kozy heat MINNETONKA 55345, MINNETONKA 55345-RF Installation And Operating Manual

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury or loss of life.

MINNETONKA

Direct Vent Gas Fireplace

MODELS: #55345

#55345-RF

INSTALLATION AND

OPERATING MANUAL

‚ Do not store or use gasoline or other flammable

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

WHAT TO DO IF YOU SMELL GAS

‚ Do not try to light any appliance. ‚ Do not touch electrical switches; do not use the

phone in your building.

‚ Immediately call your gas supplier from a

neighbor’s phone. Follow your gas supplier’s instructions.

‚ If you cannot reach your gas supplier, call the fire

department.

Installation & service must be performed by a qualified installer, service agency, or the gas supplier.

This appliance may be installed in an aftermarket permanently located, manufactured (mobile) home, where not prohibited by local codes.

US Patent #6004493

This appliance is only for use with the type(s) of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used. An LP Gas conversion kit is included with this fireplace.

IMPORTANT:

READ INSTRUCTIONS CAREFULLY BEFORE INSTALLATION. FAILURE TO

INSTALL THIS FIREPLACE CORRECTLY CAN CAUSE SERIOUS STRUCTURAL

AND FIRE HAZARDS AND MAY VOID YOUR WARRANTY.

www.kozyheat.com

July 2006

INDEX

DESCRIPTION

PAGE

SAFETY REQUIREMENTS / SPECIFICATIONS .............................................................................. 2-3

MINIMUM CLEARANCES ................................................................................................ 4-5

TYPICAL INSTALLATION OPTIONS .........................................................................................5

VENTING REQUIREMENTS .............................................................................................. 5-9

MINIMUM / MAXIMUM VENTING REQUIREMENTS ......................................... 6

HORIZONTAL VENTING ..............................................................6-7

TERMINATION CAP LOCATION......................................................... 8

VERTICAL VENTING.................................................................. 9

DETERMINE LOCATION .............................................................................................. 10-11

VENT SYSTEM FRAMING .............................................................10

ROUGH-IN DIMENSIONS ..............................................................11

PREPARE THE FIREPLACE ........................................................................................... 12-13

POSITION THE FIREPLACE ..............................................................................................13

REMOVE THE GLASS ASSEMBLY ......................................................13

DIRECT VENT CHIMNEY INSTALLATION ................................................................................ 14-15

FAN INSTALLATION.................................................................................................. 16-18

Model #55345 .................................................................... 16-17

Model #55345-RF ................................................................... 18

GAS LINE SPECIFICATIONS ........................................................................................... 19-20

SECURE THE MILLIVOLT BOARD ......................................................................................... 20

ADJUST COMBUSTION AIR INTAKE SHIELD - VERTICAL TERMINATIONS ONLY .................................................20

LOG INSTALLATION ....................................................................................................21

THERMOSTAT - WALL SWITCH - REMOTE CONTROL INSTALLATION .......................................................... 22

COMPLETE THE INSTALLATION ....................................................................................... 23-24

MODEL #55345 LIGHTING & SHUTDOWN ............................................................................ 25-26

MANIFOLD & INCOMING PRESSURE CHECK PROCEDURES ................................................. 27

MODEL #55345-RF LIGHTING & SHUTDOWN ............................................................................ 28-29

MANIFOLD & INCOMING PRESSURE CHECK PROCEDURES ................................................. 30

CLEANING & MAINTENANCE REQUIREMENTS .............................................................................. 31

MILLIVOLT BOARD REMOVAL / INSTALLATION .......................................................................... 32-33

TROUBLE SHOOTING ................................................................................................ 34-35

REPLACEMENT PARTS LISTS ............................................................................................36

WARRANTY POLICY ................................................................................................. 37-38

Page 1

IMPORTANT:

READ THIS MANUAL BEFORE INSTALLING AND USING THIS FIREPLACE

‘MINNETONKA’ DIRECT VENT GAS FIREPLACE

This fireplace has been tested to and complies with ANSI Z21.88B-2003 CSA 2.33B-2003 “VENTED GAS FIREPLACE HEATERS” by OMNI-Test Laboratories, Beaverton, OR. Installation must conform with local building codes or in the absence of local building codes, with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 - Current Edition, or the Natural or Propane Installation Code, CSA B149.1.

COMMONWEALTH OF MASSACHUSETTS

INSTALLATIONS

WARNING: This Product Must Be Installed By A Licensed

Plumber Or Gas Fitter When Installed Within The Commonwealth of Massachusetts.

IMPORTANT: Installation of a CO detector is required in the fireplace room.

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.

DO NOT REPLACE THIS BURNER UNIT WITH ANY OTHER SIZED BURNER. REPLACEMENT WITH AN UNAUTHORIZED BURNER CAN RESULT IN TEMPERATURES EXCEEDING THE LIMITS FOR THIS UNIT, AND VOID YOUR WARRANTY.

IMPORTANT: NON-COMBUSTIBLE FACING MATERIAL MAY BE APPLIED OVER THE FACE. TO PREVENT THE FACING MATERIAL FROM CRACKING AND FALLING OFF DUE TO EXPANSION OF THE FACE WHEN HEATED, DO NOT ATTACH FACING MATERIAL DIRECTLY TO THE FACE OF THE UNIT. DO NOT OBSTRUCT THE FLOW OF VENTILATION AIR.

CONSULT YOUR LOCAL OR NATIONAL INSTALLATION CODES TO ASSURE THAT ADEQUATE COMBUSTION AND VENTILATION AIR IS AVAILABLE.

WARNING:

INSPECT THE FIREPLACE & ALL COMPONENTS

Inspect the fireplace, vent system & all components. Contact your dealer if any parts are damaged or missing. Do not install the fireplace with damaged, incomplete, or substitute parts.

PLANNING THE INSTALLATION Prior to installation of this fireplace, the following must be considered:

‚ Location of fireplace. ‚ Configuration of vent system. ‚ Gas piping. ‚ Electrical wiring (for fan, optional on Model #55345) ‚ Framing. ‚ Hearth height, width & depth. NOTE: A hearth is not required. ‚ Materials used for finishing the fireplace. ‚ Optional accessories used: Fan, wall switch, remote control, thermostat, etc..

NOTE: When the unit is installed directly on carpeting, tile, or other combustible materials other than wood flooring, it must be installed on a metal or wood panel extending the full width and depth of the unit. The minimum for the support platform under the unit is 40 7/8" wide by 21 3/8" deep.

If masonry is to be used (optional), prepare the necessary foundation for the masonry load. When masonry construction is being used, a lintel must be used over the top of the unit to support the added weight.

(Model #55345)

Page 2

SPECIFICATIONS

Height .................................34 ½"

Height to top of stand-off .................. 44 1/2"

Front width ............................ 40 7/8"

Back width............................. 29 1/4"

Depth................................. 21 3/8”

Refer to Diagrams for additional measurements.

Top

Left side Right side

Front

FIGURE 1

Page 3

INSTALLATION REQUIREMENTS:

Minimum clearances from the fireplace to combustible materials:

From unit face top: 10 " From unit left & right sides & back: 1/2" Surround Sides 1/4" Unit bottom to flooring: 0" Unit top to ceiling: 31" Unit side to adjacent sidewall: 12"

MANTEL REQUIREMENTS*:

Unit top to 10" mantel: 15" minimum* Projection: 3/4" maximum projection allowed

a minimum of 10" from unit top.

*Mantel height must be raised 1" for every additional 1" of depth. See chart at right for mantel requirements. No mantel is allowed from 0" - 15" from the top of the fireplace.

HEARTH REQUIREMENTS - Figures 2A & 2B When the fireplace is installed on carpet, tile or other combustible material, it must be installed on a metal or wood

panel extending the full width & depth of the fireplace. The minimum platform size is 40 7/8" wide X 21 3/8" deep.

HEARTH EXTENSIONS:

If a hearth extension is desired, combustible materials may be used.

Figure 2A

Figure 2B

Page 4

VENT SYSTEM CLEARANCES:

Dura-Vent or Selkirk Metalbestos chimney systems: Horizontal Sections: All Sides: 3"

#800 Series Flex Vent System: All sides: 3"

Vertical Sections: All sides: 1"

IMPORTANT: THE KOZY HEAT WALL THIMBLE PASS-THRU, PART #MTK-WPT MUST BE USED ON

ALL HORIZONTAL VENT RUNS. THE MINIMUM WALL THICKNESS FOR THIS PASSTHRU IS 4 ½" AND THE MAXIMUM WALL THICKNESS IS 8"

TYPICAL INSTALLATION OPTIONS:

Typical Horizontal Installation - Figure 3A Typical Vertical Installation - Figure 3B

Typical Corner Installation - Figure 3C

Clearance to Combustible Material diagram - Figure 3D

VENTING REQUIREMENTS:

THIS FIREPLACE IS APPROVED FOR USE WITH THE SIMPSON DURA-VENT DV-GS 5" X 8" DIRECT VENT SYSTEM & SELKIRK METALBESTOS DIRECT CHIMNEY SYSTEM 5" X 8" DIRECT VENT SYSTEM FOR HORIZONTAL & VERTICAL TERMINATIONS.

