kozy heat MPS-30 Minneapolis, RFD-30 Rockford, JOR-30, RFD-34 Rockford XL, MPS-34 Minneapolis XL Installation And Operation Manual
Quality Fireplaces for Life
INSTALLATION AND OPERATION MANUAL
DO NOT
DISCARD
INSTALLER: LEAVE THIS MANUAL WITH THE APPLIANCE.
CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.
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.
Shown with optional Frosted White Glass Media Kit
◙ 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.
www.kozyheat.com
July 2010
MPS-30-REV-02
INTRODUCTION
Read this manual before installing or operating this appliance.
Please retain this owner‟s manual for future reference.
CONGRATULATIONS!
We welcome you as a new owner of a Kozy Heat gas fireplace. Kozy Heat products are
designed with superior components and materials and assembled by trained craftsmen who
take pride in their work. The burner and valve assembly are 100% test-fired and the complete
fireplace is thoroughly inspected before packaging to ensure that you receive a quality product.
Our commitment to quality and customer satisfaction have remained the same for over 30
years. We offer a complete line of gas and wood fireplaces, unique cabinets and stylish
accessories to compliment any décor. Adding a fireplace is one of the best ways to increase the
value of your home and we are proud to offer a network of dealers throughout the country to
help make your experience everything you imagine. We pride ourselves in being dedicated to
not only function and reliability, but customer safety as well. We offer our continual support
and guidance to help you achieve the maximum benefit and enjoyment from your Kozy Heat
gas fireplace.
Jim Hussong Dudley Hussong
President Board Chairman
Homeowner Reference Information
We recommend that you record the following information about your fireplace.
Model Name:______________________________ Date purchased/installed:___________________________
Serial Number:____________________________ Location on fireplace:_______________________________
Dealership purchased from:__________________ Dealer Phone:____________________________________
Notes:_____________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
PAGE 1
TABLE OF CONTENTS
INTRODUCTION
Introduction and Homeowner Reference Information 1
CONTENTS
Table of Contents 2
SAFETY INFORMATION
Safety Information 3
FEATURES
Features 4
COMMONWEALTH OF MASSACHUSETTS INFORMATION
Commonwealth of Massachusetts Information 5
SPECIFICATIONS
Fireplace Dimensions 6
Parts Diagram 6
Minimum Clearances to Combustibles 7
Components List 8
Additional Components Required 8
Placement Clearance Requirements 8
EXISTING FIREPLACE SPECIFICATIONS
Existing Fireplace Requirements 9
PREPARE EXISTING FIREPLACE
Existing Fireplace Minimum Opening Requirements 10
Prepare Existing Fireplace 10
ELECTRICAL WIRING
Electrical Wiring 10
GAS LINE CONNECTION
Gas Line Connection 11
CONVERSION KIT INSTRUCTIONS
Conversion Kit Instructions 12-13
GLASS FRAME ASSEMBLY / CLEAN FACE FRAME
Glass Frame Assembly / Clean Face Frame Re moval & Installation 14
INSTALLATION
Approved Venting 14
Combustion Air Venting Options 14
Air Duct Removal 15
Kozy Heat #816-CL Co-Linear Vent System 15
Run Vent System Through Existing Chimney 16
Connect Vent System to Air Duct 17
SHROUD INSTALLATION
Shroud Installation 17
GLASS MEDIA KIT INSTALLATION
Glass Media Kit Installation 18
OPERATING INSTRUCTIONS
Wiring Schematics 19
Valve and Pilot Assembly Components 20
Control Module Components 21
Remote Control Components 22
Information and Remote Control Operation 23-26
Lighting and Shutdown 27-28
Pressure Testing 29
Error Codes 30
FINALIZING THE INSTALLATION
Flame Appearance 31
To Adjust Venturi 31
MAINTENANCE
Maintenance 32
TROUBLESHOOTING
Remote Troubleshooting 33-34
REPLACEMENT PARTS LIST
Replacement Parts List 35
WARRANTY
Warranty 36-37
PAGE 2
SAFETY INFORMATION
This fireplace has been tested to and complies with ANSI Z21.88-2009·CSA 2.33-2009·CSA P.4.1-09 “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
#JOR-057T, 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.
PAGE 3
FEATURES
Please consult with your dealer for a detailed list of optional accessories available for this fireplace insert.
STANDARD FEATURES
High efficiency
High quality lifetime glass
17-1/2” x 25-5/8” (445 mm x 651 mm)
Quick latch glass frame assembly
Black firebox liner
Black Glass Media Kit
IPI control system with remote control
Engineer-designed burner system
Automatic fan kit (2) - 75 CFM
Co-linear vent system - 3” combustion air / 3” exhaust
Innovative vent connection system
Minnesota Energy Code compliant to 50 pascals
OPTIONAL FEATURES
Glass media kits in various colors
Standard size or custom sized shrouds
Decorative doors in various colors
Screen Fronts in various finishes
Flex vent adaptor kit
SAFETY FEATURES
Each unit factory tested!
Tested by OMNI - Test Laboratories
Sealed combustion chamber
Intermittent or Standing pilot ignition
Flame sensing system (safety shutoff)
Automatic pressure relief glass system
Battery back-up in the event of power failure
(excluding fan)
Bedroom and mobile home approved
Canadian approved
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 wir ed 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 2 034 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
FIREPLACE
DIMENSIONS
SPECIFICATIONS
FIREPLACE DIMENSIONS
DESCRIPTION Height Width Back Width Depth Height to Air
INCHES 19-3/4 30 24-5/16 15-1/2 20-5/8 6-9/16 1-1/2 9-7/16 5-7/8
MILLIMETERS 501 762 618 394 524 167 38 240 149
Chute Top
Back to Elec.
Access
Back to Gas
Line Access
Front to Vent
Center
Back to Vent
Center
Figure 6a
PARTS DIAGRAM
WARNING: Failure to position components in accordance with these diagrams or failure to use only parts specifically approved for use with
MPS-30 may result in property damage or personal injury.
1. Fireplace insert
2. Air chute
3. Module panel assembly
4. Valve access panel
5. Control board assembly
6. Burner
7. Glass frame assembly
8. Firebox liner
9. Black glass media kit (not shown)
10. Fan kit (not shown)
8
4
5
7
6
1
2
3
Figure 6b
PAGE 6
SPECIFICATIONS
Y
X
Combustible Floor
Hearth Protection
9"
229mm
12"
305mm
19"
22"
483mm
559mm
14"
356mm
17"
432mm
0mm
0"
102mm
4"
203mm
8" 0"
13mm
2
1
2
"
64mm
5"
127mm
X Y
Floor Protector
3"
76mm
Combustible Material
MINIMUM CLEARANCES TO COMBUSTIBLES
Figure 7a
PAGE 7
SPECIFICATIONS
#MPS-30 COMPONENTS
PART NUMBER DESCRIPTION
MPS-600-IPI Control Board Assembly
700-203 Manual Gas Shut-off Valve
MPS-135 Burner Assembly
RFD-B-900 Firebox Liner Set
101-BLK Black Glass Media Kit
JOR-057T Glass Frame Assembly
OCK-A53L-IPI LP Conversion Kit
816-CL1 Co-Linear Air Duct
700-208 Remote Control
700-GLT Glass Latch Tool
ADDITIONAL COMPONENTS REQUIRED
Vent System; Part #816-CL: For use with minimum 6” x 8” I.D. masonry or 7” I.D. Class A metal chimneys - Includes 12 ft. (3.66 m)
compressed, expandable to 35 ft (10.67 m) co-linear 3” x 3” flexible chimney, and termination cap.
