kozy heat CSK-29-G, CHASKA 29-LOG CSK-29-L, CHASKA 29-ROCK CSK-29-R, CSK-29-R Installation And Operation Manual

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HUSSONG MANUFACTURING CO., INC.

CHASKA 29-GLASS

OMNI-Test

Laboratories, Inc.

Model #CSK-29-G Direct Vent Gas Fireplace Insert

Installation and

Operation Manual

WARNING: FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury, death, or property damage.

ͷ Do not store or use gasoline or other

ammable vapors and liquids in the vicinity of this or any other appliance.

ͷ WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• 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 re department.

ͷ Installation and service must be performed

by a qualied installer, service agency or the gas supplier.

Tested & Listed By

C US

Portland Oregon USA

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 certied kit is used.

INSTALLER: Leave this manual with the appliance.

CONSUMER: Retain this manual for future reference.

Hussong Mfg. Co., Inc. • CSK-29-G Report No.: 0216GN047S • Rev. 01, January 2015

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.

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 replace. 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-red, and the complete replace is thoroughly inspected before packaging. Our

commitment to quality and customer satisfaction has remained the same for over 30 years. We offer a complete line of gas and

wood replaces, along with stylish accessories to complement any decor. Adding a replace 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 benet and enjoyment from your Kozy

Heat gas replace.

Jim Hussong

President

Homeowner Reference Information

We recommend you record the following information:

Model Name: ___________________________________________

Serial Number: __________________________________________

Dealership Purchased from: _______________________________

Notes: _____________________________________________________________________________________________________________

____________________________________________________________________________________________________________________

Date purchased/installed: _________________________________

Location of ﬁreplace: _____________________________________

Dealer phone: ___________________________________________

Dudley Hussong Board Chairman

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 Part Assembly Overview ...............................................................10

2.5 Safety Barriers ................................................................................11

3.0 EXISTING FIREPLACE REQUIREMENTS ............................. 12

3.1 Appliance Placement Considerations ........................................ 12

3.2 Existing Fireplace Speciﬁcations ............................................... 12

4.0 TERMINATION LOCATION .....................................................13

4.1 Vent Termination Clearances .......................................................13

5.0 INSTALLATION PREPARATION .............................................14

5.1 Inspect and Clean Existing Chimney ......................................... 14

5.2 Flue Damper ...................................................................................14

5.3 Gas Line...........................................................................................14

5.4 Electrical Wiring ............................................................................. 14

5.5 Fireplace Conversion ................................................................... 14

6.0 INSTALLATION ........................................................................15

6.1 Kozy Heat #816-CL Co-Linear Vent System ............................15

6.2 Remove Air Duct ............................................................................16

6.3 Run Vent System ............................................................................16

6.4 Connect Vent Pipe to Air Duct ....................................................17

6.5 Place and Secure Appliance ....................................................... 17

7.0 GAS LINE CONNECTION ........................................................ 18

7.1 Gas Conversion (sold separately) ..............................................18

7.2 Gas Line Installation ...................................................................... 18

8.0 FACING AND FINISHING ........................................................ 19

8.1 Clearances to Combustibles ....................................................... 19

8.2 Shroud Installation ......................................................................... 20

8.3 Safety Barrier Installation .............................................................20

9.0 GAS FIREPLACE INSERT SETUP .......................................... 21

9.1 Glass Assembly ............................................................................ 21

9.2 Light Kit ............................................................................................ 21

9.3 Glass Media Installation .............................................................. 21

9.4 Control Board Removal and Installation .................................... 22

10.0 ELECTRICAL INFORMATION ............................................... 23

10.1 Electrical Speciﬁcations ............................................................. 23

10.2 Wiring Requirements ...................................................................23

11.0 OPERATING INSTRUCTIONS .............................................. 24

11.1 Setup Proﬂame 2 IFC Module ................................................... 25

11.2 Initialize the Control System ......................................................25

11.3 Reset the System for Manual Operation .................................25

11.4 Automatic Safety Restart ............................................................25

11.5 Backup Battery Operation ........................................................ 25

11.6 IFC Module Ignition Sequence ................................................. 26

11.7 Additional Diagnostic Information ............................................. 26

11.8 Remote Control Operation ........................................................ 27

12.0 ADJUSTMENT ....................................................................... 30

12.1 Pressure Testing ..........................................................................30

12.2 Burner Flame Adjustments ........................................................31

13.0 TROUBLESHOOTING ........................................................... 32

14.0 MAINTENANCE ..................................................................... 34

14.1 Burner and Pilot System ............................................................ 34

14.2 Fans ................................................................................................34

14.3 Vent System ..................................................................................34

14.4 Glass Assembly ........................................................................... 34

15.0 REPLACEMENT PARTS LIST ............................................... 35

LIMITED WARRANTY ..................................................................... 37

LIFETIME WARRANTY ...................................................................39

TABLE OF CONTENTS 5

1.0 INTRODUCTION

1.1 Appliance Certiﬁcation

Laboratory: OMNI-Test Laboratories in Portland, Oregon

Standards:

• 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

• CSA P.4.1-2009, Testing Method for Measuring Annual Fireplace Eﬃciency

This installation must conform with local codes, or in the absence of local codes, with the NFPA 54, or the B149.1.

