kozy heat BAYPORT-41-LE Installation And Operation Manual
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kozy heat BAYPORT-41-LE Installation And Operation Manual

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HUSSONG MANUFACTURING CO., INC.
B A Y P O R T - 4 1 - L E
Model #BAY-41-LE
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.
— 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.
• 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.
— Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
Hussong Mfg. Co., Inc. • BAY-41-LE
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: 19-508 • Rev. 5, July 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. B A Y P O R T - 4 1 - L E Model #BAY-41-LE 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 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

    6.2 Minimum Termination Clearances ............27 14.0 REPLACEMENT PARTS LIST..........54 7.0 VENTING .................. 28 LIMITED LIFETIME WARRANTY ............ 55 7.1 Rear Vent Conversion Instructions............28 #BAY-41-LE R.5 July 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. #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces INTRODUCTION 7...

  • Page 8: Specifications

    When the appliance is installed at elevations above 4,500 ft (1,372 m), the certified high altitude rating shall be reduced at the rate of 4% for each additional 1,000 ft (305 m). 8 SPECIFICATIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 9: Appliance Dimensions

    ” ” (169mm) (58mm) (955mm) (300mm) ¾ ” 2” (1035mm) (51mm) BACK VIEW ¾ ” ⁄ ” (70mm) (156mm) ⁄ ” (955mm) Figure 2.1, Appliance Dimensions #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces SPECIFICATIONS 9...

  • Page 10: Safety Barrier Dimensions

    SAFETY SCREEN B41-PTF2 REQUIRES THE FIREPLACE TO BE 2-1/4” (57mm) ABOVE THE ½ HEARTH AND 3” (76mm) ” CLEARANCE FROM THE OUTSIDE (1004mm) EDGE TO A SIDEWALL B41-PTF2 10 SPECIFICATIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 11: Framing

    Align the in the stand-off heat shields with the holes in the top stand-off brackets Secure with (8) screws provided in the fireplace components packet. Figure 3.1, Stand-Off Assembly and Installation #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 11...

  • Page 12: Nailing Flange Assembly And Installation

    FLANGE NAILING FLANGE INSTALLED NAILING FLANGE AS SHIPPED FRAMING STUD TOP VIEW FRAMING STUD STAND-OFF FLANGE 1/4” (6mm) CLEARANCE Figure 3.2, Nailing Flange Assembly and Installation 12 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 13: Clearances To Combustibles

    1” (25mm) clearance from the vent pipe to combustible material. ⁄ ” (1012mm) 13” ¼ ” (331mm) (6mm) ⁄ ” (716mm) ¼ ” (1048mm) ⁄ ” (1431mm) Figure 3.3, Typical Installation Options #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 13...

  • Page 14: Wall Enclosure Rough Opening

    SINGLE VERTICAL HEADER BOARD IS REQUIRED TO MAINTAIN CLEARANCES TO COMBUSTIBLES ½ ” (1130mm) ⁄ ” (1051mm) ½ ” (445mm) Figure 3.4, Framing Dimensions and Requirements 14 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 15: Vent Termination Framing

    Cut and frame an opening in the wall to allow the vent system to run level through the wall pass-through. Follow the vent pipe manufacturer’s installation instructions for vent installation. ½ ” (1359mm) Figure 3.5, Horizontal Vent Terminations #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 15...

  • Page 16: Outdoor Covered Fireplace Installation

    The width of the overhang to EACH side of the replace (C) must be 5 ft or greater. Figure 3.6, Outdoor Covered Fireplace Install - 1 16 FRAMING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 17 MINIMUM WEATHERPROOF OVERHANG IN FRONT AND SIDES INSIDE OUTSIDE FREE STANDING STRUCTURE (WEATHERPROOF ENCLOSURE) Figure 3.7, Outdoor Covered Fireplace Install - 2 #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING 17...

  • Page 18: Facing And Finishing

    54” (1372mm) • Top vent minimum horizontal vent terminations using flex pipe minimum chamber height: 58” (1473mm) 18 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 19 **NON-COMBUSTIBLE ZONE: 54” (1372mm) minimum chamber height for Natural Gas & Propane top vent minimum horizontal vent terminations using rigid pipe ***NON-COMBUSTIBLE ZONE: 58” (1473mm) minimum chamber height for top vent minimum horizontal vent terminations using ex pipe Figure 4.2, B41-RSF2 Mantel Requirements #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 19...
  • Page 20 NOTE: 42-7/8” x 10-1/2” NON-COMBUSTIBLE MATERIAL SUPPLIED WITH FIREPLACE ALLOWS 3/4” OVERLAP ONTO FRAMING SIDES AND 1/2” ONTO HEADER. Figure 4.4, BAY-41 Non-Combustible Zone 20 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 21: Finishing Trim Kit Assembly #B41-Ftk

    Secure with screws previously removed from the heat shields and Figure 4.5, Finishing Trim Kit Installation #B41-FTK #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 21...

