kozy heat CALLAWAY 72 Installation And Operation Manual
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kozy heat CALLAWAY 72 Installation And Operation Manual

Direct vent gas fireplace
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HUSSONG MANUFACTURING CO., INC.
C A L L A W A Y 7 2
Model #CLW-72
Direct Vent Gas Fireplace
English and French installation manuals are available through your
local dealer. Visit our website www.kozyheat.com.
Les manuels d'installation en français et en anglais sont disponibles
chez votre détaillant local. Visitez www.kozyheat.com .
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly
could result in serious injury, death, or
property damage.
ͷ Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
ͷ 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.
• Leave the building immediately.
• 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.
ͷ Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
Hussong Mfg. Co., Inc. • CLW-72
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.
INSTALLATION AND
OPERATION MANUAL
This
appliance
an
aftermarket,
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.
DANGER
A barrier designed to reduce the risk of burns
from the hot viewing glass is provided with this
appliance and shall be installed for the protection
of children and other at-risk individuals.
Report No: 18-441 • Rev. 1, April 2019
may
be
installed
permanently
located,
HOT GLASS WILL
CAUSE BURNS
DO NOT TOUCH GLASS
UNTIL COOLED
NEVER ALLOW CHILDREN
TO TOUCH GLASS
in

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  • Page 1 INSTALLATION AND OPERATION MANUAL HUSSONG MANUFACTURING CO., INC. C A L L A W A Y 7 2 Model #CLW-72 Direct Vent Gas Fireplace English and French installation manuals are available through your local dealer. Visit our website www.kozyheat.com. Les manuels d’installation en français et en anglais sont disponibles chez votre détaillant local.
  • Page 3 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. To ensure you receive a quality product, the burner and valve assembly are 100 percent test-fired, and the complete fireplace is thoroughly inspected before packaging.

  • Page 5: Table Of Contents

    6.1 Vertical Vent Cap Termination ..............34 6.2 Minimum Termination Clearances ............35 14.0 REPLACEMENT PARTS LIST..........59 7.0 VENTING .................. 36 LIMITED LIFETIME WARRANTY ............ 60 #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces TABLE OF CONTENTS 5...

  • Page 7: Introduction

    Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces INTRODUCTION 7...

  • Page 8: Specifications

    Verify the household breaker is shut off prior to working on any electrical lines. • The AC power supply to this appliance must be hot at all times and shall not have a switch installed in it. 8 SPECIFICATIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 9: Appliance Dimensions

    ⁄ ” (108mm) ¾ ” (130mm) GAS LINE (248mm) ELECTRICAL ACCESS HOLE ACCESS ½ ½ ⁄ ” ” ” (140mm) (2071mm) (68mm) Figure 2.1, CLW-72 Dimensions #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces SPECIFICATIONS 9...

  • Page 10: Barrier Dimensions

    RECTANGLE SURROUND (1 PIECE) RECTANGLE SURROUND (4 PIECE) CW72-RS CW72-RS4 ⁄ 87” ” (2210mm) (2062mm) ⁄ ½ ” ” (580mm) (622mm) GALLERY SURROUND FORGED SURROUND CW72-GS CW72-FS 10 SPECIFICATIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 11: Framing

    NOTE: If installing a heat transfer kit(s), please reference the manual included with the kit. Figure 3.1, Stand-off Assembly and Installation #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 11...

  • Page 12: Nailing Flange Assembly And Installation

    NAILING FLANGE AS SHIPPED FRONT VIEW TOP VIEW FRAMING STUD " STAND-OFF FLANGE NAILING FLANGE (64mm) Clearance FRAMING STUD NAILING FLANGE Figure 3.2, Nailing Flange Installation 12 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 13: Clearances To Combustibles

    (2197mm) TYPICAL CORNER INSTALLATION ¼ ” (793mm) ⁄ ” (1552mm) ⁄ ½ ” ” ⁄ ” (2197mm) (3129mm) (2212mm) 1” (25mm) Figure 3.3, Clearance to Combustibles #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 13...

