kozy heat Jackson 911, Jackson 911-IPI, Jackson 911-RAD, Jackson XL 911XL, Jackson XL 911XL-RAD Installation And Operation Manual
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INSTALLATION AND OPERATION MANUAL
INSTALLER: LEAVE THIS MANUAL WITH THE APPLIANCE.
CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.
DO NOT
DISCARD
DIRECT VENT FIREPLACE INSERT
WARNING: This product must be installed by a licensed plumber or gas fitter when installed in the
commonwealth of Massachusetts.
This appliance may be installed in an aftermarket permanently located, manufactured (mobile) home, where not prohibited by local codes.
A manufactured home (USA only) or mobile home OEM installation must conform with the Manufactured Home Construction and Safety
Standard, Title 24 CFR, Part 3280, or when such a standard is not applicable, the Standard for Manufactured Home Installations, ANSI/NCSBCS A225.1,
or Standard for Gas Equipped Recreational Vehicles and Mobile Housing, CSA Z240.4
WARNING: If the information in these instructions are not followed exactly, a fire or explosion may
result, causing property damage, personal injury or loss of life.
◙ Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other
appliance.
IF YOU SMELL GAS:
◙ Do not light any appliance.
◙ Do not touch any electrical switch: do not use any phone in your building.
◙ Immediately call gas supplier from a neighbors phone. Follow the gas supplier instructions.
◙ If you cannot reach your gas supplier, call the fire department.
◙ Installation and service must be performed by a qualified installer, service agency or the gas supplier.
This appliance is only for use with the type (s) of gas indicated on the rating plate.
A conversion kit is supplied with the appliance.
WARNING
HOT GLASS WILL CAUSE BURNS.
DO NOT TOUCH GLASS UNTIL COOLED.
NEVER ALLOW CHILDREN TO TOUCH GLASS.
Report Number: 216-F-22-4
www.kozyheat.com
JAN 2011
911-R18
INTRODUCTION
Read this manual before installing or operating this appliance.
Please retain this owner‘s manual for future reference.
CONGRATULATIONS!
We welcome you as a new owner of a Kozy Heat gas fireplace. Kozy Heat products are
designed with superior components and materials and assembled by trained craftsmen who
take pride in their work. The burner and valve assembly are 100% test-fired and the complete
fireplace is thoroughly inspected before packaging to ensure that you receive a quality product.
Our commitment to quality and customer satisfaction have remained the same for over 30
years. We offer a complete line of gas and wood fireplaces, unique cabinets and stylish
accessories to compliment any décor. Adding a fireplace is one of the best ways to increase the
value of your home and we are proud to offer a network of dealers throughout the country to
help make your experience everything you imagine. We pride ourselves in being dedicated to
not only function and reliability, but customer safety as well. We offer our continual support
and guidance to help you achieve the maximum benefit and enjoyment from your Kozy Heat
gas fireplace.
Jim Hussong Dudley Hussong
President Board Chairman
Homeowner Reference Information
We recommend that you record the following information about your fireplace.
Model Name:______________________________ Date purchased/installed:___________________________
Serial Number:____________________________ Location on fireplace:_______________________________
Dealership purchased from:__________________ Dealer Phone:____________________________________
Notes:_____________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
PAGE 1
TABLE OF CONTENTS
INTRODUCTION
Introduction and Homeowner Reference Information 1
TABLE OF CONTENTS
Table of Contents 2
SAFETY INFORMATION
Safety Information 3
FEATURES
Features 4
COMMONWEALTH OF MASSACHUSETTS INFORMATION
Commonwealth of Massachusetts Information 5
SPECIFICATIONS
Fireplace Insert Dimensions 6
Clearances 6
Components List 7
Additional Components Required 7
Placement Clearance Requirements 7
EXISTING FIREPLACE SPECIFICATIONS
Existing Fireplace Requirements 8
Existing Fireplace Minimum Opening Requirements 8
PREPARE EXISTING FIREPLACE
Prepare Existing Fireplace 9
GLASS FRAME ASSEMBLY
Remove Glass Frame Assembly 9
Install Glass Frame Assembly 9
FAN DIRECT WIRE INSTALLATION
Fan Direct Wire Installation 10
THERMOSTAT / WALL SWITCH / REMOTE
Thermostat / Wall Switch / Remote 11
GAS LINE CONNECTION
Gas Line Connection 12
INSTALLATION
Approved Venting 13
Air Duct Removal 13
911-MSP Masonry Side Panel Installation (Optional) 13
Restrictor 13
VENTING INSTALLATION
Kozy Heat #815-CL Co-Linear Vent System 14-16
Kozy Heat #815-CA Co-Axial Vent System 17-18
COMPLETE FAN WIRING INSTALLATION
Complete Fan Wiring Installation 19
CONTROL BOARD
Control Board Installation 20
Control Board Removal 20
ZC SHROUD ASSEMBLY AND INSTALLATION
ZC Shroud Assembly and Installation 21