Other approved venting: ICC, Selkirk, American Metals, Simpson Dura-Vent, RLH, Security, Metal Fab
Approved caps listed on page 14.
Shrouds: 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 the existing fireplace front opening height and width.
or
Blank Shrouds: 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).
To be used with;
Screen Fronts: Screen fronts in various finishes.
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 8
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 the insert.
Provisions made to provide electrical power for operation.
Any chimney clean-outs must fit properly.
Existing Chimney must be comprised of one of the following: Factory built solid fuel chimney: 7” minimum inside diameter.
Masonry chimney: 6" x 8" minimum inside diameter.
Existing Chimney Height: Minimum: 10 ft. (3.05m)
Maximum: 35 ft. (10.67m)
DETERMINE LENGTH OF EXISTING CHIMNEY
1. Remove and discard existing chimney cap.
NOTE: It is helpful to have two people complete next step to determine chimney
height.
2. Position one person at fireplace and another person at top of chimney.
Measure from fireplace base to top of chimney.
Subtract 19-3/4” (501 mm) (height of insert).
This is the total length of co-linear flexible aluminum you will require.
MEASUREMENT FROM FIREPLACE BASE TO TOP OF CHIMNEY:_________________
LESS 19-3/4" (501 mm) (HEIGHT OF INSERT): -19-3/4" (501 mm)
TOTAL CHIMNEY LENGTH REQUIRED: _________________
MIN. 10 ft. (3.05 m)
MAX. 35 ft. (10.67m)
CAUTION: This appliance must not be connected to or joined with any other
chimney flue serving another appliance.
PAGE 9
Figure 9a
PREPARE EXISTING FIREPLACE
EXISTING FIREPLACE MINIMUM OPENING REQUIREMENTS
Minimum Requirements
(A) Height: ……….19-3/4" (501 mm)
(B) Front Width:…30" (762 mm)
(C) Depth:………...15-5/16" (389 mm)
(D) Back Width:….24-5/16" ( 618mm)
Figure 10a
PREPARE EXISTING FIREPLACE
ATTENTION: Any removed parts must be capable of reinstallation if this insert is ever removed (removal of rivets or screws is acceptable).
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.
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. If using this method, Kozy Heat Floor Protector Kit (#JOR-FLP), must be used.
Place „THIS UNIT HAS BEEN MODIFIED‟ label at bottom of existing firebox so it will be visible if this gas fireplace insert is removed.
Run any necessary electrical wiring to insert.
ELECTRICAL WIRING
ATTENTION: Electrical wiring must be installed by a licensed electrician.
ATTENTION: This appliance must be electrically wired and grounded in accordance with local codes or, in the absence of local codes, with
Nation Electric Code, ANSI/NFPA 70-latest edition, or the Canadian Electric Code, CSA C221.1
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 excess cord to touch fireplace.
WIRING SCHEMATIC
Figure 10b
PAGE 10
GAS LINE CONNECTION
GAS CONVERSION
This fireplace is manufactured for use with Natural Gas. An LP conversion kit is included with this fireplace.
Follow instructions included with conversion kit if converting to LP gas.
ATTENTION: The conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdiction and
in accordance with the requirements of the ANSI Z223.1 installation code.
CAUTION: Installation of the gas line must only be done by a qualified person in accordance with local building codes, if any.
If not, follow ANSI 223.1.
Commonwealth of Massachusetts: Installation must be done by a licensed plumber or gas fitter.
NOTE: A listed (and Commonwealth of Massachusetts approved) 12” (13 mm) manual shut-off valve and flexible gas connector
(included) are connected to the 1/2” (13 mm) control valve inlet. If substituting for these components, please consult local
codes for compliance.
NOTE: This fireplace is equipped with a 3/8”(10 mm) x 18” (457 mm) long flexible gas connector and manual shut-off valve. The gas
pressure testing of the gas line at test pressures equal to or less than ½ psi (3.5 kPa).
line should be run to the point of connection where the shut-off valve and flexible gas line will connect.
NOTE: The appliance and its individual shutoff valve must be disconnected from gas supply piping system during any pressure
testing of that system at pressures in excess of ½ psi.
NOTE: The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any
NOTE: For high altitude installations, consult local gas distributor or authority having jurisdiction for proper rating methods.
IMPORTANT: The efficiency rating of this appliance is a product of thermal efficiency rating determined under continuous operating
conditions and was determined independently of any installed system.
Run gas line through left gas line access hole at back corners of insert. For your convenience, access hole may be removed an d rotated to
accommodate side gas line installation.
NOTE: If installing this gas fireplace insert into a factory-built fireplace and the factory-built fireplace has no access hole provided, an
access hole of 1-1/2"(38 mm) or less may be drilled through the lower sides or bottom of the firebox in a proper workmanship
like manner. This access hole must be plugged with non-combustible insulation after the gas supply line has been installed.
MPS-30
NATURAL GAS LP GAS
MINIMUM INLET GAS PRESSURE 5.0 inches W.C. (7.0 W.C. recommended) 11.0 inches W.C. (recommended)
MAXIMUM INLET GAS PRESSURE 10.5 inches W.C. 13.0 inches W.C.
MANIFOLD PRESSURE (HI) 3.5 10
MANIFOLD PRESSURE (LO) 0.7 2.8
ORIFICE SIZES #42 #53
INPUT BTU/hr. 26,000 26,000
MINIMUM INPUT BTU/hr. 12,500 14,500
MANUAL SHUT-OFF VALVE
The manual shut-off valve is located on left side wall of insert. Use glass
latch attachment tool (included in components packet) to open or close
valve.
SHOWN IN OPEN POSITION
Figure 11a
PAGE 11
CONVERSION KIT INSTRUCTIONS
IMPORTANT: This fireplace is NAT gas ready. If converting to LP gas, do so now before installing into existing fireplace.
#OCK-A42N-IPI NAT GAS CONVERSION KIT / #OCK-A53L-IPI LP GAS CONVERSION KIT
WARNING: This conversion kit shall be installed by a qualified service agency in accordance with the manufacturers instructions and
all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not
followed exactly, a fire, explosion or productions of carbon monoxide may result, causing property damage, personal injury
complete until operation of the converted appliance is checked as specified in the instructions supplied with the kit. Refer to
appliance owner‟s manual or product data plate for proper inlet and manifold pressure adjustments and orifice sizing.
or loss of life. The qualified service agency is responsible for proper installation of this kit. The installation is not proper and
IMPORTANT: For high altitude installations: Above 2000ft. (610m) US / 4500 ft. (1372m) Canada, consult local gas distributor or authority
having jurisdiction for proper de-rating methods.