  • Page 14: Wall Enclosure Rough Opening

    The bottom of the fireplace must be placed directly on a wood or non-combustible surface (not linoleum or carpet). If the fireplace ⁄ ” (1235mm) ¼ ” (2013mm) ½ ” (2197mm) 22” (559mm) Figure 3.4, Framing Dimensions 14 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 15: Floor Support And Protection

    FIREPLACE ENCLOSURE FLOOR Figure 3.6, Recess Framing - Side View ¼ ” (108mm) ⁄ ” (1311mm) ¼ ” ½ ” (2013mm) (2197mm) 22” (559mm) Figure 3.5, Recess Framing #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 15...

  • Page 16: Vent Termination Framing

    Follow the vent pipe manufacturer’s installation instructions for vent installation. ½ ” (2070mm) Figure 3.7, Vent Termination Locations 16 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 17: Outdoor Covered Fireplace Installation

    The width of the overhang to EACH side of the replace (C) must be 5 ft or greater. Figure 3.8, Outdoor Covered Fireplace Install #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 17...

  • Page 18: Heat Distribution Cover Plates

    REMOVE (6) CIRCLE COVER PLATES FOR KZK-072 OR VENTED CAVITY OPTIONS FRONT AND TOP VENTED CAVITY Figure 3.9, Cover Plate Removal 18 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 19: Vented Cavity

    30 for vented cavity facing and mantel requirements. Figure 3.13, Convection Baffle Removal 60” (1524mm) CEILING AIR DISCHARGE OPENING Figure 3.11, Clearance from Air Discharge Opening to Sprinkler Head #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 19...
  • Page 20 NOTE: ALL FRAMING REQUIREMENTS OUTLINED IN SECTION 3.5, 3.6, & 3.7 APPLY TO THIS INSTALLATION Figure 3.17, Front Vented Cavity Crown Molding Installation Figure 3.14, Front Vented Cavity Standard Installation 20 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...
  • Page 21 ” MIN 8” AIR DISCHARGE OVERHANG 3” MIN 70” MIN AIR DISCHARGE OPENING 6” MAX 76” MIN Figure 3.18, Front Vented Cavity Alternative Installation with Overhang #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 21...
  • Page 22 ” (38mm) ½ ” (38mm) NOTE: ALL FRAMING REQUIREMENTS OUTLINED IN SECTION 3.5, 3.6, & 3.7 APPLY TO THIS INSTALLATION Figure 3.19, Top Vented Cavity Installation 22 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...
  • Page 23 MUST BE INSTALLED 6” MAX ¼ ” MIN 6” AIR DISCHARGE OVERHANG AIR DISCHARGE OPENING 6” MAX 6” Figure 3.21, Top Vented Cavity Alternative Installation with Overhang #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 23...

  • Page 24: Facing And Finishing

    In Figure 4.5, screws can only penetrate the fireplace outer shell up to 1/2" (13mm) in the allowed areas. 24 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...
  • Page 25 14” (356mm) ¼ ” 6” (2013mm) 11” (279mm) (152mm) 8” (203mm) FINISHING EDGE ¼ ” (718mm) FIREPLACE ENCLOSURE FLOOR Figure 4.2, Non-combustible Mantel Clearances #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 25...
  • Page 26 (517mm) ⁄ ” ½ ” (1235mm) (1791mm) ⁄ ” ⁄ ” (142mm) (465mm) ¾ ” (247mm) ½ ” (2197mm) Figure 4.3, Finished Opening Clearances 26 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...
  • Page 27 NO SCREWS ALLOWED NO SCREWS ALLOWED ¾ ¾ 13” 13” ” ” (330mm) (330mm) (95mm) (95mm) Figure 4.5, Minimum Non-Combustible Finishing Dimensions Screw Locations #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 27...

  • Page 28: Cw72-Sck Optional Skim Coat Kit

    Figure 4.4, Minimum Non-Combustible Finishing Dimensions on page 20 for maintaining required areas. Figure 4.6, Hand Bend Tab Figure 4.9, Installed Panels and Non-Combustible Material Figure 4.7, Aligned Corners 28 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 29: Masonry Finishing Guidelines For Optional Surrounds

    1-1/2" (38mm) 1-1/2" (38mm) CW72-RS4 2-5/8" (66mm) 2-5/8" (66mm) CW72-GS 6" (152mm) 2-1/2" (64mm) CW72-FS 3-1/8" (79mm) 3-1/8" (79mm) Figure 4.10, Masonry Finishing Materials Guidelines #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 29...