MASONRY SHROUD ASSEMBLY AND INSTALLATION
Masonry Shroud Assembly and Installation 22-23
LOG SET INSTALLATION
Log Set Installation 24
911 / 911-RAD OPERATING INSTRUCTIONS
911 / 911-RAD Valve and Pilot Assembly Components 25
911 / 911-RAD Lighting and Shutdown 26-28
911 / 911-RAD Pressure Testing 29
911-IPI OPERATING INSTRUCTIONS
911-IPI Wiring Schematics 30
911-IPI Valve and Pilot Assembly Components 31
911-IPI Control Module Components 32
911-IPI Remote Control Components 33
911-IPI Information 34
911-IPI Remote Control Operation 35-37
911-IPI Lighting and Shutdown Instructions 38-39
911-IPI Pressure Testing 40
911-IPI Error Codes 41
FINALIZING THE INSTALLATION
Flame Appearance 42
Venturi Adjustment 42
Restrictor Usage / Troubleshooting / Installation / Modification 43
Seasonal Heat Dump 44
MAINTENANCE
Maintenance 45
TROUBLESHOOTING
911 / 911-RAD Troubleshooting 46-48
911-IPI Troubleshooting 49-50
CONVERSION KIT INSTRUCTIONS
911 / 911-RAD Conversion Kit Instructions 51
911-IPI Conversion Kit Instructions 52-53
REPLACEMENT PARTS LIST
Replacement Parts List 54
WARRANTY
Warranty 55-56
PAGE 2
SAFETY INFORMATION
This fireplace has been tested to and complies with ANSI Z21.88a-2007·CSA 2.33a-2007·M02 “VENTED GAS FIREPLACE HEATERS” by OMNI-
Test Laboratories, Portland, OR. Installation must conform with local building codes or in the absence of local building codes, with the National
Fuel Gas Code, ANSIZ223.1/NFPA 54 - Current Edition, or the Natural or Propane Installation Code, CSAB149.1
Installation and repair should be done only by a qualified service person. The appliance should be inspected by a
qualified service person before use. Annual inspection by a qualified service person is required to maintain warranty.
More frequent cleaning may be required due to excessive lint from carpeting, bedding materials, etc. It is imperative
that control compartments, burners and circulation air passageways of the appliance be kept clean.
This fireplace insert is to be installed into a solid fuel masonry or factory built non-combustible fireplace that has
been installed in accordance with the National, Provincial, State and local building codes.
Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid
burns or clothing ignition.
Young children should be carefully supervised when they are in the same room as the appliance. Toddlers, young
children and others susceptible to accidental contact burns. A physical barrier is recommended if there are at risk
individuals in the house. To restrict access to a fireplace or stove, install an adjustable safety gate to keep toddlers,
young children and other at risk individuals out of the room and away from hot surfaces.
Clothing or other flammable material should not be place on or near the appliance.
Adequate accessibility clearances for servicing and proper operation must be maintained.
This appliance must not share or be connected to a chimney flue serving any other appliance.
Keep area around the appliance clear of combustible materials, gasoline and other flammable vapor and liquids.
The flow of combustion and ventilation air must not be obstructed.
Due to high temperatures the appliance should be located out of traffic and away from furniture and draperies.
The glass front or any part removed for servicing the appliance must be replaced prior to operating the appliance.
Work should be done by a qualified service technician.
Clean glass only when cool and only with non-abrasive cleansers.
Do not operate this appliance with the glass/frame assembly removed, cracked or broken. The glass assembly, Part
#700-08T, shall only be replaced as a complete unit, as supplied by Hussong Mfg. Co., Inc. Replacement of glass
assembly must only be performed by a licensed or qualified service person. DO NOT SUBSTITUTE MATERIALS.
Do not strike or slam glass assembly.
Any safety screen or guard removed for servicing the appliance must be replaced prior to operating the appliance.
Under no circumstances should any solid fuel (wood, coal, paper or cardboard etc.) be used in this appliance.
Keep burner and control compartment clean.
Do not use this fireplace if any part has been under water. Immediately call a qualified service technician to inspect
this appliance and to replace any part of the control system and any gas control which has been under water.
Do not operate without refractory brick lining installed.
PAGE 3
FEATURES
STANDARD FEATURES
High efficiency
High quality lifetime glass
12‖ x 27‖ (305 mm x 686 mm)
Quick latch glass frame assembly
Co-linear vent system - (manifold)
Seasonal heat dump baffle
Patented burner system and log design
High - Low regulator
Automatic fan kit (2) - 75 CFM**
Refractory brick lining
Minnesota Energy Code compliant to 50 pascals
*Standard on RAD models
**Standard on 911 and 911-IPI models
***Standard on 911-IPI models
****Standard on 911 and 911-RAD models
SAFETY FEATURES
Each unit factory tested!