Natural Gas and Propane Installation Code

National Fuel Gas Code

, ANSI Z223.1/

, CSA

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.

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 OBSTRUCTIONS”.

1.2.4 Inspection

The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08 (2) (a) 1 through 4.

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

1.2.6.1 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.

1.2.6.2 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

INTRODUCTION 7

2.0 SPECIFICATIONS

2.1 Appliance Components

Part Number Description

CK29G-150 Control Board Assembly

700-203 Manual Gas Shut-oﬀ Valve

CK29G-135 Burner Assembly

CK29-LKT Light Kit

701-009T Glass Assembly

CK29-028 Fan Kit (1)-69 CFM

700-408 Remote Control

2.1.1 Additional Components Required

2.1.1.1 Shrouds

Part Number Description

CK29-004 Blank Shroud (4 pc.)

CK29-2538 25” x 38” shroud (1 pc.)

CK29-27542 27½” x 42” shroud (1 pc.)

CK29-3044 30” x 44” shroud (1 pc.)

CK29-A2838 28” X 38” Arched shroud (1 pc.)

2.1.1.2 Approved Vent Systems

Kozy Heat #816-CL co-linear vent system

For use with minimum 6” x 8” I.D. masonry or 7” I.D. Class A metal chimneys; includes 12 ft. (3.66 m) compressed, expandable colinear 3” x 3” ﬂexible pipes and termination cap.

Other approved vent manufacturers

BDM, American Metals (Amerivent), Metal Fab, Selkirk, Simpson Dura-Vent, and ICC TM-IVT cap only.

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 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.

2.2.1.2 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).

2.2 Heating Speciﬁcations

Natural Gas LP Gas

Maximum Input Rating

Minimum Input Rating

Manifold Pressure (High)

Manifold Pressure (Low)

Oriﬁce Size (DMS) #42 #53

30,500 Btu/h

(9.0 kW)

16,000 Btu/h

(4.7 kW)

3.8” WC (.95 kPa) 11” WC (2.74 kPa)

1.1” WC (.27 kPa) 2.9” WC (.72 kPa)

30,000 Btu/h

(8.8 kW)

16,000 Btu/h

(4.7 kW)

8 SPECIFICATIONS

2.3 Appliance Dimensions

Table 2.1, Physical Dimensions

Description Height Width Back Width Depth Back Height Back to Gas

Line Access

Inches 19-1/4 29 18-7/8 14-1/2 14-1/8 7-3/16 8-7/8 5-5/8

Millimeters 488 737 479 368 360 183 225 143

TOP

⁄”

(479mm)

14½”

(368mm)

Front to Vent

Center

Back to Vent

Center

(143mm)

⁄”

(360mm)

⁄”

⁄”

(214mm)

(46mm)

ELECTRICAL ACCESS

LEFT FRONT RIGHT

Figure 2.1, CSK-29 Unit Dimensions

⁄”

¼”

(488mm)

29”

(737mm)

½”

(750mm)

⁄”

(388mm)

⁄”

(225mm)

2”

(51mm)

⁄”

(183mm)

GAS LINE HOLE

SPECIFICATIONS 9

2.4 Part Assembly Overview

WARNING: Failure to position these parts in accordance with these diagrams, or failure to use only speciﬁed approved parts with this appliance, may result in property damage or personal injury.

Figure 2.2, Proper Positioning of CSK-29-G (Exploded View)

A Fireplace Insert F Control board and module

B Spring-loaded latch glass assembly G Fan kit

C Burner cover H Co-linear air duct

D Heat shield I Glass media (not shown)

E Burner tube

10 SPECIFICATIONS

Table 2.2, Field-Assembled Parts

2.5 Safety Barriers

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 8.3 Safety Barrier Installation on page 20 for installation instructions.

⁄”

(513mm)

21⁄”

(535mm)

⁄”

(855mm)

¼”

(539mm)

¼”

(922mm)

CK29-BSF CK29-CXF

¾”

(807mm)

⁄”

(513mm)

¾”

(807mm)

⁄”

(513mm)

31⁄”

(802mm)

CK29-PSF CK29-RSF CK29A-MSF

¾”

(807mm)

¾”

(807mm)

31⁄”

(802mm)

¼”

(515mm)

CK29A-SF CK29A-PSF CK29A-FPDSF

20¼”

(515mm)

⁄”

(513mm)

SPECIFICATIONS 11

3.0 EXISTING FIREPLACE REQUIREMENTS

3.1 Appliance Placement Considerations

WARNING: Due to high surface temperatures, the ﬁreplace insert should be located out of traﬃc and away from furniture and draperies.

• This ﬁreplace must be installed on a level surface capable of

supporting the ﬁreplace insert and venting.

• This ﬁreplace insert may be installed in a bedroom.

• Please be aware of the large amount of heat this ﬁreplace

insert will produce when determining a location.

3.2 Existing Fireplace Speciﬁcations

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

• Any smoke shelves, shields, and baﬄes may be removed

if attached by mechanical fasteners. If necessary, remove ﬁrebrick to obtain at least the minimum opening requirements.

• Cutting of any sheet metal parts of the existing ﬁreplace is

prohibited.