  • Page 30: Vented Cavity Facing And Finishing Options

    (467mm) ” (715mm) FINISHING EDGE 14” (356mm) 17” (432mm) ½ ” (248mm) 20” (508mm) Figure 4.11, Vented Cavity No Surround Facing and Finishing Clearances 30 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...
  • Page 31 ⁄ ” (784mm) EDGE OF SURROUND 14” (356mm) ¼ ” 17” (432mm) (184mm) 20” (508mm) Figure 4.14, Vented Cavity CW72-RS Facing and Finishing Clearances #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 31...

  • Page 32: Barrier Installation

    Secure with (4) truss head screws (provided). Reinstall safety barrier. (2) TRUSS HEAD SCREWS - LEFT SIDE MOUTNING NUTS Figure 4.17, Surround Installation 32 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 33: Gas Line Connection

    Fuel Minimum Pressure Maximum Pressure Natural Gas 5” WC (1.25 kPa) 10.5” WC (2.62 kPa) Propane 12” WC (2.99 kPa) 13” WC (3.24 kPa) #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces GAS LINE CONNECTION 33...

  • Page 34: Termination Locations

    Over 12/12 to 14/12 1.52 Over 14/12 to 16/12 1.83 Over 16/12 to 18/12 2.13 Over 18/12 to 20/12 2.27 Over 20/12 to 21/12 2.44 34 TERMINATION LOCATIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 35: Minimum Termination Clearances

    VINYL SOFFIT, VINYL CEILING, AND VINYL OVERHANG DISCLAIMER: Clearances to heat resistant material (i.e. wood, metal). This does not include vinyl. Hussong Manufacturing Co., Inc. will not be held responsible for heat damage caused from terminating under vinyl overhangs, vinyl ceilings, or vinyl ventilated/unventi- lated soffits. #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces TERMINATION LOCATIONS 35...

  • Page 36: Venting

    (203mm) air intake co-axial vent pipe system. fuel quality, venting configuration, and other factors. To achieve This appliance is approved for use for Kozy Heat Power Venting #KPV desirable flame appearance, the vent exhaust may be restricted by (sold separately).

  • Page 37: Natural Draft Vent Installation

    Minimum/ Maximum Vertical Venting: 45° vertical elbow + 3’ (914mm) minimum vertical length / 50’ (15.24m) maximum vertical length + termination cap 50’ (15.24m) 3’ (914mm) #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 37...
  • Page 38 15.2 m 36” (914mm) VENT PIPE Maximum number of elbows: 5 6’ (1.83m) 9” (229mm) 48” (1219mm) VENT PIPE Figure 7.2, Natural Gas Natural Draft Combination Venting 38 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...
  • Page 39 Minimum/ Maximum Vertical Venting: 45° vertical elbow + 3’ (914mm) minimum vertical length / 50’ (15.24m) maximum vertical length + termination cap 50’ (15.24m) 3’ (914mm) #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 39...
  • Page 40 15.2 m 48” (1219mm) VENT PIPE Maximum number of elbows: 5 8’ (2.44m) 9” (229mm) 60” (1524mm) VENT PIPE Figure 7.3, Propane Natural Draft Combination Venting 40 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 41: Fireplace Setup

    Figure 8.2, Glass Media Installation PROVIDED LATCH TOOL ATTACHED VALANCE AGAINST UNIT TO TOP LATCH ASSEMBLY ALL FOUR LATCHES SECURING VALANCE Figure 8.1, Glass Frame Assembly Removal #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FIREPLACE SETUP 41...

  • Page 42: Control Board Removal And Installation

    10. Turn the manual valve counterclockwise to the ON position. 11. Reconnect electrical power. 12. Verify proper media placement, operation of fireplace, and any electrical components. Figure 8.3, Control Board Removal and Installation 42 FIREPLACE SETUP Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 43: Electrical Information

    National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.1. Figure 9.1, Wiring Schematics #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces ELECTRICAL INFORMATION...

