kozy heat CHASKA-XL CSK-335 Installation & Operating Manual
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kozy heat CHASKA-XL CSK-335 Installation & Operating Manual

Chaska - xl direct vent gas fireplace insert
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See also: Operation & Installation Manual , Installation Manual
Models
#CSK-335
#CSK-335-RF
CHASKA - XL
Direct Vent Gas Fireplace Insert
INSTALLATION & OPERATING
MANUAL
FAILURE TO INSTALL THIS FIREPLACE CORRECTLY CAN CAUSE
READ INSTRUCTIONS CAREFULLY BEFORE INSTALLATION.
SERIOUS STRUCTURAL AND FIRE HAZARDS AND MAY VOID
YOUR WARRANTY.
www.nficertified.org
This fireplace may be covered under one or more of
the following U.S. Patents: #5,931,154 , #6,004,493, #6,029,655
www.kozyheat.com
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 electrical switches; do not use the
phone in your building.
♦ Immediately call your gas supplier from a
neighbor's phone. Follow your gas supplier's
instructions.
♦ If you cannot reach your gas supplier, call the fire
department.
Installation & service must be performed by a qualified
installer, service agency, or the gas supplier.
This appliance may be installed in an aftermarket
permanently located, manufactured (mobile) home,
where not prohibited by local codes. This appliance is
only for use with the type(s) of gas indicated on the
rating plate. This appliance is not convertible for use
with other gases, unless a certified kit is used.
IMPORTANT:
We recommend that our gas
hearth products be installed
and
serviced
by
profes-
sionals who are certified in
the U.S. by the National
®
Fireplace Institute
(NFI) as
NFI Gas Specialists.
Sept. 2008
CSK-335-R05

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Summary of Contents for kozy heat CHASKA-XL CSK-335

  • Page 1 Models #CSK-335 ♦ Do not store or use gasoline or other flammable #CSK-335-RF vapors and liquids in the vicinity of this or any other appliance.

  • Page 2: Table Of Contents

    Remove the Glass Assembly …………..............6 Remove the Air Duct …………………………………..........6 Fan Installation ………………………………….................. 7-8 Model #CSK-335 …………………................7 Model #CSK-335-RF …………………………………..........8 Installing the Insert …………………………………................. 9-14 Co-Linear Vent System …………................ 9-11 Position the Insert …..

  • Page 3: Commonwealth Of Massachusetts

    COMMONWEALTH OF MASSACHUSETTS NOTE: The following requirements reference various Massachusetts and national codes not contained in this document. REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall 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 seven (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:...

  • Page 4: Fireplace Insert Specifications

    MODEL: #CSK-335 / #CSK-335-RF CHASKA-XL DIRECT VENT GAS FIREPLACE INSERT INSTALLATION & OPERATING INSTRUCTIONS IMPORTANT: READ THIS MANUAL BEFORE INSTALLING AND USING THIS FIREPLACE This fireplace has been tested to and complies with ANSI Z21.88a-2007 CSA 2.33a-2007 “VENTED GAS FIREPLACE HEATERS” by OMNI-Test Laboratories, Portland, OR. Installation must conform with local building codes or in the absence of local building codes, with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 -...

  • Page 5: Requirements Of Existing Fireplace

    The efficiency rating of this appliance is a product thermal efficiency rating determined under continuous operating conditions and was determined independently of any installed system. THIS INSERT IS APPROVED FOR INSTALLATION IN MASONRY AND FACTORY-BUILT SOLID FUEL BURNING FIREPLACES. CAUTION: THIS APPLIANCE MUST NOT BE CONNECTED TO A CHIMNEY FLUE SERVING A SEPARATE SOLID-FUEL BURNING APPLIANCE.

  • Page 6: Fireplace Insert Components

    6. Refractory Panels. Model CSK-335 includes 150 CFM fan with limit switch and speed control. Model CSK-335-RF includes modulating valve on millivolt board, fan kit and remote control. WARNING: Failure to position the parts in accordance with the diagrams in this installation manual or failure to use only parts specifically approved for this appliance may result in property damage or personal injury.

  • Page 7: Preparing The Existing Fireplace

    A) PREPARE THE EXISTING FIREPLACE WARNING: CUTTING ANY SHEET-METAL PARTS OTHER THAN COMPONENTS LISTED IN THIS SECTION OF THE EXISTING FIREPLACE IN WHICH THIS GAS FIREPLACE INSERT IS TO BE INSTALLED IS PROHIBITED. 1) The refractory, glass doors, screen rails, screen mesh and log grates may be removed from the fireplace before installing this gas fireplace insert.
  • Page 8 Pressure check taps for both the manifold (outgoing) and inlet (incoming) pressures are located in front of the gas valve. The right pressure tap is the manifold pressure and the left pressure tap is the incoming pressure. Follow instructions on page #21 for Model #CSK-335 and page #24 for Model CSK-335-RF for checking these pressures.