• If the metal ﬂoor is removed, the insert must be placed

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

3.2.2 Chimney Speciﬁcations

WARNING: Any chimney clean-outs must ﬁt properly.

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

The existing chimney must be comprised of one of the following:

• Factory-built solid fuel chimney: 7 in (178mm) minimum inside diameter

• Masonry chimney: 6 in x 8 in (152mm x 203mm) minimum inside diameter

Existing chimney height:

• Minimum: 10 ft (3.05 m) Maximum: 50 ft (15.24 m)

3.2.2.1 Determine Length of Existing Chimney

1. Remove and discard existing chimney cap.

2. It is helpful to have two people complete this step. Position one person at the ﬁreplace and another person at the top of the chimney.

3. Measure from the ﬁreplace base to the top of the chimney.

4. Subtract the height of the insert from the previous measurement. This is the total length of the co-linear ﬂexible aluminum pipe required for your installation.

3.2.1 Existing Fireplace Opening Minimum Requirements

See Figure 3.1.

(A) Height............................................................... 19¼ in (489 mm)

(B) Front Width ..................................................... 29½ in (749 mm)

(D) Back Width ..................................................... 18⅞ in (479 mm)

Figure 3.1, Existing Fireplace Opening

MIN: 10 ft (3.05m) MAX: 50 ft (15.24m)

12 EXISTING FIREPLACE REQUIREMENTS

Figure 3.2, Min/Max Chimney Length

4.0 TERMINATION LOCATION

4.1 Vent Termination Clearances

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

• Approved vent caps require 12 in (305mm) clearance to

intersecting walls, overhangs or eaves as veriﬁed by test.

APPROVED

VENT CAP

MINIMUM

12”

(305mm)

CLEARANCE

Figure 4.1, Vent Cap Clearance

TERMINATION LOCATION 13

5.0 INSTALLATION PREPARATION

NOTE: This gas ﬁreplace insert is approved for installation in masonry and factory-built solid fuel burning ﬁreplaces.

ATTENTION: Any removed parts must be capable of reinstallation if this insert is ever removed. Removal of rivets or screws is acceptable.

5.1 Inspect and Clean Existing Chimney

• Verify existing chimney is constructed of non-combustible

material.

• Verify existing chimney is clean and in good working order.

Clean existing chimney and ﬁreplace to prevent a creosote odor from entering the home.

• Verify combustible mantel and sidewall clearances comply

with Section 8.1 Clearances to Combustibles on page 19.

• The refractory, glass doors, screen rails, screen mesh, and

log grates may be removed from existing ﬁreplace before installing this gas ﬁreplace insert.

5.2 Flue Damper

• The ﬁreplace ﬂue damper can be fully blocked open or

removed for installation of this gas ﬁreplace insert. Remove existing chimney cap.

5.3 Gas Line

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

Section 7.0 Gas Line Connection on page 18 .

• If the factory-built ﬁreplace has no gas access hole(s)

provided, an access hole of 1½ in. (37.5 mm) or less may be drilled through the lower sides or bottom of the ﬁrebox in a proper workmanship like manner. The access hole must be plugged with non-combustible insulation after the gas supply line has been installed.

• Run gas line to the gas ﬁreplace insert through the gas line

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

• If the gas ﬁreplace insert is to be installed into minimum

opening dimensions, the gas line may need to be run after appliance placement due to space limitations.

5.4 Electrical Wiring

• Provisions must be made to provide electrical power for

appliance operation.

• Refer to Section 2.3 Appliance Dimensions (Figure 2.1)

on page 9 for electrical outlet box location to run any necessary electrical wiring to the gas ﬁreplace insert.

5.5 Fireplace Conversion

• Mechanically attach the label with the following warning to

at the bottom existing ﬁrebox so it will be visible if this gas ﬁreplace insert is removed.

WARNING: This ﬁreplace has been converted for use with a gas ﬁreplace insert only and cannot be used for burning wood or solid fuels unless all original parts have been replaced, and the ﬁreplace re-approved by the Authority Having Jurisdiction.

14 INSTALLATION PREPARATION

6.0 INSTALLATION

6.1 Kozy Heat #816-CL Co-

Linear Vent System

IMPORTANT: Proper operation of this insert requires the exhaust and combustion air pipes to be connected to the correct collar, on both the termination kit and the gas ﬁreplace insert air duct.

The ﬁreplace insert air duct exhaust collar is located on the right side. Install termination cap with the exhaust collar on the right side.

NOTE: The exhaust pipe will have a red marking.

IMPORTANT: Maximum horizontal vent runs of 24 in (609 mm) require a 1 in (25mm) rise per 12 in (305 mm) run.

1. Carefully extend the exhaust and combustion air intake pipes

to total chimney length required (see Section 3.2.2 on page

12).

#816-CL CO-LINEAR VENT SYSTEM

(A) Intake Collar (extends through bottom plate)

(B) Exhaust Collar (extends through middle

divider plate)

2. Slide the combustion air intake pipe (the end without a collar) over termination cap collar (A). Secure to termination cap (E) with provided (3) self-tapping screws (D) .