THIS FIREPLACE IS ALSO APPROVED FOR USE WITH THE KOZY HEAT #800 SERIES FLEXIBLE VENT SYSTEM FOR HORIZONTAL VENTING APPLICATIONS.

THIS FIREPLACE IS DESIGNED TO BE USED WITH ANY OF THE ABOVE VENT SYSTEMS WITHOUT ADAPTOR.

Contact your dealer for the appropriate venting components for your specific application. Refer to the vent system manufacturer’s installation manual for complete installation instructions. Installation must conform with the venting

requirements & restrictions as outlined in this manual. IMPORTANT: Consult the local and national installation codes to assure that adequate combustion and ventilation air is available.

Page 5

THE USE OF AN ADDITIONAL

VENTING SPECIFICATIONS:

IMPORTANT: Flame height and appearance will vary depending upon venting configuration and type of fuel used. Venting

requirements apply to both Natural Gas & LP Gas.

HORIZONTAL TERMINATIONS:

IMPORTANT: The horizontal heat shield included with this fireplace must be installed when using a 45-degree elbow to horizontally position the vent system.

Minimum: 45-degree elbow at start followed by 6" section, then termination cap. Maximum: US INSTALLATIONS: 45-degree elbow at start followed by a maximum 10 ft.

CANADA INSTALLATIONS: 0 to 2000 ft.: 45-degree elbow at start followed by a maximum 10 ft.

2000 - 4500 ft.: Must de-rate burner orifices: Natural Gas: #56 & #35

LP Gas: #69 & #52

45-degree elbow at start followed by maximum 10 ft.

VERTICAL TERMINATIONS: Minimum: 45-degree elbow at start followed by 2 ft.

Maximum: 45-degree elbow at start followed by a maximum 30 ft.

ELBOWS: FOR EACH ADDITIONAL ELBOW USED AFTER THE FIRST ELBOW, 3 FT. MUST BE SUBTRACTED FROM THE

MAXIMUM VENTING ALLOWED. NOTE: (2) 45-DEGREE ELBOWS MAY BE USED IN PLACE OF (1) 90DEGREE ELBOW.

HORIZONTAL & VERTICAL COMBINATION: 25 ft. - 10 ft. maximum horizontal / 15 ft. maximum vertical

Page 6

MINIMUM HORIZONTAL VENTING

IMP0RTANT: THE KOZY HEAT WALL THIMBLE PASS-THRU MUST BE USED ON ALL HORIZONTAL VENT RUNS. THE

MINIMUM WALL THICKNESS FOR THIS PASS-THRU IS 4 ½" AND THE MAXIMUM WALL THICKNESS IS 8".

Minimum horizontal venting

NOTE: Horizontal Vent Heat shield must be installed when using

a 45-degree elbow to horizontally position the vent system.

Figure 4A

Minimum corner installation

NOTE: Horizontal Vent Heat shield is not used on

corner venting configurations.

Figure 4B

Page 7

TERMINATION VENT CAP LOCATION:

This gas appliance must not be connected to a chimney flue serving another type of appliance.

GENERAL:

1. Terminations against vinyl siding must use a vinyl siding protector. Follow instructions included.

2. DO NOT RECESS TERMINATION KIT INTO OUTSIDE BUILDING MATERIALS - i.e.: brick, stone, siding, etc.. If necessary, extend framing so that termination kit will be exposed once building materials are installed.

3. Vent termination must not be located where it will become plugged by snow or other material. The flow of combustion and ventilation air must be not obstructed.

LOCATION CLEARANCES:

1. Above grade, veranda, porch, deck, balcony - 12". (A)

2. Operable window - 12" (B)

3. Permanently closed window* - 12" (recommended to prevent condensation on window) (C)

4. Ventilated soffit* - 24" (D)

5. Unventilated soffit* - 12" (E)

6. Outside / inside corner* - 12" (F)

7. Meter / Regulator: NOT TO BE INSTALLED ABOVE within 3 ft. horizontally from the center line of the regulator.

8. Service regulator vent outlet - 3 ft. radius

9. Non-mechanical air supply inlet to building - 12"

10. Combustion air inlet to any other appliance - 12"

11. Mechanical air supply inlet (G) - CANADA: 6 ft. US: 3 ft. above if within 10 ft. horizontally.

12. Above furnace exhaust or inlet - 12"

13. Above paved side-walk or paved driveway located on public property - 7 ft. (H) NOTE: A vent cannot be located directly above a side-walk or paved driveway that is located between two single family

dwelling and serves both dwellings.

14. Under veranda, porch, deck, or balcony (must be fully opened on a min. of 2 sides) - 12" (I)

15. Between two horizontal terminations - 12"

16. Between two vertical terminations - 12" (J) - Note: May be the same height

NOTE: Massachusetts installations: 10 ft.

*Clearance must be in accordance with local installation codes & the requirements of the gas supplier.

FIGURE 5

Page 8

WHEN VERTICALLY TERMINATING, THE MINIMUM CHIMNEY HEIGHT ABOVE THE ROOF LINE IS DETERMINED BY THE FOLLOWING CHART:

Roof Pitch Minimum Chimney Height Roof Pitch Minimum Chimney Height

Flat to 6/12 1 ft. 13/12 to 16/12 6 ft. 6/12 to 9/12 2 ft. 17/12 to 21/12 8 ft 10/12 to 12/12 4 ft.

CAUTION: This gas appliance must not be connected to or joined with any chimney flue

serving any other appliance.

Figure 6A

NOTE: Horizontal Vent Heat shield is not used on

vertical venting configurations.

Page 9

DETERMINE LOCATION

1. Determine the exact position of your fireplace, the width, depth and height of the hearth (optional), and location of the vent system

termination. If possible place the fireplace in such a manner that the vent termination will be placed between two studs so additional framing is not necessary

HEARTH REQUIREMENTS: When the fireplace is installed directly on carpet, tile or other combustible material, it must be installed on a wood or metal panel extending the full width and depth of the fireplace. The minimum platform size is 40 7/8" wide X 21 3/8" deep.

If masonry is to be used (optional), prepare the necessary foundation for the masonry load. When masonry construction is being used, a lintel must be used over the top of the fireplace to support the added weight.

IMPORTANT - Vent cap location must be in compliance with the guidelines on page 8 of this manual.

2. HORIZONTAL TERMINATIONS:

IMPORTANT: The horizontal vent heat shield must be installed when using a 45-degree elbow to horizontally position the vent system or when using the #800 series Kozy Heat flexible vent system for horizontal terminations. Refer to page #12 of this manual for instruction on attaching the horizontal vent heat shield.

Frame a 14 1/8" high (H) x 14 1 / 8 " wide (W) opening on the

exterior wall for the chimney termination. This opening size includes the required 3" clearance on all

sides of approved rigid vent systems and the Kozy Heat #800 series flexible vent system.

To achieve the minimum horizontal venting requirements RIGID PIPE APPLICATIONS top of the vent pipe and 39 1/2" (B) to the top of the framed opening from the floor or hearth the fireplace is setting on is required. See Figure 7A.

To achieve the minimum venting requirements VENT APPLICATIONS, a minimum of 40" (A) to the top of the vent pipe and 43" (B) to the top of the framed opening from the floor or hearth the fireplace is setting on is required. See Figure 7A.

3. VERTICAL TERMINATIONS: Follow vent pipe manufacturer’s installation instructions for vertical terminations. A minimum 1"

clearance on all sides of vertical vent pipe sections must be maintained. The horizontal vent heat shield is not used for vertical venting configurations.

, a minimum of 36 1/2" (A) to the

for

, for FLEX

FIGURE 7A

CAUTION: COLD AIR TRANSFER AREA. THE SURROUNDING CHASE OF THE FIREPLACE MUST COMPLY WITH ALL CLEARANCES AS OUTLINED IN THIS MANUAL AND BE CONSTRUCTED IN COMPLIANCE WITH LOCAL BUILDING CODES. OUTSIDE WALLS SHOULD BE INSULATED TO PREVENT COLD AIR FROM ENTERING THE ROOM.

NOTE: Due to high temperatures, this unit should be located out of traffic areas and away from furniture and draperies.

4. Build the hearth to the desired size and height. If a hearth extension is desired, combustible material may be used.

Page 10

5. Rough in the wall enclosure. Figure 7B.

IMPORTANT: Framing dimensions should allow for wall covering thickness and fireplace facing materials. Adjust rough opening size as necessary to maintain at least the minimum clearance requirements.

