kozy heat BAY-41-G, Installation And Operation Manual

Page 1: ...G FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property damage 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 wit...

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Page 3: ...er 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 ____________________________________________ Serial Number ___________________________________________ Dealership...

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Page 5: ...MINATION LOCATIONS 22 7 1 Vertical Vent Cap Termination 22 7 2 Minimum Termination Clearances 23 8 0 VENTING 24 8 1 Rear Vent Conversion Instructions 24 8 2 Approved 4 x 65 8 Vent Systems 26 8 3 Venting Requirements 26 8 4 Use of Elbows 26 8 5 Restrictor Assembly and Installation 26 8 6 Top Venting 27 8 7 Rear Venting 29 8 8 700 1 Series Direct Vent Termination Kit s 30 9 0 FIREPLACE SETUP 31 9 1 ...

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Page 7: ...n 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 ...

Page 8: ... 2 74 kPa Manifold Pressure Low 1 1 WC 0 27 kPa 2 9 WC 72 kPa Orifice Size DMS 42 53 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 2 2 1 1 US Installations Refer to the ...

Page 9: ...ent Center Floor to Rear Vent Center Inches 34 1 2 40 3 4 21 3 4 17 37 5 8 29 5 16 10 6 1 8 2 3 4 7 1 4 28 3 8 Millimeters 876 1035 553 431 955 745 254 156 70 184 721 21 553mm 7 184mm 17 431mm 25 16 58mm 65 8 169mm 34 876mm 375 8 955mm 40 1035mm 295 16 745mm 10 254mm 1113 16 300mm 2 51mm 65 8 169mm 61 8 156mm 2 70mm 283 8 721mm TOP FRONT BACK LEFT SIDE RIGHT SIDE ELECTRICAL ACCESS GAS LINE HOLE Fi...

Page 10: ...ing options TOP AND SIDES OVERLAP NO OVERLAP INSIDE FIT TOP AND SIDES OVERLAP TOP AND SIDES OVERLAP TOP AND SIDES OVERLAP TOP AND SIDES OVERLAP TOP AND SIDES OVERLAP B41 PSF B41 FRSF B41R MSF B41A MSF B41R CSF B41 RSF B41A FPDSF SIDE OVERLAP TOP OVERLAP SIDE OVERLAP TOP OVERLAP SIDE OVERLAP TOP OVERLAP SIDE OVERLAP TOP OVERLAP TOP OVERLAP at CORNER SIDE OVERLAP TOP OVERLAP TOP OVERLAP SIDE OVERLAP...

Page 11: ...nly non combustible material in this area for the entire width of the fireplace DO NOT use wood sheetrock et cetera in this zone Top stand off brackets must be formed and attached prior to positioning fireplace into framed opening 1 Remove and save 4 screws securing stand off heat shields and stand off brackets on top of the fireplace 2 Form each top stand off bracket by bending at perforations as...

Page 12: ...28 717mm 41 1048mm 17 445mm 41 1048mm 13mm 41 1048mm 565 16 1431mm 283 16 716mm 6mm 3913 16 1012mm 13 331mm 13mm 17 445mm 41 1048mm TYPICAL VERTICAL INSTALLATION TOP VENT TYPICAL HORIZONTAL INSTALLATION TOP VENT 17 445mm 41 1048mm 13mm TYPICAL HORIZONTAL INSTALLATION REAR VENT TYPICAL VERTICAL INSTALLATION REAR VENT TYPICAL CORNER INSTALLATION TOP VENT DIMENSION SHOWN WITH LISTED DURAVENT ELBOW NO...

Page 13: ...using a hearth adjust the rough opening size as necessary to maintain minimum clearance requirements If masonry is to be used optional prepare the necessary foundation for the masonry load When masonry construction is to be used a lintel must be used over the top of the appliance to support the additional weight If installing the optional heat duct kit refer to Section 4 0 970 Heat Duct Kit on pag...

Page 14: ...llow vent pipe manufacturer s installation instructions for vent installation Flex pipe vent systems require a minimum of 1 in 25 mm clearance from the top sides and bottom surfaces of horizontal pipe Rigid pipe vent systems require a minimum of 11 2 in 38 mm from the top surface of horizontal pipe and 1 in 25 mm from the sides and bottom surfaces of horizontal pipe Refer to Table 3 2 Table 3 3 Ta...