Kit includes: (1) Gas Conversion Label (1) Burner Orifice: NAT #42 / LP #53
(1) Gas Type Label (1) Pilot Orifice: NAT #62 / LP #35 (1) Low Limit Screw: NAT #50 / LP #56
WARNING: SHUT OFF GAS SUPPLY AND ELECTRICAL POWER TO FIREPLACE.
SHUT OFF GAS SUPPLY BEFORE DISCONNECTING ELECTRICAL POWER.
PREPARE THE FIREPLACE:
1. Remove screen front*, glass frame assembly*, and glass media* from insert.
REPLACE BURNER ORIFICES:
1. Remove burner by lifting front up and pulling towards you to release venturi from
orifice.
2. Remove existing orifice cap. Replace with orifice cap included with kit, making
sure to tighten cap securely.
NAT. GAS: #42 orifice
L.P. GAS: #53 orifice
CONVERT PILOT ASSEMBLY:
Follow instruction sheet included with kit to convert pilot to either Nat. or LP.
BURNER ORIFICE
Figure 12a
PRESSURE REGULATOR CAP
GAS TYPE CONVERSION:
Press and hold Learn Button on Main Control Module for 20 seconds (access hole on right
hand side of outer wrap). A beep will be heard letting you know the procedure has been
completed.
If converting from NAT to LP gas: one (1) second long beep
If converting from LP to Nat gas: three (3) second long beep
CONVERT THE GAS CONTROL VALVE:
1. Remove black cap covering the pressure regulator.
2. Press down on pressure regulator tube and rotate 90˚. The shaft should pop out and point to chosen gas. Re-attach black cap.
3. Remove low limit screw (above valve motor; see page 20). Replace with one included in kit.
NAT. GAS: #50
L.P. GAS: #56
PAGE 12
NAT. SETTING
Figure 12b
L.P. SETTING
CONVERSION KIT INSTRUCTIONS
COMPLETE THE CONVERSION:
1. Adjust burner tube venturi to correct setting by loosening screws adjusting cap and retightening screw.
CORRECT SETTINGS: NAT: 1/16” (2mm) open / L.P: 100% open
2. Re-install burner into fireplace, making sure orifice is properly seated inside burner venturi and lip on burner front is seated inside
firebox.
3. Re-install glass media*.
4. Turn on gas and electrical supplies. Check for leaks at all connections, whether field or factory made.
6. Test inlet pressure*. Visually check pilot flame. Flame should envelope top of flame sensor and extend onto burner far enough for
proper ignition. To Adjust pilot: Turn pilot adjustment screw clockwise to decrease or counter-clockwise to increase pilot flame.
7. Turn fireplace off.
8. Affix gas type sticker to label.
9. Re-install glass frame and screen front assemblies*.
10. Verify proper ignition and operation of fireplace.
11. Complete and affix „Gas Conversion‟ label to outer wrap close to gas valve.
Fireplace Model No.:_________________________________________
This appliance and control was converted on______________________________
To___________________ gas with Kit No.____________________________ by:
Company:___________________________________________
Address:____________________________________________
Which accepts responsibility that this conversion has been properly made.
Minimum / Maximum inlet pressures: Refer to Rating Plate.
Manifold Pressure: Refer to Rating Plate.
Orifice size:___________________ Input Rating:______________________ BTU
GAS CONVERSION LABEL (included with conversion kit)
Figure 13a
PAGE 13
GLASS FRAME / SCREEN FRONT
WARNING: DO NOT OPERATE THIS FIREPLACE WITH GLASS REMOVED, CRACKED OR BROKEN. REPLACEMENT OF GLASS FRAME
ASSEMBLY, #JOR-057T SHOULD BE DONE BY A LICENSED OR QUALIFIED SERVICE PERSON.
WARNING: DO NOT REMOVE THESE COMPONENTS WHEN HOT!
REMOVE GLASS FRAME ASSEMBLY
Upper tab (1 ea. side)
A. Locate spring-loaded latches securing glass frame assembly at bottom of firebox.
B. Using glass latch tool (included in components packet) pull bottom latches out and „up‟
to release glass frame assembly latch tabs.
C. Lift glass frame assembly up off tabs located at top of firebox.
INSTALL GLASS FRAME ASSEMBLY
Lower latch (1 ea. side)
A. Make certain bottom latches are pushed „down‟ to allow for easier installation.
Latch tab
B. Align slots at top of glass frame assembly over tabs at top of firebox while lowering
bottom of glass frame assembly into position.
C. Using glass latch tool, pull latches out and „down‟ over latch tabs to secure glass frame
assembly bottom.
Insert glass latch tool here
SCREEN FRONT (sold separately)
To install: Align tabs on back of frame with slots on insert, set into position.
To remove: Lift frame up and out of slots.
Figure 14a
INSTALLATION
IMPORTANT: All steps as outlined in „PREPARE EXISTING FIREPLACE‟ must be completed before continuing with this installation.
IMPORTANT: Please refer to Matching Security Code instructions on pages 23-24 prior to installation. Easy access to LEARN button is reached through hole
on outer right side of insert before installation. After installation, some disassembly is required to reach LEARN button. After installation
LEARN button access instructions on pages 23-24 also.
IMPORTANT: Follow instructions included from vent pipe manufacturer as well as venting requirements as outlined in this installation manual.
APPROVED VENTING
MANUFACTURER APPROVED CAPS
Kozy Heat 816-CL Vent System
ICC TM-IVT
Selkirk 4DT-VC
American Metals 4DVC
Simpson Dura-Vent 46DVA-VCH
Security 3PDVCV
Metal Fab 4DVT
TM-SVT
HS-C33U99 RLH
HS-C33F1313
HS-CD3333-1313
COMBUSTION AIR VENTING OPTIONS
OPTION 1: FULL CONNECTION: Combustion air intake pipe is run entire chimney length and connected to termination cap.
OPTION 2: STUB VENTING: Combustion air intake pipe is extended a minimum of 4 ft. (1.22 m) past damper opening into
existing chimney. It is not connected to termination cap.
PAGE 14
INSTALLATION
AIR DUCT REMOVAL
1. Remove refractory clips from inside top of firebox. Remove side firebox panels
2. Remove (3) screws securing firebox liner back and baffle to firebox back wall. Remove liner. Pull baffle forward and down to remove.
3. Remove access plate (secured with (2) screws) from firebox ceiling.
4. Locate and remove nuts securing air duct top to firebox; 2 nuts reached through access holes, 2 inside air duct.
5. Remove air duct top.
Access Plate
Figure 15a
KOZY HEAT #816-CL CO-LINEAR VENT SYSTEM
The co-linear pipes included in this vent system are designed to extend up to 35 ft. (10.67m)
IMPORTANT: IDENTIFICATION: Exhaust Pipe: red marking.