Tested by OMNI - Test Laboratories
Sealed combustion chamber
Standing pilot ignition****
Intermittent or Standing pilot ignition***
30-second delay pilot****
Flame sensing system (safety shutoff)***
Automatic pressure relief glass system
Requires no electricity to operate** (excluding fan )
Battery back-up in the event of power failure***
(excluding fan)
Bedroom and mobile home approved
Canadian approved
*Standard on 911 models
**Standard on 911 and 911-IPI models
***Standard on 911-IPI models
****Standard on 911 and 911-RAD models
OPTIONAL FEATURES
Co-linear vent system
Co-axial vent system
Grills – several styles/finishes
Arched valance brass or chrome trim
Rectangular valance (replaces arched valance)
Valance Screen
On-off remote control or thermostatic remote control
Wall mount thermostat / wireless wall mount thermostat
Decorative screen doors in various styles and finishes
Decorative full door shrouds in various styles and finishes
3 pc. or 4 pc. shrouds (Masonry or ZC style)
Shroud trim in various finishes
Custom shrouds (Masonry or ZC style)
Clean face frames in various colors
Masonry side panels
Automatic fan kit**
*Standard on RAD models
**Standard on 911 and 911-IPI models
***Standard on 911-IPI models
****Standard on 911 and 911-RAD models
WEIGHT
Fireplace Weight (as packaged for shipment)
119 lbs. (53.98 kg)
PAGE 4
COMMONWEALTH OF MASSACHUSETTS REQUIREMENTS
NOTE: The following requirements reference various Massachusetts and national codes not contained in this manual.
For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes,
including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than (7) feet above finished grade in the
area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
INSTALLATION OF CARBON MONOXIDE DETECTORS
At time of installation of side wall horizontally vented gas fueled equipment, the installing plumber or gas-fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber
or gas-fitter shall observe that a battery operated or hard wired carbon monoxide detector is installed on each additional level of the dwelling, building or
structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified
licensed professionals for the installation of hard wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or attic, the hard wired carbon monoxide detector with
alarm and battery back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days
to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an
alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS
Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS
certified.
SIGNAGE
A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum of eight (8 ) feet above grade directly in line
with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print no less the one-half inch
(1/2) in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
INSPECTION
The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the
inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08 (2) (a) 1 through 4.
EXEMPTIONS
The following equipment is exempt from 248 CMR 5.08 (2) (a) 1 through 4:The equipment listed in Chapter 10 entitled ―Equipment Not Required To Be
Vented‖ in the most current edition of NFPA 54 as adopted by the Board; and Product Approved side wall horizontally vented gas fueled equipment installed
in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components
with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:
Detailed instructions for the installation of the venting system design or the venting system components; and
A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED
When the manufacturer of Product Approved side wall horizontally vented gas equipment does not provide the parts for venting the flue gases, but identifies
―special venting systems‖, the following requirements shall be satisfied by the manufacturer:
The referenced ―special venting systems‖ instructions shall be included with the appliance or equipment installation instructions and;
The ―special venting systems‖ shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed
installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all vent ing instructions, all parts lists for
venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
PAGE 5
SPECIFICATIONS
31
1
4
"
794mm
18"
457mm
19
1
2
"
495mm
2
1
4
"
57mm
14
1
2
"
368mm
29
1
2
"
749mm
4
3
4
"
121mm
16
1
8
"
410mm
20
7
8
"
530mm
TOP
FRONT
RIGHT
LEFT
FIREPLACE DIMENSIONS
DESCRIPTION Height Width Back Width Depth Back Height Back to Vent Center
FIREPLACE
DIMENSIONS
Figure 6a
INCHES 18 31-1/4 20-7/8 16-1/8 19-1/2 4-3/4
MILLIMETERS 457 794 530 410 495 121
WARNING: FAILURE TO POSITION PARTS IN ACCORDANCE WITH THESE DIAGRAM S OR FAILURE TO USE ONLY PARTS SPECIFICALLY
APPROVED WITH THIS APPLIANCE MAY RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY.
