Kozyheat Chaska Owner Manual

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Kozyheat Chaska Owner Manual | Manualzz

Quality Fireplaces for Life

INSTALLATION AND OPERATION MANUAL

INSTALLER: LEAVE THIS MANUAL WITH THE APPLIANCE.

CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.

DO N

OT

DIRECT VENT FIREPLACE INSERT

Shown with 3 piece Shroud

WARNING: This product must be installed by a licensed plumber or gas fitter when installed in the

commonwealth of Massachusetts.

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

A manufactured home (USA only) or mobile home OEM installation must conform with the Manufactured Home Construction and Safety

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

WARNING: If the information in these instructions are not followed exactly, a fire or explosion may

result, causing property damage, personal injury or loss of life.

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

appliance.

IF YOU SMELL GAS:

Do not light any appliance.

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

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

◙ If you cannot reach your gas supplier, call the fire department.

◙ Installation and service must be performed by a qualified installer, service agency or the gas supplier.

This appliance is only for use with the type (s) of gas indicated on the rating plate.

A conversion kit is supplied with the appliance.

WARNING

HOT GLASS WILL CAUSE BURNS.

DO NOT TOUCH GLASS UNTIL COOLED.

NEVER ALLOW CHILDREN TO TOUCH GLASS.

April 2010

CSK-31-REV-11

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:_____________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

PAGE 1

TABLE OF CONTENTS

INTRODUCTION

Introduction and Homeowner Reference Information

CONTENTS

Table of Contents

SAFETY INFORMATION

Safety Information

FEATURES

Features

COMMONWEALTH OF MASSACHUSETTS INFORMATION

Commonwealth of Massachusetts Information

SPECIFICATIONS

Fireplace Dimensions

Clearances

Components List

Additional Components Required

Placement Clearance Requirements

EXISTING FIREPLACE SPECIFICATIONS

Existing Fireplace Requirements

PREPARE EXISTING FIREPLACE

Existing Fireplace Minimum Opening Requirements

Prepare Existing Fireplace

FAN DIRECT WIRE INSTALLATION

Fan Direct Wire Installation

THERMOSTAT / WALL SWITCH / REMOTE - CSK-31

Thermostat / Wall Switch / Remote - CSK-31

GLASS FRAME ASSEMBLY

Glass Frame Assembly Removal / Installation

INSTALLATION

Approved Venting

Combustion Air Venting Options

Air Duct Removal

Kozy Heat #816-CL Co-Linear Vent System

Run Vent System Through Existing Chimney

Connect Vent System to Air Duct

Position Fireplace Insert

GAS LINE CONNECTION

Gas Line Connection

Check Control Board Installation

1

2

3

4

5

16

16

6

6

7

7

7

8

12

12

12

13

14

15

15

9

9

10

11

12

COMPLETE FAN WIRING INSTALLATION

Complete Fan Wiring Installation

3 PIECE SHROUD ASSEMBLY AND INSTALLATION

3 Piece Shroud Assembly and Installation

LOG SET INSTALLATION

Log Set Installation

CONTROL BOARD REMOVAL

Control Board Removal

CONTROL BOARD INSTALLATION

Control Board Installation

CSK-31 / CSK-31-RAD OPERATING INSTRUCTIONS

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

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

CSK-31 / CSK-31-RAD Pressure Testing

CSK-31-IPI OPERATING INSTRUCTIONS

CSK-31-IPI Wiring Schematics

CSK-31-IPI Valve and Pilot Assembly Components

CSK-31-IPI Control Module Components

CSK-31-IPI Remote Control Components

CSK-31-IPI Information and Remote Control Operation

CSK-31-IPI Lighting and Shutdown

CSK-31-IPI Pressure Testing

CSK-31-IPI Error Codes

FINALIZING THE INSTALLATION

Flame Appearance

To Adjust Venturi

MAINTENANCE

Maintenance

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

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

TROUBLESHOOTING (CSK-31-IPI)

IPI Remote Troubleshooting (CSK-31-IPI)

GAS CONVERSION INSTRUCTIONS

CSK-31 / CSK-31-RAD Gas Conversion Instructions

CSK-31-IPI Gas Conversion Instructions

REPLACEMENT PARTS LIST

Replacement Parts List

WARRANTY

Warranty

17

22

23-25

26

20

21

18

19

31-34

35-36

37

38

27

28

29

30

39

39

40

41-43

44-45

46-47

48

46

47-48

PAGE 2

SAFETY INFORMATION

This fireplace has been tested to and complies with ANSI Z21.88a-2007·CSA 2.33a-2007·CSA P.4.1-02 “VENTED GAS FIREPLACE HEATERS” by OMNI-Test Laboratories, Portland, OR. Installation must conform with local building codes or in the absence of local building codes, with the

National Fuel Gas Code, ANSIZ223.1/NFPA 54 - Current Edition, or the Natural or Propane Installation Code, CSAB149.1

Installation and repair should be done only by a qualified service person. The appliance should be inspected by a qualified service person before use. Annual inspection by a qualified service person is required to maintain warranty.

More frequent cleaning may be required due to excessive lint from carpeting, bedding materials, etc. It is imperative that control compartments, burners and circulation air passageways of the appliance be kept clean.

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.

Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing ignition.

Young children should be carefully supervised when they are in the same room as the appliance.

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

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

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

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

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

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

The glass front or any part removed for servicing the appliance must be replaced prior to operating the appliance.

Work should be done by a qualified service technician.

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

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

#CSK-057T, shall only be replaced as a complete unit, as supplied by Hussong Mfg. Co., Inc. Replacement of glass assembly must only be performed by a licensed or qualified service person. DO NOT SUBSTITUTE MATERIALS.

Do not strike or slam glass assembly.

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

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

Keep burner and control compartment clean.

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

PAGE 3

FEATURES

STANDARD FEATURES

High efficiency

High quality lifetime glass

14-1/4” x 29” (362 mm x 737 mm)

Quick latch glass frame assembly

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

Innovative vent connection system

Engineer-designed burner system

High - Low regulator

Automatic fan kit (2) - 75 CFM**

Refractory brick lining

(2) hoods / lower grill (black)

Minnesota Energy Code compliant to 50 pascals

*Standard on RAD models

**Standard on CSK-31 and IPI models

***Standard on IPI models

****Standard on CSK-31 and RAD models

SAFETY FEATURES

Each unit factory tested!

Tested by OMNI - Test Laboratories

Sealed combustion chamber

Standing pilot ignition****

Intermittent or Standing pilot ignition***

30-second delay pilot****

Flame sensing system (safety shutoff)***

Automatic pressure relief glass system

Requires no electricity to operate (excluding fan** )

Battery back-up in the event of power failure***

(excluding fan)

Bedroom and mobile home approved

Canadian approved

*Standard on RAD models

**Standard on CSK-31 and IPI models

***Standard on IPI models

****Standard on CSK-31 and RAD models

OPTIONAL FEATURES

Red brick refractory

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

Surrounds

Flex vent adaptor kit

Remote control or thermostat remote control***

Wall mount thermostat / wireless wall mount thermostat

Decorative full door faces in various styles and finishes

Mission design doors in various finishes

Automatic fan kit **

Speed Control / Receptacle Assembly (RAD model)

*Standard on RAD models

**Standard on CSK-31 and IPI models

***Standard on IPI models

****Standard on CSK-31 and RAD models

WEIGHT

Fireplace Weight (as packaged for shipment)

127 lbs. (57.61 kg)

PAGE 4

COMMONWEALTH OF MASSACHUSETTS REQUIREMENTS

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

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

INSTALLATION OF CARBON MONOXIDE DETECTORS

At 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 of the installation.

PAGE 5

DESCRIPTION

FIREPLACE

DIMENSIONS

INCHES

MILLIMETERS

Height

19-1/4

489

SPECIFICATIONS

Width

FIREPLACE DIMENSIONS

Back Width Depth Back Height Back to Elec.

Access

Back to Gas

Line Access

30-7/8

784

23-1/8

587

14-1/2

368

14-5/8

371

9-1/8

232

4-7/8

124

Front to Vent

Center

9-14

235

Back to Vent

Center

5-1/2

140

TOP

23

1

8

"

587mm

14

1

2

"

368mm

14

1

2

"

368mm

5

1

2

"

140mm

19

1

4

"

489mm

30"

762mm

30

7

8

"

784mm

FRONT

14

5

8

"

371mm

9

1

4

"

235mm

1

7

8

"

48mm

RIGHT

9

1

8

"

232mm

4

7

8

"

124mm

Figure 6a

LEFT

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

appliance may result in property damage or personal injury.

1. Fireplace insert

2. Spring-loaded latch glass assembly

3. Control board with burner cover

4. Co-linear air duct

5. Log set (see page 19)

6. Refractory panels

Model CSK-31 includes 2 (75 CFM) fan with limit switch and speed control.

Model CSK-31-IPI includes fan kit and remote control.

Figure 6b

MINIMUM CLEARANCES TO COMBUSTIBLES

Insert to sidewall: 10” (254 mm)

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

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

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

PAGE 6

SPECIFICATIONS

#CSK-31/CSK-31-RAD COMPONENTS #CSK-31-IPI COMPONENTS

PART NUMBER

CSK-800

700-203

CSK-135

CSK-G900

CSK-50A

CSK-057T

OCK-H52L

816-CL1

CSK-028*

500-CSK

* CSK-31 only

DESCRIPTION

Millivolt Board Assembly

Manual Gas Shut-off Valve

Burner Assembly

Refractory Set

Log Package

Glass Frame Assembly

LP Conversion Kit

Co-Linear Air Duct

Fan Kit (2)-75 CFM

Grill Assembly

PART NUMBER

CSK-600-IPI

700-203

CSK-135

CSK-G900

CSK-50A

CSK-057T

OCK-A52L-IPI

816-CL1

IPI-028

500-CSK

700-208

DESCRIPTION

Control Board Assembly

Manual Gas Shut-off Valve

Burner Assembly

Refractory Set

Log Package

Glass Frame Assembly

LP Conversion Kit

Co-Linear Air Duct

Fan Kit (2)-75 CFM

Grill Assembly

Remote Control

ADDITIONAL COMPONENTS REQUIRED

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

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

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

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

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

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

or

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

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

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

or

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

hood and lower grill are included with fireplace.

PLACEMENT CLEARANCE REQUIREMENTS

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

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.

PAGE 7

EXISTING FIREPLACE SPECIFICATIONS

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

EXISTING FIREPLACE REQUIREMENTS

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

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

Provisions made to provide electrical power for operation, if applicable.

Any chimney clean-outs must fit properly.

Existing Chimney must be comprised of one of the following: Factory built solid fuel chimney: 7” minimum inside diameter.

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

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

Maximum: 30 ft. (9.14m)

DETERMINE LENGTH OF 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 19-1/2” (489 mm) (height of insert).

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

MEASUREMENT FROM FIREPLACE BASE TO TOP OF CHIMNEY:_________________

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

TOTAL CHIMNEY LENGTH REQUIRED: _________________

CAUTION: This appliance must not be connected to or joined with any other

chimney flue serving another appliance.

MIN. 12 ft. (3.66 m)

MAX. 30 ft. (9.14 m)

PAGE 8

Figure 8a

PREPARE EXISTING FIREPLACE

EXISTING FIREPLACE MINIMUM OPENING REQUIREMENTS

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

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

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

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

All dimensions are minimum requirements

Figure 9a

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. If using this method, Kozy Heat Floor Protector Kit (#CSK-FLP), must be used.

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

Run any necessary electrical wiring to insert.

PAGE 9

DIRECT WIRE INSTALLATION

DIRECT WIRE CONNECTION MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN.

CSK-31-RAD: Optional: #CSK-028 fan kit

#600-083C speed control, receptacle assembly

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

CSK-31-IPI: This fireplace insert comes complete with a fan kit already installed. A double receptacle and power cord have been installed, wired and mounted in a removable electrical box panel on right side of fireplace

NOTE: If wiring to pre-installed electrical box is desired, wiring should be run prior to permanently setting insert in place and connecting vent system.

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

WARNING: This appliance is equipped with a three-prong (grounding) plug for protection against shock hazard and should be plugged

directly into a properly grounded three-prong receptacle. Do not cut or remove grounding prong from this plug. Do not allow

any excess fan cord to touch fireplace.

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

DIRECT WIRE INSTALLATION: The cord must be removed and wiring disassembled. Insert 110V-120V wiring (with ground) through

romex connector and wire to box cover assembly, matching black, white & green (ground) wires to

corresponding wires on electrical box cover assembly.

CSK-31 WIRING SCHEMATIC

CSK-31-IPI WIRING SCHEMATIC

Figure 10a Figure 10b

DIRECT WIRE INSTALLATION

1. CSK-31: Loosen (but do not remove) screw securing removable access panel (with electrical box & romex connector installed) from

right side of fireplace. Remove access panel.

2. CSK-31 / CSK-31-RAD / CSK-31-IPI: Remove box cover assembly to expose wiring.

3. Remove existing cord and insert 110V-120V wiring (with ground) through romex connector, wiring to box cover assembly, matching black (hot), white (neutral), and green (ground) wires to corresponding wires on box cover assembly using (3) wire nuts obtained when removing existing cord.

4. Reattach box cover assembly with (2) screws provided.

Refer to page 17 for instructions on completing fan wiring after insert has been installed.

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

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

PAGE 10

THERMOSTAT / WALL SWITCH / REMOTE

(CSK-31 & CSK-31-RAD only)

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 BE PERFORMED BY A QUALIFIED INSTALLER.

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

Thermostat Wiring Diagram

Remote Control Wiring Diagram

OPTIONAL: Disconnect ON/OFF

rocker switch wires

from back of gas

Figure 11a Figure 11b

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.

IMPORTANT: 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.

Fireplace must be turned „ON‟ and „OFF‟ by same method.

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.

PAGE 11

GLASS FRAME ASSEMBLY

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

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

WARNING: DO NOT REMOVE GLASS ASSEMBLY WHEN HOT!

REMOVE GLASS FRAME ASSEMBLY

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

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

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

INSTALL GLASS FRAME ASSEMBLY

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

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

Figure 12a

INSTALLATION

IMPORTANT: All steps as outlined in „PREPARE EXISTING FIREPLACE‟ must be completed before continuing with this installation.

APPROVED VENTING

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

ICC

Selkirk

American Metals

Simpson Dura-Vent

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

COMBUSTION AIR VENTING OPTIONS

OPTION 1:

OPTION 2:

FULL CONNECTION: Combustion air intake pipe is run entire chimney length and connected to termination cap.

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

AIR DUCT REMOVAL

Remove air duct at top of insert, sliding backwards out of channel.

Refer to instructions on following pages for vent system attachment to air duct.