MINIMUM FINISHED

facing materials included):

HORIZONTAL TERMINATIONS:

44 1/2" high x 41 3/8" wide x 21 7/8" deep* *½" clearance at the back & sides of the fireplace must be

maintained for horizontal terminations. See Figure 3A, page #5.

VERTICAL TERMINATIONS:

44 1/2" high x 41 3/8" wide x 23 7/8" deep* *2½" clearance at the back to maintain required vent

system clearance and ½" at the sides of the fireplace must be maintained for vertical terminations. See Figure 3B, page #5.

OPENING DIMENSIONS (Wall covering /

FIGURE 7B

Horizontal termination shown above.

FIGURE 7C

NOTE: Provide adequate clearance in front of the fireplace to access the control valve, install and attach gas line, install a fan, etc..

Do not obstruct the upper and lower convection air passage areas to allow proper ventilation air around the unit. Room air enters through the lower passage, is heated and exits at the upper passage. Blocking these passages may result in overheating the fireplace creating a potentially hazardous situation.

Page 11

PREPARE THE FIREPLACE

STAND-OFF ASSEMBLY & INSTALLATION

1. The top stand-off brackets must be formed and correctly

positioned prior to positioning the fireplace into the framed opening. Figure 8A

The top stand-off brackets are attached to the top of the fireplace in a flat state when the fireplace is shipped.

2. Remove the screws securing each stand-off bracket and

remove from the fireplace.

3. Remove the remaining (2) sets of screws under the stand-off

brackets and set aside.

4. Form each stand-off as shown in Figure 8B.

Figure 8B

Figure 8A

5. Re-attach the stand-off brackets to the top of the fireplace

using the screws removed in steps 2 & 3 above. Figure 8C.

Figure 8C

HORIZONTAL VENT APPLICATIONS: This fireplace is approved for use with the Simpson Dura-Vent 5" x 8" direct vent system, the Selkirk Metalbestos 5" x 8" direct vent

system, and the Kozy Heat #800 Series flexible direct vent system for horizontal vent applications. No additional adaptor is necessary to begin installing the chimney components.

ATTACH THE HORIZONTAL VENT HEAT SHIELD:

1. Loosen, but do not remove the center three screws at the back of the fireplace as shown in Figure 9A.

2. Slide the (3) slots on the horizontal vent heat shield under the screws. Re-tighten the screws to secure in place. Refer to Figure 9B.

Figure 9B

Figure 9A

Page 12

VERTICAL VENT APPLICATIONS This fireplace is approved for use with the Simpson Dura-Vent 5" x 8" direct vent system and the Selkirk Metalbestos 5" x 8" direct vent

system for vertical vent applications. There is no additional adaptor necessary to begin installing the chimney components.

POSITION THE FIREPLACE

1. Place the fireplace into position. Figure 10.

NOTE: Shown in horizontal vent

configuration

2. REMOVE THE GLASS ASSEMBLY. See Figure 11.

A. Locate the spring-loaded handles securing the

glass assembly at the top & bottom of the firebox.

CAUTION: TO PREVENT THE GLASS ASSEMBLY FROM FALLING FROM THE FIREPLACE AND BECOMING DAMAGED, FOLLOW THESE DIRECTIONS EXACTLY WHEN REMOVING THE GLASS ASSEMBLY.

B. Pull the handles out, then ‘do wn’ to release the

glass assembly at the bottom.

C. Pull the handles out, then ‘up’ to release the glass

assembly at the top.

D. Lift the glass assembly off from the front of the

fireplace and set aside where it will not be broken.

E. Remove the log package from the firebox and set

aside.

Figure 10

Figure 11

Page 13

VENT SYSTEM INSTALLATION:

Install the vent system components for your specific venting configuration. Follow the vent system manufacturer’s installation instructions in conjunction with the venting requirements in this installation manual.

HORIZONTAL & VERTICAL TERMINATIONS: All firestops, support brackets, etc. must be used as specified by the vent system manufacturer.

All clearances and venting requirements as specified in this manual must be followed.

VERTICAL TERMINATIONS: Restrictor usage

1. The restrictor plate (included in the fireplace

components packet) must be placed inside the 5" flue collar on the top of the fireplace before connection of the chimney to the fireplace is made. This is required for vertical vent runs of 8' - 30'.

a. Bend the (3) tabs on the restrictor plate far enough

so that it will securely fit inside the groove on the 5" collar on the fireplace. (Note: The tabs should be in the ‘up’ position.) Refer to Figure 12.

2. Proceed with the vent system installation, following

instructions included with the vent system as well as the requirements listed in this installation manual.

Refer to pages 5 - 9 of this installation manual for complete venting requirements and restrictions.

Figure 12

HORIZONTAL TERMINATIONS:

IMPORTANT: The Kozy Heat wall pass-thru, part #MTK-WPT, must be used on all horizontal vent applications regardless of which vent system you are using.

INSTALLATION OF #800 SERIES DIRECT VENT TERMINATION KIT(S)

IMPORTANT: The flex pipe is permanently attached to the exterior plate. DO NOT ATTACH the #844 or #845 termination kit to the fireplace (or extension kit) until it has passed through the wall or roof. The termination plates should all be installed on the exterior of the outside wall.

HORIZONTAL TERMINATIONS:

IF TERMINATING AGAINST VINYL SIDING, A VINYL SIDING PROTECTOR, INCLUDED WITH THE #844 and #845 DIRECT VENT KITS, MUST BE USED. FOLLOW INSTRUCTIONS INCLUDED.

CAUTION: This gas appliance must not be connected to a chimney flue serving another type of appliance.

1. If your vent system application is 8' or less from the top of the fireplace and doesn’t require an extension kit, proceed to step #7.

2. If your vent system application will require one or more extension kits (part #846), proceed with the following steps. Each #846 extension kit contains enough 5" and 8" flexible aluminum to extend the chimney an additional 6'.

Page 14

3. Gently stretch the 5" & 8" flexible aluminum pipes on the termination kit (#844 or #845) and on each extension kit, if used, the length required so when all the sections are connected together, the vent system length for your installation is attained.

IMPORTANT: DO NOT STRETCH THE EXTENSION KIT BEYOND 6'. DO NOT STRETCH BEYOND WHAT IS REQUIRED - IT IS VERY DIFFICULT TO RECOMPRESS THE FLEX PIPES ONCE STRETCHED.

4. Using your extension kit pieces, place a bead of sealant outside the 5" flex pipe collar (C) - the end with the EXTERNAL lip - and slide it inside the 5" pipe on top of the fireplace (D). Secure with 3 additional evenly spaced screws.

5. Place a bead of sealant inside the 8" flex pipe collar (E) - the end with the internal lip - and slide i t over the 8" pipe on top of the fireplace (F). Secure with 3 additional evenly spaced screws.

Minimum venting requirements: A minimum of 40" to the top of the vent pipe and 43" to the top of the framed opening from the floor or hearth the fireplace is setting on is required.

Refer to pages 5 - 9 for complete venting requirements & restrictions.

FIGURE 13

6. If additional extension kits are being used, repeat steps 4 and 5, placing the 5" & 8" pipes onto the previous extension kit.

Referring Figure 13:

7. A MTK-WPT wall pass-thru must be used for horizontal runs that pass through either interior or exterior walls. Install the MTKWPT wall pass-thru on both sides of the 14 1/8" square opening and secure with nails or screws.

NOTE: Attachment brackets are included with the termination kit. These optional brackets should be screwed or nailed (screws not provided) onto the top and bottom of the 14 1/8" square opening, on the exterior of the house. The termination plates then fit between these brackets, and using the screws provided, screw the brackets to the termination kit box (A). Attach the vinyl siding protector (G).

8. Apply a liberal bead of exterior sealant around the outer edge of the plate (A), and place the assembly through the 14 1/8" square opening in the exterior wall. Place screws through the four slots (B) securing it in place.

9. Gently pull the 5" & 8" flexible aluminum down to the top of the extension kit, or the top of the unit if no extension kits were used.

10. Place a bead of sealant outside the 5" flex pipe collar (C) and slide it into the 5" pipe on the extension kit or top of the stove (D). Secure with 3 additional evenly spaced screws.

NOTE: This connection is very difficult to remove without damaging the collars once installed.

11. Place a bead of sealant inside the 8" flex pipe collar (E) and slide it over the 8" pipe on the extension kit or top of the stove (F). Secure with 3 additional evenly spaced screws.

NOTE: This connection is very difficult to remove without damaging the collars once installed.

12. OPTIONAL: Place insulation between the 8" pipe and the wall studs.

Page 15

MODEL #55345 ONLY: OPTIONAL FAN KIT INSTALLATION INSTRUCTIONS

NSTALLATION OF THIS FAN SHOULD BE DONE ONLY BY A QUALIFIED INSTALLER

IMPORTANT: If a fan is going to be installed, it is easier to complete before the millivolt board is connected to the gas line.