3. Place a bead of sealant around the inner edge at the end of the exhaust pipe (without collar / red marking) and slide onto the corresponding labeled collar (B) on termination cap (E).

4. Secure the exhaust pipe to termination cap (E) with the provided (3) self-tapping screws. Apply additional sealant around joint to ensure a proper seal.

5. Complete vent system installation by following the instructions outlined in Sections 6.2 through 6.5.

(D) Self-Tapping Screws - (3) total (2 shown)

(E) Termination Cap

Figure 6.1, #816-CL Termination Cap (Your component may look diﬀerent than the one shown)

INSTALLATION 15

6.2 Remove Air Duct

ATTENTION: All information outlined in Section 5.0 Installation Preparation on page 14 must be completed before continuing with this installation.

1. Remove the air duct at the top of appliance by sliding the air duct back out of channels. Refer to the following instructions for vent system attachment to the air duct.

Figure 6.2, Air Duct Removal

6.3 Run Vent System

NOTE: If oﬀsets are present in existing chimney, place a weighted rope around the pipe ends to guide them through the chimney. DO NOT ATTEMPT TO TIE ONE ROPE AROUND BOTH PIPES.

• To prevent cold air drafts, Hussong Manufacturing recommends to insulate the 3” x 3” ﬂexible vent pipes and chimney using unfaced insulation products listed as noncombustible per ASTM E 136.

1. OPTIONAL: Before installing vent system down through the chimney, place unfaced insulation around the ﬁrst 3 ft (914 mm) of vent system below termination cap. Secure with wire.

2. Install the 3” x 3” ﬂexible pipes down through existing chimney. Guide ropes (if used) to aid installation.

3. To secure chimney termination cap to chimney, apply a liberal bead of sealant (provided) around the top of the chimney. Set termination cap into position as instructed by vent system manufacturer’s installation manual.

OPTIONAL Kozy Heat #816-CL: Secure termination cap to existing chimney with 2 in (50 mm) self-tapping screws and anchor straps (provided) through the pilot holes, located on the sides of the termination cap.

4. From inside the existing ﬁreplace, carefully pull ropes (if used) or the ﬂexible pipes down until both exhaust pipe and combustion air intake are into the existing ﬁreplace ﬁrebox.

5. OPTIONAL: To prevent heat loss up chimney, place unfaced insulation products between the 3” x 3” ﬂexible vent pipes and chimney.

Figure 6.3, Chimney Vent Run

16 INSTALLATION

6.4 Connect Vent Pipe to Air Duct

IMPORTANT: Proper operation of this appliance requires exhaust and combustion air pipes to be connected to the correct collar, on both the termination kit and the gas ﬁreplace insert air duct.

1. Place previously removed air duct (Section 6.2 on page

16) into existing ﬁreplace opening.

2. Connect exhaust vent pipe (red marking) to exhaust collar on air duct. Apply a bead of sealant (provided) around exhaust pipe and slide inside collar marked ‘EX.’ Secure with provided (3) ½ in (13 mm) self-tapping screws. Apply additional sealant around joint to ensure an air tight seal.

3. Connect air intake vent pipe to intake collar on air duct. Apply a liberal bead of sealant around intake collar on air duct. Slide combustion intake pipe over the collar and secure with provided (3) ½ in (13 mm) self-tapping screws. Apply additional sealant around joint to ensure an air tight seal.

4. Visually check vent pipe connection to air duct.

6.5 Place and Secure Appliance

1. Slide the gas ﬁreplace insert into existing ﬁreplace opening until the channels on top of the appliance are aligned with the air duct.

2. Insert the air duct pull rod handle through access slot at the top of appliance and place pull handle hook through the hole in pull rod. Simultaneously push the gas insert into existing ﬁreplace and pull the air duct forward until seated.

3. Secure air duct to appliance by using slots at the top of the appliance to secure with (2) ½ in (13 mm) sheet metal screws (included in components packet).

4. Use the pull rod handle to pull the air duct back to starting position. Remove pull handle. Verify vent system connection.

5. If necessary, level the gas insert by threading leveling bolts (included in components packet) into nuts at the bottom of the insert (2 each side) . Verify appliance is properly positioned.

AIR DUCT

Figure 6.5, Air Duct in Existing Fireplace

FLEXIBLE PIPES

SHEET METAL SCREWS (3 TOTAL)

SEALANT

Figure 6.6, Secured Vent Pipes to Air Duct

SEALANT

ALIGNED GAS INSERT

Figure 6.7, Aligned Gas Insert in Existing Fireplace

SECURE WITH (2) SCREWS

PULL ROD

Figure 6.4, Seated Air Duct (shown without venting attached for clarity purposes only)

INSTALLATION 17

7.0 GAS LINE CONNECTION

7.1 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.

7.2 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.

• If installing this insert into minimum opening dimensions, the gas line may need to be run after placement due to space limitations. Refer to Section 3.2.1 Existing Fireplace Opening Minimum Requirements on page 12.

• This ﬁreplace is equipped with a ⅜” (10 mm) x 18” (457 mm) long ﬂexible gas connector and manual shut-oﬀ valve.

