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Installation Manual
INSTALLATION AND OPERATION MANUAL
D I R E C T
V E N T
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.
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 of gas indicated on the rating plate. This
appliance is not convertible for use with other gases, unless a certified kit is used.
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.
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 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.
WARNING
HOT GLASS WILL CAUSE BURNS.
DO NOT TOUCH GLASS UNTIL COOLED.
NEVER ALLOW CHILDREN TO TOUCH GLASS.
G A S
F I R E P L A C E
www.kozyheat.com
English and French Installation Manuals
Available Through Your Local Dealer or
Visit Our Website at www.kozyheat.com
Report No. 216-S-37-6.5
FEB 2012
ALP-36-L-REV-01
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Table of Contents
Troubleshooting
Related Manuals for kozy heat Alpha ALP-36-L
Summary of Contents for kozy heat Alpha ALP-36-L
- Page 1 INSTALLATION AND OPERATION MANUAL English and French Installation Manuals Available Through Your Local Dealer or Visit Our Website at www.kozyheat.com D I R E C T V E N T G A S F I R E P L A C E INSTALLER: Leave this manual with the appliance.
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Page 2: Introduction And Homeowner Reference Information
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. -
Page 3: Table Of Contents
TABLE OF CONTENTS INTRODUCTION VENTING (cont.) Introduction and Homeowner Reference Information Restrictor CONTENTS Elbows Table of Contents Horizontal & Vertical Combination Venting Illustrations SAFETY INFORMATION #800-1 Series Flex Vent Installation Instructions 23-24 Safety Information Termination Vent Cap Location FEATURES Vent Termination Clearances Features LIGHT KIT COMMONWEALTH OF MASSACHUSETTS INFORMATION... -
Page 4: Safety Information
SAFETY INFORMATION This fireplace has been tested by OMNI-Test Laboratories, Portland, Oregon and complies with: ANSI Z21.88-2009/CSA 2.33-2009, “Standard for Vented Gas Fireplace Heaters.” CAN/CGA 2.17-M91 (R2009), “Gas-Fired Appliances for Use at High Altitudes”. CAN/CSA P.4.1-09, “Testing Method for Measuring Annual Efficiency”. This installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1 The appliance, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, wth the National... -
Page 5: Features
FEATURES STANDARD FEATURES High efficiency High quality lifetime glass 37” x 32” (940mm x 813mm) IPI control system with remote control Engineer-designed burner system Log Set Automatic Fan Kit (2) -75 CFM Top Light Kit Firebox Bottom Refractory Exterior Bottom Refractory Minnesota Energy Code compliant to 50 pascals SAFETY FEATURES Each unit factory tested! -
Page 6: Commonwealth Of Massachusetts Information
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... -
Page 7: Specifications
SPECIFICATIONS FIREPLACE DIMENSIONS FIREPLACE DESCRIPTION Height Width Back Width Depth Opening Glass Frame Top Stand-off Back to vent Width Height Height center DIMENSIONS INCHES 41-11/16 46-1/2 41-11/16 23-3/8 5-5/16 9-3/8 MILLIMETERS 1059 1182 1059 All stand-off brackets must be attached to fireplace. Do not remove. Top stand-off brackets are not load bearing. Non-combustible zone: Top stand-offs provide 5-5/16”... -
Page 8: Components List
SPECIFICATIONS COMPONENTS LIST PART NUMBER DESCRIPTION AL36-L-100 Control Board Assembly 700-203 Manual Gas Shut-off Valve AL36-500 Log Set AL36-L-135 Burner Assembly AL36-CAD Component Access Doors AL36-HP Hearth Plate AL36-LKT Light Kit AL36-208 Fan Kit AL36-057T Glass Frame Assembly 700-308 Remote Control 600-002 Double Receptacle Assembly 942-085... -
Page 9: Placement Clearance Requirements