1. Fireplace insert
2. Spring-loaded latch glass frame assembly
3. Control board with burner cover
4. Log set (see page 24)
5. *150 CFM fan kit
6. Co-linear air duct
*911 and 911-IPI models only
Figure 6b
MINIMUM CLEARANCES TO COMBUSTIBLES
Insert glass to sidewall: 10‖ (254 mm)
Insert top to combustible mantel: 12‖ (305 mm)
PAGE 6
SPECIFICATIONS
#911 / 911-RAD COMPONENTS
911-770 Millivolt Control Board Assembly
700-203 Manual Gas Shut-off Valve
911-135 Burner Assembly
911-G900 Refractory Set
932-500A Log Package
911-002 Glass Frame Assembly
OCK-S50A LP Conversion Kit
815-CL1 Co-Linear Air Chute
911-028* Fan Kit (2)-75 CFM
900-085 4‖ Restrictor Plate
*911 only
#911-IPI COMPONENTS LIST
911-600-IPI IPI Control Board Assembly
700-203 Manual Gas Shut-off Valve
911-135 Burner Assembly
911-G900 Refractory Set
932-500A Log Package
911-002 Glass Frame Assembly
OCK-A50L-I-911-PSE LP Conversion Kit
911-028-IPI Fan Kit (2)-75 CFM
900-085 4‖ Restrictor Plate
700-208
Remote Control
ADDITIONAL COMPONENTS REQUIRED
Vent System; Part #815-CL: For use with minimum 6‖ x 8‖ I.D. masonry or 8‖ I.D. Class A metal chimneys - Includes 12 ft. (3.66 m)
compressed, expandable to 25 ft (7.62 m) co-linear 3‖ x 4‖ flexible chimney, and termination cap.
Part #510: Used in conjunction with #815-CL to extend termination up to a maximum of 30 ft. (9.14 m).
Part #815-CA: For use with minimum 7‖ I.D. Class ‗A‘ metal chimneys - Includes 12 ft. (3.66 m) compressed expandable
to 32 ft. (9.75 m) co-axial 4‖ x 6‖ flexible chimney system, co-axial air duct, and termination cap.
Part #716A: Used in conjunction with #815-CA to extend termination up to a maximum of 40ft. (12.19 m).
Other approved venting: Selkirk, ICC, American Metals, Security
Shrouds - 3 pc & 4 pc.: Standard shrouds are available for this insert and will fit most applications. Custom shrouds may be ordered on a
non-returnable basis. When ordering a custom shroud, please specify existing fireplace front opening height and
width. Grill set or clean face frame (required) in various finishes purchased separately.
or
Blank Shrouds - 3 & 4 pc.: Blank shrouds are available for on-site custom fit applications and are sized to the opening after the insert has
been installed. The interior perimeter is properly sized to fit onto the insert. The outer perimeter must be cut,
formed and finished (painted). Grill set or clean face frame (required) in various finishes purchased separately.
or
Full Door Shrouds: Full door decorative shrouds are available for this insert and are used in place of a standard or blank shroud.
PLACEMENT CLEARANCE REQUIREMENTS
This fireplace must be installed on a level surface capable of supporting the fireplace and venting.
This fireplace insert is to be installed into a solid fuel masonry or factory built non-combustible fireplace that has been installed in
accordance with the National, Provincial, State and local building codes.
Due to high surface temperatures, fireplace should be located out of traffic and away from furniture and draperies.
This fireplace may be installed in a bedroom.
Please be aware of the large amount of heat this fireplace will produce when determining a location.
PAGE 7
EXISTING FIREPLACE SPECIFICATIONS
THIS INSERT IS APPROVED FOR INSTALLATION IN MASONRY AND FACTORY-BUILT SOLID FUEL BURNING FIREPLACES.
EXISTING FIREPLACE REQUIREMENTS
The existing fireplace & chimney must be clean and in good working order and constructed of non-combustible materials.
A gas line must be able to be installed to insert.
Provisions made to provide electrical power to operate insert fan and thermostatic control (if used).
Any chimney clean-outs must fit properly.
Existing Chimney must be comprised of one of the following: Factory built chimney: Co-linear - 8‖ (203 mm) minimum inside diameter.
Co-axial - 7‖ (178 mm) minimum inside diameter.
Masonry Chimney: 6" x 8" minimum inside diameter.
Existing Chimney Height: Minimum: 12 ft. (3.66 m)
Maximum: Co-axial venting: 40 ft. (12.19 m)
Co-linear venting: 30 ft. (9.14 m)
NOTE: It is helpful to have two people complete next step in determining
chimney height.
Determine length of your existing chimney:
1. Remove and discard existing chimney cap.
2. Measure from fireplace base to top of chimney.
Subtract 24‖ (610 mm).
This is total length of co-linear flexible aluminum required.
MEASUREMENT FROM FIREPLACE BASE TO TOP OF CHIMNEY:____________
LESS 24" (610 mm) (HEIGHT OF INSERT): -24" (610 mm)
TOTAL CHIMNEY LENGTH REQUIRED: ____________
CAUTION: This appliance must not be connected to or joined with any other
chimney flue serving another appliance.
EXISTING FIREPLACE MINIMUM OPENING REQUIREMENTS
(A) Height: ……………………………………..19" (483 mm)
(B) Front Width:……………………………….31-1/2" (800 mm)
(C) Depth:………………………………………16-1/4" (413 mm)
(D) Back Width:………………………………..21" (606 mm)
Figure 8a
All dimensions are minimum requirements
PAGE 8
PREPARE EXISTING FIREPLACE
Any removed parts must be capable of reinstallation if this insert is ever removed (removal of rivets or screws is acceptable).