• Run gas line into ﬁreplace, preferably through left or right gas line holes provided. 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 7.1, Inlet Gas Supply Pressures

Fuel Minimum Pressure Maximum Pressure

Natural Gas 5” WC (1.25 kPa) 10.5” WC (2.62 kPa)

LP Gas 11” WC (2.74 kPa) 13” WC (3.24 kPa)

18 GAS LINE CONNECTION

8.0 FACING AND FINISHING

8.1 Clearances to Combustibles

COMBUSTIBLE MANTEL

12” (305mm)

10” (254mm)

(895mm)

¼”

(946mm)

45˚

¼”

16”

(407mm)

COMBUSTIBLE MATERIAL

6” (152mm) CLEARANCE TO ADJACENT SIDEWALL

Figure 8.1, Mantel Requirements

FACING AND FINISHING 19

8.2 Shroud Installation

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

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

For shrouds #CK29-2538, #CK29-27542, #CK29-3044, and #CK29-A2340.

1. Remove the upper hood by lifting up and out of the mounting ﬂanges.

2. Remove lower louver by lifting the louver out of the slots on the mounting bracket.

3. Remove the glass assembly.

4. Align the mounting holes on the shroud to the corresponding mounting nuts on the sides of the insert metal cabinet.

5. Secure with (4) truss head screws (provided).

6. Reinstall all components previously removed.

8.3 Safety Barrier Installation

For safety barriers CK29-BSF, CK29-CXF, CK29-PSF, CK29RSF, CK29A-MSF, CK29A-SF, CK29A-PSF, and CK29A-FPDSF.

1. Locate the (4) slots on the shroud (2 each side).

2. Align the tabs located on the back of the safety barrier with the slots on the shroud.

3. Raise the safety barrier slightly into the slots and allow the tabs to lower into position.

• To remove safety screen: lift the screen up and out of slots.

Figure 8.2, Upper Hood Removal

Figure 8.3, Lower Louver Removal

MOUNTING NUTS (2 EACH SIDE)

Figure 8.4, Mounting Nuts Location

20 FACING AND FINISHING

9.0 GAS FIREPLACE INSERT SETUP

9.1 Glass Assembly

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.

9.1.1 Remove Glass Assembly

WARNING: Do not remove the glass assembly when hot.

1. Locate (2) spring-loaded latches securing the glass assembly at the bottom of the ﬁrebox.

2. Pull the spring-loaded latches out and down to release the bottom of the glass assembly.

3. Lift glass assembly up and oﬀ of the (2) tabs located at the top of the ﬁrebox.

9.1.2 Install Glass 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.

9.2 Light Kit

ATTENTION: If converting to LP (propane) gas, complete the conversion before installing any media. Follow instructions included with the gas 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 the heat shield. Slide light bars out away from screws, tipping upwards to expose lamp bases.

3. Install (6) halogen bulbs (included in components packet) into lamp bases. Re-tighten light bar screws.

4. Reinstall burner cover, securing with screws previously removed.

(4) SCREWS SECURING LIGHT BARS

HEAT SHIELD

Figure 9.2, Light Bar Screws (Heat shield only shown for clarity purposes)

9.3 Glass Media Installation

WARNING: DO NOT BLOCK PILOT WITH GLASS MEDIA. A BLOCKED PILOT MAY CAUSE DELAYED IGNITION.

IMPORTANT: Use only #108 Series Glass Media (8 lbs. / 3.6 kg) in this ﬁreplace. DO NOT substitute materials or use more than speciﬁed.

1. Install 8 lbs. (4.5 kg) of glass beads onto burner assembly and pilot shield.

2. Verify the glass media is one layer deep across the ﬁrebox. Do not block pilot assembly.

3. Save any unused media for later use.

(8) SCREWS SECURING BURNER COVER

Figure 9.1, Burner Cover Screw Location

Figure 9.3, Pilot Assembly Area (must be clear)

GAS FIREPLACE INSERT SETUP 21

9.4 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.

9.4.1 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 assembly.

5. Remove glass media.

6. Remove burner cover from ﬁrebox (8) screws.

7. Remove burner tube from heat shield (2) screws.

8. Remove halogen bulbs.

9. Remove heat shield from ﬁrebox.

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.

CONTROL BOARD

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 ON THE BOTTOM OF THE FIREBOX.

2. Secure the control board with screws previously removed.

3. Reinstall heat shield and halogen bulbs.

4. Reinstall burner tube, positioning burner venturi over burner

oriﬁce, aligning mounting holes with corresponding holes in control board assembly. Secure with (2) screws previously removed.

5. Reinstall burner cover, aligning holes in cover to corresponding

holes on burner. Secure with (8) screws previously removed.

6. Reinstall glass media, being careful not to block pilot.

7. Turn the manual valve counterclockwise to the ON position.

8. Reconnect electrical power.

9. Reinstall glass assembly and safety barrier.

10. Verify proper glass media placement, operation of ﬁreplace,

and any electrical components.

BURNER TUBE

BURNER COVER

Figure 9.4, Control Board Removal and Installation

HEAT SHIELD

22 GAS FIREPLACE INSERT SETUP

10.0 ELECTRICAL INFORMATION

BATTERY PACK

885 PROFLAME

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.

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.

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.