Proper operation of this insert requires exhaust and combustion air pipes be connected to correct collars on termination
kit and insert air duct.
A. Carefully extend exhaust and combustion air intake pipes to equal total chimney length required.
NOTE: If using „stub‟ method for combustion air pipe, extending it is not necessary. Determine length needed from air duct on insert (4 ft.
(1.22 m) minimum) to above damper opening in existing chimney. Remove excess combustion air pipe from end without a collar.
Continue with Step B. below.
If using „Full Connection‟ method: Slide intake pipe (end without collar) over collar on termination cap. Secure with 3 self-tapping
screws (provided).
B. Place bead of sealant around inner edge at end of exhaust pipe (without collar / red marking) and slide onto corresponding collar on
termination cap (collar with label). Secure with 3 self-tapping screws (provided). Apply additional sealant around joint to ensure a
proper seal.
IMPORTANT: EXHAUST COLLAR ON FIREPLACE AIR DUCT IS ON RIGHT SIDE. INSTALL TERMINATION CAP WITH EXHAUST COLLAR
ON RIGHT SIDE.
INTAKE COLLAR
NOTE: Collar extends through bottom plate.
SEALANT
SHEET METAL SCREWS (3 TOTAL)
TERMINATION CAP
EXHAUST COLLAR
NOTE: Collar extends through middle divider plate
SEALANT
Figure 15b
Your vent cap may look slightly different than one shown.
PAGE 15
RUN VENT SYSTEM THROUGH EXISTING CHIMNEY
We strongly suggest wrapping first 3 ft.(914 mm) of vent system below termination cap
with non-faced fiberglass insulation (secure with wire) before running it through existing
chimney. This will prevent cold air from coming down existing chimney.
DO NOT USE THIS METHOD IF YOU ARE STUBBING COMBUSTION AIR
PIPE FROM BOTTOM OF EXISTING CHIMNEY.
NOTE: If offsets are present in existing chimney, place a weighted rope around
pipe ends to guide them through chimney.
DO NOT ATTEMPT TO TIE ONE ROPE AROUND BOTH PIPES.
Figure16a
1. Guide rope, if used, and flexible pipe(s) down existing chimney. See illustration at lower left.
2. To secure chimney termination cap to existing chimney, apply a liberal bead of sealant (provided) around top of existing chimney. Set
termination cap into position as instructed in installation manual included with chosen vent system .
OPTIONAL: #816-CL kits - Secure termination cap to existing chimney with 2" self-tapping screws and anchor straps (provided)
through pilot holes located at sides of termination cap.
3. From inside existing fireplace, CAREFULLY pull ropes down until exhaust pipe and combustion air intake (if using „full connection
method‟) are into existing fireplace.
STUB VENTING: From inside existing fireplace, insert a minimum of 4 ft. (1.22m) of combustion air pipe (end without collar) past the
damper opening and into existing fireplace. See illustration at lower right.
4. We strongly suggested placing non-faced fiberglass insulation between vent pipes and existing chimney to prevent heat loss up chimney,
being careful not to block pipe end if using stub method.
Figure 16b
Minimum 4 ft. (1.22m) section
of 3" combustion air flex pipe
DO NOT block pipe end
with insulation or any other
sealing materials
PAGE 16
3" exhaust flex pipe
must be connected
to collar on
fireplace insert and
termination cap
Seal area around
vent pipes with
non-faced fiberglass
insulation
VENT SYSTEM CONNECTION
Sheet metal
screws (3 total)
Figure 17a
1. Place air duct (previously removed, page 15) into existing fireplace opening.
2. Place a bead of sealant (provided) around exhaust collar (“EX” marking) Slide exhaust pipe over “EX” collar on air duct. Secure with
(3) ½" self-tapping screws, provided. Apply additional sealant around joint to ensure an air tight seal.
3. Apply a liberal bead of sealant (provided) around collar on air duct. Slide combustion intake pipe over collar. Secure with (3) ½"
self-tapping screws, provided. To ensure an air-tight seal, apply additional sealant around joint.
4. Slide insert into fireplace opening. Check for level. If necessary, leveling bolts are included in components packet and are threaded
through bottom of insert into nuts located on each corner of insert. Remove insert, install leveling legs as necessary, slide insert into
fireplace opening.
Figure 17b
Sealant
Figure 17c
Figure 17d
5. Use glass latch tool included in components packet, to pull air duct down onto insert, aligning mounting studs to holes in top of
firebox. Secure with nuts previously removed.
6. Reinstall access panel plate, baffle and firebox liners.
SHROUD INSTALLATION
This kit includes: Shroud and (4) phillips truss head screws.
1. Remove screen front and glass frame assembly from fireplace.
2. Align leg section holes to corresponding mounting nuts in mounting brackets on sides of fireplace
opening. Secure with phillips truss head screws (2 ea. side).
3. Re-install glass frame assembly and screen front.
Figure 17e
PAGE 17
GLASS MEDIA INSTALLATION
ATTENTION: Do not operate this fireplace without glass media installed. Various colors available. See Dealer for details.
WARNING: Do not block pilot assembly with glass media. A blocked pilot assembly may result in a delayed ignition.
Install glass media onto burner assembly and pilot shield, being careful not to block pilot assembly.
Figure 18a
DO NOT BLOCK THIS AREA
Shown with optional Frosted White media kit for clarity purposes.
PAGE 18
WIRING SCHEMATICS
Figure 19a
IMPORTANT: THIS SYSTEM REQUIRES ELECTRICITY (110 V)
AND / OR BATTERIES TO OPERATE.
USING BATTERY BACK UP WILL OPERATE BURNER ONLY.
FAN COMPONENTS WILL NOT FUNCTION ON BATTERY
BACK-UP POWER.
PAGE 19
VALVE & PILOT ASSEMBLY COMPONENTS
FLAME SENSOR
BLACK CAP
LOW LIMIT SCREW
IGNITER
PILOT
IPI PILOT ASSEMBLY
OUTLET (MANIFOLD)
PRESSURE SCREW
PILOT INTERNAL SOLENOID CONNECTION
VALVE STEP MOTOR
STEP MOTOR
WIRE HARNESS
MAIN VALVE INTERNAL SOLENOID CONNECTION
IPI GAS VALVE
Figure 20a
PILOT ADJUSTMENT SCREW
INLET PRESSURE SCREW
PAGE 20
CONTROL MODULE COMPONENTS
COMMUNICATION LINK
TO EXTENSION MODULE
AC ADAPTOR
CONNECTION
VALVE STEP MOTOR
TERMINAL
LEARN BUTTON
MAIN CONTROL MODULE
CONTINUOUS PILOT
ON/OFF SWITCH
REMOTE ON/OFF
SWITCH
BACK-UP BATTERY PACK
POWER TO LIGHT KIT
(not available in all models )
COMMUNICATION LINK
TO CONTROL MODULE
NON-OPERATIONAL
„S‟ SENSOR PILOT
CONNECTION
FAN CORD PLUG-IN
„I‟ IGNITER PILOT
CONNECTION
NON-OPERATIONAL
AC ADAPTOR
Figure 21a
EXTENSION MODULE
PAGE 21
REMOTE CONTROL INFORMATION
MANUAL ON / OFF
ROOM TEMPERATURE
FAN SPEED
CONTINUOUS PILOT
THERMOSTAT MODE ICON
BATTERY LIFE ICON
SET TEMPERATURE
(visible only in THERMO MODE)
LIGHT LEVEL
CHILD PROOF ICON
FLAME HEIGHT
Figure 22a
PAGE 22
IPI INFORMATION
ELECTRICAL WARNING AND INFORMATION:
Electrical wiring must be installed by a licensed electrician.
