
(ADJUST AS NECESSARY FOR YOUR INSTALLATION)
NATURAL GAS LP (PROPANE) GAS
3/16” (5mm) OPEN 5/8” (16mm) OPEN
VENTURI POSITION
Closed too far
Open too far
BURNER TUBE VENTURI ADJUSTMENT GUIDELINES
FLAME COLOR VENTURI ADJUSTMENT
Dark orange flame with black tips
Blue flames
Open venturi setting slightly
Close venturi setting slightly
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:
1. Remove glass frame assembly.
2. Remove log set.
3. Remove burner assembly.
4. Loosen screw on burner venturi and adjust as necessary. Tighten screws.
5. Reinstall all components previously removed.
6. Light fireplace and wait 15 minutes before determining if any further adjustments are needed.
Figure 15c
BURNER VENTURI
15
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 16a
911 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.
The flow of combustion and ventilation air must not be obstructed.
GLASS CLEANING & REPLACEMENT
Clean glass only when cool and only with non-abrasive cleansers.
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 SUBSTITUTE MATERIALS.
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.
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
Hussong Manufacturing Co., Inc.
P.O. Box 577
204 Industrial Park Drive
Lakefield, MN 56150-0577
USA
911
www.kozyheat.com
17
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.
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
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.
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 No. 216-F-22b-6.5
MAY 2013
911-IPI-SUP-REV-02
www.kozyheat.com
SAFETY INFORMATION
Safety Information
SPECIFICATIONS
Components List
Gas Pressure Requirements / BTU’s
WIRING SCHEMATICS
Wiring Schematics
OPERATING INSTRUCTIONS
Control System Components
System Operations
Lighting and Shutdown
Pressure Testing
TROUBLESHOOTING
Troubleshooting
CONVERSION KIT INSTRUCTIONS
Conversion Kit Instructions
MAINTENANCE
Maintenance
REPLACEMENT PARTS
Replacement Parts
TABLE OF CONTENTS
4
5-6
7-10
11-12
13
2
3
3
14-15
16-18
19
20
1
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.
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
Manual Gas Shut-off Valve
Burner Assembly
Firebrick Refractory Set
Log Package
Glass Assembly
Co-Linear Air Chute
Fan Kit
Remote Control
4” Restrictor Plate
MINIMUM INLET GAS PRESSURE
MAXIMUM INLET GAS PRESSURE
MANIFOLD PRESSURE (HI)
MANIFOLD PRESSURE (LO)
ORIFICE SIZE
INPUT BTU/hr. (kW)
MINIMUM INPUT BTU/hr. (kW)
NATURAL GAS
5” WC (1.25 kPa) (7” WC (1.74 kPa) (recommended)
911-IPI
LP GAS
11” WC (2.74 kPa) (recommended)
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
CONTROL SYSTEM COMPONENTS
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
SYSTEM OPERATION
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
SYSTEM OPERATION
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
SYSTEM OPERATION
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
LIGHTING AND SHUTDOWN
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.
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.
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
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.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS
OR ANY OTHER APPLIANCE.
NOTE
A PAINT SMELL WILL OCCUR DURING THE FIRST FEW HOURS OF BURNING. IT IS RECOMMENDED TO LEAVE
THE FAN OFF DURING THIS PERIOD TO HELP SPEED THE PAINT CURING PROCESS.
THIS FIREPLACE MAY PRODUCE NOISES OF VARYING DEGREE AS IT HEATS AND COOLS DUE TO METAL
EXPANSION AND CONTRACTION. THIS IS NORMAL AND DOES NOT AFFECT THE PERFORMANCE OR
LONGEVITY OF THE FIREPLACE.
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.
11
LIGHTING AND SHUTDOWN (cont.)
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.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electric switch; do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s phone.
Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department.
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
When fireplace is initially lit, condensation will appear on the glass; this is normal in all gas fireplaces and will disappear after several minutes.
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
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 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).
INLET PRESSURE TEST:
1. Loosen inlet (IN) pressure tap screw (counter-clockwise).
2. Attach manometer using a 5/16” I.D. hose.
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.
7. Disconnect hose and tighten screw (clockwise). Screw should be snug, do not over tighten.
8. Relight pilot. Reattach manometer to inlet pressure tap to verify that it is completely sealed. Manometer should read no pressure.
NOTE
If inlet pressure reading is too high or too low, contact the gas company. Only a qualified gas service technician should adjust
incoming gas pressure.