END

MALE

APPLIANCE

GROUND STAR

10.2 Wiring Requirements

• The IFC System Module requires 120V of electricity and/or batteries to operate.

• Using the battery back-up will operate the burner only.

• Optional light components will not function on battery back up power.

VARIABLE

SPEED FAN

VARIABLE LIGHTS

IGNITER

PILOT

Figure 10.1, Wiring Schematics

FLAME

SENSOR

MAIN

ON/OFF

SWITCH

PILOT

BURNER

SWI BUTTON (RED)

ELECTRICAL INFORMATION 23

OFF

11.0 OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPER ATING

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.

OPERATING INSTRUCTIONS

1. STOP! Read all the safety information above on this page.

2. Press the wireless remote OFF button.

3. Turn oﬀ all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

5. Locate the manual valve installed by your qualiﬁed service technician.

6. Turn the manual valve clockwise to the OFF position.

7. 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.

8. Turn the manual valve counterclockwise to the ON position.

phone. Follow the gas supplier’s instructions.

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

C. 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.

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

Immediately call a qualiﬁed service technician to inspect the appliance and to replace any part of the control system 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.

9. Turn on all electric power to the appliance.

10. Press the wireless remote ON button.

11. If the appliance will not operate, follow the instructions, “To Turn Oﬀ Gas To Appliance” and call your service technician or gas supplier.

ON/OFF

1. Press the wireless remote OFF button.

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

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.

24 OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

3. Locate the manual valve installed by your qualiﬁed service technician.

4. Turn the manual valve clockwise to OFF position.

NOTE

11.1 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.

3. Install (3) AAA batteries (included in the components packet) in the remote control battery bay, located at the base of the remote.

4. Connect the IFC Module to an AC power supply.

11.2 Initialize the Control System

IMPORTANT: Remove all packaging and combustible material from the ﬁrebox before initializing the control system.

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.

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.

• 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.

11.4 Automatic Safety Restart

• 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.

• After the turn OFF sequence is completed, the IFC module will re-execute the latest command.

11.5 Backup Battery Operation

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.

• 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.

SW1

BUTTON

LEDs

Figure 11.1, IFC Module

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 automatically light.

• Turn the main burner ON by setting the ON/OFF switch in ON

position. The main burner will only operate on HI.

OPERATING INSTRUCTIONS 25

11.6 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.

11.6.1 Reset IFC Module after Lockout

11.6.1.1 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.

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 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.

11.7 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 11.2 Initialize the Control System on page 25.

26 OPERATING INSTRUCTIONS

PROFLAME 2 TRANSMITTER

BLUE BACK LCD DISPLAY

TRANSMISSION

THERMOSTAT

OFF/ON/SMART

LCD DISPLAY

KEY LOCK

LOW BATTERY ALARM

ROOM TEMPERATURE

CPI MODE

TEMPERATURE/LEVEL/STATE

ON/OFF KEY

THERMOSTAT KEY

UP/DOWN ARROWS

MODE KEY

FLAME ON

11.8 Remote Control Operation

11.8.1 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.

SYSTEM OFF

SET POINT

SPLIT FLOW

FAN

LIGHT ON

11.8.3 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

11.8.2 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.

SYSTEM OFF

OPERATING INSTRUCTIONS 27

11.8.4 Turn ON the Appliance

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.

ROOM TEMPERATURE

11.8.5 Turn OFF the appliance

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.

11.8.6 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.

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.

SYSTEM ON

FLAME OFF

FLAME LEVEL 5 FL AME LEVEL MAXIMUM

FLAME LEVEL 1

SET TEMPERATURE

11.8.7.2 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.

11.8.7.3 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,

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.

11.8.7 Remote Control Thermostat Operation

11.8.7.1 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.

28 OPERATING INSTRUCTIONS

11.8.8 Fan Speed Control

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.

11.8.9 Accent Light Kit (Optional)

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 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.

OPERATING INSTRUCTIONS 29

12.0 ADJUSTMENT

12.1 Pressure Testing

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).

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.

12.1.1 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 12.1.

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.

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 manifold (OUT) pressure tap by turning screw counter-clockwise. See (B) in Figure 12.1.

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 12.1, Inlet Pressures

Fuel Natural Gas LP Gas

Gas Supply Min - Max Min - Max

Inlet Pressure Tap (A)

Fuel Natural Gas LP Gas

Gas Supply Low - High Low - High

Manifold Pressure Tap (B)

5” - 10.5” WC (1.25 - 2.62 kPa)

Table 12.2, Manifold Pressure

1.1” - 3.8” WC (.27 - .95 kPa)

12” - 13” WC (2.99 - 3.24 kPa)

2.9” - 11” WC (.72 - 2.74 kPa)

Figure 12.1, Pressure Check Taps

30 ADJUSTMENT

12.2 Burner Flame Adjustments

IDEAL

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.

12.2.1 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 12.3.

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.

Table 12.3, Factory Set Venturi Openings

Fuel Air Shutter Opening

Natural Gas 1/8” (3 mm) OPEN

LP Gas 5/8” (15 mm) OPEN

IMPORTANT: Slight adjustments to the venturi opening will create dramatic results. Adjust at slight increments until desired look is achieved. Always burn the ﬁreplace for at least 15 minutes, and always allow the appliance ample time to cool before making any further adjustments.