Page 15: ... metal screws 1 Register cover with screws 4 Sheet rock screws 1 Duct collar 3 Flange nuts 1 Fan assembly 1 Strapping cord 1 Fan housing cover plate 3 Wire nuts 1 Speed control mounting bracket 2 Fan wire connectors 1 Speed control 4 2 Specifications The appliance is manufactured with 2 heat duct knock outs One or both may be utilized The register mounting frame is designed to fit between 2 x 4 st...

Page 16: ...o allow for sheetrock installation 5 Secure the mounting bracket to framing with the provided 4 sheetrock screws 6 Install the junction box on the wall at desired location The junction box is used to house the speed control assembly which controls fan speed and operation 4 5 Install and Wire Fan Assembly 1 Attach but do not tighten flange nuts to the mounting studs on the back of the register moun...

Page 17: ...e speed control through the mounting bracket Secure with the mounting nut 4 Secure mounting bracket to the junction box with the 2 screws provided 5 Center the register cover over the fan housing cover plate to install Secure register cover to stud wall with the provided mounting screws 6 Attach a cover plate not provided then install the control knob for the speed control 7 Complete the fireplace...

Page 18: ...ng away from the fireplace 3 Secure the nailing flanges to the fireplace with screws provided through the slots in nailing flanges 4 Bend perforation on nailing flange until parallel with fireplace face Do not bend toward fireplace face 5 Position framing stud against the small stand off located on backside of nailing flange Secure with nails or screws When installed the nailing flanges provide th...

Page 19: ...M HORIZONTAL VENT TERMINATIONS 1 38mm CLEARANCE TO COMBUSTIBLE MATERIAL ABOVE THE TOP SURFACE OF HORIZONTAL PIPE MUST BE MAINTAINED FOR EVERY VENTING CONFIGURATION FIREPLACE ENCLOSURE FLOOR 48 1219mm NON COMBUSTIBLE ZONE 13mm NON COMBUSTIBLE MATERIAL ONLY SINGLE VERTICAL HEADER 16 406mm 18 457mm 10 254mm 12 305mm 14 356mm 14 356mm 19mm 10 254mm ...

Page 20: ...e screen front until the notched tabs are firmly in position verifying the depth accommodates finish material To remove safety screen lift the screen up and out of slots 5 3 3 Overlap Fit Direct Mount Installation Option Models B41 PSF B41R MSF and B41A MSF recommended for low height clearance applications 1 Locate the 4 acorn nuts on the left and right side of the screen front face 2 each side 2 ...

Page 21: ...kPa For test pressures equal to or less than 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 in 13 mm tee handle manual shut off valve and flexible gas connector are to be connected to the in 13 mm control valve inlet If substituting for these components please consult l...

Page 22: ...2 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 12 x ROOF PITCH x 12 H H LOWEST DISCHARGE OPENING APPROVED CAP APPROVED VENT PIPE H MINIMUM HEIGHT FROM ROOF TO LOWEST DISCHARGE OPENING MINIMUM 12 30 m If vent is closer than 12 in 30 ...

Page 23: ... combustion air inlet to any other appliance 12 in 30 cm 9 in 23 cm K Clearance to mechanical air supply inlet 6 ft 1 83 m 3 ft 91 cm above if within 10 ft 3 m horizontally Massachusetts 10 ft 3 m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13 m M Clearance under veranda porch deck or balcony 12 in 30 cm 12 in 30 cm N Clearance between two horizontal termin...

Page 24: ...onents removed from the top vent exit will be reinstalled for the rear vent 8 1 1 Remove Top Vent Collars 1 2 3 1 2 3 8 1 2 Remove Back Vent Combustion Air Intake and Exhaust Collars REMOVE THE ATTACHMENT SCREW SECURING COVER REMOVE 4 SCREWS SECURING 6 168mm COMBUSTION AIR INTAKE COLLAR REMOVE 6 SCREWS SECURING 4 101mm EXHAUST COLLAR REMOVE ATTACHMENT SCREW SECURING THE BACK COVER PLATE REMOVE 4 S...