CAUTION
A LOW PRESSURE READING CAN CAUSE DELAYED IGNITION.
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. 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.
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 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.
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.
14
TROUBLESHOOTING
PILOT AND BURNER EXTINGUISH WHILE IN OPERATION
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.
FLAME BURNS BLUE AND LIFTS OFF BURNER
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
CONVERSION KIT INSTRUCTIONS
#NCK-911-S NAT GAS CONVERSION KIT / #LCK-911-S 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) 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 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 16a
Figure 16b
CONVERT PILOT ASSEMBLY:
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
CONVERSION KIT INSTRUCTIONS
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).
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 logs.
4. Turn on gas and electrical supplies. Check for leaks at all connections with soapy water, whether field or factory made.
5. 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.
6. Turn fireplace off.
7. Affix gas type sticker to label.
8. Re-install glass frame.
9. Verify proper ignition and operation of fireplace.
10.
Complete and affix ‘Gas Conversion’ label to outer wrap close to gas valve.
PROPER BURNER / PILOT ORIENTATION
(Your pilot may look slightly different than one shown)
Figure 17a
GAS CONVERSION LABEL
(included with conversion kit)
Figure 17b
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)
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
CONVERSION KIT INSTRUCTIONS
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 18a
Correct pilot flame
Figure 18b
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:
1. Remove glass frame assembly.
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.
18
BURNER VENTURI
Figure 18c
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 19a
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.
The flow of combustion and ventilation air must not be obstructed.
GLASS CLEANING & REPLACEMENT
Clean glass only when cool and only with non-abrasive cleansers.
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 SUBSTITUTE MATERIALS.
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.
19
REPLACEMENT PARTS LIST
Replacement parts are available through your local dealer. Contact them for availability and pricing.
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
REFRACTORY PANELS
(Sandstone)
Back / Sides Refractory Panels - 3pc.
911-G900B Back Refractory Panel (only)
911-G900S Side Refractory Panel (1side only)
911-005
900-006
700-08T
GLASS & GLASS GASKET
Replacement Valance - only
1-1/8” Glass Gasket w/ Adhesive
12” x 27” Glass with Gasket
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
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
Burner Plate
Burner Tube
Pilot Igniter (with wire)
Pilot Flame Sensor (with wire)
Hussong Manufacturing Co., Inc.
P.O. Box 577
204 Industrial Park Drive
Lakefield, MN 56150-0577
USA
911-IPI
www.kozyheat.com
20
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.
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
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.
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 No. 216-F-22b-6.5
MAY 2013
911-MV-SUP-REV-02
www.kozyheat.com
SAFETY INFORMATION
Safety Information
SPECIFICATIONS
Components List
Gas Pressure Requirements / BTU’s
WIRING SCHEMATICS
Wiring Schematics
OPERATING INSTRUCTIONS
Control System Components
System Operations
Lighting and Shutdown Instructions
Pressure Testing
TROUBLESHOOTING
Troubleshooting
CONVERSION KIT INSTRUCTIONS
Conversion Kit Instructions
MAINTENANCE
Maintenance
REPLACEMENT PARTS
Replacement Parts
TABLE OF CONTENTS
5-6
7-9
10-12
13
14-15
16-18
19
2
3
3
4
20
1
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.
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
Manual Gas Shut-off Valve
Burner Assembly
Refractory Set
Log Package
Glass Assembly
Co-Linear Air Chute
4” Restrictor Plate
IPI Fan Kit
Remote Control
MINIMUM INLET GAS PRESSURE
MAXIMUM INLET GAS PRESSURE
MANIFOLD PRESSURE (HI)
MANIFOLD PRESSURE (LO)
ORIFICE SIZE
INPUT BTU/hr. (kW)
MINIMUM INPUT BTU/hr. (kW)
NATURAL GAS
5” WC (1.25 kPa) (7” WC (1.74 kPa) (recommended)
911-MV
LP GAS
11” WC (2.74 kPa) (recommended)
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
CONTROL SYSTEM COMPONENTS
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
CONTROL SYSTEM COMPONENTS
Figure 6a
FAN CONTROL MODULE
Figure 6b
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. 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
SYSTEM OPERATION
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
SYSTEM OPERATION
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
SYSTEM OPERATION
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
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.
10
LIGHTING AND SHUTDOWN (cont.)
