kozy heat CHASKA-XL CSK-335 Installation & Operating Manual
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kozy heat CHASKA-XL CSK-335 Installation & Operating Manual

Direct vent gas fireplace insert
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See also: Operation & Installation Manual , Installation & Operating Manual
Models #CSK-335
#CSK-335-RF
CHASKA - XL
Direct Vent Gas Fireplace Insert
INSTALLATION & OPERATING
MANUAL
CAUSE SERIOUS STRUCTURAL AND FIRE HAZARDS AND MAY VOID
READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION.
FAILURE TO INSTALL THIS FIREPLACE INSERT CORRECTLY CAN
This fireplace may be covered under one or more of
the following U.S. Patents: #5,931,154 , #6,004,493, #6,029,655
WARNING: If the information in these
instructions are not followed exactly, a fire or
explosion may result causing property damage,
personal injury or loss of life.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
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 the gas supplier's 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 may be installed in an aftermarket
permanently located, manufactured home (USA only) or
mobile home, where not prohibited by local codes. This
appliance is only for use with the type(s) of gas indicated
on the rating plate. This appliance is convertible for use
with other gases, an LP gas conversion kit is included.
IMPORTANT:
YOUR WARRANTY.
www.kozyheat.com
September 2006

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Summary of Contents for kozy heat CHASKA-XL CSK-335

  • Page 1 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. Models #CSK-335 Do not store or use gasoline or other flammable vapors #CSK-335-RF and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: CHASKA - XL ‚...

  • Page 2: Table Of Contents

    INDEX Fireplace Insert Specifications ............. . . 1 Safety Requirements .

  • Page 3: Fireplace Insert Specifications

    MODEL: #CSK-335 / #CSK-335-RF CHASKA-XL DIRECT VENT GAS FIREPLACE INSERT INSTALLATION & OPERATING INSTRUCTIONS IMPORTANT: READ THIS MANUAL BEFORE INSTALLING AND USING THIS FIREPLACE This fireplace has been tested to and complies with ANSI Z21.88-2005 CSA 2.33-2005 “VENTED GAS FIREPLACE HEATERS” by ...

  • Page 4: Requirements Of Existing Fireplace

    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. THIS INSERT IS APPROVED FOR INSTALLATION IN MASONRY AND FACTORY-BUILT SOLID FUEL BURNING FIREPLACES. CAUTION: THIS APPLIANCE MUST NOT BE CONNECTED TO A CHIMNEY FLUE SERVING A SEPARATE SOLID-FUEL BURNING APPLIANCE.

  • Page 5: Fireplace Insert Components

    FIREPLACE COMPONENTS: Check the assembly diagram below to ensure you have all the necessary components to properly install this fireplace insert. This insert includes the following: 1. Fireplace insert. 4. Co-linear air duct 2. Spring-loaded latch glass assembly. 5. Log set (See page #16) 3.

  • Page 6: Preparing The Existing Fireplace

    A. PREPARE THE EXISTING FIREPLACE WARNING: CUTTING ANY SHEET-METAL PARTS OTHER THAN COMPONENTS LISTED IN THIS SECTION, OF THE EXISTING FIREPLACE, IN WHICH THIS GAS FIREPLACE INSERT IS TO BE INSTALLED, IS PROHIBITED. The refractory, glass doors, screen rails, screen mesh and log grates may be removed from the fireplace before installing this gas fireplace insert.

  • Page 7: Gas Line Installation Requirements - Minimum/Maximum Pressures

    Figure B-1 This fireplace is designed to accept either a 3/8" NOTE: This appliance and its individual shut off valve or 1/2" gas line approved for gas appliances. must be disconnected from the gas supply Consult local building codes to properly size the piping system during any pressure testing of gas supply line leading to a 3/8"...

  • Page 8: Insert Preparation

    C. REMOVE THE FOLLOWING ITEMS FROM THE FIREPLACE INSERT: 1. GLASS ASSEMBLY: Figure C-1 A) Locate the spring-loaded latches securing the glass assembly (under the firebox). B) While holding onto the glass frame, pull the latch handles out, then down to release from the clips on the glass assembly.

  • Page 9: Fan Installation

    D. MODEL #CSK-335 ONLY: FAN INSTALLATION INSTRUCTIONS This fireplace insert comes complete with a fan and temperature control switch already installed. A speed control, receptacle and 8 ft. fan cord have been installed, wired and mounted in a removable electrical box panel on the right side of the fireplace. If wiring to the pre-installed electrical box is desired, the wiring should be run prior to permanently setting the insert in place and connecting the vent system.

  • Page 10: Model #Csk-335-Rf

    MODEL #CSK-335-RF ONLY: FAN INSTALLATION INSTRUCTIONS NSTALLATION 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 CSK-335-RF models. A receptacle and 8 ft. fan cord have been installed, wired and mounted in a removable electrical access panel on the right side of the fireplace.

  • Page 11: Installing The Insert

    ‘stubbed’ into the existing chimney from inside the fireplace using the minimum of 4' combustion air intake pipe. KOZY HEAT #816-CL CO-LINEAR VENT SYSTEM: The co-linear pipes included in this vent system is designed to extend up to 35 ft.
  • Page 12 2. RUN THE VENT SYSTEM THROUGH THE EXISTING CHIMNEY ˆ OPTIONAL: We recommend wrapping the first 3 ft. of the vent system below the termination cap with non-faced fiberglass insulation (secure with wire) before running it through the existing chimney. This will prevent cold air from coming down the existing chimney.