Table 12.4, Venturi Adjustment Guidelines

Flame Characteristic

Dark, orange ﬂame with black tips

Short, blue ﬂames Venturi open too far Close setting slightly

Lifting (ghosting) ﬂames

Cause Solution

Venturi closed too far Open venturi slightly

Gas pressure too high

Venturi closed too far

Check manometer settings

Open venturi setting slightly

LAZY, YELLOW FLAMES

12.2.1.1 Venturi Adjustment

1. Remove the safety barrier, glass frame assembly, and glass media.

2. Remove burner cover and burner tube.

3. Loosen screw on burner venturi and adjust as necessary. Retighten screw.

4. Reinstall all components previously removed.

BURNER VENTURI

Figure 12.2, Burner Venturi

DARK, ORANGE FLAME

WITH BLACK TIPS

SHORT, BLUE FLAMES

LIFTING (GHOSTING) FLAMES

Figure 12.3, Flame Appearance and Characteristics

ADJUSTMENT 31

13.0 TROUBLESHOOTING

ATTENTION: Troubleshooting must be performed by a qualiﬁed technician.

Before proceeding with the steps in the following troubleshooting guide,

• 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.

Issue Cause Solution

Pilot will not light Electrical power interrupted or

disconnected

Wiring disconnection Ensure batteries are fully charged if using battery back-up as

Gas supply turned oﬀ Check remote shut-oﬀ valves from the appliance. Usually there is

Pilot will not stay lit No LP (propane) gas in tank Check LP (propane tank). Reﬁll if necessary.

Low gas pressure Consult a plumber or a gas supplier.

• Verify all connections between the wire harnesses and the system components are proper and positive.

• Verify the communication link is established between the remote control and the IFC module.

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

Restore electrical power to appliance or use battery back-up.

power source.

Use wiring schematic (See Figure 10.1 on page 23) to determine that all wiring connections are secure and correct.

a valve near the main gas line. There may be more than (1) valve between the appliance and main gas line.

Can be caused by situations such as a bent line, too narrow diameter or pipe, or a low line pressure.

Pilot ﬂame always on, or will not extinguish

Main burner ﬂame will not light

Pilot ﬂame not making contact with the ﬂame rectiﬁcation sensor on the pilot assembly

Pilot adjustment screw not sealed

Control system set to CPI mode Set control system to IPI mode (See Section 11.8.3 on page 27).

ON/OFF rocker switch in OFF position

Gas supply turned oﬀ Check for multiple shut-oﬀs in the supply line. Verify gas supply is

Low gas supply Consult with plumber or gas supplier.

Wiring disconnection or improper wiring

Plugged main burner oriﬁce Remove blockage.

Pilot ﬂame Verify the pilot ﬂame is properly directed to ignite burner. See pilot

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.

Seal pilot adjustment screw. Do not over-tighten.

Switch rocker switch to ON position.

turned on.

Check LP (propane) tank. Reﬁll if necessary.

Check for faulty or incorrect wiring.

ﬂame troubleshooting above.

Remote control not working properly

No call for heat Verify remote control is powered ON and thermostat operation is

32 TROUBLESHOOTING

Replace batteries.

turned OFF.

Issue Cause Solution

Pilot and burner

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

extinguish while in operation

Incorrect glass assembly installation

Incorrect vent cap installation Adjust if necessary.

Vent cap blockage Remove debris if necessary.

Exhaust vent pipe leaking exhaust gases back into ﬁrebox

Soot appears on glass Incorrect glass media

installation

Improper venturi setting Venturi air shutter may need to be opened slightly to allow more air

Incorrect vent cap installation Adjust if necessary.

Vent cap blockage Remove debris if necessary.

Flame burns blue and lifts

Improper venturi setting Venturi air shutter may need to be opened slightly to allow more air

oﬀ burner

Incorrect vent cap installation Adjust if necessary.

Refer to Section 9.1 Glass Assembly on page 21.

Check for leaks and repair if necessary.

Refer to Section 9.3 Glass Media Installation on page 21.

into the gas mix. Refer to Section 12.2.1.1 Venturi Adjustment on page 31.

Blockage or leakage of the vent system

No reaction to command Battery back batteries or

remote control batteries low

No communication between remote control and IFC module

A maximum number of failed ignitions or ﬂame restorations has been reached

Check the vent pipes for leaks, and the vent cap for debris. Repair the vent pipes or remove debris from vent cap, if necessary.

Replace batteries.

Reprogram remote control to IFC module (See Section 11.2 on page

25).

Rest IFC module (See Section 11.6 on page 26).

TROUBLESHOOTING 33

14.0 MAINTENANCE

ATTENTION: Installation and repair shall only be done by a qualiﬁed service person. The appliance should be inspected before use by a qualiﬁed service person. This appliance is required to be inspected at least once a year by a professional service person.

WARNING: The appliance area must be kept clear and free from combustible materials, gasoline and other ﬂammable vapors and liquids.

IMPORTANT: The compartment below the ﬁrebox must be cleaned at least once a year. More frequent cleaning may be required due to excessive lint from carpeting, bedding materials, etc. It is imperative that the control compartments and circulation air passageways of the appliance be kept clean. Use a vacuum to clean all components.

