kozy heat CARLTON 46 Installation And Operation Manual
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kozy heat CARLTON 46 Installation And Operation Manual

Direct vent gas fireplace
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C A RLTO N 4 6
INSTALLATION AND OPERATION MANUAL
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.
This appliance may be installed in 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.
permanently
located,
HOT GLASS WILL
CAUSE BURNS
DO NOT TOUCH GLASS
UNTIL COOLED
NEVER ALLOW CHILDREN
TO TOUCH GLASS
Rev. 12, February 2022
Starting Serial Number: 09 455950 22

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Summary of Contents for kozy heat CARLTON 46

  • Page 1 C A RLTO N 4 6 INSTALLATION AND OPERATION MANUAL 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: Homeowner Reference Information

    Read this manual before installation or operating this appliance. Please retain this owner’s manual for future reference. CONG R ATU L ATI ONS ! 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

    15.0 LIMITED LIFETIME WARRANTY ........... 62 7.0 VENTING .................. 33 7.1 Approved Vent Systems ................33 7.3 Vent Restriction ..................34 7.4 Vent Heat Shield Assembly Installation ..........35 #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • 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 #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022 R.12 February 2022...

  • Page 8: Specifications

    • The AC power supply to this appliance must be hot at all times and shall not have a switch installed in it. #CAR-46 #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022 R.12 February 2022...

  • Page 9: Appliance Dimensions

    Electrical access ⁄ ” ¾ (82mm) ⁄ ” ⁄ ” ” (1085mm) (340mm) (217mm) ¾ ⁄ 2” ” ” (51mm) (1162mm) (58mm) FIGURE 2.1 #CAR-46 Dimensions #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 10: Barrier Dimensions

    ” (8mm) (1076mm) ⁄ SIDE ” 32” OVERLAP (923mm) (812mm) ⁄ ” (9mm) C46A-FPDSF2 C46-RSF2 (TOP AND SIDES OVERLAP) NO OVERLAP - INSIDE FIT FIGURE 2.2 Safety Barrier Dimensions #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 11: Framing

    • This fireplace may be installed in a bedroom. • Please be aware of the large amount of heat this fireplace will produce when determining a location. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 12: Stand-Off Assembly And Header Heat Shield

    1/2” (12mm) non-combustible material material will overlap the front face of the replace Side View Side View Non-combustible Non-combustible material material FIGURE 3.1 Stand-off Assembly, Header Heat Shield, and Insulation Piece Adjustment #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 13 Place the insulation piece in between the two stand-off Stand-o Assembly, Insulation piece, and Header Heat Shield Installation (overlap installation shown) FIGURE 3.2 Stand-off Assembly, Header Heat Shield, and Insulation Piece Installation #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 14: Nailing Flange Assembly And Installation

    Stand-o ange Nailing ange Framing stud Nailing ange as shipped Nailing ange installed Top View Framing Stud Side View Stand-o ange 1/4” (6mm) CLEARANCE FIGURE 3.3 Nailing Flange Installation #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 15: Clearances To Combustibles

    ¼ ” (6mm) ¾ ” ¼ ” (1163mm) (1175mm) ⁄ ” ¾ (822mm) ” (1644mm) Includes 1/2” (13mm) typical nish material with ush mount FIGURE 3.4 Clearance to Combustibles #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 16: Rough Framing

    ” nish material (1175mm) ½ ” (546mm) 1/2” (13mm) typical nish material Includes 1/2” (13mm) typical nish material with ush mount FIGURE 3.5 Framing Dimensions and TV Recess Construction #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 17 Kozy Heat’s #800-WPT3, or wall thimble products that comply with the required 1” (25mm) top clearance to combustibles, must be installed for all horizontal (rigid or flexible) vent runs that pass through interior or exterior walls.
  • Page 18 ¾ ¾ ” ” (1366mm) (1366mm) ¾ ” (1214mm) #800-WPT3* Framing Dimensions *Ships with #800-1 Kit 11” (279mm) 11” (279mm) ⁄ ” (139mm) FIGURE 3.6 Vent Termination Framing Dimensions #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 19: Outdoor Covered Fireplace Installation

    EXAMPLE: If roo ine (B) is 10’ above the base of replace, the overhang (A) must be 5’ or greater. The width of the overhang to EACH side of the replace (C) must be 5’ or greater. FIGURE 3.7 Outdoor Covered Fireplace Install - 1 #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 20 Minimum weatherproof overhang in front and sides INSIDE OUTSIDE Free standing structure (weatherproof enclosure) FIGURE 3.8 Outdoor Covered Installation - 2 (your fireplace may look different than the one shown) #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 21: Exterior And Interior Heat Transfer Kit Cover Plate(S)

    Kits installed at the same time. It can be up to two of the same heat transfer kit or a combination of interior and exterior kits. FIGURE 3.9 Cover Plate Removal #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 22: Facing And Finishing

    Joint compound must be cured as per manufacturer’s recommendations. • For a painted surface, use a high quality acrylic latex primer and finish coat. Avoid flat or light-colored paints to prevent discoloring. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 23 (457mm) 16” Trim (406mm) 14” (356mm) 10” (254mm) 66” (1676mm) Non-combustible material only Insulation piece MUST rest against non-combustible material 36” (914mm) Combustible oor FIGURE 4.1 Combustible Mantel Requirements #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 24 6” (152mm) 12” Non-combustible (305mm) material only 6” (152mm) 66” (1676mm) Non-combustible material only Insulation piece MUST rest against non-combustible material 36” (914mm) Combustible oor FIGURE 4.2 Non-combustible Mantel Requirements #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 25 SECTION 4 FACING AND FINISHING Facing and Finishing Requirements 66” (1676mm) unlimited 2” (50mm) FIGURE 4.3 Sidewall Clearance #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 26 3/4” overlap onto framing sides and 1/2” onto header. Screws are allowed to penetrate the stand-o assembly to attach non-combustible material (board). FIGURE 4.4 Non-Combustible Material #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 27: Optional Finishing Trim Kit (Ftk): #C46-Ftk

    (8) screws. shown below. Insert the tabs on the trim panel into the slots on the bottom opening of the fireplace. 3/4” Trim FIGURE 4.5 Finishing Trim Kit #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 28: 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 4.6 #C46-RSF2 Installation #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 29 To remove safety screen: lift the screen up and out of slots. FIRST POSITION NOTCHED TAB LOUVER FIRST POSITION LOUVER NOTCH FIGURE 4.7 Safety Screen Louver and Notch locations FIGURE 4.9 Adjust Louver #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 30: Gas Line Connection

    Natural Gas Propane Minimum Inlet 5” WC (1.25 kPa) 12” WC (2.99 kPa) Pressure Maximum Inlet 10” WC (2.49 kPa) 13” WC (3.24 kPa) Pressure #CAR-46 #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022 R.12 February 2022...

  • Page 31: 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 FIGURE 6.1 Vertical Vent Cap Clearance #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 32: Minimum Natural Draft 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. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 33: Venting

    This appliance is equipped for use with a 5” (127mm) exhaust by 8” (203mm) air intake co-axial vent pipe system. This appliance is approved for use for Kozy Heat 800 Series Flexible Vent Kit (sold separately). Vertical 5” x 8” co-axial flexible vent pipe with vertical terminations are not approved for use with this fireplace.

  • Page 34: Vent Restriction

    Remove innermost circle to create less restriction Remove all inner rings for the least restriction Ba e restrictor Vent exhaust Thumb screws FIGURE 7.1 Restrictor Plate Installation #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 35: Vent Heat Shield Assembly Installation

    (25mm) vent stand-off tab will rest on top of the vent pipe. FIGURE 7.4 Vent Heat Shield on a Corner Installation Shown at location for natural gas Attachment screws FIGURE 7.2 Installed Vent Heat Shield Assembly #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 36: Vent Installation

    35. 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 #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 37 18” (457mm) minimum vertical rise + 90° elbow + 6” (152mm) minimum horizontal run / 20’ (6m) maximum horizontal run + termination cap 20’ (6m) 6” (152mm) 18” (457mm) #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 38 = 50’ (15.2m) of total length • (2) 45° degree elbows may be used in place of (1) 90° elbow. • Maximum of (5) 90° elbows. FIGURE 7.5 Natural Gas Combination Venting #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 39 Horizontal Termination 18” (457mm) vertical rise + 90° elbow + 6” (152mm) minimum horizontal run / 8’ (2.4m) maximum horizontal run + termination 8’ (2.4m) 6” (152mm) 18” (457mm) #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 40 = 50’ (15.2m) of total length • (2) 45° degree elbows may be used in place of (1) 90° elbow. • Maximum of (5) 90° elbows. FIGURE 7.6 Propane Combination Venting #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 41: 800-1 Series Direct Vent Termination Kit(S) Installation

    Mount the required #800-WPT3 wall pass through (G) with the required 1” (25mm) top clearance and 1” (25mm) side clearances to the exterior wall, and seal. (OPTIONAL) insulate the wall-pass through with any unfaced #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 42: Fireplace Setup

    Place the crushed glass media (included with the fireplace) into cavity in front of the burner. Randomly place lava rock on top of glass media. Reinstall log set, glass frame assembly, and safety barrier. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 43: 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 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 44: Control Board Removal And Installation

    11. Reinstall the glass frame assembly and safety barrier. 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. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 45: Electrical Information

    AUX 1 (LIGHT KIT) LIGHT KIT GREEN BLACK (MAIN) BATTERY PACK 6V DC ORANGE (with 1 amp fuse) (PILOT) ON/OFF ROCKER SWITCH GROUND FIGURE 9.1 Komfort 8K1 Wiring Diagram #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • 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. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 47: Setup Komfort 8K1 Control Module

    A single beep will be emitted from the control module indicating pilot-on-demand feature has been activated. • A double beep will be emitted from the control module indicating the pilot-on-demand feature has been deactivated. #CAR-46 #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022 R.12 February 2022...

  • Page 48: Remote Control Operation

    (5) seconds. Press any button to in ON mode. resume full functionality. In idle mode, only active functions will show on the screen. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 49 Only active functions will be displayed when the remote control is ON. • The transmission indicator icon will flash and a single beep will confirm the reception of the command. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 50 If the room temperature rises above the set temperature, the fireplace will shut down the main burner. The fireplace will turn back on after the room temperature drops below the set temperature. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 51 The transmission indicator icon will flash to confirm the intensity. reception of the command. • The transmission indicator icon will flash and a single beep will confirm the reception of the command. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 52: Adjustment

    (0.67 - 2.49 kPa) inlet pressure tap (A) to verify the tap is completely sealed. Manometer should read no pressure. Manifold pressure tap Inlet pressure tap FIGURE 11.1 Pressure Check Taps #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 53: Burner Flame Adjustments

    Venturi(s) open too far. Close venturi settings(s) slightly. Lifting (ghosting) ames Venturi settings(s) closed too far. Open venturi(s) slightly OR gas pressure too high - check manometer settings FIGURE 11.3 Flame Appearance and Characteristics #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 54 Remove innner ring(s) on restrictor plate or remove restrictor plate Insert restrictor into the 5” (127mm) exhaust pipe with the tabs FIGURE 11.6 Flame Appearance and Characteristics for Restricting Vent #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 55: Troubleshooting

    Control system set to Pilot-on- Set control system to intermittent pilot ignition mode. Refer to section will not extinguish 10.8.7, PILOT IGNITION SELECTION on page 50. Demand ignition mode #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 56 Venturi air shutter may need to be opened slightly to allow more air into the gas mix. Refer to section 11.2.1, BURNER VENTURI on page 54. Incorrect vent cap installation Adjust if necessary. Vent cap blockage Remove debris if necessary. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...
  • Page 57 A maximum number of failed Reset Komfort 8K1 control module. Refer to section 10.2, INITIALIZE THE KOMFORT 8K1 CONTROL SYSTEM on page 48. ignitions or flame restorations has been reached #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 58: Maintenance

    7.0, VENTING on page 33. Performed by: Qualified Service Person Frequency: Annually Action: • Examination of the vent system is required. • The flow of combustion and ventilation air must not be obstructed. #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 59: Burner And Pilot System

    It must de-energize the safety shutoff in no more than (30) seconds. FIGURE 13.2 Pilot and Burner Correct Flame Appearance Pilot assembly Back burner ori ce Front burner ori ce FIGURE 13.1 Burner System #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 60: Replacement Parts List

    700-203 Manual Gas Shut-off Valve C46-HHS Vent Heat Shield Assembly C46-201B Bottom Frame Hussong Manufacturing Co., Inc. 204 Industrial Park Drive PO Box 577 Lakefield, MN 56150-0577, USA CAR-46 #CAR-46 HUSSONG MFG. CO., INC. KOZY HEAT FIREPLACES R.12 February 2022...

  • Page 62: 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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