  • Page 9: Insert Preparation

    C. REMOVE THE FOLLOWING ITEMS FROM THE FIREPLACE INSERT: 1. GLASS ASSEMBLY: Figure C-1 A) Locate the spring-loaded latches securing the glass assembly (under the firebox). B) While holding onto the glass frame, pull the latch handles out, then down to release from the clips on the glass assembly.

  • Page 10: Fan Installation

    D. MODEL #CSK-335 ONLY: FAN INSTALLATION INSTRUCTIONS This fireplace insert comes complete with a fan and thermostatic control switch already installed. A speed control, receptacle and 8 ft. fan cord have been installed, wired and mounted in a removable electrical box panel on the right side of the fireplace.

  • Page 11: Model #Csk-335-Rf

    INSTALLATION OF THIS FAN WIRING SHOULD BE DONE ONLY BY A QUALIFIED INSTALLER. IMPORTANT: A fan assembly is pre-installed and wired to the RF gas valve in the CSK-335-RF models. A receptacle and 8 ft. fan cord have been installed, wired and mounted in a removable electrical box panel on the right side of the fireplace.

  • Page 12: Installing The Insert

    ‘stubbed’ into the existing chimney from inside the fireplace using a minimum of 4' combustion air intake pipe. KOZY HEAT #816-CL CO-LINEAR VENT SYSTEM: The co-linear pipes included in this vent system is designed to extend up to 35 ft.
  • Page 13 2. RUN THE VENT SYSTEM THROUGH THE EXISTING CHIMNEY OPTIONAL: We recommend wrapping the first 3 ft. of the vent system below the termination cap with non- faced fiberglass insulation (secure with wire) before running it through the existing chimney. This will prevent cold air from coming down the existing chimney.

  • Page 14: Position The Insert

    OPTIONAL: We recommend placing non-faced fiberglass batting insulation between the pipes and existing chimney to prevent heat loss up the chimney. (See Figure E-4) OPTIONAL: PLACE NON-FACED FIBERGLASS BATTING INSULATION BETWEEN THE PIPES AND EXISTING CHIMNEY TO PREVENT HEAT LOSS UP THE CHIMNEY. Figure E-4 3.

  • Page 15: Secure The Air Duct

    F. POSITION THE FIREPLACE INSERT: Slide the insert into the fireplace opening. Figure F-1 2. Secure the air duct onto the insert by positioning the air duct into the channels at the top of the insert and sliding the air duct forward until it stops. Figures F-2 & F-3. Position air duct into the channels and slide forward Figure F-2...

  • Page 16: Complete The Gas Line Installation

    4. If necessary, level the insert by threading the leveling bolts (included in the components packet) into the nuts mounted in the bottom of the insert behind the lower air passage - 2 each side. See Figure F-5. Figure F-5 LEVELING LEGS (2 PER SIDE) Complete the gas line installation 1.

  • Page 17: Complete Fan Wiring Installation (Models #Csk-335 & #Csk-335-Rf)

    I. Complete the fan wiring installation: Model #CSK-335 only: Refer also to Figure D-1, page #7. 1. Secure the electrical access panel to the side of the fireplace. 2. Place the thermostatic control switch on the bottom of the fireplace.

  • Page 18: Assemble & Attach The Shroud

    J) ATTACH THE 3 pc.SHROUD (If installing a Full Door Shroud, refer to the instructions that are included with that component.) Shroud assembly includes: (1) Shroud top (2) 10-24 x 1" RH Philips Mch Screw (#300388) (1) Shroud left side (6) 8 x 3/8"...

  • Page 19: Log Installation

    K. LOG INSTALLATION - Log Set #CXL-500 This log set includes 11 logs and 1 pkg. rock wool burning embers. Note: Each log is numbered on the bottom and should be installed according to the instructions and diagrams below. 1. Install base logs, CX1, CX2, CX3, onto the burner as shown in Figure K-1, aligning the mounting holes in the bottom of the logs to the mounting studs in the burner.

  • Page 20: Complete The Installation

    A) Perform lighting and shutdown procedures as described on pages #19-#20 for Model #CSK-335 and pages #22-#23 for Model #CSK-335-RF. This should be done prior to re-installing the glass so that any necessary adjustments can be made and proper operation and log position verified.

  • Page 21: Thermostat - Remote Control - Wall Switch Installation (Model #Csk-335 Only)

    M. MODEL CSK-335 ONLY: THERMOSTAT - WALL SWITCH - REMOTE INSTALLATION CAUTION: DO NOT CONNECT HIGH VOLTAGE (115V) WIRE TO THE GAS VALVE! Thermostat Wiring Diagram If desired, a thermostat (wireless style available), wall switch, or remote control assembly may be used to turn the fireplace ‘OFF’ and ‘ON’. Only Figure M-1 ONE of these may be installed.

  • Page 22: Lighting & Shutdown Procedures

    N. MODEL #CSK-335 ONLY: LIGHTING AND SHUTDOWN PROCEDURES NOTE: Prior to lighting, check all fittings for leakage. This is accomplished by applying soapy water on all connections made. If there is any leakage, bubbles will appear at the point of connection. If bubbles occur, tighten the fittings until the bubbles no longer appear.
  • Page 23 The pilot will generally light with two or three pushes on the igniter. Hold the knob in for about one (1) minute after the pilot is lit. Release knob and it will pop back out. Pilot should remain lit. If it goes out, repeat steps 4 through 8. *If knob does not pop out when released, stop and immediately call your service technician or gas supplier.

  • Page 24: Manifold (Outgoing) & Inlet (Incoming) Pressure Check Procedures

    MODEL #CSK-335 ONLY: PRESSURE TEST - MANIFOLD & INLET PRESSURE IMPORTANT NOTICE: A pressure check tap for both the manifold (outgoing) and inlet (incoming) pressure has been incorporated into the valve. The left pressure tap is the manifold pressure and the right pressure tap measures the incoming pressure. Follow the instructions below for proper pressure testing procedures.

  • Page 25: Model #Csk-335-Rf

    MODEL #CSK-335-RF ONLY: LIGHTING AND SHUTDOWN PROCEDURES NOTE: Prior to lighting, check all fittings for leakage. This is accomplished by applying soapy water on all connections made. If there is any leakage, bubbles will appear at the point of connection. If bubbles occur, tighten the fittings until the bubbles no longer appear.
  • Page 26 *If knob does not pop out when released, stop and immediately call your service technician or gas supplier. *If the pilot will not stay lit after several tries, turn the gas control knob to "OFF" and call your service technician or gas supplier. Push the control knob on the gas valve in slightly and turn counterclockwise to the "ON"...

  • Page 27: Manifold (Outgoing) & Inlet (Incoming) Pressure Check Procedures

    MODEL #CSK-335-RF ONLY: PRESSURE TEST - MANIFOLD & INLET PRESSURE IMPORTANT NOTICE: A pressure check tap for both the manifold (outgoing) and inlet (incoming) pressure has been incorporated into the valve by HONEYWELL Controls. The left pressure tap is the manifold pressure and the right pressure tap measures the incoming pressure.

  • Page 28: Maintenance Requirements

    It is imperative that the burner be cleaned once a year. The fan should be disconnected from electrical current, and CSK-335 Pilot CSK-335-RF Pilot cleaned (vacuumed) every six months. The bearings are sealed and require no oiling.

  • Page 29: Millivolt Board Removal / Installation Procedures

    6. Model #CSK-335-RF: Unplug the fan cord from the receptacle, then disconnect the (2) wires from the fan cord. Note: The wires will remain connected to the back of the gas valve. Refer to wiring diagram, Figure D- 2, page #8.
  • Page 30 7. Model #CSK-335: Re-connect any wall switch, remote control or thermostat wires onto the top & bottom terminals on the gas valve marked ‘TH’. 8. Model #CSK-335-RF: Re-connect the wires from the valve to the fan cord. Refer to wiring diagram, Figure Q-2, page #29. Plug the 3-prong plug on the fan cord into the receptacle.

  • Page 31: Troubleshooting Guide

    Pilot hood misdirecting pilot flame Check pilot flame location. Flame must be from thermocouple (or Generator - RF Valve). burning on generator(s) and thermocouple (CSK-335). Refractory panels not positioned Secure refractory panels with against firebox back & sides. high-temp sealant.

  • Page 32: Wiring Diagram

    Turn valve to "ON" Rocker switch not turned “ON”. (Model CSK-335). Depress switch. Rocker switch wires not connected. (Model CSK-335). Check wiring diagram Figure Q-1 to ensure that all wires are secure. Generator wires loose at regulator terminals Reposition wire an tighten screws. See Figures Q-1 &...

  • Page 33: Replacement Parts

    This appliance tested & certified by: OMNI-Test Laboratories, Inc. 13327 NE Airport Way Portland, Oregon 97230 Hussong Manufacturing Company, Inc. Models #CSK-335 / CSK-335-RF - US & CANADIAN INSTALLATIONS 204 Industrial Park Drive September 2008 Lakefield, MN 56150 www.kozyheat.com Page 30...

  • Page 34: Limited 10 Year Warranty

    Hussong Manufacturing Co., Inc. warranties to the original purchaser of this Kozy Heat Fireplace, that it is YEARS 2 - 10: Subject conditions &...

  • Page 35: Warranty Policy

    LIFETIME WARRANTY IS EXTENDED AS FOLLOWS: Hussong Manufacturing warranties to the original purchaser that the firebox, heat exchanger, fiber logs, burner tube and glass of this Kozy Heat fireplace will not be defective in material or workmanship under normal use and service for as long as you own this product.

This manual is also suitable for:

Chaska-xl csk-335-rfChaska-xlCsk-31Csk-31-rf

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