  • Page 44: Light Kit

    Figure 9.2, Light Kit Location YELLOW FEMALE CONNECTORS RED MALE CONNECTORS BLUE FEMALE CONNECTORS RED MALE CONNECTORS (from control module) Figure 9.3, Light Kit Wiring 44 ELECTRICAL INFORMATION Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 45: Sl42-028 Optional Fan Kit

    See Section Figure 9.1, Wiring Schematics on page 43. 10. Reinstall the glass frame assembly, access cover and safety barrier. Figure 9.5, Steps 5 through 9 Figure 9.4, Steps 3 and 4 #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces ELECTRICAL INFORMATION...

  • Page 46: Operating Instructions

    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. 46 OPERATING INSTRUCTIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 47: Setup Proflame

    Turn the main burner OFF by setting the ON/OFF switch in the OFF position. The pilot will remain lit even if burner is turned off, provided CPI mode is turned on. #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces OPERATING INSTRUCTIONS 47...

  • Page 48: Ifc Module Ignition Sequence

    Red LED Indicator will blink (3) times in intervals. • Verify gas is turned on. • Verify sensor is not shorted. • Follow Section 10.2 Initialize the Control System. 48 OPERATING INSTRUCTIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 49: Remote Control Operation

    LCD screen. Simultaneously press the mode key and the up arrow key to activate or deactivate this function. #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces OPERATING INSTRUCTIONS 49...
  • Page 50 ‘ON’ or ‘OFF’ . Verify all (3) AAA batteries are installed in the remote control. Remove (1) AAA battery. 50 OPERATING INSTRUCTIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...
  • Page 51 A single ‘beep’ will confirm reception of the command. 10.8.9.1 Deactivate Light Kit Modulation Verify all (3) AAA batteries are installed in the remote control battery bay. Remove (1) AAA battery. #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces OPERATING INSTRUCTIONS 51...

  • Page 52: Adjustment

    (A) to verify the tap is completely sealed. Manometer should read no pressure. (A) INLET PRESSURE (B) MANIFOLD PRESSURE TAP Figure 11.1, Pressure Check Taps 52 ADJUSTMENT Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 53: Burner Flame Adjustments

    Loosen screw on venturi and adjust as necessary. Re-tighten screw. Reinstall all components previously removed. SHORT, BLUE FLAMES LIFTING (GHOSTING) FLAMES Figure 11.3, Flame Appearance and Characteristics BURNER VENTURI Figure 11.2, Burner Venturis #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces ADJUSTMENT 53...
  • Page 54 (127 mm) exhaust pipe. Make necessary modifications to achieve desired flame appearance. Insert restrictor plate into the 5 in (127 mm) exhaust pipe with the tabs pointing towards you. Reinstall all components previously removed. 54 ADJUSTMENT Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 55: Troubleshooting

    Remote control not working Replace batteries. properly No call for heat Verify remote control is powered ON and thermostat operation is turned OFF. #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces TROUBLESHOOTING 55...
  • Page 56 Reprogram remote control to IFC module. remote control and IFC module A maximum number of failed Reset IFC module. ignitions or flame restorations has been reached 56 TROUBLESHOOTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 57: Maintenance

    Qualified Service Person Performed by: Annually Frequency: Action: • Examination of the vent system is required. • The flow of combustion and ventilation air must not be obstructed. #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces MAINTENANCE 57...

  • Page 58: Burner And Pilot System

    Figure 13.2, Pilot and Burner Correct Flame Appearance safety system. It must de-energize the safety shutoff in no more than (30) seconds. BURNER ORIFICE Figure 13.1, Burner System 58 MAINTENANCE Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CLW-72 R.1 April 2019...

  • Page 59: Replacement Parts List

    Manual Gas Shut-off Valve 700-203 Glass Latch Tool JOR-GLT Hussong Manufacturing Co., Inc. P.O. Box 577 204 Industrial Park Drive Lakefield, MN 56150-0577 CLW-72 #CLW-72 R.1 April 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces REPLACEMENT PARTS LIST 59...

  • Page 60: Limited Lifetime Warranty

    • All parts and material except the items listed in the 30 day Kozy Heat gas appliance from the date of purchase to the original warranty and any exclusions or limitations that may apply. purchaser, that it is free of defects in materials and workmanship at *Hussong Mfg.

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