The wiring must be done prior to enclosing the sides of the unit. An electrical box and romex connector are preinstalled on a removable panel on the right side of the fireplace. A receptacle / speed control assembly and (3) wire nuts are included in the fireplace components packet.

This optional fan kit #TRF-028 includes:

Right & left fan assemblies with thermostatic control switch Components package: installation instructions

NOTE: Code approved line voltage wiring 14 gauge or better must be used when wiring this assembly. Refer to your local

electrical codes for specific requirements in your area.

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 the grounding prong from this plug.

FIGURE 14

Page 16

INSTALLATION INSTRUCTIONS

THE FOLLOWING COMPONENTS MUST BE REMOVED FROM THE FIREPLACE PRIOR TO INSTALLATION OF THIS FAN. REFER TO THE CORRESPONDING PAGES IN THIS INSTALLATION MANUAL FOR ASSISTANCE IF NECESSARY.

1. Upper hood, upper louver & lower grill, if installed. Refer to page #24 if necessary.

2. Glass assembly.

Note: Millivolt board has been removed for clarity. It is not

necessary to remove the millivolt board to install this optional fan kit.

INSTALL THE FANS:

1. Slide the left and right fans through the lower grill opening (left side of the valve) and push all the way to the fireplace back.

2. Slide the left fan assembly to the left until it stops and slide the right fan assembly to the right until it stops. NOTE: The fans will be behind the legs. Figure 15A.

NOTE: Each fan bracket is held in position by a magnetic strip attached to the bottom of each bracket.The mounting studs are not used when installing this fan assembly.

3. Connect the fan wiring by inserting the red connectors on the right fan wires onto the terminals on the left fan assembly. It does not matter which connector is on each terminal. Figure 15B.

44. Remove the (2) screws securing the removable access panel (with electrical box & romex connector installed) from the right side of the fireplace.

5. Insert 115V wiring (with ground) through the romex connector and wire to the speed control / receptacle assembly matching the black (hot) white (neutral) and green (ground) wire to the corresponding wire on the sp eed control / receptacle assembly. NOTE: (3) wire nuts are included in the fireplace components packet.

6. Secure the speed control / receptacle assembly into the electrical box with the (2) screws provided.

7. Replace the electrical access panel and secure with the (2) screws removed.

8. Place the thermostatic control switch on the bottom of the firebox.

9. Plug cord into receptacle in the electrical box.

10. Turn on/off speed control counter-clockwise until it ‘clicks’. This is the ‘OFF’ position.

11. Turn the speed control ‘ON’ by turning the knob clockwise past the ‘click’ - this is the highest setting.

12. Replace the glass assembly.

13. Replace the lower grill, upper louver & upper hood. Refer to page #24 if necessary.

Slide to the left.

Slide to the right.

Figure 15A

Connect fan

wiring

Figure 15B

Speed Control /

receptacle assembly

Thermostatic

Control Switch

Figure 15C

TEMPERATURE CONTROL SWITCH POSITION: Prior to adjusting the temperature control switch, unplug the 3-prong plug on the fan cord from the receptacle. Adjust the position of the temperature control switch to a warmer location under the firebox to turn the fan ‘ON’ sooner or move it to a cooler location under the firebox to turn the fan ‘ON’ later. The fan will turn on when the sensor in the temperature control switch reaches 110 ‘OFF’ when the sensors reach 90 on the fan cord into the receptacle.

F. After adjustment, plug the 3-prong plug

F and will turn

NOTE: The fan will not operate unless the speed control has been turned ‘ON’ and sufficient heat has been applied to the temperature control switch. The fan will turn ‘ON’ and ‘OFF’ automatically when the fireplace heats and cools. Adjust fan to desired speed while it is running.

NOTE: This appliance must be electrically grounded and connected in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70-Current edition, or the Canadian Electrical Code, CSA C22.1.

Page 17

MODEL #55345-RF ONLY: FAN INSTRUCTIONS

INSTALLATION OF THIS FAN WIRING SHOULD BE DONE ONLY BY A QUALIFIED INSTALLER

IMPORTANT: A fan assembly is pre-installed and wired to the RF gas valve in the Model #55345-RF.

The wiring must be done prior to enclosing the sides of the unit. An electrical box & romex connector are pre-installed on a removable panel on the right side of the fireplace. A duplex receptacle and cover is included in the fireplace components packet.

NOTE: Code approved line voltage wiring 14 gauge or better must be used when wiring this assembly. Refer to your local

electrical codes for specific requirements in your area.

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 the grounding prong from this plug.

Figure 15

1. Remove the (2) screws securing the removable access panel (with electrical box & romex connector installed) from the right side of the fireplace.

2. Insert 115V wiring (with ground) through the romex connector and wire to the duplex receptacle. Secure the duplex receptacle to the electrical box.

3. Place the cover on the electrical box and secure with screw.

4. Replace the electrical access panel and secure with the (2) screws removed.

5. Plug the 3-prong plug on the fan cord into the receptacle.

6. Upon complete installation of this fireplace, follow the lighting & shutdown instructions at the back of this manual as well as the instructions included in the remote transmitter for complete fan operation guidelines.

Page 18

RUN THE GAS LINE.

CAUTION: Installation of the gas line must only be done by a qualified person in accordance with local building codes.

GAS CONVERSIONS - Models #55345

This fireplace is manufactured for use Natural Gas. An LP gas conversion kit, part #OCK-H5168L, is included with this fireplace. Follow instructions included with this conversion kit.

GAS CONVERSIONS - Model #55345-RF

This fireplace is manufactured for use with Natural Gas. An LP gas conversion kit, part #OCK-H5168L-RF, is included with this fireplace. Follow instructions included with this conversion kit.

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.

NOTE: This fireplace is equipped with a 3/8" x 18” long flexible gas connector and manual shut off valve. NOTE: The gas line should be run to the point of connection where the shut-off valve and flexible gas line will connect. CAUTION: The manual shut-off valve or flexible gas tubing must not extend outside of the unit cavity. See the WARNING label

affixed to the flexible tubing for additional installation instructions and warnings.

NATURAL GAS

The minimum inlet gas supply pressure: 5.0 inches W.C. ( 7.0 inches W.C. recommended) The maximum inlet gas supply pressure: 10.5 inches W.C. Manifold pressure: 3.5 inches W.C. Manifold pressure (lo setting): 1.7 inches W.C.

Orifices sizes: #55 & #34 Input: 40,000 BTU/hr. Efficiency: 69% AFUE: 68% P-4 AFE: 66%

Minimum input: 21,500 BTU/hr

LP GAS:

The minimum inlet gas supply pressure: 11.0 inches W.C. (recommended) The maximum inlet gas supply pressure: 13.0 inches W.C. Manifold Pressure: 10.0 inches W.C. Manifold Pressure (lo setting): 6.5 inches W.C.

Orifices size: #68 & #51 Input: 40,000 BTU/hr. Efficiency: 73% AFUE: 72% P-4 AFE: 63%

Minimum input: 26,500 BTU/hr

This fireplace is equipped for use at altitudes of 0-2,000 ft. in the U.S. and 0-4,500 ft.* in Canada.

*HORIZONTAL VENT RESTRICTIONS APPLY FOR CANADA - REFER TO PAGE 6 OF THIS MANUAL FOR COMPLETE INFORMATION.

IMPORTANT: The efficiency rating of this appliance is a product thermal efficiency rating determined under

continuous operating conditions and was determined independently of any installed system.

NOTE: For high altitude installations consult the local gas distributor or the authority having jurisdiction for proper rating methods.

Page 19

1. Run the gas line. Gas line holes are positioned on both sides of the fireplace for gas line connection. An accessible shut off valve (included) must be installed up stream from the regulator.

NOTE: Do not run the incoming gas line in a manner that would obstruct the operation of the optional fan.

2 . This fireplace is designed to accept either a 3/8" or 1/2" gas line approved for gas appliances. Consult local building codes

to properly size the gas supply line leading to a 3/8" reduction.

3. Connect the gas line to the manual shut-off valve.

4. Connect the flexible gas line (installed on the millivolt board valve) to the manual shut off valve.

IMPORTANT:

ALL CONNECTIONS WHETHER FIELD OR FACTORY MADE MUST BE CHECKED FOR LEAKS!

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 test pressures in excess of ½ psi.

NOTE: The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi.

Pressure check taps for both the manifold (outgoing) & inlet (incoming) pressures are located in front of the gas valve. The left pressure tap is the manifold pressure and the right pressure tap is the incoming pressure. Follow instructions on page #27 for Model #55345 and page #30 for Model #55345-RF for checking these pressures.

(H) SECURE THE MILLIVOLT BOARD:

This unit is equipped with the millivolt board , burner, log grate, pilot shield, & cover assembly already installed.

1. Referring to the ‘INSTALLING THE MILLIVOLT BOARD’ section on pages #32-#33, check to ensure that all (8) screws securing the millivolt board are in place and properly tightened.