Most TV manufacturers specify in their instructions that a TV should not be installed on, near, or above a heat source. Television location rests solely on the homeowner. Hussong Manufacturing will not be held liable for any adverse effects on a TV located near a Kozy Heat Fireplace that may be caused by heat. -
Page 10: Fireplace Preparation
FIREPLACE PREPARATION STAND-OFF / STAND-OFF HEAT SHIELD ASSEMBLY & INSTALLATION Top and back stand-off brackets must be formed and attached prior to positioning fireplace into framed opening. Top stand-offs provide 5-5/16” (135mm) minimum clearance to header. Use only non-combustible material in this area for entire WARNING width of fireplace. -
Page 11: Nailing Flange Assembly & Installation
FIREPLACE PREPARATION NAILING FLANGE ASSEMBLY & INSTALLATION Remove (4) nailing flanges from fireplace sides. With the 1/2” (13mm) long stand-offs on nailing flanges facing away from fireplace, align nailing flange with holes on outside corners of fireplace. Secure with screws (provided in components packet) through slots in nailing flanges. Bend perforation on nailing flange until parallel with fireplace face. -
Page 12: Framing
FRAMING WALL ENCLOSURE ROUGH OPENING Determine whether wall surface will be flush with fireplace face (wall and fireplace face will be covered with non-combustible material such as tile) or, framing will be flush with fireplace face, which results in a flat wall appearance. IMPORTANT Framing dimensions should allow for wall covering thickness and fireplace facing materials. -
Page 13: Vertical Terminations
FRAMING Determine exact position of your fireplace, including hearth height, width, and depth, (if applicable). If possible, place fireplace in such a manner that vent termination will be placed between two studs, eliminating the need for additional framing. If masonry is to be used (optional), prepare necessary foundation for the masonry load. When masonry construction is being used, a lintel must be used over top of fireplace to support the added weight. -
Page 14: Facing And Finishing
FACING AND FINISHING This fireplace was designed to accommodate non-combustible facing material up to 1/2” (13mm) thick. Install non-combustible facing material up to facing flange surrounding the glass frame assembly. Do not apply any material beyond this point. The glass frame assembly must be removable. -
Page 15: Typical Installation Options
TYPICAL INSTALLATION OPTIONS Kozy Heat wall pass-thru (#800-WPT or #800-WPT2) must be used on all horizontal vent runs. The horizontal heat shield included with this fireplace must be installed when incorporating minimum horizontal venting. IMPORTANT This applies to Nat. and LP minimum horizontal venting configurations. -
Page 16: Mantel Requirements
MANTEL REQUIREMENTS Non-combustible zone: No combustible materials allowed on top of fireplace within shaded area for entire width and depth WARNING of fireplace with the exception of the header. Figure 15a... -
Page 17: Hearth Plate / Component Access Doors
HEARTH PLATE / COMPONENT ACCESS DOORS INSTALL HEARTH PLATE / COMPONENT ACCESS DOORS Install glass frame assembly. Install component access doors by rotating bottoms toward center of fireplace far enough to insert mounting studs at top of glass valance through hole at top of access door. Lower bottom into position. Install hearth plate, making sure long angled flange sits behind access door handles, securing in place. -
Page 18: Gas Line Connection
GAS LINE CONNECTION GAS CONVERSION This fireplace is manufactured for use with Natural Gas. An LP conversion kit, is included with fireplace. Follow instructions included with conversion kit if converting to LP gas. The conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdiction and in ATTENTION accordance with the requirements of the ANSI Z223.1 installation code. -
