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-S-03-5
www.kozyheat.com
NOVEMBER 2010
911XXL-R08
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:_______________________________
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
#700-01T, 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
21” x 35” (533mm x 889mm)
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
* Model #911XXL only
OPTIONAL FEATURES
Co-linear vent system
Co-axial vent system
Grills (required) – 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)
SAFETY FEATURES
Each unit factory tested!
Tested by OMNI - Test Laboratories
Sealed combustion chamber with standing pilot ignition
Removable millivolt board with 30-second delay pilot
Automatic pressure relief glass system
Requires no electricity to operate (excluding fan)
Bedroom and mobile home approved
WEIGHT
Fireplace Weight (as packaged for shipment)
167 lbs. (75.75kg)
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
TOP
FRONT
RIGHT
LEFT
38
1
4
"
971mm
27
1
2
"
699mm
25
1
4
"
641mm
28
1
2
"
724mm
5"
127mm
36
1
2
"
927mm
21
5
8
"
549mm
26
1
2
"
673mm
16
1
8
"
410mm
FIREPLACE DIMENSIONS
DESCRIPTION Height Width Back Width Depth Back Height Back to Vent Center
FIREPLACE
DIMENSIONS
INCHES 25-1/4 38-1/4 26-1/2 16-1/8 28-1/2 5
MILLIMETERS 641 971 673 410 724 127
Figure 6a
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. Millivolt board with burner cover
4. Log set (see page 22)
5. *150 CFM fan kit
6. Co-linear air duct
*911XXL only
Figure 6b
MINIMUM CLEARANCES TO COMBUSTIBLES
Insert glass to sidewall: 4-1/2” (114mm)
Insert top to 10 (254mm) mantel: 16” (406mm)
PAGE 6
SPECIFICATIONS
#911XXL COMPONENTS LIST
XXL-770Millivolt Board Assembly
700-203Manual Gas Shut-off Valve
XXL-135Burner Assembly
XXL-G900Refractory Set
XXL-500Log Package
700-01T Glass with Gasket
XXL-005Glass Valance
OCK-S47ALP Conversion Kit
815-CL2Co-Linear Air Chute
XXL-028Fan Kit (2)-75 CFM
900-0854” Restrictor Plate
ADDITIONAL COMPONENTS REQUIRED
#911XXL-RAD COMPONENTS LIST
XXL-770Millivolt Board Assembly
700-203Manual Gas Shut-off Valve
XXL-135Burner Assembly
XXL-G900Refractory Set
XXL-500Log Package
700-01T Glass with Gasket
XXL-005Glass Valance
OCK-S47ALP Conversion Kit
815-CL2Co-Linear Air Chute
900-0854” Restrictor Plate
Vent System; Part #815-CL: For use with minimum 6” x 8” I.D. masonry or 8” I.D. Class A metal chimneys - Includes 12ft. (3.66m)
compressed, expandable to 25ft. (7.62m) 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 40ft. (12.19m).
Other approved venting: Selkirk
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 (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 (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: 8” (203mm) minimum inside diameter. Masonry Chimney: 6" x 8" minimum inside diameter.
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” (610mm).
This is total length of co-linear flexible aluminum required.
MEASUREMENT FROM FIREPLACE BASE TO TOP OF CHIMNEY:____________
LESS 24" (610mm) (HEIGHT OF INSERT): -24" (610mm)
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: ……………………………………..28" (711mm)(B) Front Width:……………………………….38-1/2" (978mm)
(C) Depth:………………………………………16-1/2" (419mm)
(D) Back Width:………………………………..26-3/4" (697mm)
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, #700-01T 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.
911XXL: This fireplace insert comes complete with a fan and thermostatic control switch already installed. A speed control, receptacle,
and fan cord have been installed, wired and mounted in a removable electrical box panel on right side of fireplace. If wiring to
pre-installed electrical box is desired, wiring should be run prior to permanently setting insert in place and connecting vent system.
911XXL-RAD: A speed control, receptacle, and fan cord have been installed, wired and mounted in an electrical box panel included with
fan kit. If hardwiring to electrical box is desired, wiring should be run prior to permanently setting insert in place and
connecting vent system.
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
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.
DIRECT WIRE INSTALLATION: The cord must be removed and wiring disassembled. Insert 110V-120V wiring (with ground) through
Ground Wire
Electrical Box
110V-120V
Incoming wiring
Figure 10a
110V-120V
60Hz
Speed Control / Receptacle Assembly
Temperature Switch:
Magnetically attaches to bottom
of firebox.
1. 911XXL: Remove speed control / receptacle assembly from right side of insert floor.
2. 911XXL / 91XL-RAD: Remove (2) screws securing speed control / receptacle to expose wiring.
3. Remove existing cord and insert 110V-120V wiring (with ground) through romex connector, wiring to speed control / receptacle assembly, matching black (hot), white (neutral), and green (ground) wire to the corresponding wires on speed control / receptacle assembly.
NOTE: The (3) wire nuts obtained when removing existing cord may be used for this purpose.
4. Secure speed control / receptacle assembly into the electrical box with (2) screws provided.
5. Attach electrical box to insert floor with nut.
NOTE: A mounting stud has been provided on right side of fireplace to reposition speed control / receptacle assembly if desired.
Refer to page 17for 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
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 millivolt 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
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