2. Ensure that the burner tubes are properly positioned over each burner orifice.

(I) ADJUST COMBUSTION AIR INTAKE SHIELD - VERTICAL TERMINATIONS ONLY:

Flame height & appearance will vary depending upon venting configuration and type of fuel used. Use the following as a guideline when adjusting the combustion air intake shield to achieve desired flame appearance.

NOTE: Straight vertical runs typically would require the more restriction, while a venting configuration with elbows,

would require less restriction.

The intake shield is marked as shown in Figure 16. Make sure that it is positioned for the type of gas you are using. Adjust from that point according to vertical venting.

Vertical terminations 0-10 ft. should be placed at the #1 setting. Vertical terminations 11-20 ft. should be placed at the #2 setting Vertical terminations 21-30 ft. should be placed at the #3 setting.

TO ADJUST: Loosen the (2) screws securing the intake

shield, move to desired position and re-tighten the screws.

Figure 16

Page 20

LOG INSTALLATION

The MTK-500 log set includes 12 logs, 1 bag klinkers & 2 pkgs. rock wool burning embers. The logs are numbered on the bottom side - refer to the instructions below for proper placement.

1. Position base log #1 onto the burner setting the backside of

the log against the flange at the back. Pull the log forward approximately ½". DO NOT ALLOW THE LOGS TO COVER THE PORT HOLES ON THE BURNER. Figure 17A.

1. Position base logs #2 - #6 onto the burner as shown in Figure

17A. NOTE: There are (2) #6 logs and no #5 log.

Figure 17A

1 2 6 3

3. Brush rockwool burning embers onto the burner and place klinkers

onto the burner as shown in Figures 17B & 17C.

Figure 17B Rockwool burning embers

4. Position logs #7, #8, #9 onto base logs, aligning the holes in the logs to the protrusions on the base logs. Refer to Figure 17D.

5. Set logs #10 & #11 into position as shown in Figure 17D below.

7 8 9

Figure 17D

6. Align the mounting hole in top log #12 to the protrusion in log #8 and align the notched out section in log #12 to the log grate. Refer to Figure 17E.

Figure 17E

Figure 17C - Klinker Installaton

Rockwool / Klinker close-up

Page 21

MODEL #55345: THERMOSTAT - WALL SWITCH - REMOTE INSTALLATION

CAUTION: DO NOT CONNECT HIGH VOLTAGE (115V) WIRE TO THE GAS VALVE!

If desired, a thermostat (wireless style available), wall switch, or remote control assembly may be used to turn the fireplace ‘OFF’ and ‘ON’. ONLY one of these may be installed. Follow instructions included with each assembly.

OPTIONAL: Disconnect the on/off rocker switch wires from the top & bottom terminals on the gas valve. Refer to Figure 26, page #35 of this manual.

NOTE: INSTALLATION OF A THERMOSTAT OR WALL SWITCH SHOULD ONLY BE DONE BY A QUALIFIED INSTALLER.

WALL SWITCH / THERMOSTAT USERS:

Run low-voltage (thermostat) wires from the terminals on the gas valve to the desired location of the wall switch or thermostat.

Attached the appropriate connector to each wall switch / thermostat wire and connect to the top and bottom terminals on the gas valve marked ‘TH’.

Thermostat Wiring Diagram

Figure 18A

IMPORTANT: If the ON/OFF rocker switch wires are not disconnected, the ON/OFF rocker switch on the millivolt board must be in the ‘OFF’ position for proper operation of any of these components.

REMOTE CONTROL USERS:

Follow instructions included with the remote control.

IMPORTANT: The insulated cover included with the remote control must be placed over the remote receiver to protect it from overheating.

Remote Control Wiring Diagram

Figure 18B

If the rocker switch is ‘ON’, the fireplace burner will operate until it is turned ‘OFF’ by the rocker switch. A wall switch, thermostat, or remote control will not turn the fireplace ‘OFF’ when it has been turned ‘ON’ by the rocker switch.

NOTE: The fireplace must be turned ‘ON’ and ‘OFF’ by the same method. For example: If the fireplace is turned ‘ON’ by the remote control, it must be turned ‘OFF’ by the remote control.

Page 22

COMPLETE THE INSTALLATION

1. A) If not previously done, plumb & level the unit and secure the fireplace to the framing using the stud tabs located on the sides of the unit. The stud-tabs are adjustable to accommodate the thickness of finish material you are using. To adjust, loosen the screws securing it to the sides of the fireplace and slide to desired position. Re-tighten the screws to secure in place.

CAUTION: NEVER PERMANENTLY REMOVE THIS ASSEMBLY FROM THE FIREPLACE - IT MUST BE

SECURED IN PLACE REGARDLESS OF FINISH MATERIAL USED.

B) Use screws (not provided) to secure the unit to the flooring through the holes located in the bottom of the outer box.

IMPORTANT - MOBILE HOME INSTALLATIONS: THE FIREPLACE MUST BE SECURED TO THE FLOOR.

C) Complete the fireplace walls, and the fireplace facing.

IMPORTANT: This fireplace has a 10" clearance requirement from the top of the fireplace. If not previously done, position & secure the top stand-off brackets. Refer to page #12 for complete information.

If tile or marble is used around or over the face of the fireplace, we recommend using rock board as a backer at the top of the fireplace.

CAUTION: ONLY NON-COMBUSTIBLE MATERIAL MUST BE USED FOR A MINIMUM OF 10" FROM

THE TOP OF THE FACE AT THE FRONT OF THE FIREPLACE.

COLD AIR TRANSFER: The surrounding wood chase of the outside wall must be insulated to prevent cold

air from entering the room.

2. Heat Damper Control:

This fireplace has been de-signed certified to be operated with the damper fully opened or completely closed depending on the heat output desired without compromising flame appearance.

To reduce the amount of heat entering the room, pull the damper control handle (located behind the lower grill) down and slightly to the right to the fully open position. This allows more the heat generated from the fireplace to exit through the vent system rather than into the home.

If more heat is desired, slide the damper control handle to the left and release to it’s original position.

NOTE: The damper position is located in the upper portion of the firebox and may be visually checked by looking through the front viewing glass. Refer to Figure 19.

Damper

Damper Control

Figure 19

3. THIS STEP SHOULD ONLY BE DONE BY A QUALIFIED INSTALLER OR SERVICE TECHNICIAN:

A) Perform lighting and shutdown procedures as described on pages #25-#26 for Model #55345 and pages #28-#29 for Model

#55345-RF. This should be done prior to replacing the glass so that any necessary adjustments can be made and proper operation verified.

Page 23

4. Replace the glass.

A) Place the glass assembly onto the front of the fireplace an d se cure with the spring-loaded handles FIRST AT THE TOP,

THEN AT THE BOTTOM of the firebox. CAUTION: TO PREVENT THE GLASS ASSEMBLY FROM FALLING OFF WHEN INSTALLING ON THE FIREPLACE, SECURE THE TOP GLASS LATCH BRACKETS FIRST

, THEN THE BOTTOM.

WARNING: DO NOT OPERATE THIS FIREPLACE WITH THE GLASS ASSEMBLY REMOVED,

CRACKED OR BROKEN. Replacement of the glass assembly, part #TRF-007T should be done by a licensed or qualified service person.

5. Upper louver, Hood & Lower Grill Installation - Refer to Figures 20A - 20C.

A) Align the hooks (A) in the upper louver to the slots

located in the face of the fireplace and set down into position. Figure 20A.

B) Insert the flange at the top of the upper hood into the

clips located in the top of the upper air passage. NOTE: This is a fairly tight fit. Figure 20B

C) Partially thread the (2) screws included in the

components packet into the nuts (B) at each end of the lower grill as shown in Figure 20C.

D) Place the lower grill into the lower grill opening and

secure to the fireplace by threading the screws into the corresponding holes in the inside flange of the lower grill opening. The lower grill can now be opened and closed to access the gas valve and controls.

Remove:

A) Grasp the bottom of the upper hood at each end and

pull the hood out of the clips at the top of the air passage.

B) Lift the upper louver up out of the slots and remove

from the fireplace.

C) Remove the screws securing the lower grill at each

side and remove from the fireplace.

Figure 20A

Figure 20B

Figure 20C

Thread screws into nuts on

each end of grill and secure to lower grill opening

Page 24

Upper Hood & Lower Grill Installed

MODEL #55345: LIGHTING AND SHUTDOWN PROCEDURES

NOTE: Prior to lighting, check all fittings for leakage. This is accomplished by applying soapy water on all connections made. If there is any leakage, bubbles will appear at the point of connection. If bubbles occur, tighten the fittings until the bubbles no longer appear.

IMPORTANT: TEST ALL CONNECTIONS WHETHER FIELD OR FACTORY MADE.

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 test 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 pressure testing of the gas line at test pressures equal to or less than 1/2 psig (3.5 kPa).