Page 19: Venting
1 inch (25mm) 1 inch (25mm) ALL APPROVED VENTING Kozy Heat Wall Pass-Thru, #800-WPT (4-1/2” (114mm) - 6-1/2” (165mm) wall thickness), or #800-WPT2 (6-1/2” (165mm) -12-1/2” (318mm) IMPORTANT wall thickness) must be used on all horizontal vent runs. The horizontal heat shield included with this fireplace must be installed when incorporating minimum horizontal venting. This applies to Nat. -
Page 20: 800-Wpt Wall Pass-Thru Installation
WARNING MAINTAIN ALL CLEARANCES AS STATED IN THIS INSTALLATION MANUAL. If using Kozy Heat 800-1 Series Flexible Vent System, remove inner ring on each wall pass-thru section with a tin snips. IMPORTANT This will provide adequate room for the flexible vent system. -
Page 21: Horizontal Vent Heat Shield Installation Instructions
VENTING HORIZONTAL VENT HEAT SHIELD Loosen, but do not remove center two screws on top of fireplace. Bend horizontal heat shield at perforation to a 90° angle. Slide (2) slots on horizontal vent heat shield under loosened screws. Re-tighten screws. ATTACHMENT SCREWS Figure 20a HORIZONTAL TERMINATIONS... -
Page 22: Vertical Vent System Clearances
VENTING VERTICAL VENT SYSTEM CLEARANCES ALL SIDES ALL APPROVED VERTICAL PIPE 1 inch (25mm) VERTICAL TERMINATIONS MIN. / MAX. VERTICAL VENTING TERMINATION CAP MINIMUM: 4ft. (1.22m) + termination cap. MAXIMUM: 50ft. (15.24m) + termination cap. MINIMUM: 4ft. (1.22m) MAXIMUM: 50ft. (15.24m) Figure 21a RESTRICTOR Each installation is unique and affected by various factors including venting configuration, altitude and climate. -
Page 23: Elbows
VENTING ELBOWS For each additional 90° elbow used after first elbow, 3ft. (914mm) must be subtracted from maximum allowed venting. For each 45° elbow used, 1-1/2ft. (457mm) must be subtracted from maximum venting allowed. (2) 45° degree elbows may be used in place of (1) 90° elbow. Horizontal sections require 1/4”... -
Page 24: Series Flex Vent Installation Instructions
IF TERMINATING AGAINST VINYL SIDING, A VINYL SIDING PROTECTOR, INCLUDED WITH #844-1 AND #845-1 DIRECT VENT KITS, MUST BE USED. FOLLOW INSTRUCTIONS INCLUDED. The Kozy Heat Wall Pass-Thru, part #800-WPT or #800-WPT2, must be used on all horizontal vent applications regardless of IMPORTANT which vent system you are using. - Page 25 VENTING FLEXIBLE #800-1 SERIES cont. TERMINATION BOX MOUNTING HOLES IN EXTERIOR WALL PLATE 5” FLEX PIPE COLLAR 5” PIPE ON FIREPLACE OR EXTENSION KIT 8” FLEX PIPE COLLAR 8” PIPE ON FIREPLACE OR EXTENSION KIT VINYL SIDING PROTECTOR (not shown) INTERIOR FIRESTOP Figure 24a...
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Page 26: Termination Vent Cap Location
TERMINATION VENT CAP LOCATION This gas appliance must not be connected to a chimney serving any other appliance. Terminations against vinyl siding must use a vinyl siding protector. Follow instructions included. 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. -
Page 27: Vent Termination Clearances
VENTING (Vertical Cap Requirements) VENT TERMINATION CLEARANCES Roof Pitch H (Min.) Ft. H (Min.) m Flat to 6/12 0.30 Over 6/12 to 7/12 1.25 0.38 Over 7/12 to 8/12 0.46 Over 8/12 to 9/12 0.61 Over 9/12 to 10/12 0.76 Over 10/12 to 11/12 3.25 0.99... -
Page 28: Light Kit
LIGHT KIT CAUTION Disconnect all electric power from fireplace before performing this task. NOTE To avoid damage and prolong the life of halogen bulbs, never touch with bare hands. Always use a soft cloth when handling. Remove glass frame assembly. Page 16. Remove light kit access panel at inside top of firebox - secured with (2) screws. -
Page 29: Firebox Liner Kit Information