LIGHTING INSTRUCTIONS
5 MINUTES
1. Turn off all electrical power to appliance.
2. Open lower grill to access gas valve & controls.
3. Push gas control knob in slightly and turn clockwise to OFF.
4. 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
WHAT TO DO IF YOU SMELL GAS:
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
CAUTION
Gas control knob cannot be turned from PILOT to OFF unless knob is pushed in slightly.
Do not force.
5. Locate pilot - follow metal tube from gas control. (Located inside combustion chamber).
6. Push gas control knob on gas valve in slightly and turn counterclockwise to PILOT.
7. Push valve knob in and hold while repeatedly pressing piezo igniter button until pilot is lit while continuing to hold in gas control knob.
8. Hold gas control knob in for one (1) minute after pilot is lit.
Release gas control knob. If pilot goes out, repeat steps 3-8.
When pilot is lit, proceed to step 9.
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.
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
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 11a
1 MINUTE
11
LIGHTING AND SHUTDOWN (cont.)
TO TURN OFF GAS TO APPLIANCE
TURN BURNER OFF
To turn burner OFF, press hand held remote OFF button.
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).
Figure 12a
12
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 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).
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 hand held remote ON button. Check pressure to ensure it stays near maximum inlet pressure.
6. Press hand held remote OFF button.
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 hand held remote ON button and note manometer reading.
6. Press hand held remote OFF button.
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 burner is turned on.
CAUTION A LOW PRESSURE READING CAN CAUSE DELAYED IGNITION.
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.
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.
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.
14
TROUBLESHOOTING
PILOT AND BURNER EXTINGUISH WHILE IN OPERATION
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.
FLAME BURNS BLUE AND LIFTS OFF BURNER
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
CONVERSION KIT INSTRUCTIONS
#NCK-911MV-SH NAT GAS CONVERSION KIT / #LCK-911MV-SH 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) 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 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 16a
LP
NAT
Figure 16b
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.
16
CONVERSION KIT INSTRUCTIONS
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).
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 logs.
4. Turn on gas and electrical supplies. Check for leaks at all connections with soapy water, whether field or factory made.
5. 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.
6. Turn fireplace off.
7. Affix gas type sticker to label.
8. Re-install glass frame.
9. Verify proper ignition and operation of fireplace.
10.
Complete and affix ‘Gas Conversion’ label to outer wrap close to gas valve.
PROPER BURNER / PILOT ORIENTATION
(Your pilot may look slightly different than one shown)
Figure 17a
GAS CONVERSION LABEL
(included with conversion kit)
Figure 17b
* REFER TO FIREPLACE INSTALLATION MANUAL IF NECESSARY.
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)
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
CONVERSION KIT INSTRUCTIONS
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 18a
Correct pilot flame
Figure 18b
Dark orange flames / black tips
Venturi closed too far
Excessive burner media
Lifting (ghosting) flames
Improper Venting
Gas pressure too high
WARNING Burner tube adjustable venturi positioning should only be performed by a qualified professional service technician.
FACTORY SET BURNER TUBE VENTURI SETTINGS
(ADJUST AS NECESSARY FOR YOUR INSTALLATION)
NATURAL GAS LP (PROPANE) GAS
3/16” (5mm) open 5/8” (16mm) open
VENTURI POSITION
Closed too far
Open too far
BURNER TUBE VENTURI ADJUSTMENT GUIDELINES
FLAME COLOR VENTURI ADJUSTMENT
Dark orange flame with black tips
Blue flames
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:
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.
5. Light fireplace and wait 15 minutes before determining if any further adjustments are needed.
18
BURNER VENTURI
Figure 18c
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 19a
911-RAD 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.
The flow of combustion and ventilation air must not be obstructed.
GLASS CLEANING & REPLACEMENT
Clean glass only when cool and only with non-abrasive cleansers.
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 SUBSTITUTE MATERIALS.
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.
19
REPLACEMENT PARTS LIST
Replacement parts are available through your local dealer. Contact them for availability and pricing.
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
Pilot Assembly - LP 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
REFRACTORY PANELS
Back / Sides Refractory Panels - 3pc.
911-G900B Back Refractory Panel (only)
911-G900S Side Refractory Panel (1side only)
911-005
900-006
700-08T
GLASS & GLASS GASKET
Replacement Valance - only
1-1/8” Glass Gasket w/ Adhesive
12” x 27” Glass with Gasket
CONTROL BOARD AND PARTS
700-095 LP Gas Pilot Orifice
700-203
700-213B
700-226
Manual Shut-off Valve
18” Flexible Gas Line-Black
Flexible Gas Line-Valve to Burner Connection
700-232
700-250
Natural Gas Orifice #32
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
Hussong Manufacturing Co., Inc.
P.O. Box 577
204 Industrial Park Drive
Lakefield, MN 56150-0577
USA
911-MV
www.kozyheat.com
20
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 INSERT
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.
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
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.
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 No. 216-F-22b-6.5
MAY 2013
911-RAD-SUP-REV-02
www.kozyheat.com
SAFETY INFORMATION
Safety Information
SPECIFICATIONS
Components List
Gas Pressure Requirements / BTU’s
FAN INSTALLATION
Fan Installation
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
TABLE OF CONTENTS
2
14-16
17
6
7-9
10
4
3
3
5
11-13
18
1
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.
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
Manual Gas Shut-off Valve
Burner Assembly
Refractory Set
Log Package
Glass Assembly
Co-Linear Air Chute
4” Restrictor Plate
MINIMUM INLET GAS PRESSURE
MAXIMUM INLET GAS PRESSURE
MANIFOLD PRESSURE (HI)
MANIFOLD PRESSURE (LO)
ORIFICE SIZE
INPUT BTU/hr. (kW)
MINIMUM INPUT BTU/hr. (kW)
NATURAL GAS
5” WC (1.25 kPa) (7” WC (1.74 kPa) (recommended)
911-RAD
LP GAS
11” WC (2.74 kPa) (recommended)
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.
2. Remove glass frame assembly.
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
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.
7
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
WHAT TO DO IF YOU SMELL GAS:
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 8a
8
LIGHTING AND SHUTDOWN (cont.)
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 9a
Figure 9b
Figure 9c
9
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.
6. Press rocker switch to OFF.
7. Disconnect manometer hose and tighten screw (clockwise). Screw should be snug, do not over tighten.
8. Attach manometer to manifold pressure tap to verify 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 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
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.
♦ 1/4” (6mm) rise per foot is required 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.
13
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 14a
LP
NAT
Figure 14b
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.
14
CONVERSION KIT INSTRUCTIONS
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.
7. Turn fireplace off.
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 15a
PROPER BURNER / PILOT ORIENTATION
(Your pilot may look slightly different than one shown)
Figure 15b
GAS CONVERSION LABEL
(included with conversion kit)
Figure 15c
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)
MANIFOLD PRESSURE (HI)
MANIFOLD PRESSURE (LO)
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
CONVERSION KIT INSTRUCTIONS
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 16a
Correct pilot flame
Figure 16b
Dark orange flames / black tips
Venturi closed too far
Excessive burner media
Lifting (ghosting) flames
Improper Venting
Gas pressure too high
WARNING Burner tube adjustable venturi positioning should only be performed by a qualified professional service technician.
FACTORY SET BURNER TUBE VENTURI SETTINGS
(ADJUST AS NECESSARY FOR YOUR INSTALLATION)
NATURAL GAS LP (PROPANE) GAS
3/16” (5mm) OPEN 5/8” (16mm) OPEN
VENTURI POSITION
Closed too far
Open too far
BURNER TUBE VENTURI ADJUSTMENT GUIDELINES
FLAME COLOR VENTURI ADJUSTMENT
Dark orange flame with black tips
Blue flames
Open venturi setting slightly
Close venturi setting slightly
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:
1. Remove glass frame assembly.
2. Remove log set.
3. Remove burner assembly.
4. Loosen screw on burner venturi and adjust as necessary. Tighten screws.
5. Reinstall all components previously removed.
6. Light fireplace and wait 15 minutes before determining if any further adjustments are needed.
Figure 16c
BURNER VENTURI
16
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 17a
911-RAD 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.
The flow of combustion and ventilation air must not be obstructed.
GLASS CLEANING & REPLACEMENT
Clean glass only when cool and only with non-abrasive cleansers.
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 SUBSTITUTE MATERIALS.
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.
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
REPLACEMENT PARTS LIST
Replacement parts are available through your local dealer. Contact them for availability and pricing.
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
Pilot Assembly - LP 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
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
8 pc. Log Set
AD Log
AG Log
HB Log
BI Log
M Log
C Log
AJ Log
LOG SET
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
1-1/8” Glass Gasket w/ Adhesive
12” x 27” Glass with Gasket
900-REMB Rock Wool Embers
Hussong Manufacturing Co., Inc.
P.O. Box 577
204 Industrial Park Drive
Lakefield, MN 56150-0577
USA
911-RAD
www.kozyheat.com
18
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