Pressure check taps for the manifold (outgoing) and inlet (incoming) pressures are located in front of the gas valve. The left pressure tap is the manifold pressure and the right pressure tap is the incoming pressure. Follow instructions on page #27 for checking these pressures.

FOR YOUR SAFETY - READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

1. This appliance has a pilot which must be lighted by hand. When

lighting the pilot, follow these instructions exactly.

2. BEFORE LIGHTING, smell all around the appliance for gas. Be

sure to smell next to the floor because some gas is heavier that air and will settle on the floor.

3. Use only your hand to push in or turn the gas control knob. Never

use tools. If the knob will not push in, or turn by hand, don’t try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion, and loss of warranty.

4. 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 which has been under water.

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

DUE TO HIGH SURFACE TEMPERATURES, KEEP CHILDREN, CLOTHING AND FURNITURE AWAY.

This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

WHAT TO DO IF YOU SMELL GAS: *Do not touch electrical switches. *Do not try to light any appliance. *Do not use any phone in your building. *Follow the gas supplier’s instructions. *Immediately call your gas supplier from a neighbor’s phone. *If you cannot reach your gas supplier, call the fire department.

LIGHTING INSTRUCTIONS

NOTE: Read 1-8 before lighting the unit for the first time. Refer to Figure 21, page #26.

1. Set the thermostat to the lowest setting, if installed.

2. Turn off all electric power to the appliance. (Fan)

3. To access the gas valve & controls, open the lower grill.

4. Push in control knob (A) slightly and turn clockwise to "OFF”. Honeywell Gas Valve

NOTE: Knob cannot be turned from "PILOT" to "OFF" unless knob is pushed in slightly. Do not force.

5. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow the safety information on the front cover of this installation manual. If you don't smell gas, go to the next step.

6. Find the pilot - follow metal tube from gas control. The pilot is located inside the combustion chamber.

7. Push the control knob (A) on the gas valve in slightly and turn counterclockwise to "PILOT".

Page 25

Pilot

8. Push in the control knob all the way and hold in. Press the BLACK piezo igniter button (B). The pilot will generally light with two or three pushes on the igniter. Hold the knob in for about one (1) minute after the pilot is lit.

Release knob and it will pop back out. Pilot should remain lit. If it goes out, repeat steps 4 through 8.

*If knob does not pop out when released, stop and immediately call your service technician or gas supplier. *If the pilot will not stay lit after several tries, turn the gas control knob to "OFF" and call your service technician or gas supplier.

9. Push the control knob on the gas valve in slightly and turn

Figure 21

counterclockwise to the "ON" position.

10. The burner can now be turned ‘ON’ or lit by depressing the ON/OFF rocker switch (C) located beside the valve OR by setting the thermostat or remote control to the desired setting.

11. NOTE: When the unit is initially lit, condensation will appear on the glass, this is normal in all gas fireplaces, and will disappear in one to three minutes.

TO TURN THE BURNER OFF: To turn the burner ‘OFF’, depress the ON/OFF rocker switch to ‘OFF’, flip ‘off’ the wall switch or adjust the setting on the thermostat or

remote control. NOTE: The pilot will stay lit. TO TURN THE PILOT OFF: To turn off the pilot, push in and turn the control knob to the "OFF" position. DO NOT FORCE. WARNING: This control valve has an interlock device. After turning off the pilot, it cannot be relit until the thermocouple has cooled,

(approximately 60 seconds).

NOTE: A PAINT SMELL WILL OCCUR DURING THE FIRST FEW HOURS OF BURNING. IT IS RECOMMENDED TO LEAVE THE FAN OFF DURING THIS PERIOD AS THIS WILL SPEED UP THE PAINT CURING PROCESS.

INITIAL BURN PERIOD

DUE TO THE MAKEUP OF THE FIBER LOGS & REFRACTORY, THE CURING PROCESS MAY TAKE UP TO 4 HOURS OF BURN TIME. DURING THIS PERIOD, THE LOGS & REFRACTORY WILL DISCOLOR, BUT WILL RETURN TO THEIR TRUE COLOR ONCE THE CURING PROCESS IS COMPLETE. DO NOT BURN THIS FIREPLACE WITHOUT THE GLASS PROPERLY IN PLACE.

**MAKE SURE THE HOMEOWNER IS AWARE OF THIS**

NOTE: 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.

Clothing or other flammable material should not be placed on or near the appliance.

NOTE: THIS FIREPLACE MAY PRODUCE NOISES OF VARYING DEGREE AS IT HEATS AND COOLS TO DUE METAL

EXPANSION AND CONTRACTION. THIS IS NORMAL AND DOES NOT AFFECT THE PERFORMANCE OR LONGEVITY OF THE FIREPLACE.

Page 26

MODEL #55345: PRESSURE TEST - MANIFOLD & INLET PRESSURE

IMPORTANT NOTICE: A pressure check tap for both the manifold (outgoing) and inlet (incoming) pressure has been incorporated into the valve by HONEYWELL. The left pressure tap is t he manifold pressure and the right pressure tap measures the incoming pressure. Follow the in structions below for proper pressure testing procedures.

TO CHECK THE MANIFOLD PRESSURE:

1. Light pilot .

2. Loosen the manifold pressure tap [D] by turning the screw counter-clockwise.

3. Attach manometer to pressure tap using a 5/16" I.D. hose [F].

4. Push the control knob [A] on the gas valve in slightly and turn to the ‘ON’ position.

5. Turn the burner ‘ON’ by depressing the rocker switch [C] and note manometer reading.

6. Depress the rocker switch [C] to the ‘OFF’ position.

7. Disconnect manometer hose and tighten screw (clockwise). Screw should be snug, do not over tighten.

8. Attach manometer to manifold pressure tap to verify that it is completely sealed.

Manometer should read no pressure when the rocker switch is depressed to the ‘ON’ position.

NOTE: If manifold pressure reading is within the normal range, an incoming pressure check is not necessary. A too high or too

low pressure reading warrants an inlet (incoming) gas pressure check.

TO CHECK THE INLET PRESSURE:

1. Loosen Inlet pressure tap screw [E] by turning screw counter-clockwise.

2. Attach manometer using a 5/16" I.D. hose [F].

3. Light the pilot.

4. Push t h e control knob on the gas valve (A) in slightly and turn to the ‘ON’ position. (Burner should not come ‘ON’ ) an d n o te manometer reading.

5. Turn the rocker switch [C] to the ‘ON’ position by depressing the switch and check the pressure to ensure that it stays near the maximum inlet pressure.

6. Depress the rocker switch [C] to the ‘OFF’ position.

7. Turn the pilot to the ‘OFF’ position.

8. Disconnect hose and tighten screw (clockwise). Screw should be snug, do not over tighten.

9. Relight pilot. Push the control knob [A] in slightly and turn to the ‘ON’ position. Attach manometer to the inlet pressure tap to verify that it is completely sealed. Manometer should read no pressure.

NOTE: If Inlet pressure reading is too high or too low, contact the gas company. Only a qualified gas service technician should adjust the incoming gas pressure.

CAUTION: A LOW PRESSURE READING

CAN CAUSE DELAYED IGNITION.

Figure 22

Page 27

MODEL #55345-RF: LIGHTING AND SHUTDOWN PROCEDURES

NOTE: Prior to lighting, check all fittings for leakage using a gas leak detector.

IMPORTANT: TEST ALL CONNECTIONS WHETHER FIELD OR FACTORY MADE.

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 test pressures in excess of ½ psi.

FOR YOUR SAFETY - READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

1. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.

2. BEFORE LIGHTING, smell all around the appliance for gas. Be sure to smell next to the floor because some gas is heavier that air and will settle on the floor.

3. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in, or turn by hand, don’t try to repair it, call a qualified service technician. Forced or attempted repair may result in a fire or explosion, and loss of warranty.

4. 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 which has been under water.

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

DUE TO HIGH SURFACE TEMPERATURES, KEEP CHILDREN, CLOTHING AND FURNITURE AWAY.

This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

NOTE: Read 1-8 before lighting the unit for the first time. Refer to Figure 23, page #29.

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance.

3. Open the lower air passage panel to access the gas valve & controls.

4. Push in control knob slightly and turn clockwise to the "OFF” position. NOTE: Knob cannot be turned from "PILOT" to "OFF" unless knob is pushed in slightly. Do not force.

5. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow the safety information on the above. If you don't smell gas, go to the next step.

6. Find the pilot - follow metal tube from gas control. The pilot is located inside the combustion chamber.

7. Push the control knob on the gas valve in slightly and turn counterclockwise to "PILOT".

8. Push in the control knob all the way and hold in. Push the plunger on the piezo until the pilot is lit. RF Pilot The pilot w ill generally light with two or three pushes on the igniter. When the pilot is lit, the LED on the control will come on after

approximately 60 seconds and will blink continuously. Release knob and it will pop back out. Pilot should remain lit. If it goes out, repeat steps 4 through 8.