  • Page 13: Position The Insert

    ˆ OPTIONAL: We recommend placing non-faced fiberglass batting insulation between the pipes and existing chimney to prevent heat loss up the chimney. (See Figure E-4) OPTIONAL: PLACE NON-FACED FIBERGLASS BATTING INSULATION BETWEEN THE PIPES AND EXISTING CHIMNEY TO PREVENT HEAT LOSS UP THE CHIMNEY. Figure E-4 3.

  • Page 14: Secure The Air Duct

    F. POSITION THE FIREPLACE INSERT: 1. Slide the insert into the fireplace opening. Figure F-1 2. Secure the air duct onto the insert by positioning the air duct into the channels at the top of the insert and sliding the air duct forward until it stops. Figures F-2 & F-3. Position air duct into the channels and slide forward.

  • Page 15: Complete The Gas Line Installation

    4. If necessary level the unit by threading the leveling bolts (included in the components packet) into the nuts mounted in the bottom of the insert behind the lower air passage - 2 each side. See Figure F-5. Figure F-5 Complete the gas line installation 1.

  • Page 16: Complete Fan Wiring Installation (Models #Csk-335 & #Csk-335-Rf)

    I. Complete the fan wiring installation: Model #CSK-335 only: Refer also to Figure D-1, page #7. 1. Secure the electrical access panel to the side of the fireplace. 2. Place the thermostatic control switch on the bottom of the fireplace. 3.

  • Page 17: Assemble & Attach The Shroud

    J. ATTACH THE SHROUD Shroud assembly includes: (1) Shroud top (2) 10-24 x 1" RH Philips Mch Screw (#300388) (1) Shroud left side (6) 8 x 3/8" Phillips PH-Type B Blk Zinc SMS (#300121) (1) Shroud right side (4) 10-24 x 1/2" PH Phillips Truss head Screw BZ (300338-1) (1) Upper Hood (1) Lower grill ASSEMBLE THE SHROUD - Figure J-1...

  • Page 18: Log Installation

    K. LOG INSTALLATION - Log Set #CXL-500 This log set includes 11 logs and 1 pkg. rock wool burning embers. Note: Each log is numbered on the bottom and should be installed according to the instructions and diagrams below. Install base logs, CX1, CX2, CX3, onto the burner as shown in Figure K-1, aligning the mounting holes in the bottom of the logs to the mounting studs in the burner.

  • Page 19: Complete The Installation

    L. COMPLETE THE INSTALLATION THIS STEP SHOULD ONLY BE DONE BY A QUALIFIED INSTALLER OR SERVICE TECHNICIAN: A) Perform lighting and shutdown procedures as described on pages #19-#20 for Model #CSK-335 and pages #22-#23 for Model #CSK-335-RF. This should be done prior to replacing the glass so that any necessary adjustments can be made and proper operation and log position verified.

  • Page 20: Thermostat - Remote Control - Wall Switch Installation (Model #Csk-335 Only)

    M. MODEL CSK-335 ONLY: 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 Thermostat Wiring Diagram ‘OFF’...

  • Page 21: Lighting & Shutdown Procedures

    N. MODEL #CSK-335 ONLY: 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.
  • Page 22 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.

  • Page 23: Manifold (Outgoing) & Inlet (Incoming) Pressure Check Procedures

    MODEL #CSK-335 ONLY: 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.

  • Page 24: Model #Csk-335-Rf

    MODEL #CSK-335-RF ONLY: 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.
  • Page 25 *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. Push the control knob on the gas valve in slightly and turn counterclockwise to the "ON"...

  • Page 26: Manifold (Outgoing) & Inlet (Incoming) Pressure Check Procedures

    MODEL #CSK-335-RF ONLY: 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.

  • Page 27: Maintenance Requirements

    O. MAINTENANCE REQUIREMENTS MILLIVOLT BOARD SYSTEM 1. The appliance should be inspected at least once a year by a professional service person. 1. Annual cleaning of the burner is required. The burner assembly may be removed for easier NOTE: INSTALLATION AND REPAIR SHOULD BE DONE access.

  • Page 28: Millivolt Board Removal / Installation Procedures

    P. MILLIVOLT BOARD REMOVAL & INSTALLATION. See Figures P-1 - P-3. REMOVE THE MILLIVOLT BOARD ASSEMBLY: Open the doors or lower grill to access the gas valve & controls. NOTE: It is not necessary to remove the shroud or full door shroud to remove the millivolt board.
  • Page 29 INSTALL THE MILLIVOLT BOARD ASSEMBLY: NOTE: The millivolt board must be fitted with a gasket, (included) to seal the board. Make certain this gasket is properly placed around the opening before installing the millivolt board. Grasp the millivolt board with both hands and place into the insert firebox, aligning the (6) mounting holes in the board to the mounting studs on the bottom of the firebox.

  • Page 30: Troubleshooting Guide

    O. TROUBLE SHOOTING GUIDE NOTE: The millivolt board includes the following items: Valve, pilot assembly, piezo, electrode, on/off rocker switch, burner, burner venturi tube, & burner orifice. 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.
  • Page 31 PROBLEM CAUSE SOLUTION Burner won't light. Pilot not lit. Relight pilot. Regulator valve not turned “ON”. Turn valve to "ON". Rocker switch not turned “ON”. (Model CSK-335) Depress switch. Rocker switch wires not connected. (Model CSK-335) Check wiring diagram, Figure Q-1, to ensure that all wires are secure.

  • Page 32: Replacement Parts

    REPLACEMENT PARTS Replacement parts are available through your local dealer. Information on optional components not listed below, is also available through your dealer. MILIIVOLT BOARD AND PARTS - CSK-335 CXL-800 Chaska Millivolt Board - Natural Gas 700-224 3/8" Flexible Gas Line - Valve to Burner connection 700-023 On/Off Rocker Switch 700-235...

  • Page 33: Warranty Policy

    Page 31...
  • Page 34 Page 32...

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