  • Page 22: Exterior Trim Kit Assembly

    Remove and save the top and bottom screw on each side of the corners of the unit, as shown below. outer shell of the unit. Figure 4.6, Exterior Trim Kit Installation #B41-081 22 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 23: Safety Barrier Installations

    Figure 4.7, #B41-RSF2 Installation BACK OF THE FIREPLACE SAFETY SCREEN FRONT MUST MAKE CONTACT WITH THE FIREPLACE FACE/ FINISH MATERIAL Figure 4.8, Side View Gasket Install #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 23...
  • Page 24 To remove safety screen: lift the screen up and out of slots. FIRST POSITION NOTCHED TAB LOUVER FIRST POSITION LOUVER NOTCH Figure 4.9, Safety Screen Louver and Notch Locations Figure 4.11, Adjust Louver 24 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 25: Gas Line Connection

    Natural Gas 5” WC (1.25 kPa) 10.5” WC (2.62 kPa) 7” WC 1.74 kPa recommended Propane 12” WC (2.99 kPa) 13” WC (3.24 kPa) recommended #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces GAS LINE CONNECTION 25...

  • Page 26: 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 26 TERMINATION LOCATIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 27: 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/unventilated soffits. #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces TERMINATION LOCATIONS 27...

  • Page 28: Venting

    2) REMOVE (4) SCREWS SECURING 6 (168mm) COMBUSTION AIR INTAKE COLLAR 3) REMOVE (6) SCREWS SECURING EXHAUST COVER REAR PLATE 3) REMOVE (6) SCREWS SECURING 4” (101mm) EXHAUST COLLAR 28 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 29 3) INSERT TABS ON OUTER COVER PLATE INTO SLOTS ON APPLIANCE TOP. SECURE WITH (1) SCREW PREVIOUSLY REMOVED. 3) INSERT TABS ON REAR COVER PLATE INTO SLOTS. SECURE WITH (1) SCREW PREVIOUSLY REMOVED. #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 29...

  • Page 30: Approved Vent Systems

    • For each additional 90° elbow used after the first elbow, 3 ft (91.4 use with Kozy Heat 4” x 7” #700 Series Flexible Direct Vent system cm) must be subtracted from maximum venting allowed. (horizontal terminations only). Refer to Section 7.8 #700-2 Series •...

  • Page 31: Coaxial Rigid Pipe Venting Configurations

    914 mm 50 ft 15.2 m (i) Minimum / Maximum Vertical Venting: 3’ (914mm) minimum vertical length / 50’ (15.24m) maximum vertical length + termination cap #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 31...
  • Page 32 CORNER INSTALLATION 9” (229mm) V + 90° ELBOW + 18” (457mm) H 15” (381mm) V + 90° ELBOW + 48” (1219mm) H (ii) 32 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 33 25 ft 7.6 m 25 ft 7.6 m 50 ft 15.2 m Maximum number of 90° elbows: 4 Figure 7.2, NG/Propane - Top Vent Combination Venting (V/H) #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 33...
  • Page 34 *It does not matter whether it turns right or left See Figure 7.3 on page 35 for natural gas and propane combination venting from the rear. NATURAL GAS ONLY 18” (457mm) 45° ELBOW (horizontal) (ii) 34 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 35 25 ft 7.6 m 25 ft 7.6 m 50 ft 15.2 m Maximum number of 90° elbows: 4 Figure 7.3, NG/Propane - Rear Vent Combination Venting (H/V) #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 35...

  • Page 36: Converting To A Direct Vent System

    4” x 6-5/8” rigid pipe + Retro Connector + 10’ (3.05m) minimum length of 4” aluminum flexible pipe / 50’ (15.24m) maximum length of 4” aluminum flexible pipe + top adapter + termination cap 36 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 37 (3.05m) minimum length of 3” x 3” aluminum flexible pipe / 50’ (15.24m) maximum length of 3” x 3” aluminum flexible pipe + 50’ (15.24m) termination cap 10’ (3.05m) (iii) 24” (610mm) maximum #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 37...