14.1 Burner and Pilot System

The burner assembly may be removed for easier access to the control compartment. Refer to Section 9.4 Control Board Removal and Installation on page 22, for instructions.

Performed by: Qualiﬁed Service Person

Frequency: Annually

Action:

• Vacuum all components of the burner system.

• Visually check burner ports for blockage, especially near the pilot.

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

BURNER PORTS

Figure 14.1, Burner and Pilot System

14.2 Fans

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 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 6.0 Installation on page 15.

Performed by: Qualiﬁed Service Person

Frequency: Annually

Action:

• Examination of the vent system is required.

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

14.4 Glass Assembly

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:

• 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:

• Inspect the glass for cracks, scratches, and nicks.

• Verify the glass assembly is properly intact and not damaged.

• Replace the glass and the assembly #CK29-057T as necessary.

• Only Hussong Mfg. Co., Inc. will supply the replacement of glass assembly as a complete unit.

34 MAINTENANCE

15.0 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 CK29G-150 Valve Step Motor - NG 700-504

Control Board - LPG CK29G-151 Valve Step Motor - LPG 700-504-1

S.I.T. IPI Gas Valve - NG 700-567 18 in. Flexible Gas Line - Black 700-213B

S.I.T. IPI Gas Valve - LPG 700-567-1 Flexible Gas Line - Valve to Burner Connection 700-226

Proﬂame 2 IFC Board 700-652 NG Burner Oriﬁce #42 700-242

IFC Wire Harness Assembly 700-653 LPG Burner Oriﬁce #53 700-253

Pilot Assembly - NG 700-596 Conversion Kit - NG NCK-CK29G- SP

Pilot Assembly - LPG 700-596-1 Conversion Kit - LPG LCK-CK29G-SP

Transmitter (Remote Control) 700-408 Burner Tube CK29-035

.023N Pilot Oriﬁce - NG 700-123 Media Tray CK29-350

.014LP Pilot Oriﬁce - LPG 700-114

GLASS AND GLASS GASKET

Glass with gasket 14⅝” x 27½” 701-009T

Glass Gasket 900-006

SAFETY BARRIERS

Beveled Screen Front CK29-BSF

Convex Screen Front CK29-CXF

Prairie Screen Front CK29-PSF

Rectangular Screen Front CK29-RSF

Arched Mission Screen Front CK29A-MSF

Arched Prairie Screen Front CK29A-PSF

Arched Screen Front CK29A-SF

Arched Full Prairie Door Screen Front CK29A-FPDSF

LIGHT KIT

Light kit (bottom) CK29-BLK

20W 130V Halogen Bulb 600-676A

Hussong Manufacturing Co., Inc.

P.O. Box 577

204 Industrial Park Drive

Lakeﬁeld, MN 56150-0577 USA

CSK-29-G

REPLACEMENT PARTS LIST 35

LIMITED WARRANTY

Kozy Heat Limited 10 Year Warranty

This limited 10 Year Warranty will not become eﬀective until the Warranty Registration Form has been completed and mailed to Hussong Manufacturing Co., Inc., P.O. Box 577, Lakeﬁeld, MN

56150. This registration form must be received within 30 days of installation. Failure to do so may result in delayed warranty coverage and submission of proof of purchase will be required.

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

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

Year 1

Subject to the conditions & requirements listed below, within the ﬁrst year from date of purchase, Hussong Manufacturing Co., Inc. shall, at its discretion, replace or repair any such defect in material or workmanship, at Hussong Manufacturing Co., Inc.’s expense, including reasonable labor costs to repair or replace the defective component, if a factory pre-authorization is given for the repair.

Years 2 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.

Limitation of Liability

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

This limited warranty will be void if the ﬁreplace is not installed by a qualiﬁed installer and according to the installation instructions. Use of unauthorized components will make this warranty null and void.

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

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

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

It is expressly agreed and understood that this warranty is Hussong Manufacturing Co., Inc.’s sole obligation and purchaser’s exclusive remedy for defective ﬁreplace equipment. Hussong Manufacturing Co., Inc. shall not be liable for any consequential, incidental or contingent damages whatsoever. The foregoing warranty is exclusive and in lieu of all other expressed warranties. Hussong Manufacturing Co., Inc. shall not be held to implied warranties or merchantability and ﬁtness for a particular purpose. This warranty replaces all previous warranty policies.

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

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

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).

LIMITED WARRANTY 37

LIFETIME WARRANTY

HUSSONG MANUFACTURING CO., INC.

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.

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: _______________________________

ADDRESS: ________________________________________

__________________________________________________

TELEPHONE: _____________________________________

__________________________________________________

INSTALLER NAME: _________________________________

ADDRESS: ________________________________________

__________________________________________________

TELEPHONE: _____________________________________

__________________________________________________

INSTALLATION DATE: ______________________________

MODEL NUMBER: _________________________________

SERIAL NUMBER: _________________________________

LIFETIME WARRANTY 39

kozy heat CSK-29-G, CHASKA 29-LOG CSK-29-L, CHASKA 29-ROCK CSK-29-R, CSK-29-R Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual