kozy heat CARLTON 46 Installation And Operation Manual

kozy heat CARLTON 46 Installation And Operation Manual

Direct vent gas fireplace
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HUSSONG MANUFACTURING CO., INC.
C A R L T O N 4 6
Model #CAR-46
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.
CAR-46 Report No: 19-536
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.
may
be
installed
permanently
located,
HOT GLASS WILL
CAUSE BURNS
DO NOT TOUCH GLASS
UNTIL COOLED
NEVER ALLOW CHILDREN
TO TOUCH GLASS
Rev. 10, February 2020
Starting Serial Number: 20 454200 09
in

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Summary of Contents for kozy heat CARLTON 46

  • Page 1 INSTALLATION AND OPERATION MANUAL HUSSONG MANUFACTURING CO., INC. C A R L T O N 4 6 Model #CAR-46 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. CON GRAT ULAT I ON S! 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.
  • Page 5: Table Of Contents

    14.0 REPLACEMENT PARTS LIST..........51 7.3 Use of Elbows ....................27 7.4 Vent Restriction ..................27 LIMITED LIFETIME WARRANTY ............ 52 7.5 Rigid Pipe Vent Installation..............28 #CAR-46 R.10 February 2020 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. #CAR-46 R.10 February 2020 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 #CAR-46 R.10 February 2020...
  • Page 9: Appliance Dimensions

    Hole Gas Line Electrical Hole Access ¾” ¾ ⁄ ” ” (1085mm) (349mm) (217mm) ⁄ ¾ ” ” 2” (58mm) (1162mm) (51mm) Figure 2.1, #CAR-46 Dimensions #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces SPECIFICATIONS 9...
  • Page 10: Barrier Dimensions

    TOP OVERLAP ” (8mm) (1076mm) ⁄ SIDE ” 32” OVERLAP (923mm) (812mm) ⁄ ” (9mm) C46A-FPDSF2 C46-RSF2 (TOP AND SIDES OVERLAP) NO OVERLAP - INSIDE FIT 10 SPECIFICATIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • 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. Stand-o Heat Shields installed Figure 3.1, Stand-off Assembly and Installation #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING...
  • Page 12: Nailing Flange Assembly And Installation

    Nailing Flange Framing Stud Nailing Flange Installed Nailing Flange Top View as Shipped Framing Stud Stand-o Flange Side View ½ ” (13mm) CLEARANCE Figure 3.2, Nailing Flange Installation Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020 FRAMING...
  • Page 13: Clearances To Combustibles

    (1175mm) Typical Corner Installation ⁄ ” (338mm) ¼ ” (6mm) ¾ ¼ ” ” (1163mm) (1175mm) ⁄ ” (822mm) ¾ ” (1644mm) Figure 3.3, Clearance to Combustibles #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING...
  • Page 14: Rough Framing

    ” (1175mm) ” ½ 1/2” (13mm) typical (546mm) nish material *Includes 1/2” (13mm) typical nish material with ush mount Figure 3.4, Framing Dimensions and TV Recess Construction Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020 FRAMING...
  • Page 15: Vent Termination Rough Framing

    Attic insulation shields may be insulated using unfaced insulation products listed as non-combustible per ASTM E 136. Kozy Heat’s #800-WPT series, or wall thimble products that comply with the required 3” (76 mm) top clearance to combustibles, must 3.6.2 Horizontal Terminations be installed for all horizontal vent runs that pass through interior or IMPORTANT: Horizontal vent sections require 1/4”...
  • Page 16: Outdoor Covered Fireplace Installation

    EXAMPLE: If roo ine (B) is 10 ft above the base of replace, the overhang (A) must be 5 ft or greater. 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 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020 FRAMING...
  • Page 17 INSIDE OUTSIDE Free standing structure (weatherproof enclosure) Figure 3.7, Outdoor Covered Installation 2 (your fireplace may look different than the one shown) #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FRAMING...
  • Page 18: Facing And Finishing

    • For a painted surface, use a high quality acrylic latex primer and finish coat. Avoid flat or light-colored paints to prevent discoloring. 18 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 19 1/2” (13mm) Non-Combustible Material Only 36 ” Insulation Piece (914mm) NOTE: Insulation piece MUST rest against non-combustible material Combustible Flooring Figure 4.1, Combustible Mantel Requirements #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 19...
  • Page 20 NOTE: A 46¼” x 10½” Non-Combustible Material (board) is supplied with the replace and allows a 3/4” overlap onto framing sides and 1/2” onto header Figure 4.3, Non-Combustible Zone 20 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 21: Optional Finishing Trim Kit (Ftk): #C46-Ftk

    Use screws included in the components packet to complete side page 11. panel installation. If installed, remove and discard the existing bottom front frame 3/4” Trim Figure 4.4, Finishing Trim Kit #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 21...
  • Page 22: Safety Barrier Installation

    Lower screen front until the notched tabs are firmly in position. • To remove safety screen: lift the screen up and out of slots. Upper Hood Safety Screen Figure 4.5, #C39-RSF2 Installation 22 FACING AND FINISHING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 23 To remove safety screen: lift the screen up and out of slots. FIRST POSITION NOTCHED TAB LOUVER FIRST POSITION LOUVER NOTCH Figure 4.6, Safety Screen Louver and Notch locations Figure 4.8, Adjust Louver #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FACING AND FINISHING 23...
  • Page 24: Gas Line Connection

    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 24 GAS LINE CONNECTION Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 25: 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 #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces TERMINATION LOCATIONS 25...
  • Page 26: Minimum Vent 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. 26 TERMINATION LOCATIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 27: 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 800 Series Flexible desirable flame appearance, the vent exhaust may be restricted by Vent Kit (sold separately).
  • Page 28: Rigid Pipe Vent Installation

    7.5.1 Natural Gas and Propane Vertical Terminations (i) Minimum / Maximum Vertical Terminations: 4’ (1219mm) minimum vertical length / 50’ (15.24m) maximum vertical length + termination cap 28 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 29 = 50 ft (15.2m) of total length 6” (152mm) • Maximum of (5) 90° elbows. 20’ (6m) 6” (152mm) 18” (457mm) Figure 7.2, Natural Gas Combination Venting #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 29...
  • Page 30 = 50 ft (15.2m) of total length • Maximum of (5) 90° elbows. 8’ (2.4m) 6” (152mm) 18” (457mm) Figure 7.3, Propane Combination Venting 30 VENTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 31: 800-1 Series Direct Vent Termination Kit(S) Installation

    8” pipe on fireplace or extension kit (not shown) Stand-o Brackets #800-WPT Series with 3” (25mm) top clearance Vinyl Siding Protector (not shown) Figure 7.4, Installation and Assembly #800-1 Series #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 31...
  • Page 32 IMPORTANT: The heat shield within the wall thimble must overlap a minimum of 1-1/2” (38mm). An extension will be needed if going If installing Kozy Heat #800 Series Flexible Vent System with either through a thicker wall than 6-1/2” (165mm). Refer to BDM vent #800-WPT or #800-WPT2, remove inner ring on each wall thimble manufacturer if wall extension is necessary.
  • Page 33: Vent Heat Shield Assembly Installation

    (25mm) vent stand-off tab will rest on top of the vent pipe. Figure 7.10, Vent Heat Shield on a Corner Installation Shown at location for Natural Gas Attachment Screws Figure 7.8, Installed Vent Heat Shield Assembly #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces VENTING 33...
  • Page 34: Fireplace Setup

    10. Randomly place lava rock on top of glass media. 11. Reinstall log set, glass frame assembly, and safety barrier. 34 FIREPLACE SETUP Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 35: C46-50B Log Set Installation

    Distribute rock wool embers onto logs and burner using a stiff bristle brush. Position the ember panel in front of the burner. Figure 8.2, Base Logs Figure 8.3, Installed Log Set #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces FIREPLACE SETUP 35...
  • Page 36: Control Board Removal And Installation

    12. Turn the manual valve counterclockwise to the ON position. 13. Reconnect electrical power. 14. Verify proper log placement, operation of fireplace, and any electrical components. 36 FIREPLACE SETUP Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 37: Electrical Information

    This appliance, when installed, must be electrically grounded in accordance with local codes, or in the absence of local codes, with Figure 9.1, Wiring Schematics #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces ELECTRICAL INFORMATION 37...
  • Page 38: 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. 38 OPERATING INSTRUCTIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 39: 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. #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces OPERATING INSTRUCTIONS 39...
  • Page 40: 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. 40 OPERATING INSTRUCTIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 41: Remote Control Operation

    LCD screen. Simultaneously press the mode key and the up arrow key to activate or deactivate this function. #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces OPERATING INSTRUCTIONS 41...
  • Page 42 ‘ON’ or ‘OFF’ . Verify all (3) AAA batteries are installed in the remote control. Remove (1) AAA battery. 42 OPERATING INSTRUCTIONS Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 43 10.9.10 Accent Light Kit (if applicable) The light intensity can be adjusted through (6) levels. Press the mode key to index to the light icon. #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces OPERATING INSTRUCTIONS 43...
  • Page 44: 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 44 ADJUSTMENT Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 45: Burner Flame Adjustments

    Venturi settings(s) closed too far. Open venturi(s) slightly Figure 11.2, Burner Venturis OR gas pressure too high - check manometer settings Figure 11.3, Flame Appearance and Characteristics #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces ADJUSTMENT 45...
  • Page 46 Remove innermost circle to create less restriction Remove all inner rings for the least restriction Ba e Restrictor Figure 11.5, Restrictor Plate Exhaust Thumb Screws Figure 11.4, Baffle Restrictor 46 ADJUSTMENT Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 47: Troubleshooting

    Remote control not working Replace batteries. properly No call for heat Verify remote control is powered ON and thermostat operation is turned OFF. #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces TROUBLESHOOTING 47...
  • Page 48 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 48 TROUBLESHOOTING Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 49: 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. #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces MAINTENANCE 49...
  • Page 50: Burner And Pilot System

    (30) seconds. Lazy, yellow ames Figure 13.2, Pilot and Burner Correct Flame Appearance Pilot Assembly Front Burner Ori ce Rear Burner Ori ce Figure 13.1, Burner System 50 MAINTENANCE Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces #CAR-46 R.10 February 2020...
  • Page 51: Replacement Parts List

    700-203 Vent Heat Shield Assembly C46-HHS Hussong Manufacturing Co., Inc. Bottom Frame C46-201B P.O. Box 577 204 Industrial Park Drive Lakefield, MN 56150-0577 CAR-46 #CAR-46 R.10 February 2020 Hussong Mfg. Co., Inc. • Kozy Heat Fireplaces REPLACEMENT PARTS LIST 51...
  • Page 52: 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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