  • Page 38: 700-2 Series Direct Vent Termination Kit(S)

    7” pipe on fireplace or extension kit STAND-OFF Vinyl siding protector (not shown) BRACKETS Wall Thimble with 1 in (25 mm) top clearance Figure 7.4, Installation and Assembly of #700-2 Series 38 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 39: Fireplace Setup

    Lift the bottom frame up and out of slots on firebox floor. To reinstall, align the tabs on the bottom frame and lower into position. Reinstall safety barrier. Figure 8.1, Bottom Louver Removal #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FIREPLACE SETUP 39...

  • Page 40: B41-500 Log Set Installation

    Position the ember panel in front of the burner. Figure 8.2, Base Logs Figure 8.3, Installed Log Set 40 FIREPLACE SETUP Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 41: Control Board Removal And Installation

    Turn the manual valve counterclockwise to the ON position. 10. Reconnect electrical power. 11. Verify proper log placement, operation of fireplace, and any electrical components. Figure 8.4, Control Board Removal and Installation #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FIREPLACE SETUP 41...

  • Page 42: Electrical Information

    Follow instructions included with assembly. • If an optional component is to be used, run low-voltage wires from control module to the location of component. 42 ELECTRICAL INFORMATION Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 43 FLAME MALE END SENSOR BATTERY PACK IPI/CPI SWITCH 886 PROFLAME PILOT BURNER Figure 9.2, Electronic Gas Valve Wiring Schematic with Thermostat or Wall Switch Wiring #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces ELECTRICAL INFORMATION 43...

  • Page 44: B41-028 Optional Fan Kit

    10. Turn speed control counter-clockwise until it ‘clicks’ . This is the OFF position. Turn speed control ON by turning knob clockwise past the ‘click’ - this is the highest setting. 44 ELECTRICAL INFORMATION Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 45: Operating Instructions

    OFF position. To access gas controls under the fireplace, remove the bottom Reinstall bottom frame portion. frame portion. Press the ON/OFF rocker switch to “OFF”. #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces OPERATING INSTRUCTIONS 45...
  • Page 46 ON. This will ignite the pilot only. The pilot will remain lit when the MODULATOR KNOB main burner ON/OFF rocker switch is pressed to OFF. Figure 10.1, Rocker Switch Locations Figure 10.2, HI/LO Pressure Regulator Knob 46 OPERATING INSTRUCTIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 47: Adjustment

    Disconnect hose and tighten the inlet (IN) pressure tap by turning screw clockwise. Screw should be snug. Do not over (B) MANIFOLD (A) INLET PRESSURE PRESSURE TAP Figure 11.1, Pressure Check Taps (Electronic Gas Valve) #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces ADJUSTMENT 47...

  • Page 48: Burner Flame Adjustments

    Reinstall all components previously removed. WITH BLACK TIPS BURNER VENTURI SHORT, BLUE FLAMES LIFTING (GHOSTING) FLAMES Figure 11.3, Flame Appearance and Characteristics Figure 11.2, Burner Venturi 48 ADJUSTMENT Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 49 Reinstall baffle by inserting the tabs on the baffle into the slots on the firebox back wall. Secure the baffle to the firebox ceiling with (3) screws. Reinstall all components previously removed. #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces ADJUSTMENT 49...

  • Page 50: Troubleshooting

    Check for faulty or incorrect wiring. wiring Plugged main burner orifice Remove blockage. Pilot flame Verify the pilot flame is properly directed to ignite burner. See pilot flame troubleshooting above. 50 TROUBLESHOOTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...
  • Page 51 Check the vent pipes for leaks, and the vent cap for debris. Repair the system vent pipes or remove debris from vent cap, if necessary. No reaction to command Battery back up batteries low Replace batteries. #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces TROUBLESHOOTING 51...

  • Page 52: 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. 52 MAINTENANCE Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 53: Burner And Pilot System

    It must de-energize the safety shutoff in no more Figure 13.2, Pilot and Burner Correct Flame Appearance than (30) seconds. BURNER ORIFICE BURNER PORTS Figure 13.1, Burner System #BAY-41-LE R.5 July 2019 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces MAINTENANCE 53...

  • Page 54: Replacement Parts List

    B41-028 Manual Gas Shut-off Valve 700-203 Bottom Frame B41-201B Hussong Manufacturing Co., Inc. P.O. Box 577 204 Industrial Park Drive Lakefield, MN 56150-0577 BAY-41-LE 54 REPLACEMENT PARTS LIST Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #BAY-41-LE R.5 July 2019...

  • Page 55: 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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