FIREBOX LINER KIT INSTALLATION FIRE RISK! DO NOT OPERATE THIS FIREPLACE WITHOUT A FIREBOX LINER KIT INSTALLED! WARNING Brick refractory panels act as insulation panels. Enamel panel kits include insulation panels for back and side walls. NOTE If converting to LP Gas, do so now before installing Firebox Liner Kit. Brick Refractory Firebox Liner Kits include: (3) pc. -
Page 30: Log Set Installation
#AL36-500 LOG SET INSTALLATION Numbers are located on the bottom of each log. Install in numerical order. NOTE Refer to following instructions and illustrations for proper placement. Do not place logs directly over burner port holes. CAUTION Improper log placement may affect flame appearance and cause excessive soot to build up on logs and glass. Figure 29a Align holes in bottom of #1-#3 logs with mounting pins on burner, setting down into position. -
Page 31: Wiring Schematics
WIRING SCHEMATICS THIS SYSTEM REQUIRES ELECTRICITY (120 V) AND / OR BATTERIES TO OPERATE. IMPORTANT USING BATTERY BACK UP WILL OPERATE BURNER ONLY. FAN AND LIGHT COMPONENTS WILL NOT FUNCTION ON BATTERY BACK-UP POWER. Pilot Assembly Green To Fan Orange To Lights Green / yellow Not used... -
Page 32: Control System Components
CONTROL SYSTEM COMPONENTS REMOTE CONTROL Figure 31a GAS VALVE Stepper motor Main valve connection (green) Outlet pressure tap Pilot connection (orange) Inlet pressure tap Figure 31b Pilot flame adjustment PILOT ASSEMBLY Igniter Pilot Flame Sensor Figure 31c... -
Page 33: Control System Components
CONTROL SYSTEM COMPONENTS RECEIVER Figure 32a FAN CONTROL MODULE Figure 32b DFC CONTROL BOARD Figure 32c... -
Page 34: System Operation
SYSTEM OPERATION INITIALIZING THE SYSTEM FOR THE FIRST TIME Move slider switch on receiver to OFF position. Install 4 AA batteries (included in components packet) into receiver battery bay. Using the end of a paper clip, or other similar object, press button through hole marked PRG on receiver front cover. - Page 35 SYSTEM OPERATION REMOTE FLAME CONTROL The remote control has six (6) flame levels. With system ON and flame level at maximum, press Down Arrow Key once to reduce flame height by one step until flame is turned off. The Up Arrow Key will increase flame height on step each time it is pressed. If Up Arrow Key is pressed while system is on but flame is off, the flame will come on in High position.
- Page 36 SYSTEM OPERATION FAN SPEED CONTROL Fan speed can be adjusted through six (6) speeds. To activate this function use Mode Key to index to fan control icon. Use Up/Down Arrow Keys to turn on, off or adjust fan speed. A single ‘beep’ will confirm reception of the command. Figure 35a ACCENT LIGHT KIT (not available in all fireplace models) The auxiliary function controls the AUX power outlet on the Fan control module which in turn controls the light kit.
- Page 37 SYSTEM OPERATION LOW BATTERY DETECTION TRANSMITTER: Remote control battery lifespan depends on various factors including battery quality, number of ignitions, changes to room thermostat set point, etc. When transmitter batteries are low, a Battery Icon will appear on the LCD display before all battery power is lost. When batteries are replaced this icon will disappear.
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Page 38: Lighting And Shutdown Instructions
LIGHTING AND SHUTDOWN FOR YOUR SAFETY - READ BEFORE OPERATING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT, WARNING CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. 1. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand. 2. - Page 39 LIGHTING AND SHUTDOWN (cont.) OPERATING INSTRUCTIONS Read safety information on previous page and front STOP! c o v e r o f t h i s m a n u a l b e f o r e c o n t i n u i n g . Turn off all electric power to the appliance.