Page 28

9. Push the control knob on the gas valve in slightly and turn counterclockwise to the "ON" position. If the manual switch is in the LOCAL position, the main burner will turn on immediately.

IMPORTANT: On the initial use of a transmitter, a recognition operation is required between the receiver / valve and the transmitter.

1. Turn the gas control to the PILOT position.

2. Move the LOCAL / REMOTE switch to the LOCAL position for at least two

seconds, then move the switch to the REMOTE position.

3. Press the FAN or FLAME button on the transmitter within 30 seconds

of the switch change.

4. Turn the gas control knob to the ON position. Figure 23 The LED will blink indicating that the transmitter will now work with the receiver / valve. If the switch stays in the REMOTE position,

the RT8220A Transmitter will control the main valve, flame modulation level and fan control. If the LOCAL / REMOTE switch is in the LOCAL position, the receiver / valve will be at the highest fixed pressure setting.

NOTE: When the unit is initially lit, condensation will appear on the glass, this is normal in all gas fireplaces, and will disappear as the fireplace

heats. TO TURN THE BURNER OFF: LOCAL SETTING: Turn the control knob clockwise to the pilot position. REMOTE SETTING: The RT8220A transmitter can shut off the main burn er an d fan. However, the control is still ‘ON’ and a command from the

transmitter can turn on the main burner and fan. TO TURN OFF THE SYSTEM:

1. Open the lower air passage panel to access the gas valve & controls.

2. Turn the gas control knob clockwise to the ‘OFF’ position. This closes the main gas and safety valves. The transmitter cannot turn on the

main burner or the fan.

NOTE: A PAINT SMELL WILL OCCUR DURING THE FIRST FEW HOURS OF BURNING. IT IS RECOMMENDED TO LEAVE THE FAN OFF DURING THIS PERIOD AS THIS WILL SPEED UP THE PAINT CURING PROCESS.

INITIAL BURN PERIOD

**MAKE SURE THE HOMEOWNER IS AWARE OF THIS**

Clothing or other flammable material should not be placed on or near the appliance.

NOTE: THIS FIREPLACE MAY PRODUCE NOISES OF VARYING DEGREE AS IT HEATS AND COOLS TO DUE METAL

EXPANSION AND CONTRACTION. THIS IS NORMAL AND DOES NOT AFFECT THE PERFORMANCE OR LONGEVITY OF THE FIREPLACE.

Page 29

MODEL #55345-RF: PRESSURE TEST - MANIFOLD & INLET PRESSURE

IMPORTANT NOTICE: A pressure check tap for both the manifold (outgoing) and inlet (incoming) pressure has been incorporated into the valve by HONEYWELL Controls. The left pressure tap is the manifold pressure and the right pressure tap measures the incoming pressure. Follow th e instructions below for proper pressure testing procedures.

NOTE: Both the inlet and outlet pressure taps have a captive screw.

1. Be sure the gas control knob is in the PILOT position.

2. Light the pilot.

3. Loosen, but do not remove the outlet tap captive screw.

4. Attach a plastic tube with a 1/4" shell ID and connect the manometer.

5. Turn the gas control knob to the ON position.

6. Check the outlet tap pressure.

7. Turn the gas control knob to the OFF position.

8. Shut off the gas supply at the manual valve in the gas piping to the appliance or, for LP, at the tank.

9. Loosen, but do not remove the inlet tap captive screw.

10. Attach a plastic tube with a 1/4" shell ID and connect the manometer.

11. Turn on the gas supply at the manual valve.

12. Check the inlet tap pressure.

13. Turn the gas control knob to the OFF position.

14. Repeat the Gas Leak Test at the pressure tap with the main burner operating.

15. Always tighten the screws in the pressure taps after disconnecting the plastic tubes.

Figure 24

GAS LEAK TEST:

1. Paint the pipe connection upstream of the gas valve with a rich soap and water solution. Bubbles indicate a

gas leak.

2. If a leak is detected, tighten the pipe connections.

3. Light the main burner.

4. With the main burner in operation, paint the pipe joints (including adaptors) and valve inlet and outlet with a

rich soap and water solution.

5. If another leak is detected, tighten the adapter screws, joint, and pipe connections.

6. Replace the part if the leak cannot be stopped.

Page 30

MAINTENANCE REQUIREMENTS

1. The appliance should be inspected at least once a year by a professional service person.

NOTE: INSTALLATION AND REPAIR SHOULD BE DONE ONLY BY A QUALIFIED SERVICE PERSON. THE APPLIANCE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY BY A QUALIFIED SERVICE PERSON. 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.

2. The compartment below the firebox (behind the lower grill) must be cleaned at least once a year, more frequent cleaning may be required due to excessive lint from carpeting, bedding materials, or other fibrous materials. It is imperative that the burner be cleaned once a year.

FAN The fan should be disconnected from electrical current, and cleaned (vacuumed) every six months. The bearings are sealed and require no oiling.

MILLIVOLT BOARD SYSTEM

1. Annual cleaning of the burner is required. The burner & cover assembly may be removed for easier access.

2. Refer to pages #32-#33 for complete instruction on removing & reinstalling the burner & cover assembly.

3. Visually check for blocked port holes, especially near the pilot. Blocked port holes may cause delayed ignition.

4. Replace the burner & cover following instructions on pages #32-#33.

5. Visually check the pilot light and burner when they are burning. The flames should be steady, not

lifting or floating.

#55345 #55345-RF Pilot Pilot

VENT SYSTEM Annual examination of the venting system by a qualified agency is required.

IF THE VENT-AIR INTAK E SYSTEM IS DISASSEMBLED FOR ANY REASON, REINSTALL PER THE INSTRUCTIONS PROVIDED WITH THE INITIAL INSTALLATION.

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

IMPORTANT: ANY SAFETY SCREEN OR GUARD REMOVED FOR SERVICING MUST BE REPLACED PRIOR TO OPERATING THE APPLIANCE.

CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

Burner Orifice

GLASS CLEANING & REPLACEMENT C Clean glass only when cool and only with non-

abrasive cleansers.

C Do not operate this fireplace with the glass/frame

assembly remove, cracked or broken.

C The glass assembly, Part #TRF-07T, shall only be

replaced as a complete unit, as supplied by Hussong Mfg. Co., Inc.

C Replacement of the glass & gasket assembly, Part

#TRF-07T, must only be performed by a licensed or qualified service person. DO NOT SUBSTITUTE MATERIALS.

C Do not strike or slam glass door assembly.

CAUTION: KEEP THE APPLIANCE AREA CLEAR OF COMBUSTIBLE MATERIALS, SUCH AS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.

Page 31

MILLIVOLT BOARD REMOVAL / INSTALLATION

NOTE: This fireplace is equipped with the millivolt board, burner & burner cover already installed. Follow instructions ‘INSTALLING THE BOARD’ on page #33 to properly secure the millivolt board in place. Follow these procedures should the millivolt board need replacing or is removed for servicing.

MILLIVOLT BOARD REMOVAL:

CAUTION: If the burner and/or pilot has been burning, the logs and refractory will be hot and continue to hold heat. Use the appropriate protection to avoid burns and place them on a properly protected surface upon removal to avoid damage to flooring or personal property.

1. Turn the black control knob to the ‘OFF’ position.

2. Shut off the gas supply at the manual shut-off valve.

3. Disconnect the gas line flex tube from the manual shut-off valve.

4. Model: #55345: Disconnect any wall switch, remote control or thermostat wires from the top & bottom terminals on the gas valve.

5. Model: #55345-RF: Unplug the fan cord from the duplex receptacle, then disconnect the (2) wires from the fan cord. Note the wires will remain connected to the back of the gas valve. Refer to wiring diagram, Figure 15 on page #18 of this installation manual.

6. Remove the upper hood, upper louver & glass assembly. Refer to the instructions in this manual if necessary.

7. Remove the logs from the burner assembly and set aside on the properly protected surface.

8. Remove the ember/log refractory and set aside.

9. Remove the pilot shield.

10. Remove the screws securing the front left and back right log grate legs.

11. Remove the burner / log grate assembly from the firebox by lifting the front of the burner assembly up out of the flange. Push the pilot assembly back slightly to allow the burner assembly to be removed from the firebox.

Figure 23A Pilot Shield

Remove screws securing the front left and back right legs.

Remove the burner / log grate

assembly.

Burner / Log Grate Assembly

Ember / Log Refractory

12. Loosen and remove the (8) screws securing the board. Figure 23B.

13. Carefully lift the board up & remove from the firebox.

Remove (8) screws securing

Figure 23B millivolt board

Page 32

MILLIVOLT BOARD INSTALLATION: NOTE: The millivolt board is fitted with a gasket to seal the millivolt board. Make certain this gasket is properly placed around the opening

before installing the millivolt board. If the gasket is damaged, a replacement one must be used.