Page 25: ...O APPLIANCE REAR VERIFY GASKET IS IN PLACE SECURE WITH 6 SCREWS PREVIOUSLY REMOVED INSTALL 6 168mm COMBUSTION AIR INTAKE COLLAR TO APPLIANCE REAR VERIFY GASKET IS IN PLACE SECURE WITH 4 SCREWS PREVIOUSLY REMOVED INSERT TABS ON REAR COVER PLATE INTO SLOTS AT THE REAR SECURE WITH 1 SCREW PREVIOUSLY REMOVED INSTALL EXHAUST COVER PLATE TO APPLIANCE TOP VERIFY GASKET IS IN PLACE SECURE WITH 6 SCREWS PR...

Page 26: ...ecking the vent connection to the appliance after the fireplace is installed 8 3 1 Vent Section Clearances Table 8 1 Vertical Pipe Section Clearances Surface Sides All Approved Venting 1 in 25 mm Table 8 2 Horizontal Pipe Section Clearances Surface Top Bottom Sides Flex Pipe 1 in 25 mm 1 in 25 mm 1 in 25 mm Rigid Pipe 1 1 2 in 38 mm 1 in 25 mm 1 in 25 mm 8 4 Use of Elbows MAXIMUM NUMBER OF 90 ELBO...

Page 27: ...rtical Rise VMIN Minimum Horizontal Run HMIN Maximum Horizontal Run HMAX 90 elbow 6 in 152 mm 18 in 457 mm 15 in 381 mm 6 in 152 mm 48 in 1219 mm Table 8 5 NG Max Vertical Max Horizontal Combination Maximum Vertical Rise Maximum Horizontal Run Total Length 20 ft 6 1 m 20 ft 6 1 m 40 ft 12 9 m Maximum number of 90 elbows 4 TOP VENTING DIAGRAM VERTICAL HORIZONTAL TERMINATIONS A Stand off Brackets B ...

Page 28: ...m Horizontal Run HMAX 9 in 229 mm 6 in 152 mm 18 in 457 mm 15 in 381 mm 6 in 152 mm 48 in 1219 mm Table 8 8 LPG Max Vertical Max Horizontal Combination Maximum Vertical Rise Maximum Horizontal Run Total Length 20 ft 6 1 m 20 ft 6 1 m 40 ft 12 9 m Maximum number of 90 elbows 4 0 2 4 6 8 10 12 14 16 20 22 18 24 26 28 30 40 38 36 34 32 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 6 1m 12 9m 6 1m 9 14m ...

Page 29: ...cal Terminations Horizontal to Vertical Venting Minimum Vertical Length Maximum Vertical Length 90 elbow 3 ft 914 mm 50 ft 15 2 m Table 8 12 NG LPG Max Vertical Max Horizontal Combination Maximum Vertical Rise Maximum Horizontal Run Total Length 20 ft 6 1 m 20 ft 6 1 m 40 ft 12 9 m Maximum number of 90 elbows 4 0 2 4 6 8 10 12 14 16 20 22 18 24 26 28 30 40 38 36 34 32 0 2 4 6 8 10 12 14 16 18 20 2...

Page 30: ...h any unfaced insulation products listed as non combustible per ASTM E 136 3 Apply a liberal bead of exterior sealant around outer edge of termination box A placing assembly through the wall pass through in exterior wall Place screws through the four holes B securing it in place 4 Form the 4 7 flexible aluminum pipes on termination kit 745 1 or 781 1 and if applicable on each extension kit 5 Gentl...

Page 31: ...conversion kit CAUTION Disconnect all electric power from the fireplace insert before performing any of these tasks NOTE To avoid damage and prolong the life of the halogen bulbs never touch with bare hands Always use a soft cloth when handling 1 Remove 8 screws securing burner cover then lift the cover out of firebox 2 Loosen but do not remove 4 screws securing light bars to firebox floor Slide l...

Page 32: ... board to firebox bottom 10 Remove and save 8 screws securing control board 11 Lift control board out of firebox being careful not to damage sealing gasket lying underneath 9 4 2 Control Board Installation 1 Place the control board in firebox aligning the holes in board with mounting studs at the bottom of the firebox VERIFY SEALING GASKET IS IN PLACE 2 Secure the control board with screws previou...

Page 33: ...t or remove the grounding prong from this plug 10 1 Electrical Specifications 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 10 2 Wiring Requirements The IFC System Module requires 120V of electricity and or batteries to operate Using...

Page 34: ...ncludes 2 75 CFM fans 4 1 4 6mm nuts 1 Remove the safety barrier glass valance and access panel 2 Remove glass media and media tray 3 Remove the control board and burner tube 4 Insert fans through the lower opening and push to the back of the firebox 5 Align the mounting slots in fan brackets with the mounting studs 6 Secure fans with the included 4 1 4 6 mm nuts 7 Plug cord into the receptacle on...

Page 35: ...will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier OPERATING INSTRUCTIONS 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 of...

Page 36: ...position for remote control operation of the main burner and fireplace features 11 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 automatic...

Page 37: ...ximately 2 seconds move the switch to the ON position The ignition sequence will start again 11 6 1 2 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 11 6 1 3 Cycling Flame 1 Press the remote control down arrow key during flame adjustment mode to reduce the flame...

Page 38: ...ilot 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 ...

Page 39: ... 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 11 8 7 2 Smart Thermostat The smart thermostat function wil...

Page 40: ...mode Fan s will operate at previous setting There is no delay in start up or stop time 11 8 9 Accent Light Kit 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 11 8 10 Remote Control Low Battery Detection Remote control battery li...

Page 41: ...aximum recommended pressure settings 4 Turn off burner and pilot 5 Disconnect hose and tighten the inlet IN pressure tap by turning screw clockwise Screw should be snug Do not over tighten 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 12 1 2 Manifold Pressure Test 1 Light pilot 2 Loosen manifo...

Page 42: ...off the burner Table 12 3 Factory Set Venturi Openings Fuel Air Shutter Opening Natural Gas 1 8 in 3 mm LP Gas 5 8 in 16 mm 12 2 1 1 Venturi Adjustment NOTE If soot is present on the glass check log positioning before adjusting the venturi Logs must not block burner ports 1 Remove the safety barrier glass frame assembly and glass media 2 Remove burner cover burner and burner venturi housing 3 Loos...

Page 43: ...s securing termination access panel located on the fireplace baffle 4 Bend the tabs on the restrictor included in fireplace components packet to approximately 80 angles This will create tension when the restrictor is inserted into the exhaust pipe 5 Insert restrictor into the 4 in 102 mm exhaust pipe with the tabs pointing towards you 6 Reinstall termination access panel Insert the panel tabs into...

Page 44: ... 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 ...

Page 45: ...d to be opened slightly to allow more air into the gas mix Refer to Section 12 2 1 Burner Venturi on page 42 Incorrect vent cap installation Adjust if necessary Vent cap blockage Remove debris if necessary Improper pitch on horizontal venting in 6 mm rise per foot 30 cm is required on horizontal venting Flame burns blue and lifts off burner Improper venturi setting Venturi air shutter may need to ...

Page 46: ... Service Person Frequency Every 6 months Action Disconnect the fans from electrical current and vacuum The bearings are sealed and require no oiling 14 3 Vent System NOTE If the vent air intake system is disassembled for any reason reinstall per instructions provided with installation Refer to Section 8 0 Venting on page 24 Performed by Qualified Service Person Frequency Annually Action Examinatio...

Page 47: ... 596 Conversion Kit NG NCK B41G SP Pilot Assembly LPG 700 596 1 Conversion Kit LPG LCK B41G SP Transmitter Remote Control 700 408 Burner Tube B41G 035 023N Pilot Orifice NG 700 123 Media Tray B41G 350 014LP Pilot Orifice LPG 700 114 LIGHT KIT Light Kit bottom B41 BLK 20W 130V Halogen Bulb 600 676 GLASS AND GLASS GASKET 36 x 28 Glass with Valance 700 179T 11 8 Glass Gasket with Adhesive 900 006 Rep...

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Page 49: ...ong 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 ...

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Page 51: ...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 ...