Do NOT wire 110V to wall switch.
Uninterrupted or continuous power is required at all times in IPI systems EXCEPT when using battery back-up.
Incorrect wiring will override IPI safety lockout and may cause an explosion.
Disconnect 110V before servicing.
ATTENTION: This system goes through a calibration mode when switching from ON to THERMO to OFF, creating a humming
sound which is a normal part of operation.
CONTINUOUS PILOT (FOR VERY COLD CONDITIONS)
The IPI gas control system has the option of a continuous (standing) pilot feature. This allows you to change from a spark-to-pilot
system to a standing pilot system during cold weather conditions. By having the pilot on continuously, the firebox will remain warm
and a draft is established in the vent, allowing the main burner to turn on with less air-flow disruption.
When continuous pilot mode is activated and fireplace is turned ON, the pilot will spark and light. When fireplace is turned OFF, the pilot
will remain lit when main burner has been turned OFF.
This pilot feature can be activated or de-activated by the hand held remote control transmitter. Instructions on page 25.
OPERATION USING BATTERY POWER
This fireplace has an optional battery operation if electrical power is lost. Battery pack is located on right access panel of firebox.
NOTE: When operating fireplace in this capacity, the only function available is flame modulation.
LEARN BUTTON ACCESS PROCEDURE
Prior to installation: Access through hole on right side of insert.
After installation: A. Remove screen front and glass frame assembly to expose components on right side wall of insert.
B. Move battery pack away from front of main control module.
C. Using a needle nose pliers, remove pilot connection tabs from main control module. Main control module
can now be rotated forward to access LEARN button.
D. Reattach pilot connection tabs (top-black, bottom-red), reattach battery pack and install glass frame
assembly and screen front.
PRE-INSTALLATION POST-INSTALLATION
LEARN BUTTON ACCESS HOLE
LEARN BUTTON
UPRIGHT ROTATED
Figure 23a
SLIDE TO REMOTE POSITION
PAGE 23
IPI INFORMATION
MATCHING SECURITY CODES
Before matching security codes make sure 120V AC is connected and powered to fireplace, and hand held remote control is installed with
(2) AA batteries.
It may be necessary to program main control module (located on right side of firebox) to LEARN the hand held remote control security
code upon initial use, if batteries are replaced, or if a replacement remote control is purchased from your dealer.
1. When matching security codes, be sure slide button on main control module is in REMOTE; the code will not “LEARN” if slide is
in OFF.
2. Following LEARN BUTTON ACCESS PROCEDURES on previous page, program main control module to LEARN a new
security code by pushing in LEARN button on main control module using a pencil point for 2 seconds (you should hear a single
„beep‟ letting you know module is ready to learn a new code).
3. Press MODE button on hand held remote control (you should hear four „beeps‟ in rapid succession in main control module, indicating
remote control‟s code has been programmed into the main control module). When an existing main control module is introduced to a
new hand held remote control, the new security code will overwrite the old one.
If it ever becomes necessary to clear the memory from the hand held remote control, simply push and hold the LEARN button for 10
seconds (you should hear three long beeps in succession). You may now follow steps outlined above to „RE-LEARN‟ security codes.
REMOTE CONTROL OPERATION
INITIAL SET-UP:
Plug Extension Module and AC Adaptor into receptacles.
Install (4) AAA batteries into battery compartment of Backup Battery Pack, making sure batteries are installed in proper direction.
Position on right side access panel. A Velcro strip has been attached to help secure in place.
The Hand Held Remote operates on (2) 1.5V AAA batteries. We recommend always using ALKALINE batteries to extend battery life and
improve operational performance.
NOTE: This system is sent to you set up for Natural Gas and
temperature units readable in Fahrenheit.
This system allows for gas type conversion and temperature unit conversion by following the setup procedure outlined below.
GAS TYPE CONVERSION:
Following LEARN BUTTON ACCESS PROCEDURES on previous page, press and hold LEARN Button on Main Control Module for
20 seconds. A beep will be heard letting you know the procedure has been completed.
If converting from NAT to LP gas: (1) one second long beep
If converting from LP to Nat gas: (3) three second long beep
Continue with gas type conversion by following instructions included with gas conversion kit.
CELSIUS/FAHRENHEIT CONVERSION:
Press UP and DOWN keys simultaneously to choose Celsius or Fahrenheit.
IMPORTANT SAFETY FEATURE:
This system has a maximum room temperature limit of 95° F (35° C) in both manual and thermostat modes. When room temperature is
at or above this point the system will shut down and the hand held remote control will read OFF. If you turn the system ON when room
temperature is still at or above this temperature, the system will again shutdown after 2 minutes when room temperature is recalculated.
PAGE 24
REMOTE CONTROL INFORMATION cont.
CONTINUOUS PILOT FEATURE:
Activation of this optional feature is accomplished by pressing the PILOT
button once. The continuous pilot icon will appear on the LCD screen.
Pressing PILOT button again will de-activate this feature.
This feature can also be activated via CONTINUOUS PILOT switch on
Main Control Module.
CHILDPROOF FEATURE:
Activation of this optional feature is accomplished by pushing SET & UP
buttons simultaneously for 5 seconds. The childproof icon will appear on the
screen. When a transmitter button is pressed the icon will flash on screen, but
no signal will be transmitted. Pressing and holding these same two buttons
again for more than 5 seconds will de-activate this function.
This feature controls only manual functions of the hand held remote,
automatic functions (thermostat mode) will not be effected.
MANUAL MODE:
Figure 25a
Figure 25b
This remote can be manually or thermostatically operated.
Press MODE button for manual ON. The flame icon will appear on the LCD
screen. Press MODE button again to put the control into THERMO mode.
Pressing MODE again will turn fireplace OFF.
NOTE: The MODE button operates in a series that will cycle from ON
to THERMO to OFF.
FAN MODE:
This remote will operate the fan, allowing for (6) different speed levels. When
the FAN button is pressed, FAN level setting will flash on the LCD screen.
Press UP or DOWN buttons to select desired fan speed level. If no adjustment is made within 7 seconds, the control will exit function setting mode and
LCD display will return to normal view.
NOTE: Delayed ON/OFF - The fan will not turn on until fireplace
has been burning for 5 minutes and will not turn off for 12
minutes after fireplace has been turned off.
EXCEPTION: If fireplace is turned back on during 12 minute off-delay time
frame, the fan will remain on.
This applies to MANUAL and THERMO modes.
LIGHTING MODE:
Figure 25c
Figure 25d
This remote will operate the lights, allowing for (6) different light levels.
When LIGHT button is pressed, LIGHT level setting will flash on the LCD
screen. Press UP or DOWN buttons to select desired light level. If no adjustment is made within 7 seconds, the control will exit function setting mode and
LCD display will return to normal view.
NOTE: There is a 3 second delay before light level setting is achieved.
NOTE: Light operations are completely independent from flame and fan
operations.
Figure 25e
PAGE 25
REMOTE CONTROL INFORMATION cont.
FLAME MODE:
This remote will operate the flame, allowing for (6) different flame height
levels. When MAIN FLAME button is pressed, FLAME level setting will
flash on the LCD screen. Press UP or DOWN buttons to select desired flame
level. If no adjustment is made within 7 seconds, the control will exit function
setting mode and LCD display will return to normal view.
NOTE: The fireplace will initially light at the highest level. After 5
seconds the flame will adjust to last chosen level before
fireplace was turned OFF.
This applies to MANUAL and THERMO modes.
THERMO (THERMOSTAT) MODE:
This remote feature allows you to thermostatically control the fireplace when hand held remote is set to
THERMO mode.
Set Temperature Range: 45˚F (7˚C) to 90˚F (32˚C).
Set remote to THERMO mode by pressing MODE button. The smaller SET window of numbers appears
on the LCD screen. The first SET number will read 45˚F. Press UP button to desired set room temperature.
Within 5 seconds fireplace will operate to that Set Temperature. The FLAME, ON and THERMO icons
will appear on the LCD screen. By pressing UP or DOWN buttons a new set temperature may be attained.
SET Temperature will only appear when THERMOSTAT MODE is activated,
but is implemented in all MODES with the exception of MANUAL MODE.
Figure 26a
NOTE: The flame height can adjust up to (6) different height levels according to amount of heat
required. This range however is dictated by the Flame Level setting (see previous page).
When desired temperature is met, the fireplace will shut off until more heat is required.
To exit THERMO mode press the MODE button. This also shuts fireplace OFF.
IMPORTANT: When in THERMO mode the fireplace will not turn on until room temperature falls
below SET TEMPERATURE.
Figure 26b
SYSTEM OPERATION WITHOUT HAND HELD REMOTE:
This system is designed to operate with the hand held remote or a thermostat, but in the unlikely event that it is required to be operated
without the hand held remote or a thermostat, follow this simple procedure.
Slide REMOTE /OFF switch on main control module to OFF. The fireplace can now be lit and shut off by use of the ON/OFF rocker
switch.
NOTE: When operating fireplace in this capacity, the only function available is burner operation on HI.
REMOTE / OFF
Figure 26c
PAGE 26
LIGHTING AND SHUTDOWN
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.
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.
1. This fireplace is equipped with an ignition device which automatically
lights the pilot and main burner. The pilot and burner light automatically
with the hand held remote only. DO NOT try to light the pilot by hand.
Before lighting this fireplace, 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 than air and will settle
on the floor.
3. 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.
WARNING: 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 MUST NOT BE PLACED ON OR NEAR THE APPLIANCE.
WHAT TO DO IF YOU SMELL GAS:
Do not touch any electrical switches
Do not try to light any appliance
Do not use the phone in your building
Immediately call your gas supplier from a neighbor‟s
phone
Follow the gas supplier‟s instructions
If you cannot reach your gas supplier, call the fire
department
NOTE: A PAINT SMELL WILL OCCUR DURING THE FIRST FEW HOURS OF BURNING. IT IS RECOMMENDED TO
LEAVE THE FAN OFF DURING THIS PERIOD TO HELP SPEED THE PAINT CURING PROCESS.
NOTE: THIS FIREPLACE MAY PRODUCE NOISES OF VARYING DEGREE AS IT HEATS AND COOLS DUE TO METAL
EXPANSION AND CONTRACTION. THIS IS NORMAL AND DOES NOT AFFECT THE PERFORMANCE OR
LONGEVITY OF THE FIREPLACE.
PAGE 27
LIGHTING
LIGHTING AND SHUTDOWN (cont.)
STOP! Read safety information on previous page and front
cover of this manual before continuing.
1. Turn off all electrical power to fireplace.
ATTENTION: This fireplace is equipped with an ignition device
which automatically lights the pilot.
DO NOT light the pilot by hand.
2. Press hand held remote MODE button to OFF.
3. Wait five (5) minutes to allow any gas that may have accumulated
inside firebox to escape. If you then smell gas, STOP! Follow
safety information on front cover and on previous page of this
installation manual. If you don‟t smell gas, go to next step.
4. Turn ON all electrical power to fireplace.
5. Press hand held remote MODE button to ON.
CAUTION: If fireplace will not operate, follow instructions
TURNING OFF GAS TO FIREPLACE and call
your service technician or the gas supplier.
NOTE: When fireplace is initially lit, condensation will appear
on the glass; this is normal in all gas fireplaces and will
disappear after several minutes.
1
3
5 MINUTES
4
Figure 28a
2
Power OFF
OFF
5
Power ON
ON
TURNING OFF GAS TO FIREPLACE
1. Press hand held remote MODE button to OFF.
2. Turn OFF all electrical power to fireplace if service is required.
3. Turn manual shut-off valve to OFF.
1
OFF
3
Figure 28b
2
Power OFF
PAGE 28
PRESSURE TESTING
IMPORTANT NOTICE: Pressure check taps for manifold (outgoing) and inlet (incoming) pressure have been incorporated into
the valve. The pressure tap marked OUT measures outgoing pressure and the pressure tap marked
IN measures incoming pressure. Follow instructions below for proper testing procedures.
NOTE: The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any
pressure testing of that system at pressures in excess of ½ psi.
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 ½ psi (3.5 kPa).
INLET PRESSURE TEST:
1. Loosen inlet (IN) pressure tap screw (counter-clockwise).
2. Attach manometer using a 1/4” I.D. hose.
3. Light fireplace using hand held remote control. Note manometer reading.
4. Turn fireplace off using hand held remote control.
5. Disconnect hose and tighten screw (clockwise). Screw should be snug, do not over tighten.
6. Relight fireplace using hand held remote control. Reattach manometer to inlet pressure tap to verify 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
CAUTION: A LOW PRESSURE READING CAN CAUSE DELAYED IGNITION
incoming gas pressure.
Outlet (Manifold) Pressure Screw
Figure 29a
Inlet Pressure Screw
PAGE 29
ERROR CODES
IGNITION SAFETY: Protection for Ignition System
Error Code: One beep every one second.
Description of Fault: Warns users if pilot is not successfully ignited in 60 seconds.
How to Clear: Press MODE button to OFF then to ON to re-attempt ignition.
What to Check:
Ensure gas supply is turned on.
Ensure black cap leads marked PILOT from module are plugged into PILOT connection on valve body.
Verify lead from igniter on pilot assembly is connected to „I‟ terminal on main control module. (Clicking sound will also be heard).
Verify lead from flame sensor on pilot assembly is connected to „S‟ terminal on main control module. (Pilot will light but main burner
will not. Pilot will extinguish after 60 seconds and error code will alarm).
Verify black ground lead is connected to tab extending from valve bracket.
SENSOR SAFETY: Protection for Flame Sensor
Error Code: Four beeps every one second.
Description of Fault: Warns users pilot flame senor detects a pilot flame already present when ignition sequence is initiated. This fault will
also occur if pilot flame senor on main control module is shorted to ground.
How to Clear: Press MODE button to OFF then to ON to re-attempt ignition.
What to Check:
Check if pilot flame is actually present when valve is turned OFF (if yes, replace valve).
Replace pilot assembly.
Replace module.
THERMAL SAFETY: Overheat Protection
Error Code: Four beeps every two seconds.
Description of Fault: Warns users that module‟s internal temperatures have exceeded 170˚ F (77˚C).
How to Clear: Module‟s internal temperatures must cool to below 160˚F (71˚C) and then press ON button.
What to Check:
Are modules located in an unapproved location. Move to cooler location.
COMMUNICATION SAFETY: Protection for Ignition System
Error Code: One beep every four seconds.
Description of Fault: Warns users the hand held remote and main control module are not communicating properly. This safety feature is
active in both manual and thermo modes. The remote control sends a communication safety signal every 15 minutes.
If the main control module does not receive this signal, it begins a 2-hour countdown. If no communication safety
signal is received at the end of this countdown, the system will enter communication safety shutdown which turns
system OFF and emits the error code.
What to Check:
Verify batteries in hand held remote control are new.
Ensure remote control is located within 20 ft. (6 m) of main control module.
Ensure remote control is not placed directly on top of or inside a metal enclosure as this can interfere with transmission.
PAGE 30
FINALIZING THE INSTALLATION
FLAME APPEARANCE:
Flame appearance is affected by several factors including altitude, venting configuration and fuel quality. Although the venturi settings
have been factory set, adjustments may be necessary for optimal performance and visual aesthetics.
When fireplace is first lit, the flames will be blue. Flames will gradually turn yellowish-orange during first 15 minutes of operation. If
flames remain blue or become dark orange with evidence of sooting (black tips), the burner tube venturis may need adjustment.
WARNING: BURNER TUBE ADJUSTABLE VENTURI POSITIONING SHOULD ONLY BE PERFORMED BY A QUALIFIED
WARNING: TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY, ALLOW FIREPLACE AMPLE TIME TO COOL
BEFORE MAKING ANY ADJUSTMENTS.
VENTURI POSITION FLAME COLOR VENTURI ADJUSTMENT
Closed too far Dark orange flame with black tips Open venturi setting slightly
NOTE: IF SOOT IS PRESENT, CHECK MEDIA POSITIONING BEFORE ADJUSTING BURNER VENTURI. MEDIA MUST NOT
IMPORTANT: SLIGHT ADJUSTMENTS TO THE BURNER VENTURI OPENING CREATE DRAMATIC RESULTS. ADJUST AT
15 MINUTES AND ALLOW TIME TO COOL BEFORE MAKING ANY FURTHER ADJUSTMENTS.
PROFESSIONAL SERVICE TECHNICIAN.
FACTORY SET BURNER TUBE VENTURI SETTINGS
(ADJUST AS NECESSARY FOR YOUR INSTALLATION)
NATURAL GAS LP (PROPANE) GAS
1/16” (2 mm) OPEN 100% OPEN
BURNER TUBE VENTURI ADJUSTMENT GUIDELINES
Open too far Blue flames Close venturi setting slightly
BLOCK PILOT ASSEMBLY.
SLIGHT INCREMENTS UNTIL DESIRED LOOK IS ACHIEVED. ALWAYS BURN FIREPLACE FOR AT LEAST
TO ADJUST VENTURIS:
1. Remove screen front and glass frame assembly. Refer to page 14.
2. Remove glass media.
3. Remove burner assembly.
4. Loosen screw on burner venturi and adjust as necessary. Tighten screws.
5. Reinstall all components previously removed.
6. Light fireplace and wait 15 minutes before determining if any further adjustments are
needed.
PAGE 31
BURNER VENTURI
Figure 31a
MAINTENANCE
The appliance is required to be inspected at least once a year by a professional service person.
The compartments on sides of firebox 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.
NOTE: INSTALLATION AND REPAIR SHOULD BE DONE ONLY BY QUALIFIED SERVICE PERSON. THE APPLIANCE SHOULD BE
INSPECTED BEFORE USE AND 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.
CONTROL BOARD SYSTEM
Annual cleaning of burner system is required.
Visually check for blocked port holes, especially near the pilot. Blocked port holes may cause delayed ignition.
Visually check pilot light and burner when in operation. The flames should be steady, not lifting or floating.
Burner Ports
IPI Pilot
Figure 32a
Burner Orifice
FAN
The fan should be disconnected from electrical current, and cleaned (vacuumed) every six months. The bearings are sealed and require no oiling.
VENT SYSTEM
Annual examination of the venting system by a qualified agency is required.
IF VENT-AIR INTAKE SYSTEM IS DISASSEMBLED FOR ANY REASON, RE-INSTALL PER INSTRUCTIONS PROVIDED WITH INITIAL
INSTALLATION.
The flow of combustion and ventilation air must not be obstructed.
GLASS CLEANING & REPLACEMENT
Clean glass only when cool and only with non-abrasive cleansers.
Do not operate this fireplace with glass/frame assembly removed, cracked or broken.
The glass assembly, part #JOR-057T, shall only be replaced as a complete unit, as supplied by Hussong Mfg. Co., Inc.
Replacement of glass & frame assembly, part #JOR-057T, must only be performed by a licensed or qualified service person.
DO NOT SUBSTITUTE MATERIALS.
Do not strike or slam glass door assembly.
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.
CAUTION: KEEP APPLIANCE AREA CLEAR OF COMBUSTIBLE MATERIALS, SUCH AS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.
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TROUBLESHOOTING
MAIN CONTROL MODULE WILL NOT LEARN TRANSMITTER
Ensure REMOTE/OFF switch on side of main control module is set to REMOTE.
Make sure batteries in both the hand held remote and backup battery pack are installed in the proper direction and are not drained.
Verify hand held remote indicates a signal is being sent. The LCD display should indicate ON or OFF depending on which button is
being pressed. The LED indicator should illuminate on wall transmitters and on/off transmitters. Buttons should be pressed and held
for 1 to 2 seconds to ensure a complete signal is sent.
Ensure 4-pin lead-set is securely connected from battery pack to main control module‟s AUX connection. If the A/C adapter is used,
check that leads from adapter are securely connected to POWER terminals on main control module.
Press and hold LEARN button on main control module for approximately 10 seconds to clear memory (you should hear a series of
beeps from the receiver), immediately press either the ON or OFF button on hand held remote (you should hear a series of beeps
indicating the transmitter code has been learned).
PILOT WILL NOT LIGHT / STAY LIT
Verify gas supply is turned on.
Verify main control module is receiving signal from hand held remote by listening for a beep from receiver when ON is pressed on
hand held remote. If you do not hear a beep, ensure main control module has learned the hand held remote. (See above).
Ensure black lead from pilot assembly igniter is securely connected to terminal labeled „I‟ and red lead from flame rectification
sensor is securely connected terminal labeled „S‟ on main control module.
Make sure black cap leads marked PILOT from main control module are securely connected to terminals labeled PILOT on valve
body.
Ensure black GROUND wire is securely connected to tab located next to ON/OFF toggle switch. A proper ground is essential to
spark igniter operation.
Make sure pilot flame is in contact with flame rectification sensor on pilot assembly. This valve is equipped with a pilot flame
adjustment screw. If pilot flame is too small it will not contact flame rectification sensor and will not complete the safety circuit.
Check continuity of pilot on valve. Remove wire connector. If there is no continuity on pin terminals, replace valve.
PILOT FLAME ALWAYS ON / WILL NOT EXTINGUISH
Ensure continuous pilot icon is not present in LCD screen. If icon is present, press PILOT button. This will de-activate the continuous
pilot feature and the icon will disappear from LCD screen.
PILOT BURNING BUT IGNITER CONTINUES TO SPARK
Check that flame sensor is fully impinged by pilot flame. If needed, adjust pilot.
Check end-to-end continuity of sensor. If sensor has continuity, replace module.
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TROUBLESHOOTING
MAIN FLAME WILL NOT LIGHT
Verify gas supply is turned on.
Ensure pilot flame will ignite. If not, see pilot flame troubleshooting on previous page.
Make sure white cap leads marked MAIN from module are securely connected to terminals marked MAIN on valve body.
Make certain pilot flame is in contact with flame rectification sensor on pilot assembly. This valve is equipped with a pilot flame
adjustment screw. If pilot flame is too small it will not contact flame rectification sensor and will not complete the safety circuit.
Ensure pilot flame is properly located to ignite main flame.
Does hand held remote show CP in the display? If yes, childproof is on. De-activate by pushing PROG/TIME & UP keys at same time
for more than 5 seconds.
Check continuity of main burner coil on gas valve. Remove wire connector. If there is no continuity on pin terminals, replace valve.
FLAME HEIGHT ADJUSTMENT NOT WORKING / WORKS BACKWARDS
Ensure „+‟ (white dotted wire) and „—‟ (black wire) leads from battery pack or module are securely connected to „+‟ (white dotted
wire) and „—‟ (black wire) leads from main control module (‟+‟ to „+‟, „—‟ to „—‟).
Check functionality with all transmitters to determine if there is an issue with the main control system or an individual transmitter. If
the issue is with an individual transmitter, make sure batteries in hand held remote and backup battery pack are installed properly and
are not drained.
ROOM TEMP. DISPLAYED ON HANDHELD REMOTE NOT CORRECT
Ensure transmitter was not recently stored in a different location (air-conditioned, heated) from that in which the hand held remote was
tested. It may take up to 3 hours for the temperature inside a packaged transmitter, and several minutes for an unpackaged transmitter
to equalize with room temperature.
FIREPLACE WILL NOT RESPOND IN “THERMO” MODE
Ensure hand held remote is within 20 ft. (6.096 m) operational range.
Make sure an ON or OFF command was not last sent from another transmitter. These commands will override thermal commands from
the handheld remote control. To return system to THERMO mode, press either ON or OFF on hand held remote, then press MODE
button to put system in THERMO mode. Press and hold SET button to change set temperature.
Verify set temperature on hand held remote is at least 2˚F (1˚C) above or below room temperature. The system will not react to
temperatures within 2˚F (1˚C) of set temperature.
PAGE 34
MPS-30 REPLACEMENT PARTS LIST
Replacement parts are available through your local dealer. Contact them for availability and pricing.
MPS-30 BOARD SYSTEM AND PARTS
MPS-600-IPI Minneapolis-IPI Control Board - Nat Gas 700-168 #35 IPI LP Gas Pilot Orifice
MPS-601-IPI Minneapolis-IPI Control Board - LP Gas 700-204 Manual Shut-off Valve
700-400-CXL Main Control Module 700-213 18” Flexible Gas Line-Black
700-404-MPS Minneapolis IPI Valve -Natural 700-226 Flexible Gas Line-Valve to Burner Connection
700-404-MPS-1 Minneapolis IPI Valve - LP 700-242 Natural Gas Orifice #42
700-200 Pilot Assembly - Natural Gas 700-253 LP Gas Orifice #53
700-200-1 Pilot Assembly - LP Gas OCK-A42N-IPI Natural Gas Conversion Kit
700-801 8-PIN Primary Wire Harness: Primary Wire Harness OCK-A53L-IPI LP Gas Conversion Kit
700-501 5-PIN Wire Harness: Main Module to Valve Step Motor MPS-135 Burner Assembly
700-120 Extension Module 700-050 Nat. Gas Low Limit Screw #50
700-401 4-PIN Wire Harness: Control Module to Extension Module 700-056 LP Gas Low Limit Screw #56
700-750 7.5 Volt Adaptor 700-752 Pilot Igniter (with wire)
700-208 IPI Remote Control 700-753 Pilot Flame Sensor (with wire)
700-166 #62 IPI NAT. Gas Pilot Orifice 700-751 Battery Back-up with (4) AA Batteries
GLASS & GLASS GASKET
JOR-005 Replacement Valance
900-006 1-1/8” Glass Gasket w/ Adhesive
JOR-057T Valance with 25-5/8” x 17-1/2” glass
FIREBOX LINER SET (Black)
RFD-B-900 (3 pc.) Firebox Liner Set
RFD-B-900B Back Firebox Liner Panel
RFD-B-G900L Left Side Firebox Liner Panel
RFD-B-900R Right Side Firebox Liner Panel
GLASS MEDIA KIT (black)
101-BLK Black Glass Media Kit
FAN ASSEMBLY
JOR-028 Fan Assembly
*Consult your dealer for information on optional accessories available for this fireplace.
This appliance tested & certified by:
OMNI - Test Laboratories, Inc.
13327 NE Airport Way
Portland, Oregon 97230
Model #MPS-30 Minneapolis
www.kozyheat.com
PAGE 35
Manufactured by:
Hussong Mfg. Co., Inc.
204 Industrial Park Drive
Lakefield, Minnesota 56150
507-662-6641
LIMITED WARRANTY
PAGE 36
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