1. Grasp the board with both hands and place inside the firebox, aligning the (8) mounting holes in the board to the corresponding holes in the bottom of the firebox. Secure with the (8) screws previously removed. Refer to Figure 23B.

2. Position the burner / log grate assembly into the firebox aligning the (2) burner venturies onto the burner orifices on the millivolt board and the pilot assembly through the rectangular opening. Set the legs of the log grate assembly into the square cut-outs on the bottom refractory and the front flange of the burner / log grate assembly behind the flange on the burner cover.

NOTE: The pilot assembly may need to be pushed slightly back to allow the burner / log grate assembly to set properly in place.

3. Secure the front left and back right legs of the burner / log grate assembly with screws previously removed. CAUTION: Ensure that the pilot assembly is above the burner / log grate assembly and the burner venturies are properly positioned

over the burner orifices.

4. Replace pilot shield.

5. Replace ember refractory.

6. Replace the logs. Refer to the instructions on page #21 for proper placement if necessary.

7. Connect the flexible gas line to the manual shut-off valve.

8. Model #55345: Re-connect any wall switch, remote control or thermostat wires onto the top & bottom terminals on the gas valve marked ‘TH’.

9. Model #55345-RF: Re-connect the wires from the valve to the fan cord. Refer to wiring diagram, Figure 15, page #18. Plug the 3-prong plug on the fan cord into the duplex receptacle.

10. Replace the glass assembly, upper single louver & upper hood.

11. Check all connections for gas leaks, whether field or factory made.

12. Verify proper operation of the fireplace & log position. Refer to the lighting instructions in this manual.

IMPORTANT: CHECK ALL CONNECTIONS, WHETHER FIELD OR FACTORY MADE, FOR LEAKS!

Burner / Log Grate Assembly

Place log grate legs into cut-outs in bottom refractory

Secure the front left and back right leg with screws

Ember / Log Refractory

Figure 23C

Page 33

TROUBLE SHOOTING GUIDE

NOTE: The millivolt board includes the following items: Valve, pilot assembly, piezo, electrode, on/off rocker switch, burner, burner venturi tubes, & burner orifices. If any of these items are defective, contact your dealer for the appropriate repair / replacement procedures to follow.

WARNING: DO NOT ATTEMPT TO SERVICE THIS UNIT IF YOU ARE NOT A QUALIFIED INSTALLER OR REPAIRMAN.

1. If the unit fails to ignite a qualified service person should check the unit installation.

2. It is imperative that the control compartment, burner and circulation air passageways of the unit be kept clean. This is necessary to provide adequate combustion and ventilation air.

3. All of the working parts of this unit can be removed at one time. Before removing millivolt board, check for loose wires.

PROBLEM CAUSE SOLUTION A) No spark when piezo Wire on back of piezo button is loose or off. Put wire back into place.

button is depressed

Wire from piezo to electrode is loose at electrode. Reconnect wire. Electrode moved out of position. Realign electrode with 1/8" space between it & the

pilot.

B) Pilot won't light Gas shut off. Turn Gas ON.

Gas line not purged. Hold black control knob in long enough to purge line. Not holding black control knob in long enough. Hold in longer. No spark at piezo. See problem A.

C) Pilot won't stay lit Not holding black control knob in long enough. Hold knob in longer to heat thermocouple.

Thermocouple (or Generator RF valve) connection Check connection on valve and tighten if necessary. loose at valve connection.

Pilot hood misdirecting pilot flame Check pilot flame location. Flame must be from thermocouple (or Generator - RF valve) burning on generator(s) and thermocouple (Model

#55345).

Refractory panels not positioned against Secure refractory panels with high-temp firebox back & sides. sealant, especially around the intake duct.

WIRING DIAGRAM MODEL #55345

Figure 26

Page 34

PROBLEM CAUSE SOLUTION D) Burner won't light Pilot not lit. Relight pilot.

Regulator valve not turned “ON”. Turn valve to "ON". Model #55345: Rocker switch

not turned “ON”. Depress switch. Model #55345: Rocker switch Check wiring diagram Figure 26

wires not connected. to ensure that all wires are secure. Generator wires loose at regulator terminals. Reposition wire and tighten screws. See Figures 26

& 27 for wiring instructions.

Generator wire grounded out Screws securing millivolt board may need due to pinching of wires. loosening to remove pinched wire.

Generator is not producing enough Replace generator. millivolts to operate burner.

Model #55345: Wall switch, remote control Connect properly or disconnect or thermostat not connected properly and use on/off switch only. or turned to wrong setting. See Figures 18A & 18B, page #22.

E) Burner won't stay lit Generator wires loose on Reposition wires and tighten screws

valve terminals. See Figures 26 & 27 for wiring instructions.

WIRING DIAGRAM

MODEL #55345-RF

Figure 27

Generator wire grounded out Screws securing millivolt board may need due to pinched wires. loosening to remove pinched wire.

Generator is not producing enough Check millivolt reading, replace millivolts to sustain burner operation. generator if necessary.

Refractory panels not positioned Secure refractory panels with against firebox. high-temp sealant, especially

around the intake duct.

Page 35

REPLACEMENT PARTS

Replacement parts are available through your local dealer. Contact them for availability and pricing.

MILLIVOLT BOARD AND PARTS - Model #55345

MTK-800 Minnetonka Millivolt Board - Natural Gas 700-223 6" Flexible Gas Line - Valve to Burner connection 700-023 On/Off Rocker Switch 700-228 3/4" Male ‘T’ 700-057 Honeywell Valve - Natural Gas 700-255 Natural Gas orifice #55- front burner 700-059 Thermocouple 700-234 Natural Gas orifice #34 - back burner 700-060 Flexible Pilot Tubing (Valve to Pilot) 700-268 LP Gas orifice #68 - front burner 700-063 Pilot/Generator/Thermocouple 700-251 LP Gas orifice #51 - back burner 700-092 Millivolt Generator 700-075 Natural Gas Conversion Cap 700-083 Piezo Ignitor w/ wire 700-076 LP Gas Conversion Cap 700-203 Manual Shut off Valve OCK-H5168L LP Gas Conversion Kit 700-213 18" Flexible Gas Line - Black MTK-135 Burner / Log grate Assembly

MILLIVOLT BOARD AND PARTS - Model #55345-RF

MTK-800RF Minnetonka Millivolt Board - Natural Gas 700-223 6" Flexible Gas Line - Valve to Burner connection 700-107 Honeywell RF Valve - Natural Gas 700-228 3/4" Male ‘T’ 700-108 Remote Control - RF Valve 700-255 Natural Gas orifice #55- front burner 700-109 Honeywell RF Pilot Assembly 700-234 Natural Gas orifice #34 - back burner 700-060 Flexible Pilot Tubing (Valve to Pilot) 700-268 LP Gas orifice #68 - front burner 700-083 Piezo Ignitor w/ wire 700-251 LP Gas orifice #51 - back burner 700-092 Millivolt Generator OCK-H5168L-RF LP Gas Conversion Kit 700-203 Manual Shut off Valve MTK-135 Burner / Log grate Assembly 700-213 18" Flexible Gas Line - Black MTK-043 Pilot Shield

MTK-043 Pilot Shield

GLASS & GLASS GASKET GRILL REPLACEMENT

TRF-07T 26" x 35" Glass with gasket TRF-200 Upper Hood 900-006 1 1/8” Glass gasket w/ adhesive TRF-201 Lower Grill MTK-005 Replacement Valance TRF-200L Upper Hood Louver

LOG SET

MTK-500 Log Set TRF-028 Fan assembly - Models #55345 & #55345-1 MTK-1 #1 Log PRC-028 Fan assembly - Model #55345-RF MTK-2 #2 Log MTK-3 #3 Log MTK-4 #4 Log REFRACTORY PANELS MTK-5 #5 Log MTK-G900 Refractory Panel Set - 3 pc. back & sides MTK-6 #6 Log MTK-G900B Back Refractory panel MTK-7 #7 Log MTK-G900S Side Refractory panel - 1 pc. MTK-8 #8 Log MTK-G902 Top Refractory panel MTK-9 #9 Log MTK-901 Bottom Refractory panel MTK-10 #10 Log MTK-900E Ember / Log Refractory MTK-11 #11 Log MTK-12 #12 Log 900-KLK Klinkers 900-REMB Rock wool Embers

*Consult your dealer for information on optional accessories available for this fireplace. This appliance tested & certified by: Manufactured by: OMNI-Test Laboratories, Inc. Hussong Mfg. Co., Inc

5465 SW Western Avenue 204 Industrial Park Drive Beaverton, Oregon 97075 Lakefield, MN 56150

FAN ASSEMBLIES - REPLACEMENT ONLY

507-662-6641

Models #55345 / #55345-RF Minnetonka

July 2006 www.kozyheat.com

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kozy heat MINNETONKA 55345, MINNETONKA 55345-RF Installation And Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual