Installation and Operation Manual HUSSONG MANUFACTURING CO., INC. BIRCHWOOD-20 LOG Model #BIR-20-L Direct Vent Gas Stove WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage. ͷͷDo not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. ͷͷWHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Leave the building immediately. • 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. ͷͷInstallation and service must be performed by a qualified installer, service agency or the gas supplier. This appliance may be installed in an aftermarket, permanently located, manufactured home (USA only) or mobile home, where not prohibited by local codes. This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used. Tested & Listed By Portland Oregon USA C US OMNI-Test Laboratories, Inc. DANGER HOT GLASS WILL CAUSE BURNS DO NOT TOUCH GLASS UNTIL COOLED NEVER ALLOW CHILDREN TO TOUCH GLASS A barrier designed to reduce the risk of burns from the hot viewing glass is provided with this appliance and shall be installed for the protection of children and other at-risk individuals. English and French installation manuals are available through your local dealer. Visit our website www.kozyheat.com or scan the QR code for our mobile app. Les manuels d’installation en français et en anglais sont disponibles chez votre détaillant local. Visitez www.kozyheat. com ou scannez ce code QR pour notre application mobile. INSTALLER: Leave this manual with the appliance. CONSUMER: Retain this manual for future reference. Hussong Mfg. Co., Inc. • BIR-20-L Report No: 0216GH050S • Rev. 02, November 2016 Read this manual before installation 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. To ensure you receive a quality product, the burner and valve assembly are 100 percent test-fired, and the complete fireplace is thoroughly inspected before packaging. Our commitment to quality and customer satisfaction has remained the same for 40 years. We offer a complete line of gas and wood fireplaces, along with stylish accessories to complement any decor. 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 not only to functionality and reliability, but also customer safety. We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your Kozy Heat gas fireplace. Jim Hussong President Dudley Hussong Board Chairman Homeowner Reference Information We recommend you record the following information: Model Name: ____________________________________________ Date purchased/installed: __________________________________ Serial Number: ___________________________________________ Location of fireplace: ______________________________________ Dealership Purchased from: ________________________________ Dealer phone: ____________________________________________ Notes: ______________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ HOMEOWNER REFERENCE 3 TABLE OF CONTENTS TABLE OF CONTENTS.................................................................... 5 1.0 INTRODUCTION....................................................................... 7 1.1 Appliance Certification..................................................................7 1.2 Requirements for the Commonwealth of Massachusetts.......7 2.0 SPECIFICATIONS..................................................................... 8 2.1 Appliance Components.................................................................8 2.2 Heating Specifications...................................................................8 2.3 Appliance Dimensions...................................................................9 2.4 Safety Barrier Dimensions............................................................12 3.0 FRAMING.................................................................................. 13 3.1 Appliance Placement Considerations.........................................13 3.2 Floor Support and Protection.......................................................14 3.3 Vent Termination Framing..............................................................14 4.0 GAS LINE CONNECTION........................................................ 15 4.1 Gas Conversion (sold separately)...............................................15 4.2 Gas Line Installation.......................................................................15 5.0 TERMINATION LOCATIONS.................................................... 16 5.1 Vertical Vent Cap Termination......................................................16 5.2 Minimum Termination Clearances...............................................17 6.0 VENTING................................................................................... 18 6.1 Approved 4” x 6⅝” Vent Systems.................................................18 6.2 Venting Requirements....................................................................18 6.3 Elbows...............................................................................................18 6.4 Vent Restriction ..............................................................................19 6.5 Vertical Terminations......................................................................20 6.6 Combination Venting......................................................................21 7.0 FIREPLACE SET UP................................................................. 22 7.1 Safety Barrier Installation..............................................................22 7.2 Glass Frame Assembly..................................................................22 7.3 #BW20-500 Log Set Installation..................................................23 7.4 Control Board Removal and Installation.....................................24 8.0 ELECTRICAL INFORMATION.................................................. 25 8.1 Electrical Specifications................................................................25 8.2 Wiring Requirements......................................................................25 8.3 #BW20-028 Optional Fan Kit.......................................................26 9.0 OPERATING INSTRUCTIONS................................................. 27 9.1 Setup Proflame 2 IFC Module......................................................28 9.2 Initialize the Control System.........................................................28 9.3 Reset the System for Manual Operation....................................28 9.4 Automatic Safety Restart...............................................................28 9.5 Backup Battery Operation ...........................................................28 9.6 IFC Module Ignition Sequence.....................................................29 9.7 Additional Diagnostic Information................................................29 9.8 Remote Control Operation ...........................................................30 10.0 ADJUSTMENT........................................................................ 33 10.1 Pressure Testing...........................................................................33 10.2 Flame Appearance Adjustment..................................................34 11.0 TROUBLESHOOTING............................................................ 37 12.0 MAINTENANCE....................................................................... 39 12.1 Burner and Pilot System ............................................................39 12.2 Fan (optional)................................................................................39 12.3 Vent System...................................................................................39 12.4 Glass Assembly............................................................................39 13.0 REPLACEMENT PARTS LIST................................................ 40 LIMITED WARRANTY...................................................................... 41 LIFETIME WARRANTY.................................................................... 43 TABLE OF CONTENTS 5 1.0 INTRODUCTION 1.1 Appliance Certification OBSTRUCTIONS”. Laboratory: OMNI-Test Laboratories in Portland, Oregon 1.2.4 Inspection Standards: 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. ANSI Z21.88-2014/CSA 2.33-2014, Vented Gas Fireplace Heaters CGA 2.17-M91 (R2009), Gas-Fired Appliances for Use at High Altitudes This installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1. 1.2 Requirements for the Commonwealth of Massachusetts 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: 1.2.1 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. 1.2.5 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. 1.2.6 Manufacturer Requirements 22.214.171.124 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. 1.2.7 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. 1.2.2 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. 1.2.3 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 (½) in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL INTRODUCTION 7 2.0 SPECIFICATIONS 2.1 Appliance Components Part Number Description BW20L-150 Control Board Assembly 700-203 Manual Gas Shut-off Valve BW20-500 Log Package BW20-057T Glass Frame Assembly 700-408 Remote Control 900-085 4 in (102 mm) Restrictor Plate 2.1.1 Additional Components Required Refer to Section 6.0 Venting on page 18 for approved vent systems. 2.2 Heating Specifications Natural Gas LP Gas Maximum Input Rating 32,500 BTU/h (9.5 kW) 32,500 BTU/h (9.5 kW) Minimum Input Rating 16,000 BTU/h (4.7 kW) 16,000 BTU/h (4.7 kW) Manifold Pressure (High) 3.8” WC (0.95 kPa) 11” WC (2.74 kPa) Manifold Pressure (Low) 1.1” WC (0.27 kPa) 2.9” WC (.72 kPa) FRONT: .0625 BACK: 44 FRONT: 61 BACK: 54 Orifice Size (DMS) 2.2.1 Altitude Adjustment This appliance may be installed at higher altitudes. Please refer to National Fuel Gas Code ANSI Z223.1/NFPA 54, CSA-B149.1 Natural Gas and Propane Installation Code, local authorities, or codes having jurisdiction in you area regarding derate guidelines. 126.96.36.199 US Installations Refer to the American Gas Association guidelines for the gas designed appliances derating method. For elevations above 2,000 ft (610 m), input ratings are to be reduced by 4% for each 1,000 ft (305 m) above sea level. 188.8.131.52 Canadian Installations When the appliance is installed at elevations above 4,500 ft (1,372 m), the certified high altitude rating shall be reduced at the rate of 4% for each additional 1,000 ft (305 m). 8 SPECIFICATIONS 2.3 Appliance Dimensions TOP VIEW 7¼” (185mm) 1713⁄16” (452mm) 27¾” (658mm) LEFT SIDE FRONT VIEW RIGHT SIDE 201⁄16” (510mm) 2313⁄16” (605mm) 141⁄8” (359mm) 7¼” (185mm) 30¾” (781mm) 615⁄16” (176mm) 2515⁄16” (658mm) 15¾” (400mm) Figure 2.1, Appliance Dimensions (shown with traditional legs) SPECIFICATIONS 9 TOP VIEW 7¼” (185mm) 1713⁄16” (452mm) 27¾” (658mm) LEFT SIDE FRONT VIEW RIGHT SIDE 201⁄16” (510mm) 2313⁄16” (605mm) 7¼” (185mm) 141⁄8” (359mm) 3515⁄16” (913mm) 121⁄8” (308mm) 181⁄8” (461mm) 27¾” (704mm) Figure 2.2, Appliance Dimensions (shown with pedestal base) 10 SPECIFICATIONS 13¾” (349mm) 17¾” (451mm) TOP VIEW 7¼” (185mm) 1713⁄16” (452mm) 27¾” (658mm) LEFT SIDE FRONT VIEW RIGHT SIDE 201⁄16” (510mm) 2313⁄16” (605mm) 7¼” (184mm) 141⁄8” (359mm) 85⁄8” (219mm) 121⁄8” (308mm) 155⁄16” (389mm) Figure 2.3, Appliance Dimensions (shown with contemporary base) SPECIFICATIONS 11 2.4 Safety Barrier Dimensions WARNING: A barrier designed to reduce the risk of burns from the hot viewing glass is provided with this appliance and shall be installed for the protection of children and other at-risk individuals. If the barrier becomes damaged, the barrier shall be replaced with Hussong Mfg.’s barriers for this appliance. Only doors certified with the appliance shall be used. Please refer to Section 7.1 Safety Barrier Installation on page 22 for installation instructions. 25¾” (653mm) 211⁄16” (536mm) 25¾” (653mm) 211⁄16” (536mm) 211⁄16” (536mm) BW20-FRSF 12 SPECIFICATIONS 25¾” (653mm) BW20-PSF BW20A-MSF 3.0 FRAMING 3.1 Appliance Placement Considerations WARNING: Due to high temperatures, the appliance should be located out of traffic and away from furniture and draperies. FIRE HAZARD: Do NOT install this appliance directly on carpeting, vinyl, or any other combustible material other than wood. • This appliance must be installed on a level surface capable of supporting the fireplace and venting. If possible, place the fireplace in a position where the vent terminates between two studs, eliminating the need for any additional framing. • 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. 157⁄8” (404mm) 147⁄8” (378mm) 1” (25mm) 1” (25mm) 5” (127mm) 1” (25mm) 31⁄8” (80mm) 31⁄8” (80mm) 31⁄8” (80mm) 35¾” (908mm) 35¾” (908mm) 35¾” (908mm) 651⁄8” (1654mm) 60” (1524mm) TRADITIONAL LEGS From From From From CONTEMPORARY BASE 651⁄8” (1654mm) PEDESTAL BASE Table 3.1, Minimum Clearances to Combustible Material appliance top corner to side wall 1 in appliance top corner to back wall 5 in appliance top to ceiling 35-3/4 in top of horizontal pipe surface to ceiling 3-1/8 in 25 mm 127 mm 908 mm 80 mm Figure 3.1, Typical Install Options FRAMING 13 3.2 Floor Support and Protection • The fireplace must be placed directly on a wood or noncombustible surface (not linoleum or carpet) extending the entire depth and width of the fireplace • If this appliance is to be installed directly on carpeting, tile, or other combustible material other than wood flooring, this appliance shall be installed on a metal or wood panel extending the full width and depth of the appliance. • If the appliance is to be installed above floor level, a solid, continuous platform must be constructed below the appliance. 3.3 Vent Termination Framing IMPORTANT: Vent cap location must be in compliance with Section 5.2 Minimum Termination Clearances on page 17. WARNING: DO NOT RECESS THE VENT CAP INTO WALL OR SIDING. 3.3.1 Vertical Terminations CAUTION: Cold air transfer area. The surrounding fireplace chase must comply with all clearances as outlined in this manual, and be constructed in compliance with local building codes. Outside walls should be insulated to prevent cold air from entering room. • Follow vent pipe manufacturer’s installation instructions for vertical terminations. • A minimum of 1 in (25 mm) clearance on all sides of the vertical vent pipe must be maintained. • Attic insulation shields may be insulated using unfaced insulation products listed as non-combustible per ASTM E 136. 3.3.2 Horizontal Terminations IMPORTANT: Horizontal vent sections require 1/4 in (6 mm) rise for every 12 in (305 mm) of travel. NOTE: Elbows listed with approved vent systems for this appliance vary in vertical length. Please consult the vent manufacturer’s instructions to determine the elbow dimension used for installation. Adjust the wall pass-through rough opening dimensions as necessary to maintain clearance requirements. 1. Measure from floor level of the fireplace to the center of where the vent pipe will penetrate the wall. 2. Cut and frame an opening in the wall to allow the vent system to run level through the wall pass-through. A minimum of 1 in (25 mm) clearance on all sides of the horizontal vent pipe at the wall pass-through must be maintained. 3. Follow the vent pipe manufacturer’s installation instructions for vent installation. 14 FRAMING 4.0 GAS LINE CONNECTION 4.1 Gas Conversion (sold separately) 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. This fireplace is manufactured for use with natural gas. Follow the instructions included with the conversion kit if converting to LP gas. 4.2 Gas Line Installation 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 installations must be done by a licensed plumber or gas fitter. 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 (3.5 kPa). For test pressures equal to or less than ½ psi (3.5 kPa), the appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve. • A listed (and Commonwealth of Massachusetts approved) ½ in. (13 mm) tee handle manual shut-off valve and flexible gas connector are to be connected to the ½ in. (13 mm) control valve inlet. If substituting for these components, please consult local codes for compliance. • This fireplace is equipped with a ⅜” (10 mm) x 36” (914 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. • Do not run gas line in a manner that would obstruct fan operation. • For high altitude installations, consult the local gas distributor or the authority having jurisdiction for proper rating methods. Table 4.1, Inlet Gas Supply Pressures Fuel Minimum Pressure Maximum Pressure Natural Gas 5” WC (1.25 kPa) 10.5” WC (2.62 kPa) LP Gas 12” WC (2.99 kPa) 13” WC (3.24 kPa) GAS LINE CONNECTION 15 5.0 TERMINATION LOCATIONS 5.1 Vertical Vent Cap Termination WARNING: This gas appliance must not be connected to a chimney serving any other appliance. LOWEST DISCHARGE OPENING APPROVED CAP MINIMUM 12” (.30m) APPROVED VENT PIPE H x 12 ROOF PITCH = x/12 H - MINIMUM HEIGHT FROM ROOF TO LOWEST DISCHARGE OPENING Figure 5.1, Vertical Vent Cap Clearance Minimum height (H) from roof Roof Pitch Feet Meters Flat to 6/12 1.0 0.30 Over 6/12 to 7/12 1.25 0.38 Over 7/12 to 8/12 1.5 0.46 Over 8/12 to 9/12 2.0 0.61 Over 9/12 to 10/12 2.5 0.76 Over 10/12 to 11/12 3.25 0.99 Over 11/12 to 12/12 4.0 1.22 Over 12/12 to 14/12 5.0 1.52 Over 14/12 to 16/12 6.0 1.83 Over 16/12 to 18/12 7.0 2.13 Over 18/12 to 20/12 7.5 2.27 Over 20/12 to 21/12 8.0 2.44 16 TERMINATION LOCATIONS 5.2 Minimum Termination Clearances O AREA WHERE TERMINAL IS NOT PERMITTED E D C H B G J K B F M N A L P I Figure 5.2, Vent Cap Locations Canadian installations US installations A Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) B Clearance to window or door that may be opened 12 in (30 cm) 9 in (23 cm) C Clearance to permanently closed window (recommended to prevent condensation on window) 12 in (30 cm)* 12 in (30 cm)* D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the cent line of the terminal 24 in (61 cm)* 24 in (61 cm)* E Clearance to unventilated soffit 12 in (30 cm)* 12 in (30 cm)* F Clearance to outside corner 0 in (0 cm)* 0 in (0 cm)* G Clearance to inside corner 12 in (30 cm)* 12 in (30 cm) H Clearance to each side of center line extended above meter/regulator assembly 3 ft (91 cm) within a height 15 ft (4.5 m) above the meter/ regulator assembly * I Clearance to service regulator vent outlet J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance K Clearance to mechanical air supply inlet L Clearance above paved sidewalk or paved driveway located on public property M Clearance under veranda, porch deck, or balcony N Clearance between two horizontal terminations O P 12 in (30 cm) 3 ft (91 cm) * 12 in (30 cm) 9 in (23 cm) 6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m) horizontally Massachusetts: 10 ft (3 m) 7 ft (2.13 m)† * 12 in (30 cm)‡ 12 in (30 cm) 12 in (30 cm) 12 in (30 cm) Clearance between two vertical terminations (may be same height) 12 in (30 cm) 12 in (30 cm) Above furnace exhaust or inlet 12 in (30 cm) 12 in (30 cm) * Clearance in accordance with local installation codes and the requirements of the gas supplier. † A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. ‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. VINYL SOFFIT, VINYL CEILING, AND VINYL OVERHANG DISCLAIMER: Clearances to heat resistant material (i.e. wood, metal). This does not include vinyl. Hussong Manufacturing Co., Inc. will not be held responsible for heat damage caused from terminating under vinyl overhangs, vinyl ceilings, or vinyl ventilated/unventilated soffits. TERMINATION LOCATIONS 17 6.0 VENTING 6.1 Approved 4” x 6⅝” Vent Systems Vent Manufacturer Direct Vent System Termination American Metal Products Ameri-Vent Horizontal & Vertical BDM Pro-Form Horizontal & Vertical ICC EXCELDirect EXCEPT CAP TM-4VT Horizontal & Vertical Metal Fab Direct Vent Chimney Horizontal & Vertical Olympia Chimney Supply, Inc. Ventis Direct Vent Horizontal & Vertical Security Direct Vent Chimney Vertical only Selkirk Direct Temp Horizontal & Vertical Simpson DuraVent DV-GS Horizontal & Vertical 6.2 Venting Requirements Consult the local and national installation codes to assure adequate combustion and ventilation air is available. Venting requirements apply to both natural gas and LP gas. • Flame height and appearance will vary depending upon venting configuration and the type of fuel used. • Refer to the vent manufacturer’s installation manual for complete installation instructions. Vent installation must conform with venting requirements and restrictions as outlined in this manual. • Provide a means for visually checking the vent connection to the appliance after the fireplace is installed. • This fireplace may be vented through a 6 in (152 mm) or larger Class-A metal chimney, or a co-axial masonry chimney if an approved adapter is used. Refer to the vent manufacturer’s installation instructions. 6.2.1 Vent Section Clearances Table 6.1, Vertical Pipe Section Clearances Surface Sides Approved Venting 1 in (25 mm) Table 6.2, Horizontal Pipe Section Clearances Surface Approved Venting Top 1 (25 mm) Bottom 1 in (25 mm) Sides 1 in (25 mm) 6.3 Elbows • MAXIMUM NUMBER OF 90° ELBOWS: 5 • For each additional 90° elbow used after the first elbow, 3 ft (91.4 cm) must be subtracted from maximum venting allowed. • For each 45° elbow used, 1½ ft (457 mm) must be subtracted from maximum venting allowed. • (2) 45° degree elbows may be used in place of (1) 90° elbow. 18 VENTING 6.4 Vent Restriction 6.4.2 Baffle Restriction Vertical terminations may display an active, compact flame. To achieve desirable flame appearance, the vent exhaust may be restricted by the restrictor plate (included in components packet) and/or by adjusting the built-in restrictor located in the fireplace baffle. This fireplace is shipped with the baffle restrictor set in position for natural gas minimum horizontal venting. This fireplace is shipped with the baffle restrictor set in position for natural gas minimum horizontal venting. Hussong Manufacturing has outlined baffle restrictor adjustments for vent configurations listed on the following pages. To adjust the baffle restrictor, Hussong Manufacturing has outlined vent restriction recommendations with for vent configurations listed in the following pages. Follow the instructions below and vent restriction recommendations on the following pages for optimal flame appearance. 2. Remove and save (1) screw to adjust the baffle restrictor to achieve desired flame appearance. 6.4.1 Restrictor Plate Assembly and Installation 1. Remove the safety barrier and glass frame assembly. 3. Secure the baffle restrictor with (1) screw previously removed. 4. Reinstall all components previously removed. A restrictor plate (included in components packet) may be installed before vent installation to achieve desired flame appearance. Hussong Manufacturing has outlined restrictor plate recommendations for vent configurations listed on the following pages. For vent restriction plate recommendations after vent installation, see Section 10.2.2 Vent Restriction on page 35 . RESTRICTOR PLATE REMOVE KNOCKOUT TO CREATE LESS RESTRICTION BEND TABS TO APPROX. 80° ANGLES AND INSERT INTO EXAHUST PIPE Figure 6.1, Restrictor Assembly and Installation Figure 6.2, Baffle Restrictor Adjustments VENTING 19 6.5 Vertical Terminations NOTE: Attic insulation shields may be insulated using unfaced insulation products listed as non-combustible per ASTM E 136. Table 6.3, NG & LPG - Minimum / Maximum Vertical Terminations Minimum Vertical Length 3 ft Maximum Vertical Length 914 mm 50 ft 15.2 m Table 6.4, Recommended Restriction for Vertical Terminations Gas Type Vent Configuration Baffle Position Restrictor NG Minimum vertical Setting (5) Install restrictor Remove knockout NG Maximum vertical Setting (5) Install restrictor Remove knockout LP Minimum vertical Setting (5) Install restrictor Remove knockout LP Maximum vertical Setting (5) Install restrictor Remove knockout VERTICAL TERMINATION CAP 50’ (15.24m) 36” (914mm) 20 VENTING 6.6 Combination Venting IMPORTANT: Horizontal vent sections require ¼ in (6 mm) rise for every 12 in (305 mm) of travel. IMPORTANT: Natural gas and LP gas vent installations terminating with a snorkel cap require a minimum of 24 in (610mm) of vertical venting off the top of the appliance before the use of an elbow. Table 6.5, NG & LPG - Minimum Horizontal Vent Terminations Minimum Vertical Rise 24 in 610 mm Minimum Horizontal Run Maximum Horizontal Run 6 in 48 in 152 mm Table 6.6, NG & LPG - Max Vertical / Max Horizontal Combination Maximum Vertical Rise 25 ft Maximum Horizontal Run 7.6 m 25 ft Total Length 7.6 m 50 ft 48” (1219mm) 1219 mm 90° ELBOW 6” (152mm) 15.2 m Maximum number of 90° elbows: 5 Table 6.7, Recommended Restriction for Combination Venting Gas Type Vent Configuration Baffle Position Restrictor NG Min vert / min horz Setting (3) None NG Min vert / max horz Setting (1) None NG Max vert / max horz Setting (5) Install restrictor LP Min vert / min horz Setting (2) None LP Min vert / max horz Setting (5) None LP Max vert / max horz Setting (5) Install restrictor 24” (610mm) HORIZONTAL TERMINATION CAP Figure 6.3, Combination Venting - Natural and LP Gas (V/H) VENTING 21 7.0 FIREPLACE SET UP 7.1 Safety Barrier Installation 7.2 Glass Frame Assembly 1. Locate the (4) slots located on each side of the fireplace frame. WARNING: Do not operate this fireplace with the glass removed, cracked, or broken. Replacement of the glass assembly, should be done by a licensed or qualified service person. 2. Align the notched tabs located on the back of the safety screen front with the slots on the fireplace frame. 3. Raise the screen front slightly into slots and allow the tabs to lower into position. • To remove safety screen: lift the screen up and out of slots. 7.2.1 Remove Glass Frame Assembly WARNING: Do not remove the glass assembly when hot. 1. Remove the safety screen. 2. Locate (2) spring-loaded latches securing the glass assembly at the bottom of the firebox. 3. Pull the spring-loaded latches out and down to release the bottom of the glass assembly. 4. Lift glass assembly up and off of the (2) tabs located at the top of the firebox. 7.2.2 Install Glass Frame Assembly 1. Align the slots on top of the glass assembly over the tabs at the top of the firebox while lowering the bottom of the glass assembly into position. 2. Pull the spring-loaded latches out and up to secure the bottom of glass to the bottom of the fireplace. 3. Reinstall the safety screen. LATCH HANDLES Figure 7.1, Safety Barrier Installation Figure 7.2, Latch Handle Location 22 FIREPLACE SET UP 7.3 #BW20-500 Log Set Installation CAUTION: Do not place logs directly over burner port holes. Improper log placement may affect flame appearance and cause excessive soot to build upon the logs and glass. • If converting to LP (propane) gas, complete the conversion before installing the log set. Follow the conversion instructions included with the kit. • Log numbers are located on the bottom of each log. Refer to the following instructions and illustrations for proper log placement. 1. Align the holes in the bottom of the ember panel with the (2) mounting pins located on left and right side of the front burner. Push to seat. 2. Align the holes in the bottom of logs BW20-1, BW20-2, and BW20-3 with the mounting pins on the back burner. Push logs down onto pins to seat. 3. Position logs BW20-4 and BW20-6 with the notches in base log BW20-1 and ember panel as shown. 4. Align log BW20-5 with the notch on log BW20-1 and the ember panel as shown. 5. Distribute rockwoll embers onto the logs and burner using a stiff bristle brush. Figure 7.3, Base Logs Figure 7.4, Completed Install FIREPLACE SET UP 23 7.4 Control Board Removal and Installation WARNING: If burner and/or pilot have been burning, use appropriate protection to avoid burns or damage to personal property before removing any components. DO NOT OPERATE THIS APPLIANCE WITHOUT THE SEALING GASKET (LOCATED UNDER THE CONTROL BOARD) IN PLACE. IF GASKETING IS DAMAGED, IT MUST BE REPLACED. CAUTION: Check all connections for leaks with soapy water, whether field or factory made. 7.4.1 Control Board Removal 1. Disconnect electrical power. 2. Locate the manual valve installed by your qualified service technician. 3. Turn the manual valve clockwise to the OFF position. 4. Remove the safety barrier and glass frame assembly. BACK BURNER 5. Remove logs. 6. Remove the back log plate (2) screws. BACK LOG PLATE 7. Remove (2) screws on each side of the back burner. Slide the burner tube venturi to the right to release from the burner orifice. 8. Remove the front burner from the firebox (4) screws. 9. Remove and save (10) screws securing the control board. Lift the control board and control module out of the firebox, being careful not to damage sealing gasket underneath. FRONT BURNER 7.4.2 Control Board Installation 1. Place the control module in the firebox, aligning the holes in the control board with the holes in the firebox bottom. VERIFY SEALING GASKET IS IN PLACE. 2. Secure the control board to the firebox using (10) screws previously removed. 3. Reinstall the front burner (4) screws, positioning the burner venturi over the burner orifice. 4. Reinstall the back burner. Position the burner tube venturi over the burner orifice. Secure with (2) screws. 5. Reinstall the back log plate (2) screws. 6. Reinstall log set. 7. Reinstall the glass frame assembly and safety barrier. 8. Turn the manual valve counterclockwise to the ON position. 9. Reconnect electrical power. 10. Verify proper log placement, operation of fireplace, and any electrical components. Figure 7.5, Control Board Removal and Installation 24 FIREPLACE SET UP 8.0 ELECTRICAL INFORMATION WARNING: 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. with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.1. WARNING - Electrical Grounding Instructions: This appliance is equipped with a three-prong (grounding) plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug. • The IFC System Module requires 120V of electricity and/or batteries to operate. • Using the battery back-up will operate the burner only. • Fan and light components will not function on battery back up power. 8.2 Wiring Requirements 8.1 Electrical Specifications VARIABLE LIGHT BURNER 885 PROFLAME BATTERY PACK PILOT FLAME SENSOR IGNITER PILOT SW1 BUTTON (RED) MAIN ON/OFF SWITCH APPLIANCE GROUND STAR MALE END VARIABLE SPEED FAN This appliance, when installed, must be electrically grounded in accordance with local codes, or in the absence of local codes, Figure 8.1 Wiring Schematics ELECTRICAL INFORMATION 25 8.3 #BW20-028 Optional Fan Kit WARNING - Electrical Grounding Instructions: This appliance is equipped with a three-prong (grounding) plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug. WARNING: Installation of this fan kit should be done by a qualified installer. Verify household breaker is shut off prior to working on any electrical lines. • 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 Code, CSA C22.1. This kit includes: (1) Fan assembly - mounted (4) Flange nuts 1. Locate (4) mounting studs underneath the rear of the gas stove. Figure 8.2, Mounting Stud Location (rear view) 2. With the motor end facing to the right, slide the fan underneath the firebox. 3. Align the (4) mounting slots in the fan bracket to the mounting studs under the firebox. 4. Lift up the fan and secure the fan assembly to the firebox with (4) flange nuts. 5. Connect the fan wires to the fan lead wires on the IFC module. See Figure 8.1 Wiring Schematics on page 25. 6. Plug the fan cord in to the IFC module. Figure 8.3, Completed Installation 26 ELECTRICAL INFORMATION 9.0 OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B. BEFORE OPERATING smell around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s WARNING Do not operate appliance with the glass front removed, cracked, or broken. Replacement of the glass should be done by a licensed or qualified service person. Under no circumstances should any solid fuel (wood, coal, paper, cardboard, etc.) be used in this appliance. Children and adults should be alerted to the hazards of high surface temperature and should stay away to avoid burns or clothing ignition. C. D. phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. Use only your hand to turn the gas control manual valve. Never use tools. If the valve will not turn by hand, do not try to repair it; call a qualified service technician. Force or attempted repair may result in a fire or explosion. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water. CAUTION Clothing or other flammable material should not be placed on or near the appliance. Young children should be carefully supervised when they are in the same room as the appliance. Toddlers, young children and others may be susceptible to accidental contact burns. A physical barrier is recommended if there are at risk individuals in the house. To restrict access to a fireplace or stove, install an adjustable safety gate to keep toddler, young children and other at risk individuals out of the room and away from hot surfaces. OPERATING INSTRUCTIONS 1. 2. 3. 4. 5. 6. 7. 8. STOP! Read all the safety information above on this page. Press the wireless remote OFF button. Turn off all electric power to the appliance. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. Locate the manual valve installed by your qualified service technician. Turn the manual valve clockwise to the OFF position. Wait five (5) minutes to clear out any gas. Then, smell for gas, including near the floor. If you smell gas, STOP! Follow ‘B’ in the safety information above. If you do not smell gas, go to the next step. Turn the manual valve counterclockwise to the ON position. 9. 10. 11. Turn on all electric power to the appliance. Press the wireless remote ON button. If the appliance will not operate, follow the instructions, “To Turn Off Gas To Appliance” and call your service technician or gas supplier. OFF ON ON/OFF TO TURN OFF GAS TO APPLIANCE 1. Press the wireless remote OFF button. 3. 2. Turn off all electric power to the appliance if service is to be performed. Locate the manual valve installed by your qualified service technician. 4. Turn the manual valve clockwise to OFF position. NOTE When this fireplace is initially lit, condensation will appear on the glass. This is normal in all gas fireplaces and will disappear after several minutes. A paint smell will occur during the first few hours of burning. It is recommended to leave the fan off during this period to help speed the paint curing process. This fireplace may produce noises of varying degree as it heats and cools due to metal expansion and contraction. This is normal, and does not affect the performance or longevity of the fireplace. OPERATING INSTRUCTIONS 27 9.1 Setup Proflame 2 IFC Module • 1. Set the main ON/OFF rocker switch in the OFF position. 2. Install (4) AA batteries (included in the components packet) into backup battery holder on the control module. Turn the main burner OFF by setting the ON/OFF switch in the OFF position. The pilot will remain lit even if burner is turned off, provided CPI mode is turned on. 9.4 Automatic Safety Restart 3. Install (3) AAA batteries (included in the components packet) in the remote control battery bay, located at the base of the remote. • This system will execute an automatic turn OFF command within (24) hours of a continued pilot flame ignition. This allows the system to verify correct safety functions. 4. Connect the IFC Module to an AC power supply. • After the turn OFF sequence is completed, the IFC module will re-execute the latest command. 9.2 Initialize the Control System IMPORTANT: Remove all packaging and combustible material from the firebox before initializing the control system. 9.5 Backup Battery Operation NOTE: Performing the next steps will initiate pilot start-up in manual mode, where the pilot igniter will spark repeatedly. The pilot will ignite if gas is supplied to the fireplace. This appliance will operate on the backup battery pack when electric power is interrupted, or in a power outage. The lifespan of the backup batteries depend on various factors, such as the quality of the batteries, number of ignitions, et cetera. 1. Locate the red SW1 button the IFC module. • 2. Press the button. The IFC module will BEEP (3) times and illuminate an amber LED. This indicates the receiver is ready to synchronize with the transmitter. 3. Within (5) seconds, push the ON/OFF button on the remote control. The receiver will BEEP (4) times to indicate the transmitter’s command is accepted, and is set to the transmitter’s particular code. The pilot will automatically ignite. 4. Press the remote control ON/OFF button again. The pilot will extinguish, confirming the remote control command. The control system is now initialized. 5. Set the main ON/OFF rocker switch to ON position for remote control operation of the main burner and fireplace features. SW1 BUTTON LEDs Figure 9.1, IFC Module 9.3 Reset the System for Manual Operation 1. Set the ON/OFF rocker switch to OFF position. 2. Press the red SWI button on the IFC module until it emits (3) beeps and an amber LED is illuminated. 3. Within (5) seconds, press the red SWI button again. This will close synchronization with the remote control. The pilot will automatically light. • Turn the main burner ON by setting the ON/OFF switch in ON position. The main burner will only operate on HI. 28 OPERATING INSTRUCTIONS • • When the backup battery pack is low, the IFC module will emit a double-beep while receiving an ON/OFF command. No commands will be accepted after this alert until the back up batteries are replaced. Once replaced, the IFC module will emit a ‘beep’ as soon as it is powered. 9.6 IFC Module Ignition Sequence The IFC module will try (2) times for ignition, each lasting approximately (60) seconds, with approximately (35) seconds between each attempt. 1. With the system in OFF position, press the remote control ON/OFF key. Approximately (4) seconds after this key is depressed, the IFC module will generate sparks to the pilot hood. 2. First ignition attempt will generate sparks for (60) seconds. 3. If there is no flame ignition (rectification) within the (60) second time frame, the IFC module will stop generating sparks for approximately (35) seconds. 4. After (35) seconds of wait time, the IFC module will generate sparks for another (60) seconds for the second ignition attempt. 5. If there is no positive rectification after (60) seconds, the IFC module will go into a lock out. The red LED will blink (3) times, in intervals, until the system is reset. 9.6.1 Reset IFC Module after Lockout 184.108.40.206 ON/OFF Rocker Switch 1. Set the ON/OFF rocker switch to the OFF position. 2. After approximately (2) seconds, move the switch to the ON position. The ignition sequence will start again. 220.127.116.11 Remote Control ON/OFF Key 1. Press the remote control ON/OFF key to turn the system OFF. 2. After approximately (2) seconds, press the ON/OFF key again. The ignition sequence will start again. 18.104.22.168 Cycling Flame 1. Press the remote control down arrow key during flame adjustment mode to reduce the flame to OFF (indicated by OFF displayed on the LCD screen). 2. After approximately (2) seconds, press the up arrow key. The ignition sequence will start again. 9.7 Additional Diagnostic Information Low Battery Condition (<4V) Remote Control: • Battery Icon will appear on LCD remote control display. • Replace batteries. Low Battery Condition (<4V) Battery Backup: • The red LED Indicator will blink (1) time in intervals. • A low double-beep emits from the IFC control module when it receives an ON/OFF command from the remote control.. • Replace Batteries. Pilot Flame Error Condition: • Red LED Indicator will blink (2) times in intervals. Contact your dealer if this occurs. System Lock Out Condition: • Red LED Indicator will blink (3) times in intervals. • Verify gas is turned on. • Verify sensor is not shorted. • Follow 9.2 Initialize the Control System. OPERATING INSTRUCTIONS 29 PROFLAME 2 TRANSMITTER LCD DISPLAY KEY LOCK TRANSMISSION BLUE BACK LCD DISPLAY LOW BATTERY ALARM THERMOSTAT OFF/ON/SMART ROOM TEMPERATURE CPI MODE SET POINT TEMPERATURE/LEVEL/STATE ON/OFF KEY FLAME ON THERMOSTAT KEY FAN LIGHT ON UP/DOWN ARROWS MODE KEY 9.8 Remote Control Operation 9.8.1 Temperature Display 1. With the system in the OFF position, simultaneously press the thermostat key and the mode key to change degrees from °F to °C. 2. Visually check the LCD screen to verify either °F or °C is displayed on the right side of the room temperature display. 9.8.3 Pilot Ignition Selection (IPI/CPI) This system has the option of a continuous (standing) pilot. This features allows the system to change from a spark-to-pilot system to the standing pilot option. The standing pilot will keep the firebox warm and establish a draft in the vent, which allows the main burner to ignite with less air-flow disruption. When the system is OFF, the LCD screen will display the snowflake icon during the setup of either IPI or CPI mode. To select the preferred pilot ignition feature, 1. With the system in the OFF position, press the mode key to index the CPI mode icon. 2. Press the up arrow key to activate CPI. 3. Press the down arrow key to return to IPI. A single ‘beep’ will confirm reception of the command. When the system is ON, IPI mode: LCD screen will not display the snowflake icon CPI mode: LCD screen will display the snowflake icon 9.8.2 Key Lock This function locks the keys to avoid unsupervised operation. Once activated, a lock icon will appear on the LCD screen. 1. Simultaneously press the mode key and the up arrow key to activate or deactivate this function. 30 OPERATING INSTRUCTIONS 9.8.4 Turn ON the Appliance ROOM TEMPERATURE 1. With the system in the OFF position, press the remote control ON/OFF key to turn ON the appliance. A single ‘beep’ will emit from the IFC module to confirm reception of the command. The LCD screen will display all active icons, and the IFC module will start the ignition sequence. 9.8.5 Turn OFF the appliance SET TEMPERATURE 1. With the system in the OFF position, press the remote control ON/OFF key to turn ON the appliance. A single ‘beep’ will emit from the IFC module to confirm reception of the command. The LCD screen will only display the room temperature and its icon, and the IFC module will turn off the main burner. 9.8.6 Remote Control Flame Adjustment This control system has (6) flame levels. If the smart thermostat operation is activated, then the manual adjustment of the flame height will be disabled. 1. Verify the system is in the ON position and the flame level is set at maximum. 22.214.171.124 Smart Thermostat The smart thermostat function will adjust the flame height based on the set temperature and the actual room temperature. The smart thermostat function automatically adjusts the flame down when the room temperature reaches the set point. To activate this function, 1. Press the thermostat key until the ‘SMART’ appears on LCD screen on the right side of the temperature bulb graphic. 2. To adjust the set temperature, press the up or down arrow keys until the desired temperature is displayed on the LCD screen. 2. Press the down arrow key once to reduce flame height by one level until the flame is turned off. 3. Press the up arrow key once to increase flame height by one step. If the up arrow key is pressed while the system is on, but the flame is off, the flame will ignite on HI. 4. A single ‘beep’ will confirm reception of the command. 126.96.36.199 Deactivate Remote Control Thermostat Operation The thermostat operation function can be deactivated. The remote control will still operate the main burner on and off, and function flame, fan, and light modulation. To deactivate this function, Flame Off Flame Level 1 1. Verify all (3) AAA batteries are installed in the remote control. 2. Remove (1) AAA battery. 3. While reinserting the battery, push and hold the thermostat key. The temperature bulb graphic will not be displayed on the LCD screen. 4. To reactivate remote thermostat operation, follow the same key sequence procedure above. The temperature bulb graphic will reappear on the LCD screen. Flame Level 5 Flame Level Maximum 9.8.7 Remote Control Thermostat Operation 188.8.131.52 Room Thermostat The remote control can operate as a room thermostat. The thermostat can be set to a desired temperature to control a room’s comfort level. To activate this function, 1. Press the thermostat key. The LCD screen will display a temperature bulb graphic, the room temperature and set temperature. 2. To adjust the set temperature, press the up or down arrow keys until the desired temperature is displayed on the LCD screen. OPERATING INSTRUCTIONS 31 9.8.8 Fan Speed Control (if applicable) Fan speed can be adjusted through (6) speeds. To activate this function, 1. Press the mode key to index to the fan control icon. 2. Press the up or down arrow keys to turn on, off, or to adjust fan speed. Thermostat mode: Fan(s) have a (5) minute delay time when the fireplace is let. This allows time for heat to build in fireplace before fan operation. The fan will continue to operate for approximately (12) minutes after the fireplace has been turned off. Manual mode: Fan(s) will operate at previous setting. There is no delay in start up or stop time. 9.8.9 Accent Light Kit (if applicable) The light intensity can be adjusted through (6) levels. 1. Press the mode key to index to the light icon. 2. Press the up or down arrow keys to adjust the intensity level. 3. A single ‘beep’ will confirm reception of the command. 9.8.10 Remote Control Low Battery Detection Remote control battery lifespan depends on various factors including battery quality, number of ignitions, changes to room thermostat set point, etcetera. • When the remote control battery are low, a battery icon will appear on the LCD display before all battery power is lost. • When the batteries are replaced, this icon will disappear. 32 OPERATING INSTRUCTIONS 10.0 ADJUSTMENT 10.1 Pressure Testing 10.1.2 Manifold Pressure Test NOTE: The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of ½ psi (3.5 kPa). 1. Light pilot. IMPORTANT: Pressure check taps for manifold (outgoing) and inlet (incoming) pressure have been incorporated into the valve. The pressure tap marked OUT measures outgoing pressure. The pressure tap marked IN measures incoming pressure. 10.1.1 Inlet Pressure Test NOTE: Make sure to apply these incoming pressure test with all other gas appliances on, or at full capacity in the house for proper pressure reading. IMPORTANT: If the inlet pressure reading is too high or too low, contact the gas company. Only a qualified gas service technician should adjust incoming gas pressure. 1. Loosen the inlet (IN) pressure tap by turning screw counterclockwise. See (A) in Figure 10.1. 2. Attach manometer using a ¼ in (6 mm) I.D. hose. 3. Light pilot and burner. Check pressure to ensure it is between the minimum and maximum recommended pressure settings. 2. Loosen manifold (OUT) pressure tap by turning screw counter-clockwise. See (B) in Figure 10.1. 3. Attach manometer to pressure tap using a ¼ in (6 mm) I.D. hose. 4. Light burner. Check manometer reading. 5. Turn burner and pilot off. 6. Disconnect manometer hose and tighten the manifold (OUT) pressure tap by turning screw clockwise. Screw should be snug. Do not over tighten. 7. Attach the manometer to the manifold pressure tap (B) to verify it is completely sealed. The manometer should read no pressure when pilot and burner are on. Table 10.1, Inlet Pressures Fuel Natural Gas LP Gas Gas Supply Min - Max Min - Max Inlet Pressure Tap (A) 5” - 10.5” WC (1.25 - 2.62 kPa) 12” - 13” WC (2.99 - 3.24 kPa) Table 10.2, Manifold Pressure 4. Turn off burner and pilot. Fuel Natural Gas LP Gas 5. Disconnect hose and tighten the inlet (IN) pressure tap by turning screw clockwise. Screw should be snug. Do not over tighten. Gas Supply Low - High Low - High Manifold Pressure Tap (B) 1.1” - 3.8” WC (.27 - .95 kPa) 2.9” - 11” WC (.72 - 2.74 kPa) 6. Relight pilot and burner. Then reattach manometer to the inlet pressure tap (A) to verify the tap is completely sealed. Manometer should read no pressure. B A Figure 10.1, Pressure Check Taps ADJUSTMENT 33 10.2 Flame Appearance Adjustment WARNING: To avoid property damage or personal injury, allow the fireplace ample time to cool before making any adjustments. Burner flame appearance and characteristics are affected by altitude, fuel quality, venting configuration, and other factors. After installation, this appliance may need additional adjustments to achieve optimum flame appearance and visual aesthetics. Table 10.4, Flame Appearance Venturi Adjustment Flame Characteristic Cause Solution Dark, orange flame with black tips Venturi closed too far Open venturi slightly Short, blue flames Venturi open too far Close setting slightly Lifting (ghosting) flames Gas pressure too high Venturi closed too far Check manometer settings Open venturi setting slightly 10.2.1 Burner Venturi WARNING: VENTURI ADJUSTMENT MUST BE DONE BY A QUALIFIED SERVICE TECHNICIAN. NOTE: Burner venturi air shutter settings have been factory set. Refer to Table 10.3. BACK BURNER VENTURI When this appliance is first lit, the burner flames will appear blue. During the first 15 minutes of operation, flame appearance will gradually turn to the desired yellow appearance. If the flames remain blue, or become dark orange with evidence of sooting (black tips), adjustment of the air shutter opening may be necessary. Regardless of venturi orientation, closing the air shutter will achieve a desired yellow flame, but may produce soot on the glass. Opening the air shutter will cause a short, blue flame that may lift off the burner. FRONT BURNER VENTURI Figure 10.2, Front and Rear Burner Venturis 10.2.1.1 Venturi Opening Adjustment NOTE: If soot is present on the glass, check log positioning before adjusting the venturi. Logs must not block burner ports. IMPORTANT: Slight adjustments to the venturi opening will create dramatic results. Adjust at slight increments until desired look is achieved. IDEAL 1. Remove the safety barrier, glass frame assembly. 2. Remove the log set and the back log plate (2) screws. 3. Remove the back burner (2) screws. LAZY, YELLOW FLAMES 4. Remove the front burner (4) screws. 5. Loosen screw on venturis and adjust as necessary. Tighten screw. 6. Reinstall all components previously removed. Table 10.3, Factory Set Venturi Openings Fuel Front Rear Natural Gas 1/8” (3 mm) 1/8” (3 mm) LP Gas 1/4” (6 mm) 1/2” (13 mm) DARK, ORANGE FLAMES WITH BLACK TIPS SHORT, BLUE FLAMES LIFTING (GHOSTING) FLAMES Figure 10.3, Flame Appearance and Characteristics 34 ADJUSTMENT 10.2.2 Vent Restriction 10.2.2.1 Baffle Restrictor Adjustment WARNING: To avoid property damage or personal injury, allow the fireplace ample time to cool before making any adjustments. 1. Remove the safety barrier and glass frame assembly to access the baffle restrictor. WARNING: Improper vent installation may cause the burner flames to lift or “ghost.” Perform a visual check on flame appearance after restrictor adjustment to ensure proper performance. 2. Remove and save (1) screw to adjust the baffle restrictor to achieve desired flame appearance. Vertical terminations may display an active, compact flame. To achieve desirable flame appearance, the vent exhaust may be restricted by the restrictor plate (included in components packet) and/or by adjusting the built-in restrictor located in the fireplace baffle. 3. Secure baffle restrictor with (1) screw previously removed. 4. Reinstall the glass frame assembly and safety barrier. This fireplace is shipped with the baffle restrictor set in position for natural gas minimum horizontal venting. Follow the tables below to adjust vent restriction to the desired flame appearance. Allow the fireplace to burn for 15 minutes before making any adjustments to these settings. For outlined vent restriction recommendations for venting installations, please refer to Table 6.4, Recommended Restriction for Vertical Terminations on page 20 and Table 6.7, Recommended Restriction for Combination Venting on page 21. Table 10.5, Restrictor Adjustment for Flame Appearance Flame Appearance Draft Problem Vent Restriction Short, flickering Excessive draft Not enough restriction Close baffle restrictor Insufficient draft Too much restriction Open baffle restrictor Lifting or ghosting* Install restrictor plate Remove inner ring(s) on restrictor plate, or remove restrictor plate *If flames continue to lift or ghost after opening the baffle restrictor or installing and verifying correct vent installation, shut off the gas supply and call a qualified service technician. Figure 10.4, Baffle Restrictor Adjustment ADJUSTMENT 35 10.2.2.2 Restrictor Plate Installation 1. Remove the safety barrier and the glass frame assembly. 2. Remove (4) screws at the firebox back wall securing the baffle. Remove baffle to access venting. 3. Bend the tabs on the restrictor plate (included in components packet) to approximately 80° angles. This will create tension when the restrictor is inserted into the exhaust pipe. 4. Insert restrictor into the 4 in (102 mm) exhaust pipe with the tabs pointing towards you. 5. Reinstall baffle by resting the front of the baffle above flange along the inside top of firebox opening. Tip the baffle against the firebox back wall, and secure with (4) screws previously removed. 6. Reinstall all components previously removed. 10.2.2.3 Restrictor Plate Modification 1. Remove the safety barrier and the glass frame assembly. 2. Remove (4) screws at the firebox back wall securing the baffle. Remove baffle to access venting. 3. Remove the restrictor by pulling it down and out of the 4 in (102 mm) exhaust pipe. Make necessary modifications to achieve desired flame appearance. 4. Insert restrictor into the 4 in (102 mm) exhaust pipe with the tabs pointing towards you. 5. Reinstall baffle by resting the front of the baffle above flange along the inside top of firebox opening. Tip the baffle against the firebox back wall, and secure with (4) screws previously removed. 6. Reinstall all components previously removed. RESTRICTOR PLATE REMOVE CIRCLE TO CREATE LESS RESTRICTION BEND TABS TO APPROX. 80° ANGLES TO CREATE TENSION TO HOLD ITSELF IN PLACE WHEN INSTALLED (4) SCREWS SECURING BAFFLE Figure 10.5, Vent Access and Restrictor Plate 36 ADJUSTMENT 11.0 TROUBLESHOOTING ATTENTION: Troubleshooting must be performed by a qualified technician. • Verify all connections between the wire harnesses and the system components are proper and positive. Before proceeding with the steps in the following troubleshooting guide, • Verify the communication link is established between the remote control and the IFC module. • Verify proper 120VAC power supply to the control module. • • Verify the control module battery pack and the remote control batteries are fresh and installed with correct polarity. Verify inlet pressure meets the recommended inlet pressure. If necessary, adjust line pressure regulator. Issue Pilot will not light Cause Solution Electrical power interrupted or disconnected Restore electrical power to appliance or use battery back-up. Wiring disconnection Ensure batteries are fully charged if using battery back-up as power source. Use wiring schematic to determine that all wiring connections are secure and correct. Gas supply turned off Check remote shut-off valves from the appliance. Usually there is a valve near the main gas line. There may be more than (1) valve between the appliance and main gas line. No LP (propane) gas in tank Check LP (propane tank). Refill if necessary. Low gas pressure Consult a plumber or a gas supplier. Can be caused by situations such as a bent line, too narrow diameter or pipe, or a low line pressure. Pilot flame not making contact with the flame rectification sensor on the pilot assembly Verify the pilot flame envelopes the top of the flame sensor and extends far enough onto burner for ignition. To adjust pilot flame, turn pilot adjustment screw on the gas valve clockwise to decrease flame, and counterclockwise to increase flame. Pilot adjustment screw not sealed Seal pilot adjustment screw. Do not over-tighten. Pilot flame always on, or will not extinguish Control system set to CPI mode Set control system to IPI mode Main burner flame will not light ON/OFF rocker switch in OFF position Switch rocker switch to ON position. Gas supply turned off Check for multiple shut-offs in the supply line. Verify gas supply is turned on. Low gas supply Consult with plumber or gas supplier. Check LP (propane) tank. Refill if necessary. Wiring disconnection or improper wiring Check for faulty or incorrect wiring. Plugged main burner orifice Remove blockage. Pilot flame Verify the pilot flame is properly directed to ignite burner. See pilot flame troubleshooting above. Remote control not working properly Replace batteries. No call for heat Verify remote control is powered ON and thermostat operation is turned OFF. Pilot will not stay lit TROUBLESHOOTING 37 Issue Pilot and burner extinguish while in operation Soot appears on glass Flame burns blue and lifts off burner No reaction to command 38 TROUBLESHOOTING Cause Solution No LP (propane) gas in tank Check LP (propane) tank. Refill if necessary. Incorrect glass assembly installation Refer to Section 7.2 Glass Frame Assembly on page 22. Incorrect vent cap installation Adjust if necessary. Vent cap blockage Remove debris if necessary. Improper pitch on horizontal venting ¼ in. (6 mm) rise per foot (30 cm) is required on horizontal venting Inner vent pipe leaking exhaust gases back into firebox Check for leaks and repair if necessary. Excessive draft Restrictor setting may need to be adjusted. Refer to Section 10.2.2 Vent Restriction on page 35. Improper log placement Refer to Section 7.3 #BW20-500 Log Set Installation on page 23. Improper venturi setting Venturi air shutter may need to be opened slightly to allow more air into the gas mix. Refer to Section 184.108.40.206 Venturi Opening Adjustment on page 39. Incorrect vent cap installation Adjust if necessary. Vent cap blockage Remove debris if necessary. Improper pitch on horizontal venting ¼ in. (6 mm) rise per foot (30 cm) is required on horizontal venting Improper venturi setting Venturi air shutter may need to be opened slightly to allow more air into the gas mix. Refer to Section 220.127.116.11 Venturi Opening Adjustment on page 39. Incorrect vent cap installation Adjust if necessary. Blockage or leakage of the vent system Check the vent pipes for leaks, and the vent cap for debris. Repair the vent pipes or remove debris from vent cap, if necessary. Battery back batteries or remote control batteries low Replace batteries. No communication between remote control and IFC module Reprogram remote control to IFC module. A maximum number of failed ignitions or flame restorations has been reached Reset IFC module. 12.0 MAINTENANCE ATTENTION: Installation and repair should only done by a qualified service person. The appliance should be inspected before use and at least annually by a professional service person. More frequent cleaning might be required due to excessive lint from carpeting, bedding material, et cetera. It is imperative that control compartments, burners, and circulating air passageways of the appliance be kept clean. Use a vacuum to clean all components. WARNING: The appliance area must be kept clear and free from combustible materials, gasoline and other flammable vapors and liquids. 12.2 Fan (optional) CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Performed by: Qualified Service Person Frequency: Every 6 months Action: • Disconnect the fan from electrical current and vacuum. • The bearings are sealed and require no oiling. 12.1 Burner and Pilot System 12.3 Vent System The burner assembly may be removed for easier access to the control compartment. Refer to Section 7.4 Control Board Removal and Installation on page 24. NOTE: If the vent-air intake system is disassembled for any reason, reinstall per instructions provided with installation. Refer to Section 6.0 Venting on page 18. Performed by: Qualified Service Person Performed by: Qualified Service Person Frequency: Annually Frequency: Annually Action: Action: • Vacuum all components of the burner system. • Examination of the vent system is required. • Visually check burner ports for blockage, especially near the pilot. • The flow of combustion and ventilation air must not be obstructed. • Visually check pilot light and burner flame pattern when in operation. Flames should be steady, not lifting or floating. Refer to Figure 10.3, Flame Appearance and Characteristics on page 34. 12.4 Glass Assembly PILOT FLAME BURNER PORTS CAUTION: Do not operate appliance with the glass assembly removed, cracked, or broken. Use protective gloves to handle any broken or damaged glass assembly components. WARNING: Do not use substitute materials. WARNING: Avoid striking or slamming glass assembly. Avoid abrasive cleaner. DO NOT clean glass while it is hot. IMPORTANT: Any safety screen, guard, or barrier removed for servicing the appliance must be replaced prior to operating the appliance. Performed by: Homeowner Frequency: Annually Action: BACK BURNER ORIFICE • Prepare a work area large enough to accommodate the glass assembly on a flat, stable surface. • Remove safety screen and glass frame assembly. • Clean glass with a soft cloth and a non-abrasive cleaner. • Reinstall glass assembly and safety screen. • Any safety screen, guard, or barrier removed for servicing the appliance must be replaced prior to operating the appliance. Performed by: Qualified Service Person Frequency: Annually Action: FRONT BURNER ORIFICE • Inspect the glass for cracks, scratches, and nicks. • Verify the glass assembly is properly intact and not damaged. • Replace the glass and the assembly #BW20-057T as necessary. • Only Hussong Mfg. Co., Inc. will supply the replacement of glass assembly as a complete unit. Figure 12.1, Burner and Pilot System MAINTENANCE 39 13.0 REPLACEMENT PARTS LIST Replacement parts are available through your local dealer. Contact your local dealer for availability and pricing. CONTROL BOARD AND PARTS Control Board - NG BW20L-150 Valve Step Motor - LPG 700-504-1 Control Board - LPG BW20L-151 36 in. Flexible Gas Line - Black 700-236B S.I.T. IPI Gas Valve - NG S.I.T. IPI Gas Valve - LPG 700-567 Flexible Gas Line - Valve to Burner Connection 700-567-1 NG Burner Orifice #.0625 FRONT 700-226 700-625 Proflame 2 IFC Board 700-652 NG Burner Orifice #44 BACK 700-244 IFC Wire Harness Assembly 700-653 LPG Burner Orifice #61 FRONT 700-261 Pilot Assembly - NG 700-551 LPG Burner Orifice #54 BACK Pilot Assembly - LPG 700-254 700-551-1 Conversion Kit - NG NCK-BW20L-S Transmitter (Remote Control) 700-408 Conversion Kit - LPG Pilot Orifice - NG #62 700-166 Front Burner BW20-350 Pilot Orifice - LPG #35 700-168 Back Burner BW20-351 Valve Step Motor - NG 700-504 Log Plate BW20-352 GLASS AND GLASS PARTS 15¾” x 215/8” Glass with Gasket 11/8” Glass Gasket LOG SET 701-013T 900-006 Replacement Valance BW20-005 SAFETY BARRIERS Full Rectangular Screen Front Prairie Screen Front BW20-FRSF BW20-PSF Arched Mission Screen Front BW20A-MSF 6 Piece Log Set Ember Panel LEG AND BASE KITS BW20-TLK Contemporary Base Kit BW20-CBK Pedestal Base Kit BW20-PBK Hussong Manufacturing Co., Inc. P.O. Box 577 204 Industrial Park Drive Lakefield, MN 56150-0577 BIR-20-L 40 REPLACEMENT PARTS LIST BW20-500 BW20-900E #BW20 1 Log BW20-1 #BW20 2 Log BW20-2 #BW20 3 Log BW20-3 #BW20 4 Log BW20-4 #BW20 5 Log BW20-5 #BW20 6 Log Rock Wool Embers Traditional Leg Kit LCK-BW20L-S BW20-6 900-REMB LIMITED WARRANTY Kozy Heat Limited 10 Year Warranty Limitation of Liability This limited 10 Year Warranty will not become effective until the Warranty Registration Form has been completed and mailed to Hussong Manufacturing Co., Inc., P.O. Box 577, Lakefield, MN 56150. This registration form must be received within 30 days of installation. Failure to do so may result in delayed warranty coverage and submission of proof of purchase will be required. To make a claim under this warranty, the purchaser must first contact the dealer/installer from whom the fireplace was purchased. Hussong Manufacturing Co., Inc. warranties to the original purchaser of this Kozy Heat Fireplace, that it is free of defects in materials and workmanship at the time of manufacture. Subject to the following conditions & requirements, Hussong Manufacturing Co., Inc. extends the following limited warranty under normal use and service, with respect to the Kozy Heat line of gas burning fireplaces. Year 1 Subject to the conditions & requirements listed below, within the first year from date of purchase, Hussong Manufacturing Co., Inc. shall, at its discretion, replace or repair any such defect in material or workmanship, at Hussong Manufacturing Co., Inc.’s expense, including reasonable labor costs to repair or replace the defective component, if a factory pre-authorization is given for the repair. Years 2 through 10 Subject to the conditions & requirements listed below, beginning with the first day of the second year and continuing through the tenth year, Hussong Manufacturing Co., Inc., will at its discretion, provide repair or replacement parts at current list prices for any defect in material or workmanship of components, including optional components and accessories (if available). Hussong Manufacturing Co., Inc. shall not be responsible for any installation, labor, transportation of other indirect costs. This limited warranty will be void if the fireplace is not installed by a qualified installer and according to the installation instructions. Use of unauthorized components will make this warranty null and void. This limited warranty also is void if the fireplace is not operated, at all times, according to the operating instructions furnished. This warranty is limited to defects in material and workmanship. It does not apply to any product that has been subject to negligence, misapplication, improper installation. No person is authorized to extend the time of this warranty or to accept on Hussong Manufacturing Co., Inc.’s behalf any additional obligation of liability connected with the unit. It is expressly agreed and understood that this warranty is Hussong Manufacturing Co., Inc.’s sole obligation and purchaser’s exclusive remedy for defective fireplace equipment. Hussong Manufacturing Co., Inc. shall not be liable for any consequential, incidental or contingent damages whatsoever. The foregoing warranty is exclusive and in lieu of all other expressed warranties. Hussong Manufacturing Co., Inc. shall not be held to implied warranties or merchantability and fitness for a particular purpose. This warranty replaces all previous warranty policies. Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. Hussong Manufacturing Co., Inc. reserves the right to make changes at any time, without notice, in design, material, specifications and prices. Hussong Manufacturing Co., Inc. reserves the right to discontinue models and products. December 2014 Warranty Conditions and Requirements 1. You are the original purchaser. This warranty is not transferable. 2. Installation of the fireplace is performed by a qualified installer. 3. Installation and operation must comply with installation and operation instructions. 4. Paint and glass gaskets are covered for 30 days from date of purchase. 5. Remote controls and all optional accessories are covered for 1 year from date of purchase. 6. This warranty does not offer coverage for Light Bulbs, Batteries or Fuses (whether factory, dealer or installer supplied). This includes any damage stemming from either component’s nonuse. 7. Components broken, (including glass panels), during shipping, careless handling of components, or defects resulting from improper installation, misuse of the fireplace and components are not covered under this warranty. 8. This warranty does not cover any part of the fireplace or any components which have been exposed to or submerged underwater. 9. Hussong Manufacturing Co., Inc. must be notified by the dealer the fireplace was purchased from or a qualified installer/service technician of the defect. 10. Annual service of the fireplace as required in the installation manual, is performed by a qualified installer/service technician. (Copies of such service records may be required to claim a warranty). 11. All previous warranty/service has been performed by a qualified installer or service technician. (Copies of such service records may be required to claim a warranty). 36 LIMITED WARRANTY LIFETIME WARRANTY LIFETIME WARRANTY COVERAGE WILL BE EXTENDED AS DESCRIBED BELOW PROVIDED ALL WARRANTY CONDITIONS AND REQUIREMENTS ARE MET AS OUTLINED IN THE 10 YEAR LIMITED WARRANTY POLICY. Lifetime Warranty Coverage LIFETIME WARRANTY IS EXTENDED AS FOLLOWS: Hussong Manufacturing Co., Inc. warranties to the original purchaser that the firebox, heat exchanger, fiber logs, burner tube and glass panel of this Kozy Heat Fireplace will not be defective in material or workmanship under normal use and service for as long as you own this product. If any of these components fail due to defects in material and workmanship under normal use and service, Hussong Manufacturing, Co., Inc. will, at its sole discretion, repair or replace the defective component. This LIFETIME WARRANTY does not cover any installation, labor, transportation or other indirect cost arising from defective components. Limitation of Liability This Lifetime Warranty will be void if the fireplace is not installed by a qualified installer and according to the installation instructions. Use of unauthorized components will make this warranty null and void. This Lifetime Warranty also is void if the fireplace is not operated, at all times, according to the operating instructions furnished. This warranty is limited to defects in material and workmanship of components specified. It does not apply to any product that has been subject to negligence, misapplication, improper installation. No person is authorized to extend the time of this Lifetime Warranty or to accept on Hussong Manufacturing Co., Inc.’s behalf any additional obligation of liability connected with the unit. Hussong Manufacturing Co., Inc. may fully discharge all obligations with respect to this Lifetime Warranty by refunding the wholesale price of the defective component(s). It is expressly agreed and understood that this Lifetime Warranty is Hussong Manufacturing Co., Inc.’s sole obligation and original purchaser’s exclusive remedy for defective fireplace equipment. Hussong Manufacturing Co., Inc. shall not be liable for any consequential, incidental or contingent damages whatsoever other than those incurred by Hussong Manufacturing Co., Inc. to repair or replace the defective component. The foregoing warranty is exclusive and in lieu of all other expressed warranties. Hussong Manufacturing Co., Inc. shall not be held to implied warranties, including but not limited to the implied warranties or merchantability and fitness for a particular purpose. This lifetime warranty replace all previous lifetime warranty policies. Hussong Manufacturing Co., Inc. reserves the right to make changes at any time, without notice, in design, material, specifications and prices. Hussong Manufacturing Co., Inc. reserves the right to discontinue models and products. To activate this Lifetime Warranty coverage, this registration card must be completed and mailed with your completed 10 Year Limited Warranty form within 30 days of installation to the following address: Hussong Manufacturing Co., Inc. P.O. Box 577 204 Industrial Park Drive Lakefield, MN 56150-0577 September 2011 CUT ALONG DOTTED LINE PURCHASER NAME:________________________________ INSTALLATION DATE:_______________________________ ADDRESS:_________________________________________ MODEL NUMBER:__________________________________ __________________________________________________ SERIAL NUMBER: __________________________________ TELEPHONE:_______________________________________ __________________________________________________ INSTALLER NAME:__________________________________ ADDRESS:_________________________________________ __________________________________________________ TELEPHONE:_______________________________________ __________________________________________________ 38 LIFETIME WARRANTY HUSSONG MANUFACTURING CO., INC.