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Page 40: Pressure Testing
PRESSURE TESTING Pressure check taps for manifold (outgoing) and inlet (incoming) pressure have been incorporated into the valve. The pressure IMPORTANT tap marked OUT measures outgoing pressure and the pressure tap marked IN measures incoming pressure. Follow instructions below for proper testing procedures. Refer to page 17 for proper NAT and LP manifold pressures. The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa). -
Page 41: Finalizing The Installation
FINALIZING THE INSTALLATION FLAME APPEARANCE: Flame appearance is affected by several factors including altitude, venting configuration and fuel quality. Although the venturi setting has 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 venturi may need adjustment. -
Page 42: Restrictor Troubleshooting / Installation After Termination Completion
FINALIZING THE INSTALLATION RESTRICTOR USAGE: Turn fireplace on and allow to burn for 15 minutes. If flames indicate there is excessive draft (flickering, short flames), a restrictor may be necessary. If flames indicate insufficient draft (lifting or ghosting flames), a previously installed restrictor may need to be modified or removed. TO AVOID PROPERTY DAMAGE OR PERSONAL INJURY, ALLOW FIREPLACE AMPLE TIME TO COOL BEFORE MAKING ANY WARNING ADJUSTMENTS AND / OR INSTALLATIONS. -
Page 43: Maintenance
MAINTENANCE The appliance is required to be inspected at least once a year by a professional service person. The compartment below 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. -
Page 44: Troubleshooting
TROUBLESHOOTING ATTENTION TROUBLESHOOTING MUST BE PERFORMED BY A QUALIFIED TECHNICIAN. Before proceeding with the steps in the following troubleshooting guide, verify the power supply (AC/DC adapter or Fan Control Module) is present and receiver batteries and/or battery pack are fresh and installed with correct polarity. Make sure all connections between wire harnesses and system components are proper and positive. - Page 45 TROUBLESHOOTING PILOT AND BURNER EXTINGUISH WHILE IN OPERATION No LP in tank. Check and refill if necessary. Glass frame assembly not installed correctly. Refer to corresponding instructions in this manual. Improper vent cap installation. Adjust if necessary. Vent cap blockage. Remove debris if necessary. Improper pitch on horizontal vent.
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Page 46: Optional #970 Heat Duct Kit Installation
#970 HEAT DUCT KIT INSTRUCTIONS CAUTION Read and follow instructions carefully prior to and during installation of this optional heat duct kit. INSTALLATION OF THIS DUCT KIT & ELECTRICAL WIRING MUST BE PERFORMED BY A QUALIFIED SERVICE PERSON AND IN ACCORDANCE WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES, WITH THE NATIONAL ELECTRICAL CODE, ANSI/ WARNING NFPA 70, OR THE CANADIAN ELECTRICAL CODE, CSA C22.1. - Page 47 #970 HEAT DUCT KIT INSTRUCTIONS INSTALL REGISTER MOUNTING FRAME, JUNCTION BOX, RUN WIRING Register mounting frame and fan housing are designed to fit between 2” x 4” stud walls, 16” (406mm) on center. Additional framing is required if larger opening exists. Fan motor on heat duct kit may be on opposite side of fan shown in photos.
- Page 48 #970 HEAT DUCT KIT INSTRUCTIONS RUN DUCT PIPE Run duct pipe to register location. If oval pipe will be used in conjunction with 6” (152mm) round duct pipe, shape round duct pipe to fit outside oval duct pipe. Secure with screws provided. If oval duct pipe has not been used, shape 6”...
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Page 49: Lp Conversion Kit Instructions
LP GAS CONVERSION KIT #LCK-AL36L-S LP GAS CONVERSION KIT FOR #ALP-36-L 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 or loss of life. - Page 50 LP GAS CONVERSION KIT CONVERT THE GAS CONTROL VALVE: Follow LP stepper motor pressure regulator instruction sheet included with LP conversion kit to convert gas valve. (LP marked on stepper motor pressure regulator). COMPLETE THE CONVERSION: Adjust burner tube venturi to correct setting by loosening screw, adjusting cap and retightening screw.
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Page 51: Replacement Parts List
REPLACEMENT PARTS LIST Replacement parts are available through your local dealer. Contact them for availability and pricing. CONTROL BOARD AND PARTS AL36-L-100 Control Board - Nat Gas 700-503 Valve Step Motor - Natural Gas AL36-L-101 Control Board - LP Gas 700-503-1 Valve Step Motor - LP Gas 700-660... -
Page 52: Warranty
Failure to do so may result in delayed warranty coverage and submission of proof of purchase will be required. Hussong Manufacturing Co., Inc. warranties to the original purchaser of this Kozy Heat Fireplace, that it is free of defects in materials and workmanship at the time of manufacture. -
Page 53: Warranty
LIFETIME WARRANTY IS EXTENDED AS FOLLOWS: Hussong Manufacturing Co., Inc. warranties to the original purchaser that the firebox, heat exchanger, fiber logs, burner tube and glass panel of this Kozy Heat Fireplace will not be defective in materia l or workmanship under normal use and service for as long as you own this product.