The refractory, glass doors, screen rails, screen mesh and log grates may be removed from existing fireplace before installing this gas
fireplace insert. Any smoke shelves, shields and baffles may be removed if attached by mechanical fasteners. If necessary, remove firebrick
to obtain at least minimum opening requirements.
The fireplace flue damper can be fully blocked open or removed for installation of this gas fireplace insert. Remove existing chimney cap.
Clean chimney and inside of fireplace to prevent creosote smell from entering the home.
Place ‗THIS UNIT HAS BEEN MODIFIED‘ label at bottom of existing firebox so it will be visible if this gas fireplace insert is removed.
Cutting of any sheet metal parts is prohibited, except the metal floor. If metal floor is removed, the insert must be placed directly on metal
base of metal fireplace.
Run any necessary electrical wiring to insert.
GLASS FRAME ASSEMBLY
WARNING: DO NOT OPERATE THIS FIREPLACE WITH GLASS REMOVED, CRACKED OR BROKEN. REPLACEMENT
OF GLASS ASSEMBLY, #700-08T SHOULD BE DONE BY A LICENSED OR QUALIFIED SERVICE PERSON.
WARNING: DO NOT REMOVE GLASS ASSEMBLY WHEN HOT!
REMOVE GLASS FRAME ASSEMBLY
1. Locate spring-loaded handles securing glass frame assembly at bottom of firebox.
2. Pull bottom handles out and ‗down‘ to release glass frame assembly bottom.
3. Pull bottom of glass frame assembly out and lift up off tabs at top of firebox.
INSTALL GLASS FRAME ASSEMBLY
A. Place glass frame assembly top over tabs at top of firebox.
B. Pull bottom handles out and ‗up‘ to secure glass frame assembly bottom.
Figure 9a
PAGE 9
FAN DIRECT WIRE INSTALLATION
DIRECT WIRE CONNECTION MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN.
911-RAD: Optional: #911-028 fan kit
#600-083C speed control, receptacle assembly
911: This fireplace insert comes complete with a fan and thermostatic control switch already installed. A speed control, receptacle,
and power cord have been installed, wired and mounted in a removable electrical box panel on right side of fireplace.
911-IPI: This fireplace insert comes complete with a fan kit already installed. A double receptacle and power cord have been installed,
wired and mounted in a removable electrical box panel on right side of fireplace.
NOTE: If wiring to pre-installed electrical box is desired, wiring should be run prior to permanently setting insert in place and
connecting vent system.
If this fireplace insert is being installed in minimum opening dimensions, wiring may need to be completed after fireplace insert
DIRECT WIRE INSTALLATION: The cord must be removed and wiring disassembled. Insert 110V-120V wiring (with ground) through
romex connector and wire to box cover assembly, matching black, white & green (ground) wires to
corresponding wires on electrical box cover assembly.
is set in place.
WARNING: This appliance is equipped with a three-prong (grounding) plug for protection against shock hazard and should be plugged
directly into a properly grounded three-prong receptacle. Do not cut or remove grounding prong from this plug. Do not allow
any excess fan cord to touch fireplace.
NOTE: Code approved line voltage wiring 14 gauge or better must be used when wiring this assembly. Refer to local electrical codes for
specific requirements in your area.
911-IPI WIRING SCHEMATIC
Figure 10a Figure 10b
911 WIRING SCHEMATIC
DIRECT WIRE INSTALLATION
1. 911: Loosen (but do not remove) screw securing removable access panel (with electrical box & romex connector installed) from
right side of fireplace. Remove access panel.
2. 911 / 911-RAD / 911-IPI: Remove box cover assembly to expose wiring.
3. Remove existing cord and insert 110V-120V wiring (with ground) through romex connector, wiring to box cover assembly, matching
black (hot), white (neutral), and green (ground) wires to corresponding wires on box cover assembly using (3) wire nuts obtained when
removing existing cord.
4. Reattach box cover assembly with (2) screws provided.
Refer to page 19 for instructions on completing fan wiring after insert has been installed.
This appliance, when installed, must be electrically grounded in accordance with local codes, or in the absence of local codes,
with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Codes, CSA C22.1
PAGE 10
THERMOSTAT / WALL SWITCH / REMOTE (911 & 911-RAD only)
If desired, a thermostat (wireless style also available), wall switch, or remote control assembly may be used to turn fireplace OFF and ON.
Only ONE of these may be installed. Follow instructions included with chosen assembly.
NOTE: INSTALLATION OF THERMOSTAT OR WALL SWITCH SHOULD BE PERFORMED BY A QUALIFIED INSTALLER .
CAUTION: DO NOT CONNECT HIGH VOLTAGE (115V) WIRE TO GAS VALVE!
Remote Control Wiring Diagram
OPTIONAL: Disconnect ON/OFF
Thermostat Wiring Diagram
rocker switch wires
from back of gas valve.
Figure 11b Figure 11a
WALL SWITCH / THERMOSTAT:
Run low-voltage (thermostat) wires from terminals on gas valve to desired location of wall switch or thermostat.
Attach appropriate connectors to wall switch / thermostat wires and connect to top and bottom terminals marked TH/TPTH on gas valve.
REMOTE CONTROL:
Follow instructions included with remote control.
IMPORTANT: If ON/OFF rocker switch wires are not disconnected, the ON/OFF rocker switch on control board must be in OFF
position for proper operation of any of these components.
thermostat, or remote control will not turn fireplace OFF when it has been turned ON by the rocker switch.
Fireplace must be turned ON and OFF by same method.
Example: If fireplace is turned ON by remote control, it must be turned OFF by remote control.
IMPORTANT: The insulated cover included with remote control must be placed over remote receiver to prevent overheating.
IMPORTANT: If rocker switch is ON, fireplace burner will operate until it is turned OFF by rocker switch. A wall switch,
PAGE 11
GAS LINE CONNECTION
#911-RAD owners: If installing optional fan kit #911-028, please do so now before connecting gas line.
GAS CONVERSION
This fireplace is manufactured for use with Natural Gas. An LP conversion kit is included with this fireplace.
Follow instructions included with conversion kit if converting to LP gas.
ATTENTION: The conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdiction and
in accordance with the requirements of the ANSI Z223.1 installation code.
CAUTION: Installation of the gas line must only be done by a qualified person in accordance with local building codes, if any.
If not, follow ANSI 223.1.
Commonwealth of Massachusetts: Installation must be done by a licensed plumber or gas fitter.
NOTE: A listed (and Commonwealth of Massachusetts approved) 12” (13 mm) T- handle manual shut-off valve and flexible gas
connector (included) are connected to the 1/2” (13 mm) control valve inlet. If substituting for these components, please
consult local codes for compliance.
NOTE: This fireplace is equipped with a 3/8”(10 mm) x 18” (457 mm) long flexible gas connector and manual shut-off valve. The gas
pressure testing of the gas line at test pressures equal to or less than ½ psi (3.5 kPa).
line should be run to the point of connection where the shut-off valve and flexible gas line will connect.
NOTE: The appliance and its individual shutoff valve must be disconnected from gas supply piping system during any pressure
testing of that system at pressures in excess of ½ psi.
NOTE: The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any
NOTE: For high altitude installations, consult local gas distributor or authority having jurisdiction for proper rating methods.
IMPORTANT: The efficiency rating of this appliance is a product of thermal efficiency rating determined under continuous operating
conditions and was determined independently of any installed system.
NOTE: If installing this insert into minimum opening dimensions, the gas line may need to be run after placement due to space
limitations.
If installing this gas fireplace insert into a factory-built fireplace and the factory-built fireplace has no access hole provided, an access
hole of 1 ½"(38 mm) or less may be drilled through the lower sides or bottom of the firebox in a proper workmanship like manner. This
access hole must be plugged with non-combustible insulation after the gas supply line has been installed.
IMPORTANT: Do not run gas line in a manner that would obstruct fan operation.
911 / 911-RAD 911-IPI
NATURAL GAS LP GAS NATURAL GAS LP GAS
MINIMUM INLET GAS PRESSURE
MAXIMUM INLET GAS PRESSURE 10.5 inches W.C. 13.0 inches W.C. 10.5 inches W.C. 13.0 inches W.C.
MANIFOLD PRESSURE (HI) 3.5 inches W.C 10.0 inches W.C. NA NA
MANIFOLD PRESSURE (LO) 1.7 inches W.C. 6.3 inches W.C NA NA
ORIFICE SIZE #32 #50 #32 #50
5.0 inches W.C.
(7.0 W.C. recommended)
11.0 inches W.C.
(recommended)
5.0 inches W.C.
(7.0 W.C. recommended)
11.0 inches W.C.
(recommended)
INPUT BTU/hr. 36,500 30,000 36,500 30,000
MINIMUM INPUT BTU/hr. 27,500 23,500 27,500 23,500
PAGE 12
INSTALLATION
IMPORTANT: All steps as outlined in „PREPARE EXISTING FIREPLACE‟ must be completed before continuing with this installation.
APPROVED VENTING
Kozy Heat #815-CL Co-Linear Vent System. Follow instructions on pages 14-16.
Kozy Heat #815-CA Co-Axial Vent System. Follow instructions on pages 17-18.
Selkirk, ICC, American Metals, Security. Follow instructions included from vent pipe
manufacturer as well as venting requirements as outlined in this installation manual.
AIR DUCT REMOVAL
Remove air duct by lifting up and off top of insert. Follow instructions below and on
following pages for vent system attachment to air duct.
#911XL-MSP MASONRY SIDE PANEL INSTALLATION (OPTIONAL)
IMPORTANT: For use when insert is installed in an existing masonry opening.
This kit must be attached to air duct (manifold) prior to vent system
connection.
Air Duct
Figure 13a
This kit includes: (1) Right side panel
(1) Left side panel
(12) Sheet metal screws
NOTE: If air duct and masonry side panels are not placed „outside‟ flanges at
insert bottom, a rattling noise may occur when fan is in operation.
1. If air duct on insert is not positioned outside flange at bottom, remove and
reposition.
2. Position each side panel outside the flanges on insert bottom, aligning (2) holes in
top and (2) holes in back of masonry side panels with corresponding holes in air
duct. Secure with screws included.
Figure 13a
Masonry side panels and air duct must be
positioned outside flange at bottom of insert
This installation will be continued at a later point.
RESTRICTOR INSTALLATION
Each installation is unique and affected by various factors including venting configuration, altitude and climate. Therefore, after fireplace
insert installation is complete, a restrictor may be required or may need to be removed or modified.
Page 41 has information on restrictor recommendations depending on burner flame appearance and instructions on installation after venting
is completed.
IMPORTANT: Do not install if venting configuration is at minimum requirements.
Large Restrictor
Figure 13b
Remove tab (s) to create
small restrictor
Bend tabs to approx. 80 degree
angles to create tension to hold
itself in place when installed.
PAGE 13
Slide restrictor into exhaust pipe with tabs
pointing toward you.
VENTING INSTALLATION
KOZY HEAT #815-CL CO-LINEAR VENT SYSTEM
NOTE: The co-linear pipe included with this vent system is designed to extend up to 25 ft. (7.62 m). If additional length is required, Part
#510 is available to extend venting to a maximum of 30 ft . (9.14 m).
NOTE: If using „stub‟ method for combustion air pipe, extending it is not necessary. Determine length needed from insert air duct
(4 ft. (1.22 m) minimum) to above damper opening in existing chimney. Remove excess combustion air pipe from end without
A. Carefully extend 3‖ combustion intake and 4‖ exhaust pipes (and extension kit if used) to equal total chimney length required.
B. If using „Full Connection‟ method:
1. Slide 3" intake pipe (end without collar) over collar on termination cap. Secure with 3 self-tapping screws (provided).
2. Place bead of sealant around inner edge of 4" exhaust pipe (end without collar) and slide onto corresponding collar on termination
cap. Secure with 3 self-tapping screws (provided). Apply additional sealant around joint to ensure a seal.
C. If an extension kit is being used, it must be connected as follows:
Exhaust extension: Apply a liberal bead of sealant around exhaust adaptor (male) extension pipe and slide into female connector on end of
4‖ exhaust pipe already attached to the chimney termination plates. Secure with 3 self-tapping screws, (provided). To
ensure an air-tight seal, additional sealant should be applied at the point of connection.
Combustion intake extension: Apply a liberal bead of sealant (provided) around male end of extension kit and slide into female end
of 3‖ combustion intake pipe attached to chimney termination plates. Secure with 3 self-tapping screws
(provided). To ensure an air-tight seal, additional sealant should be applied at point of connection.
collar. Continue with Step B. #2 below.
Figure 14a
PAGE 14
VENTING INSTALLATION KOZY HEAT #815-CL CO-LINEAR VENT SYSTEM (cont.)
RUN VENTING THROUGH EXISTING CHIMNEY
We strongly suggest wrapping first 3 ft.(914 mm) of vent system below termination cap
with non-faced fiberglass insulation (secure with wire) before running it through existing
chimney. This will prevent cold air from coming down existing chimney.
Figure 15a
NOTE: If offsets are present in existing chimney, it may be easier to place a weighted rope around the end of each pipe to guide them
through it. DO NOT ATTEMPT TO TIE ONE ROPE AROUND BOTH PIPES.
1. Guide rope, if used, and flexible pipe(s) down existing chimney. See illustration at lower left.
2. To secure chimney termination cap to existing chimney, apply a liberal bead of sealant (provided) around top of existing chimney. Set
termination cap into position as instructed in installation manual included with chosen vent system.
3. From inside existing fireplace opening, CAREFULLY pull ropes down until 4" exhaust pipe and 3‖ combustion air intake (if using
‗full connection method‘), are into existing fireplace.
STUB VENTING: From inside existing fireplace, insert a minimum 4ft. (1.22m) section of combustion air pipe (end without collar) past
damper opening and into existing fireplace. See illustration at lower right.
We strongly suggested placing non-faced fiberglass insulation between vent pipes and existing chimney to prevent heat loss up chimney,
being careful not to block end pipe if using stub method.
Figure 15b
4" exhaust flex pipe
must be connected
to collar on
fireplace insert and
termination cap
Seal area around
vent pipes with
non-faced fiberglass
insulation
PAGE 15
Minimum 4 ft. (1.22m) section
of 3" combustion air flex pipe
DO NOT block pipe
end with insulation or
any other sealing
materials
VENTING INSTALLATION
CONNECT #815-CL VENT SYSTEM TO AIR DUCT
1. Place air duct (previously removed from insert top, page 13) into existing fireplace
opening.
2. Place a bead of sealant (provided) around 4‖ exhaust pipe. Slide exhaust pipe inside
4" collar air duct. Secure with (3) ½" self-tapping screws, provided. Apply additional
sealant around joint to ensure an air-tight seal.
3. Apply a liberal bead of sealant (provided) around 3‖ collar on the air duct. Slide 3‖
combustion intake pipe over the collar. Secure with (3) ½" self-tapping screws,
provided. To ensure an air-tight seal, apply additional sealant around joint.
ATTACH AIR DUCT TO INSERT
1. Slide insert into fireplace opening.
2. If necessary, level insert by threading leveling bolts (included in components packet)
into nuts mounted inside lower air passage.
Figure 16a
3. Attach air duct to insert by aligning two holes in insert top to studs on each side of 4"
exhaust duct, and four holes at back of insert to mounting studs at lower end of air
duct.
NOTE: To prevent rattling noises that may occur during fan operation, position air
duct back and sides on the OUTSIDE of insert bottom flanges.
IMPORTANT: Before completing steps 4 & 5, ensure air duct gasket is properly seated.
4. Locate baffle with seasonal heat dump inside firebox, noting (2)access holes on each
side of heat dump. Secure air duct to insert through access holes with (2) 1/4" nuts.
5. Using a 7/16‖ wrench, secure lower end of air duct to insert firebox with (4) 1/4"
nuts.
If installing optional #911-MSP:
Align (4) holes in insert face to corresponding holes in masonry side panels. Secure with
remaining screws included with kit.
Leveling legs (2 per side)
Position air duct back
and sides outside insert
bottom flanges
(2) each side
Figure 16b
PAGE 16
VENTING INSTALLATION
KOZY HEAT #815-CA CO-AXIAL VENT SYSTEM
NOTE: The co-axial pipe included with this vent system is designed for chimneys up to 32 ft ( 9.75 m). If additional length is required,
Part #716-A is available to extend the venting to a maximum of 40 ft (12.19 m).
The 4" exhaust flex pipe and 6" combustion air flex pipe are coiled and packaged separately.
Carefully extend 4‖ and 6‖ flex pipes and extension kit (if used) to equal total chimney length required.
If an extension kit is used, it must be connected to 4" exhaust and 6" combustion air intake pipe included with #815-CA Vent Kit.
EXHAUST CONNECTION:
Apply liberal bead of sealant (provided) around 4‖ exhaust adaptor (with external notches) on extension kit and slide into female connector
on end of 4‖ exhaust pipe. Secure with 3 self-tapping screws, (provided). To ensure an air-tight seal, apply additional sealant at point of
connection.
COMBUSTION INTAKE CONNECTION:
Slide extended 6" combustion intake pipe included with 815-CA kit over extended 4" exhaust pipe included with 815-CA kit. Apply
liberal bead of sealant (provided) around 6‖ combustion intake adaptor (with external notches) on extension kit and slide it over extended
4" exhaust pipe extension and into female end of 6‖ combustion intake pipe. Secure with 3 self-tapping screws (provided). To ensure an
air-tight seal, apply additional sealant at point of connection. The 4" exhaust pipe is now inside 6" intake pipe.
A. Apply liberal bead of sealant (provided) around inside edge of 4‖ exhaust pipe, (end without collar) and slide it onto 4" collar on
vent cap. Secure with 3 equally spaced self-tapping screws through both sections. Apply additional sealant around joint to ensure
an air-tight seal.
B. Apply liberal bead of sealant (provided) around inside edge of 6‖ combustion intake pipe, (end without collar) and slide it onto 6‖
collar on vent cap. Secure with 3 equally spaced self-tapping screws through both sections. Apply additional sealant around joint
to ensure an air-tight seal. The 4" exhaust pipe will be inside the 6" combustion intake pipe.
Figure 17a
RUN VENTING THROUGH EXISTING CHIMNEY
We strongly suggest wrapping first 3 ft.(914 mm) of vent system below
termination cap with non-faced fiberglass insulation (secure with wire)
before running it through existing chimney. This will prevent cold air
from coming down existing chimney.
NOTE: If offsets are present in existing chimney, it may be easier to
place a weighted rope around end of each pipe to guide them
through it. DO NOT ATTEMPT TO TIE ONE ROPE
A. Guide ropes, if used, and flexible pipes down existing chimney.
B. To secure chimney termination cap to existing chimney, apply
liberal bead of sealant around top of existing chimney, set
termination cap into position. Secure with (4) 1-1/2‖ self-drilling
screws (provided).
Figure 17b
PAGE 17
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