Figure 12b

PAGE 12

KOZY HEAT #816-CL CO-LINEAR VENT SYSTEM

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

IMPORTANT: IDENTIFICATION: Exhaust Pipe: red marking.

Proper operation of this insert requires exhaust and combustion air pipes be connected to correct collars on termination kit and insert air duct.

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

NOTE: If using „stub‟ method for combustion air pipe, extending it is not necessary. Determine length needed from air duct on insert (4 ft.

(1.22 m) minimum) to above damper opening in existing chimney. Remove excess combustion air pipe from end without a collar.

Continue with Step B. #2 below.

If using „Full Connection‟ method: Slide 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 at end of exhaust pipe (without collar / red marking) and slide onto corresponding collar on termination cap (collar with label). Secure with 3 self-tapping screws (provided). Apply additional sealant around joint to ensure a proper seal.

IMPORTANT: EXHAUST COLLAR ON FIREPLACE AIR DUCT IS ON RIGHT SIDE. INSTALL TERMINATION CAP WITH EXHAUST COLLAR

ON RIGHT SIDE.

T

ERMINATION CAP

EXHAUST COLLAR

NOTE: Collar extends through

middle divider plate

INTAKE COLLAR

NOTE: Collar extends through

bottom plate.

SEALANT

SHEET METAL SCREWS (3 TOTAL)

SEALANT

Figure 13a

PAGE 13

Your vent cap may look slightly different than one shown.

RUN VENT SYSTEM 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.

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.

Figure14a

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 at lower right.

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.

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

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

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

Seal area around vent pipes with non-faced fiberglass insulation

Figure 14b

PAGE 14

VENT SYSTEM CONNECTION

Sheet metal screws

(3 total)

Sealant

Figure 15a

Figure 15b

Figure 15c

1. Place air duct (previously removed, page 12) into existing fireplace opening.

2. Place a bead of sealant (provided) around exhaust pipe (red marking). Slide exhaust pipe inside collar marked „Exhaust‟ on 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 collar on air duct. Slide combustion intake pipe over collar. Secure with (3) ½" self-tapping screws, provided. To ensure an air-tight seal, apply additional sealant around joint.

4. Slide insert into fireplace opening.

Figure 15d

Shown without venting attached for clarity purposes only

Secure with sheet metal screws

Figure 15e

5. Position air duct into channels located at top of insert. Slide air duct forward until seated. Secure air duct to insert front with (2) 1/2” sheet metal screws (included in components packet)

Leveling legs (2 per side)

Figure 15f

6. If necessary, level insert by threading leveling bolts (included in components packet) into nuts in bottom of insert - 2 each side.

PAGE 15

GAS LINE CONNECTION

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

GAS CONVERSION

This fireplace is manufactured for use with Natural Gas. An LP conversion kit is included with this fireplace.

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 or gas fitter.

NOTE: A listed (and Commonwealth of Massachusetts approved) 12” (13 mm) T- handle manual shut-off valve and flexible gas connector (included) are connected to the 1/2” (13 mm) control valve inlet. If substituting for these components, please consult local codes for compliance.

NOTE: This fireplace is equipped with a 3/8”(10 mm) x 18” (457 mm) 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.

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.

NOTE: The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas line at test pressures equal to or less than ½ psi (3.5 kPa).

NOTE: For high altitude installations, consult local gas distributor or 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.

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

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.

CSK-335 / CSK-335-RAD

NATURAL GAS LP GAS

MINIMUM INLET GAS PRESSURE

5.0 inches W.C.

(7.0 W.C. recommended)

11.0 inches W.C.

(recommended)

MAXIMUM INLET GAS PRESSURE 10.5 inches W.C.

MANIFOLD PRESSURE (HI) 3.5 inches W.C

MANIFOLD PRESSURE (LO) 1.7 inches W.C.

ORIFICE SIZE

INPUT BTU/hr.

MINIMUM INPUT BTU/hr.

#37

27,500

19,000

13.0 inches W.C.

10.0 inches W.C.

6.3 inches W.C

#52

28,000

20,400

PAGE 16

NATURAL GAS

CSK-335-IPI

LP GAS

5.0 inches W.C.

(7.0 W.C. recommended)

11.0 inches W.C.

(recommended)

10.5 inches W.C.

NA

NA

#37

27,500

19,000

13.0 inches W.C.

NA

NA

#52

28,000

20,400

COMPLETE FAN WIRING INSTALLATION

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

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. Refer to page 12.

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‟.

CAUTION: CHECK CONNECTION FOR LEAKS.

#CSK-31 & #CSK-31-RAD

(#600-083C Speed Control / Receptacle assy. w/ power cord available for #CSK-31-RAD models).

1. Secure electrical access panel to side of fireplace.

2. Place thermostatic control switch on bottom of firebox.

3. Plug power cord into electrical box receptacle.

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

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

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

NOTE: This fan will not operate until speed control turns „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.

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, plug 3-prong plug on fan cord into receptacle.

Temperature Control Switch (looking through lower grill opening).

Figure 17a

#CSK-31-IPI

1. Secure electrical access panel to side of fireplace.

2. Plug power cord into electrical box receptacle.

3. Upon complete installation of this fireplace, follow operating instructions as outlined in this manual.

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

PAGE 17

3 PIECE SHROUD ASSEMBLY AND INSTALLATION

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

Shroud assembly includes: (1) Shroud top

(1) Shroud left side

(1) Shroud right side

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

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

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

You will also need flanged upper hood and lower grill (included with fireplace).

1. Remove glass assembly from fireplace.

2. Lay shroud sections face down on a protective surface to assemble.

Noting orientation of leg sections in photo at right, attach leg sections to top section by aligning holes (2 ea. side) in top section with holes in leg sections. Secure with black phillips head sheet metal screws (2 ea. side).

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

2-3

Partially threaded screw. (1) ea. side.

4. Align leg section holes to corresponding mounting nuts in mounting brackets on sides of fireplace opening. Secure with phillips truss head screws (2 ea. side).

4

5.

Install upper hood with flanged ends. Align slots in hood to partially threaded screws in shroud top, slide hood back. Tighten screws.

5

6. Attach lower grill by threading 1” phillips head screws through mounting nuts (1 ea. side) on grill and into corresponding holes located at bottom of shroud leg sections.

Tighten screws.

NOTE: When completed, lower grill may be adjusted slightly from side to side.

6

Figure 18a

PAGE 18

#CSK-50A 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.

C1

C2 C3

C12

C13

Figure 19a

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

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

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

C5

C8

C6

C4 C7

Figure 19b

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

PAGE 19

CONTROL BOARD REMOVAL

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

removing any components.

1. Models CSK-31 / CSK-31-RAD:

Turn gas control knob to „OFF‟.

Model CSK-31-IPI:

Use remote to 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. Models CSK-31 / CSK-31-RAD:

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

Model CSK-31-IPI:

Unplug all components from electrical outlet, disconnect all wiring harnesses attached to gas valve.

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

5. Remove glass assembly. Page 12.

6. Remove logs.

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

8. Remove burner heat shield from firebox.

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

1

3

7

8

Burner Assembly

Heat shield

Remove nuts

2

9

Figure 20a

PAGE 20

CONTROL BOARD INSTALLATION

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

IF GASKETING IS DAMAGED, IT MUST BE REPLACED.

1. Place control board in firebox, aligning holes in board with mounting studs in firebox bottom. MAKE SURE SEALING GASKET IS IN

PLACE ON FIREBOX BOTTOM!

Secure board with nuts previously removed.

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

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

4. Reinstall log set. Page 19.

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

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

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

Model CSK-31-IPI:

Re-connect all wiring harnesses to gas valve. Plug components into electrical outlet.

7. Reinstall glass frame assembly. Page 12.

8. Turn gas on.

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

CAUTION: CHECK ALL CONNECTIONS FOR LEAKS, WHETHER FIELD

OR FACTORY MADE.

1

2

Heat shield

Burner Assembly

3

5

Secure nuts

8

PAGE 21

Figure 21a

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

THERMOCOUPLE

ELECTRODE

PILOT HOOD

THERMOPILE

Figure 22a

HI /LO FLAME ADJUSTMENT KNOB

GAS CONTROL KNOB PIEZO IGNITOR

Figure 22b

VALVE TERMINALS

PAGE 22

ON/OFF ROCKER SWITCH

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

FOR YOUR SAFETY - READ BEFORE LIGHTING

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

PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

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

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

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

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

3. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in, or turn by hand, do not try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion, and loss of warranty.

4.

Do not use this appliance if any part has been under water.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water.

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS AND LIQUIDS IN THE

VICINITY OF THIS OR ANY OTHER APPLIANCE.

WHAT TO DO IF YOU SMELL GAS:

Do not touch any electrical switches

Do not try to light any appliance

Do not use the phone in your building

Immediately call your gas supplier from a neighbor‟s phone

Follow the gas supplier‟s instructions

If you cannot reach your gas supplier, call the fire department

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

AND SHOULD STAY AWAY TO AVOID BURNS OR CLOTHING IGNITION. YOUNG CHILDREN SHOULD BE

CAREFULLY SUPERVISED WHEN THEY ARE IN THE SAME ROOM AS THE APPLIANCE. CLOTHING OR

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

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

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

LONGEVITY OF THE FIREPLACE.

PAGE 23

CSK-31/CSK-31-RAD LIGHTING AND SHUTDOWN (cont.)

5 MINUTES

LIGHTING

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.

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

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

NOTE: Gas control knob cannot be turned from

“PILOT” to “OFF” unless knob is pushed

in slightly. Do not force.

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

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

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

Release gas control knob. If pilot goes out, repeat steps C-D.

When pilot is lit, proceed to step E.

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.

E. 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.

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

A

B

C

D

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.

E

PILOT

PILOT TUBE

1 MINUTE

Figure 24a

PAGE 24

CSK-31/CSK-31-RAD LIGHTING AND SHUTDOWN (cont.)

TURN BURNER OFF

G. To turn burner „OFF‟, depress ON/OFF rocker switch to „OFF‟, flip

„off‟ wall switch or adjust setting on thermostat or remote control.

G

NOTE: Pilot will stay lit.

TURN PILOT OFF

H. 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 25a

H

Figure 25b

Figure 25c

PAGE 25

CSK-31 / CSK-31-RAD PRESSURE TESTING

IMPORTANT NOTICE: Pressure check taps for manifold (outgoing) and inlet (incoming) pressures have been incorporated into valve.

Pressure tap marked „OUT‟ measures outgoing pressure; 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.

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

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

INLET PRESSURE TEST:

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

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

3. Light pilot.

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

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

6. Press rocker switch to „OFF‟.

7. Turn gas control knob to „OFF‟.

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

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

Manometer should read no pressure.

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

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 that 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 26a

PAGE 26

CSK-31-IPI WIRING SCHEMATICS

Figure 27a

IMPORTANT: THIS SYSTEM REQUIRES ELECTRICITY (110 V)

AND / OR BATTERIES TO OPERATE.

USING BATTERY BACK UP WILL OPERATE BURNER ONLY.

FAN COMPONENTS WILL NOT FUNCTION ON BATTERY

BACK-UP POWER.

PAGE 27

CSK-31-IPI VALVE & PILOT ASSEMBLY COMPONENTS

PILOT

IGNITER

FLAME SENSOR

BLACK CAP

LOW LIMIT SCREW

VALVE STEP MOTOR

IPI PILOT ASSEMBLY

OUTLET (MANIFOLD)

PRESSURE SCREW

PILOT INTERNAL SOLENOID CONNECTION

ORANGE AND WHITE WIRES

STEP MOTOR

WIRE HARNESS

MAIN VALVE INTERNAL SOLENOID CONNECTION

GREEN AND WHITE WIRES

PILOT ADJUSTMENT SCREW

IPI GAS VALVE

Figure 28a

INLET PRESSURE SCREW

PAGE 28

CSK-31-IPI CONTROL MODULE COMPONENTS

COMMUNICATION LINK

TO EXTENSION MODULE

AC ADAPTOR

CONNECTION

VALVE STEP MOTOR

TERMINAL

LEARN BUTTON

MAIN CONTROL MODULE

CONTINUOUS PILOT

ON/OFF SWITCH

REMOTE ON/OFF

SWITCH

NON-OPERATIONAL

BACK-UP BATTERY PACK

„S‟ SENSOR PILOT

CONNECTION

„I‟ IGNITER PILOT

CONNECTION

AC ADAPTOR

Figure 29a

POWER TO LIGHT KIT

(not available in all models )

COMMUNICATION LINK

TO CONTROL MODULE

PAGE 29

NON-OPERATIONAL

FAN CORD PLUG-IN

EXTENSION MODULE

CSK-31-IPI REMOTE CONTROL INFORMATION

MANUAL ON / OFF

ROOM TEMPERATURE

FAN SPEED

THERMOSTAT MODE ICON

BATTERY LIFE ICON

SET TEMPERATURE

(visible only in THERMO MODE)

LIGHT LEVEL

CHILD PROOF ICON

CONTINUOUS PILOT

FLAME HEIGHT

Figure 30a

PAGE 30

CSK-31-IPI INFORMATION

ELECTRICAL WARNING AND INFORMATION:

Electrical wiring must be installed by a licensed electrician.

Do NOT wire 110V to wall switch.

Uninterrupted or continuous power is required at all times in IPI systems EXCEPT when using battery back-up.

Incorrect wiring will override IPI safety lockout and may cause an explosion.

Disconnect 110V before servicing

A double receptacle box cover and (3) wire nuts are supplied in fireplace components packet to be used when hardwiring to electrical box located under firebox on right side of fireplace. Ensure receptacle box cover is installed with flange to top.

ATTENTION: THIS SYSTEM GOES THROUGH A CALIBRATION MODE WHEN SWITCHING FROM „ON‟ TO „THERMO‟ TO

„OFF‟ MODES, CREATING A HUMMING SOUND WHICH IS A NORMAL PART OF OPERATION.

CONTINUOUS PILOT (

FOR VERY COLD CONDITIONS)

The IPI gas control 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.

This pilot feature can be activated or de-activated by the hand held remote control transmitter. Instructions on following page.

OPERATION USING BATTERY POWER

This fireplace has an optional battery operation if electrical power is lost. Position battery pack with four “AA” size batteries installed

between valve and front of fireplace. This is the coolest location under firebox, ensuring longer battery life.

NOTE: When operating fireplace in this capacity, the only function available is flame modulation.

MATCHING SECURITY CODES

Before matching security codes make sure 120V AC is connected and powered to fireplace, and hand held remote control is installed with (2) AA batteries.

It may be necessary to program main control module to LEARN the security code of the hand held remote control upon initial use, if batteries are replaced, or if a replacement remote control is purchased from your dealer.

1. When matching security codes, be sure slide button on main control module is in REMOTE; the code will not “LEARN” if slide is in OFF.

2. Program main control module to LEARN a new security code by pushing in

LEARN button on main control module using a pencil point for 2 seconds

(you should hear a single „beep‟ letting you know module is ready to learn a new code).

3. Press MODE button on hand held remote control (you should hear four

„beeps‟ in rapid succession in main control module, indicating remote control‟s code has been programmed into the main control module). When an existing main control module is introduced to a new hand held remote control, the new security code will overwrite the old one.

If it ever becomes necessary to clear the memory from the hand held remote control, simply push and hold the LEARN button for 10 seconds (you should hear three long beeps in succession). You may now follow steps outlined above to „RE-LEARN‟ security codes.

PAGE 31

LEARN BUTTON

Figure 31a

SLIDE TO REMOTE POSITION

CSK-31-IPI REMOTE CONTROL OPERATION

INITIAL SET-UP:

Plug Extension Module and AC Adaptor into receptacles.

Install (4) AAA batteries into battery compartment of Backup Battery Pack , making sure batteries are installed in proper direction.

Position between valve and front of stove. A Velcro strip has been attached to help secure in place.

The Hand Held Remote operates on (2) 1.5V AAA batteries. We recommend always using ALKALINE batteries to extend battery life and improve operational performance.

.

NOTE: This system is sent to you set up for Natural Gas and

This system allows for gas type conversion and temperature unit conversion by following the setup procedure outlined below.

GAS TYPE CONVERSION:

Press and hold Learn Button on Main Control Module for 20 seconds. A beep will be heard letting you know the procedure has been completed.

If converting from NAT to LP gas: (1) one second long beep

If converting from LP to Nat gas: (3) three second long beep

Continue with gas type conversion by following instructions included with gas conversion kit.

CELSIUS/FAHRENHEIT CONVERSION:

Press UP and DOWN keys simultaneously to choose Celsius or Fahrenheit.

IMPORTANT SAFETY FEATURE:

This system has a maximum room temperature limit of 95° F (35° C) in both manual and thermostat modes. When room temperature is at or above this point the system will shut down and the hand held remote control will read OFF. If you turn the system ON when room temperature is still at or above this temperature, the system will again shutdown after 2 minutes when room temperature is recalculated.

CONTINUOUS PILOT FEATURE:

Activation of this optional feature is accomplished by pressing the

PILOT button once. The continuous pilot icon will appear on the

LCD screen. Pressing PILOT button again will de-activate this feature.

This feature can also be activated via CONTINUOUS PILOT switch on

Main Control Module.

Figure 32a

CHILDPROOF FEATURE:

Activation of this optional feature is accomplished by pushing SET & UP buttons simultaneously for 5 seconds. The childproof icon will appear on the screen. When a transmitter button is pressed the icon will flash on screen, but no signal will be transmitted. Pressing and holding these same two buttons again for more than 5 seconds will de-activate this function.

This feature controls only manual functions of the hand held remote, automatic functions (thermostat mode) will not be effected.

Figure 32b

PAGE 32

CSK-31-IPI REMOTE CONTROL INFORMATION cont.

MANUAL MODE:

This remote can be manually or thermostatically operated.

Press MODE button for manual ON. The flame icon will appear on the LCD screen. Press MODE button again to put the control into THERMO mode.

Pressing MODE again will turn fireplace OFF.

NOTE: The MODE button operates in a series that will cycle from ON

to THERMO to OFF.

Figure 33a

FAN MODE:

This remote will operate the fan, allowing for (6) different speed levels. When the FAN button is pressed, FAN level setting will flash on the LCD screen.

Press UP or DOWN buttons to select desired fan speed level. If no adjustment is made within 7 seconds, the control will exit function setting mode and

LCD display will return to normal view.

NOTE: Delayed ON/OFF - The fan will not turn on until fireplace

has been burning for 5 minutes and will not turn off for 12

minutes after fireplace has been turned off.

EXCEPTION: If fireplace is turned back on during 12 minute off-delay time frame, the fan will remain on.

This applies to MANUAL and THERMO modes.

Figure 33b

LIGHTING MODE:

This remote will operate the lights, allowing for (6) different light levels.

When LIGHT button is pressed, LIGHT level setting will flash on the LCD screen. Press UP or DOWN buttons to select desired light level. If no adjustment is made within 7 seconds, the control will exit function setting mode and

LCD display will return to normal view.

NOTE: There is a 3 second delay before light level setting is achieved.

NOTE: Light operations are completely independent from flame and fan

operations.

Figure 33c

FLAME MODE:

This remote will operate the flame, allowing for (6) different flame height levels. When MAIN FLAME button is pressed, FLAME level setting will flash on the LCD screen. Press UP or DOWN buttons to select desired flame level. If no adjustment is made within 7 seconds, the control will exit function setting mode and LCD display will return to normal view.

NOTE: The fireplace will initially light at the highest level. After 5

seconds the flame will adjust to last chosen level before

fireplace was turned OFF.

This applies to MANUAL and THERMO modes.

Figure 33d

PAGE 33

CSK-31-IPI REMOTE CONTROL INFORMATION cont.

THERMO (THERMOSTAT) MODE:

This remote feature allows you to thermostatically control the fireplace when hand held remote is set to

THERMO mode.

Set Temperature Range: 45˚F (7˚C) to 90˚F (32˚C).

Set remote to THERMO mode by pressing MODE button. The smaller SET window of numbers appears on the LCD screen. The first SET number will read 45˚F. Press UP button to desired set room temperature.

Within 5 seconds fireplace will operate to that Set Temperature. The FLAME, ON and THERMO icons will appear on the LCD screen. By pressing UP or DOWN buttons a new set temperature may be attained.

SET Temperature will only appear when THERMOSTAT MODE is activated, but is implemented in all MODES with the exception of MANUAL MODE.

NOTE: The flame height can adjust up to (6) different height levels according to amount of heat

required. This range however is dictated by the Flame Level setting (see previous page).

When desired temperature is met, the fireplace will shut off until more heat is required.

To exit THERMO mode press the MODE button. This also shuts fireplace OFF.

IMPORTANT: When in THERMO mode the fireplace will not turn on until room temperature falls below SET TEMPERATURE.

Figure 34a

SYSTEM OPERATION WITHOUT HAND HELD REMOTE:

This system is designed to operate with the hand held remote or a thermostat, but in the unlikely event that it is required to be operated without the hand held remote or a thermostat, follow this simple procedure.

Slide REMOTE /OFF switch on main control module to OFF. The fireplace can now be lit and shut off by use of the ON/OFF rocker switch.

NOTE: When operating fireplace in this capacity, the only function available is burner operation on HI.

REMOTE / OFF

Figure 34b

PAGE 34

CSK-31-IPI LIGHTING AND SHUTDOWN

FOR YOUR SAFETY - READ BEFORE LIGHTING

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

PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

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

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

1. This fireplace is equipped with an ignition device which automatically lights the pilot and main burner. The pilot and burner light automatically with the hand held remote only. DO NOT try to light the pilot by hand.

Before lighting this fireplace, follow these instructions exactly.

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

3.

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

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS AND LIQUIDS IN THE

VICINITY OF THIS OR ANY OTHER APPLIANCE.

WHAT TO DO IF YOU SMELL GAS:

Do not touch any electrical switches

Do not try to light any appliance

Do not use the phone in your building

Immediately call your gas supplier from a neighbor‟s phone

Follow the gas supplier‟s instructions

If you cannot reach your gas supplier, call the fire department

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

AND SHOULD STAY AWAY TO AVOID BURNS OR CLOTHING IGNITION. YOUNG CHILDREN SHOULD BE

CAREFULLY SUPERVISED WHEN THEY ARE IN THE SAME ROOM AS THE APPLIANCE. CLOTHING OR

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

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

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

LONGEVITY OF THE FIREPLACE.

PAGE 35

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

LIGHTING

2

cover of this manual before continuing.

1. Turn off all electrical power to fireplace.

ATTENTION: This fireplace is equipped with an ignition device

which automatically lights the pilot.

DO NOT light the pilot by hand.

2. Press hand held remote MODE button to „OFF‟.

3. Wait five (5) minutes to allow any gas that may have accumulated inside firebox to escape. If you then smell gas, STOP! Follow safety information on front cover and on previous page of this installation manual. If you don‟t smell gas, go to next step.

4. Turn ON all electrical power to fireplace.

5. Press hand held remote MODE button to „ON‟.

CAUTION: If fireplace will not operate, follow instructions

TURNING OFF GAS TO FIREPLACE and call

your service technician or the gas supplier.

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.

3

5 MINUTES

4

Figure 36a

Power OFF

Power ON

OFF

5

ON

TURNING OFF GAS TO FIREPLACE

1. Press hand held remote MODE button to „OFF‟.

2. Turn OFF all electrical power to fireplace if service is required.

3. Turn manual shut-off valve to OFF.

1

2

Power OFF

OFF

3

Figure 36b

PAGE 36

PRESSURE TESTING (CSK-31-IPI)

IMPORTANT NOTICE: 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.

NOTE: The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any

pressure testing of that system at pressures in excess of ½ psi.

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

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

INLET PRESSURE TEST:

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

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

3. Light fireplace using hand held remote control. Note manometer reading.

4. Turn fireplace off using hand held remote control.

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

9. Relight fireplace using hand held remote control. 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

incoming gas pressure.

CAUTION: A LOW PRESSURE READING CAN CAUSE DELAYED IGNITION

Outlet (Manifold) Pressure Screw

Figure 37a

Inlet Pressure Screw

PAGE 37

ERROR CODES (CSK-31-IPI only)

IGNITION SAFETY: Protection for Ignition System

Error Code: One beep every one second.

Description of Fault: Warns users if pilot is not successfully ignited in 60 seconds.

How to Clear: Press MODE button to OFF then to ON to re-attempt ignition.

What to Check:

Ensure gas supply is turned on.

Ensure orange/white leads from module are plugged into “PILOT” connection on valve body.

Verify lead from igniter on pilot assembly is connected to “I” terminal on main control module. (Clicking sound will also be heard).

Verify lead from flame sensor on pilot assembly is connected to “S” terminal on main control module. (Pilot will light but main burner will not. Pilot will extinguish after 60 seconds and error code will alarm).

Verify black ground lead is connected to tab extending from valve bracket.

SENSOR SAFETY: Protection for Flame Sensor

Error Code: Four beeps every one second.

Description of Fault: Warns users pilot flame senor detects a pilot flame already present when ignition sequence is initiated. This fault will

also occur if pilot flame senor on main control module is shorted to ground.

How to Clear: Press MODE button to OFF then to ON to re-attempt ignition.

What to Check:

Check if pilot flame is actually present when valve is turned OFF (if yes, replace valve).

Replace pilot assembly.

Replace module.

THERMAL SAFETY: Overheat Protection

Error Code: Four beeps every two seconds.

Description of Fault: Warns users that module‟s internal temperatures have exceeded 170˚ F (77˚C).

How to Clear: Module‟s internal temperatures must cool to below 160˚F (71˚C) and then press ON button.

What to Check:

Are modules located in an unapproved location. Move to cooler location.

COMMUNICATION SAFETY: Protection for Ignition System

Error Code: One beep every four seconds.

Description of Fault: Warns users the hand held remote and main control module are not communicating properly. This safety feature is

What to Check:

active in both manual and thermo modes. The remote control sends a communication safety signal every 15 minutes.

If the main control module does not receive this signal, it begins a 2-hour countdown. If no communication safety

signal is received at the end of this countdown, the system will enter communication safety shutdown which turns

system OFF and emits the error code.

Verify batteries in hand held remote control are new.

Ensure remote control is located within 20 ft. (6 m) of main control module.

Ensure remote control is not placed directly on top of or inside a metal enclosure as this can interfere with transmission.

PAGE 38

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.

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

PROFESSIONAL SERVICE TECHNICIAN.

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

BEFORE MAKING ANY ADJUSTMENTS.

FACTORY SET BURNER TUBE VENTURI SETTINGS

(ADJUST AS NECESSARY FOR YOUR INSTALLATION)

NATURAL GAS LP (PROPANE) GAS

1/8” (3 mm) OPEN 1/2” (13 mm) OPEN

VENTURI POSITION

Closed too far

Open too far

BURNER TUBE VENTURI ADJUSTMENT GUIDELINES

FLAME COLOR VENTURI ADJUSTMENT

Dark orange flame with black tips Open venturi setting slightly

Blue flames Close venturi setting slightly

NOTE: IF SOOT IS PRESENT, CHECK LOG POSITIONING BEFORE ADJUSTING BURNER VENTURI. LOGS MUST NOT

BLOCK BURNER PORTS.

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

SLIGHT INCREMENTS UNTIL DESIRED LOOK IS ACHIEVED. ALWAYS BURN FIREPLACE FOR AT LEAST 15

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

TO ADJUST VENTURI:

1. Remove glass frame assembly. Refer to page 12.

2. Remove log set.

3. Remove burner assembly.

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

5. Reinstall all components previously removed.

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

BURNER VENTURI

Figure 39a

PAGE 39

MAINTENANCE

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

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

NOTE: INSTALLATION AND REPAIR SHOULD BE DONE ONLY BY 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.

The burner assembly may be removed for easier access. Refer to pages 21-22 in this installation manual for complete instruction on removing

& reinstalling burner assembly.

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

Reinstall burner assembly following instructions on page 22 of this installation manual.

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

Burner Ports

CSK-31/CSK-31-RAD Pilot

Figure 40a

CSK-31-IPI Pilot

Burner Orifice

FAN

The fan should be disconnected from electrical current, and cleaned (vacuumed) every six months. The bearings are sealed and require no oiling.

VENT SYSTEM

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

IF 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.

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

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

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

DO NOT SUBSTITUTE MATERIALS.

Do not strike or slam glass door assembly.

IMPORTANT: ANY SAFETY SCREEN OR GUARD REMOVED FOR SERVICING MUST BE REPLACED PRIOR TO OPERATING THE APPLIANCE.

CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND

DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

CAUTION: KEEP APPLIANCE AREA CLEAR OF COMBUSTIBLE MATERIALS, SUCH AS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.

PAGE 40

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

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

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

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

B. Check wiring at electrode for proper connection.

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

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

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

A. No gas or low gas pressure.

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

the fireplace and the main.

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

with plumber or gas supplier.

B. No LP in tank.

♦ Check LP (propane) tank. Refill if necessary

.

PILOT WILL NOT STAY LIT AFTER CAREFULLY FOLLOWING LIGHTING INSTRUCTIONS.

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

.

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

C. Thermocouple reading below 15 millivolts.

♦ Disconnect thermocouple from valve, place one millivolt meter lead wire on 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.

PAGE 41

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

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.

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

around intake duct.

PAGE 42

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

PILOT AND BURNER EXTINGUISH WHILE IN OPERATION

A. No LP (propane) in tank.

♦ Check tank and refill if necessary.

B. Glass frame assembly not installed correctly.

♦ Refer to page 12 in this manual for proper glass frame assembly installment instructions.

C. Defective thermopile or thermocouple.

♦ Check thermopile and thermocouple for proper millivolts.

D. Improper pitch on horizontal vent.

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

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

♦ Check for leaks. Repair if necessary.

F. Improper vent cap installation.

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

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

G. Excessive draft.

GLASS SOOTING

A. Improper log placement.

♦ Refer to log placement instructions on page 19 of this installation manual.

B. Improper venturi setting.

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

C. Improper pitch on horizontal venting.

♦ 1/4” (6 mm) 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.

PAGE 43

TROUBLESHOOTING (CSK-31-IPI only)

MAIN CONTROL MODULE WILL NOT LEARN TRANSMITTER

Ensure REMOTE/OFF switch on side of main control module is set to REMOTE.

Make sure batteries in both the hand held remote and backup battery pack are installed in the proper direction and are not drained.

Verify hand held remote indicates a signal is being sent. The LCD display should indicate ON or OFF depending on which button is being pressed. The LED indicator should illuminate on wall transmitters and on/off transmitters. Buttons should be pressed and held for 1 to 2 seconds to ensure a complete signal is sent.

Ensure 4-pin lead-set is securely connected from battery pack to main control module‟s AUX connection. If the A/C adapter is used, check that leads from adapter are securely connected to POWER terminals on main control module.

Press and hold LEARN button on main control module for approximately 10 seconds to clear memory (you should hear a series of beeps from the receiver), immediately press either the ON or OFF button on hand held remote (you should hear a series of beeps indicating the transmitter code has been learned).

PILOT WILL NOT LIGHT / STAY LIT

Verify gas supply is turned on.

Verify main control module is receiving signal from hand held remote by listening for a beep from receiver when ON is pressed on hand held remote. If you do not hear a beep, ensure main control module has learned the hand held remote. (See above).

Ensure black lead from pilot assembly igniter is securely connected to terminal labeled “I” and red lead from flame rectification sensor is securely connected terminal labeled “S” on main control module.

Make sure orange and white leads from main control module are securely connected to terminals labeled “PILOT” on valve body.

Ensure black GROUND wire is securely connected to tab located next to ON/OFF toggle switch. A proper ground is essential to

spark igniter operation.

Make sure pilot flame is in contact with flame rectification sensor on pilot assembly. This valve is equipped with a pilot flame adjustment screw. If pilot flame is too small it will not contact flame rectification sensor and will not complete the safety circuit.

Check continuity of pilot on valve. Remove wire connector. If there is no continuity on pin terminals, replace valve.

PILOT FLAME ALWAYS ON / WILL NOT EXTINGUISH

Ensure continuous pilot icon is not present in LCD screen. If icon is present, press PILOT button. This will de-activate the continuous pilot feature and the icon will disappear from LCD screen.

PILOT BURNING BUT IGNITOR CONTINUES TO SPARK

Check that flame sensor is fully impinged by pilot flame. If needed, adjust pilot.

Check end-to-end continuity of sensor. If sensor has continuity, replace module.

PAGE 44

TROUBLESHOOTING (CSK-31-IPI only cont

.)

MAIN FLAME WILL NOT LIGHT

Verify gas supply is turned on.

Ensure pilot flame will ignite. If not, see pilot flame troubleshooting on previous page.

Make sure green and white leads from module are securely connected to terminals marked “MAIN” on valve body.

Make certain pilot flame is in contact with flame rectification sensor on pilot assembly. This valve is equipped with a pilot flame adjustment screw. If pilot flame is too small it will not contact flame rectification sensor and will not complete the safety circuit.

Ensure pilot flame is properly located to ignite main flame.

Does hand held remote show CP in the display? If yes, childproof is on. De-activate by pushing PROG/TIME & UP keys at same time for more than 5 seconds.

Check continuity of main burner coil on gas valve. Remove wire connector. If there is no continuity on pin terminals, replace valve.

FLAME HEIGHT ADJUSTMENT NOT WORKING / WORKS BACKWARDS

Ensure black and red leads from battery pack or module are securely connected to red and black leads from motor drive located on valve body (red to red, black to black).

Check functionality with all transmitters to determine if there is an issue with the main control system or an individual transmitter. If the issue is with an individual transmitter, make sure batteries in hand held remote and backup battery pack are installed properly and are not drained.

ROOM TEMP. DISPLAYED ON HANDHELD REMOTE NOT CORRECT

Ensure transmitter was not recently stored in a different location (air-conditioned, heated) from that in which the hand held remote was tested. It may take up to 3 hours for the temperature inside a packaged transmitter, and several minutes for an unpackaged transmitter to equalize with room temperature.

FIREPLACE WILL NOT RESPOND IN “THERMO” MODE

Ensure hand held remote is within 20 ft. (6.096 m) operational range.

Make sure an ON or OFF command was not last sent from another transmitter. These commands will override thermal commands from the handheld remote control. To return system to THERMO mode, press either ON or OFF on hand held remote, then press MODE button to put system in THERMO mode. Press and hold SET button to change set temperature.

Verify set temperature on hand held remote is at least 2˚F (1˚C) above or below room temperature. The system will not react to temperatures within 2˚F (1˚C) of set temperature.

PAGE 45

CONVERSION KIT INSTRUCTIONS

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

#OCK-S37A NAT GAS CONVERSION KIT / #OCK-S52A 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 production 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 instructions supplied with the kit.

Refer to appliance owner‟s manual or product data plate for proper inlet and manifold pressure adjustments and orifice

Kit includes:

(1) Gas Conversion Label (1) Burner Orifice: NAT #37 / LP #52 (1) Gas Type Label

(1) Pilot Injector (1) Valve Conversion Instruction Sheet (1) Pilot Assembly Conversion Instructions

WARNING: SHUT OFF GAS SUPPLY BEFORE DISCONNECTING ANY ELECTRICAL POWER.

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.

PILOT ORIFICES

NAT LP

Figure 46a

CONVERT THE PILOT ASSEMBLY:

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

REPLACE THE BURNER ORIFICE:

1. Remove existing orifice cap. Replace with orifice cap included with kit, making sure to tighten cap securely.

CONVERT THE HI/LO REGULATOR ON GAS VALVE:

1. Follow instructions included with kit to convert gas valve to either Nat or LP.

COMPLETE THE CONVERSION:

1. Adjust burner assembly venturi by loosening screw, adjusting cap and retightening screw.

NAT - 1/8” (3 mm) open / LP - 1/2” (13mm) open

2. Re-install burner assembly into fireplace, checking to ensure burner venturi is properly seated over burner orifice and the pilot hood is above burner assembly as shown below.

3. Re-install logs .*

4. Light pilot and turn burner on.*

5. Check for leaks at all connections whether field or factory made.*

6. Test both inlet and manifold pressures.*

BURNER ORIFICE

Figure 46b

Figure 46c

Figure 46d

PAGE 46

CONVERSION KIT INSTRUCTIONS

(CSK-31/CSK-31 RAD units only) cont.

COMPLETE THE CONVERSION:

7. Visually check pilot flame. Flame should envelope top of thermocouple and thermopile 3/8” (10 mm) to 1/2” (13 mm), and extend onto burner far enough for proper ignition.

To Adjust pilot: Remove pilot adjustment screw from gas valve. Turn inner pilot adjustment screw clockwise to decrease or counterclockwise to increase pilot flame. Re-install pilot adjustment screw cover and tighten.

8. Turn burner and pilot off.

9. Affix gas type sticker over existing label on metal tag.

10. Re-install glass frame assembly*.

11. Verify proper ignition and operation of fireplace.

12. Complete and affix „Gas Conversion‟ label behind lower grill.

* REFER TO FIREPLACE INSTALLATION MANUAL IF NECESSARY.

PAGE 47

CONVERSION KIT INSTRUCTIONS (

CSK-31-IPI units only)

#OCK-A37N-IPI NAT GAS CONVERSION KIT / #OCK-A52L-IPI 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 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.

Kit includes:

(1) Gas Conversion Label (1) Burner Orifice: NAT #37 / LP #52 (1) Gas Type Label

(1) Pilot Orifice: NAT #62 / LP #35 (1) Low Limit Screw: NAT #48 / LP #55

WARNING: SHUT OFF GAS SUPPLY AND ELECTRICAL POWER TO FIREPLACE.

SHUT OFF GAS SUPPLY BEFORE DISCONNECTING ELECTRICAL POWER.

PREPARE THE FIREPLACE:

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

BURNER ORIFICE

REPLACE BURNER ORIFICE:

1. Remove existing orifice cap. Replace with orifice cap included with kit, making sure to tighten cap securely.

CONVERT PILOT ASSEMBLY:

1. Follow instruction sheet included with kit to convert pilot to either Nat. or LP.

GAS TYPE CONVERSION:

Press and hold Learn Button on the Main Control Module for 20 seconds. A beep will be heard letting you know the procedure has been completed.

If converting from NAT to LP gas: one (1) second long beep

If converting from LP to Nat gas: three (3) second long beep

Figure 48a

PRESSURE REGULATOR CAP

CONVERT THE GAS CONTROL VALVE:

1. Remove black cap covering the pressure regulator.

2. Press down on pressure regulator tube and rotate 90˚. The shaft should pop out and point to chosen gas. Re-attach black cap.

3. Remove low limit screw (above valve motor; see page 28) Replace with one included in kit.

NAT. SETTING L.P. SETTING

COMPLETE THE CONVERSION:

Figure 48b

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

CORRECT SETTINGS: NAT. :1/8” (3mm) open / L.P. :1/2 (13mm) open

2. Re-install burner into fireplace, checking to ensure burner venturi is properly seated over burner orifice.

4. Re-install logs*.

5. Turn on gas and electrical supplies.

6. Check for leaks at all connections, whether field or factory made.

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

8. Turn fireplace off.

9. Affix gas type sticker to label.

10. Re-install glass frame assembly*.

11. Verify proper ignition and operation of fireplace.

12. Complete and affix „Gas Conversion‟ label behind lower grill.

PAGE 48

REPLACEMENT PARTS LIST

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

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

CSK-770A Millivolt Board - Nat Gas 700-094 Pilot Orifice - Natural Gas

CSK-771A Millivolt Board - LP Gas 700-095 Pilot Orifice - LP Gas

700-023

700-086A

700-087A

700-063

700-063-1

700-090

700-060

700-092

700-093

On/Off Rocker Switch

Valve - Natural Gas

Valve - LP Gas

Pilot Assembly - Nat Gas

Pilot Assembly - LP Gas

Piezo Igniter w/ Nut (no wire)

Flexible Pilot Tubing (Valve to Pilot)

Millivolt Generator

Thermocouple

700-098

700-203

700-213-B

700-226F

700-237

700-252

OCK-S37A

OCK-S52A

CSK-135

Pilot Hood

Manual Shut-off Valve

18” Flexible Gas Line-Black

Flexible Gas Line-Valve to Burner Connection

Natural Gas Orifice #37

LP Gas Orifice #52

Natural Gas Conversion Kit

LP Gas Conversion Kit

Burner Assembly

CSK-31-IPI BOARD SYSTEM AND PARTS

CSK-600-IPI CSK-31-IPI Control Board - Nat Gas 700-168 #35 IPI LP Gas Pilot Orifice

CSK-601-IPI CSK-31-IPI Control Board - LP Gas 700-751 Battery Back-up with (4) AA Batteries

700-400-CSK Main Control Module

700-404-CSK Chaska IPI Valve - Natural

700-203

700-213

Manual Shut-off Valve

18” Flexible Gas Line-Black

700-404-CSK-1 Chaska IPI Valve - LP

700-199 Pilot Assembly - Natural Gas

700-199-1

700-800

Pilot Assembly - LP Gas

8-PIN Primary Wire Harness: Primary Wire Harness

700-500

700-120

700-401

700-750

700-208

700-166

700-226

700-237

700-252

OCK-A37N-IPI

Flexible Gas Line-Valve to Burner Connection

Natural Gas Orifice #37

NAT Gas Orifice #52

Natural Gas Conversion Kit

5-PIN Wire Harness: Main Module to Valve Step Motor

Extension Module

OCK-A52L-IPI LP Gas Conversion Kit

CSK-135 Burner Assembly

4-PIN Wire Harness: Control Module to Extension Module 700-048

7.5 Volt Adaptor

IPI Remote Control

#62 IPI NAT. Gas Pilot Orifice

700-055

700-752

700-753

Nat. Gas Low Limit Screw #48

LP Gas Low Limit Screw #55

Pilot Igniter (with wire)

Pilot Flame Sensor (with wire)

CSK-200

CSK-200F

CSK-201

GRILL REPLACEMENT

Upper Hood (For 3 & 4 pc. Shrouds)

Upper Hood (For Full Door Shrouds)

Lower Grill

CSK-005

900-006

CSK-057T

IPI-028

CSK-028

FAN ASSEMBLIES

Fan Assembly (CSK-31-IPI only)

Fan Assembly (CSK-31 / CSK-31-RAD)

CSK-50A

CSK-1

CSK-2

REFRACTORY PANELS

(Sandstone)

CSK-G900 (4 pc.) Refractory Panel Set

CSK-900B Back Refractory Panel

CSK-G900L Left Side Refractory

CSK-900R Right Side Refractory

CSK-G902 Top Refractory Panel

CSK-3

CSK-4

CSK-5

CSK-6

CSK-7

CSK-8

CSK-12

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

This appliance tested & certified by:

OMNI - Test Laboratories, Inc.

13327 NE Airport Way

Portland, Oregon 97230

Model #CSK-31

Model #CSK-31-RAD

Model #CSK-31-IPI

April 2010-REV11

CSK-13

900-REMB

www.kozyheat.com

GLASS & GLASS GASKET

Replacement Valance

1-1/8” Glass Gasket w/ Adhesive

Valance with 14-1/4” x 29” glass

LOG SET

10 pc. Log Set

#C1 Log

#C2 Log

#C3 Log

#C4 Log

#C5 Log

#C6 Log

#C7 Log

#C8 Log

#C12 Log

#C13 Log

Rock Wool Embers

Manufactured by:

Hussong Mfg. Co., Inc.

204 Industrial Park Drive

Lakefield, Minnesota 56150

507-662-6641

PAGE 49

LIMITED WARRANTY

PAGE 50

LIFETIME WARRANTY

PAGE 51

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