kozy heat Carlton-46 Installation And Operation Manual
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kozy heat Carlton-46 Installation And Operation Manual

Kozy heat direct vent gas fireplace
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HUSSONG MANUFACTURING CO., INC.
CARLTON-46
Model #CAR-46
Direct Vent Gas Fireplace
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.
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.
Hussong Mfg. Co., Inc. • CAR-46
may
be
installed
permanently
located,
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.
Tested &
Listed By
C
OMNI-Test Laboratories, Inc.
in
English and French installation manuals are
available through your local dealer. Visit our
website www.kozyheat.com or scan the QR
code for our mobile app.
Report No.: 0216GF044S • Rev. 02, November 2014
Installation and
Operation Manual
Portland
Oregon USA
US

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  • Page 1 Installation and Operation Manual HUSSONG MANUFACTURING CO., INC. CARLTON-46 Model #CAR-46 Direct Vent Gas Fireplace WARNING: Tested & Portland FIRE OR EXPLOSION HAZARD Listed By Oregon USA Failure to follow safety warnings exactly OMNI-Test Laboratories, Inc. could result in serious injury, death, or property damage.

  • Page 2: Table Of Contents

    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 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS ..............5 7.3 Elbows ....................23 7.4 Vertical Terminations ..............23 1.0 INTRODUCTION ..............7 7.5 Combination Venting..............24 1.1 Appliance Certification ..............7 7.6 #800-1 Series Direct Vent Termination Kit(s) ......26 1.2 Requirements for the Commonwealth of Massachusetts ..7 7.7 Vent Heat Shield Assembly Installation ........27 2.0 SPECIFICATIONS ..............

  • Page 4: Introduction

    1.0 INTRODUCTION 1.1 Appliance Certification for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print no less the one-half inch Laboratory: OMNI-Test Laboratories in Portland, Oregon (½) in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

  • Page 5: Specifications

    2.0 SPECIFICATIONS 2.1 Appliance Components Part Number Description C46-150 Control Board Assembly 700-203 Manual Gas Shut-off Valve C46-135 Burner Assembly C46-500 Log Package C46-057T Glass Frame Assembly IPI-028 Fan Kit (2)-75 CFM 700-508 Remote Control C46-HHS Vent Heat Shield Assembly 2.1.1 Additional Components Required Vent System: Refer to 7.1 Approved Vent Systems, on page 23.

  • Page 6: Appliance Dimensions

    2.3 Appliance Dimensions Table 2.1, Physical Dimensions Back to Vent Description Height Width Back Width Depth Opening Width Opening Height Stand-off Height Center Inches 45-3/4 22-3/8 21-1/2 42-3/4 30-15/16 7-3/4 Millimeters 1162 1085 ⁄ ” ¾ ” (568mm) (197mm) ½ ”...

  • Page 7: Safety Barrier Dimensions

    2.4 Safety Barrier Dimensions If the barrier becomes damaged, the barrier shall be replaced with Hussong Mfg.’s barriers for this appliance. Only doors WARNING: A barrier designed to reduce the risk of burns from certified with the appliance shall be used. the hot viewing glass is provided with this appliance and shall Please refer to 5.3 Safety Barrier Installations, on page 21, for be installed for the protection of children and other at-risk...

  • Page 8: Framing

    3.0 FRAMING 3.1 Appliance Placement material in this area for the entire width of the fireplace. DO NOT use wood, sheetrock, et cetera, in this zone. Considerations Top stand-off brackets must be formed and attached prior to WARNING: Due to high temperatures, the appliance should be positioning fireplace into framed opening.

  • Page 9: Wall Enclosure Rough Opening

    3.3 Wall Enclosure Rough Opening • If masonry is to be used (optional), prepare the necessary foundation for the masonry load. When masonry construction WARNING: Provide adequate clearances around air openings is to be used, a lintel must be used over the top of the into the combustion chamber.

  • Page 10: Floor Support And Protection

    3.4 Floor Support and Protection FIRE HAZARD: Do NOT install this appliance directly on carpeting, vinyl, or any other combustible material other than wood. • If this appliance is to be installed directly on carpeting, tile, 66 ” or other combustible material other than wood flooring, (1676mm) this appliance shall be installed on a metal or wood panel ”...

  • Page 11: Vent Termination Framing

    IMPORTANT: Horizontal vent sections require ¼ in (6 mm) rise (76mm) for every 12 in (305 mm) of travel. 3.6.3 Wall Pass-Through Kozy Heat’s #800-WPT series, or wall thimble products that 1 ” comply with the required 3 in (76 mm) top clearance to (25mm) combustibles, must be installed for all horizontal vent runs that pass through interior or exterior walls.

  • Page 12: Clearances To Combustibles

    3.7 Clearances to Combustibles TYPICAL HORIZONTAL INSTALLATION ⁄ ” (13mm) ⁄ ” (546mm) ⁄ ” (1175mm) TYPICAL VERTICAL INSTALLATION ⁄ ” (13mm) ⁄ ” (546mm) ⁄ ” (1175mm) TYPICAL CORNER INSTALLATION ⁄ ” (337mm) ⁄ ” (6mm) ¾ ” (1163mm) ⁄...

  • Page 13: 970 Heat Duct Kit

    4.0 #970 HEAT DUCT KIT 4.2 Specifications CAUTION : Read and follow instructions carefully prior to and during the installation of the optional heat duct kit. • The appliance is manufactured with (2) heat duct knock-outs. WARNING: Installation of this heat duct kit and its electrical One, or both, may be utilized.

  • Page 14: Attach Heat Duct To Fireplace

    4.3 Attach Heat Duct to Fireplace which controls fan speed and operation. Bend the tabs on fireplace top up. With circulation holes facing down, use (3) screws to fasten the tabs to the duct collar. Secure the flexible pipe to the duct collar. Verify screws penetrate both the flexible pipe and the duct collar.

  • Page 15: Run And Secure Duct Pipe

    4.6 Run and Secure Duct Pipe 4.6.1 Oval Duct Pipe Run the oval and round duct pipe to the register location. Shape the 6 in (152 mm) round duct pipe to fit outside the oval duct pipe. Secure with the screws provided. Slide the oval duct pipe over the oval collar on the register mounting bracket.

  • Page 16: Facing And Finishing

    5.0 FACING AND FINISHING 5.1 Nailing Flange Assembly Secure the nailing flanges to the fireplace with screws (provided) through the slots in nailing flanges. and Installation Bend perforation on nailing flange until parallel with fireplace NOTE: Depending on facing material, tabs can be adjusted face.

  • Page 17: Mantel And Trim Requirements

    5.2 Mantel and Trim Requirements NON-COMBUSTIBLE ZONE 66 ” (1676mm) ” (13mm) ½ NON-COMBUSTIBLE MATERIAL ONLY 36 ” (914mm) FIREPLACE ENCLOSURE FLOOR Figure 5.2, Mantel and Trim Requirements 20 FACING AND FINISHING...

  • Page 18: Safety Barrier Installations

    5.3 Safety Barrier Installations 5.3.1 Inside Fit - Recessed Installation Model #C46-RSF Locate the slots on the back side of the screen front. Partially thread (4) truss head screws, included with this assembly, into each mounting hole on the fireplace (2 each side).

  • Page 19: Gas Line Connection

    6.0 GAS LINE CONNECTION 6.1 Gas Conversion (sold separately) ATTENTION: The conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdiction and in accordance with the requirements of the ANSI Z223.1 installation code. This fireplace is manufactured for use with natural gas. Follow the instructions included with the conversion kit if converting to LP gas.

  • Page 20: Venting

    1 in (25 mm) 1 in (25 mm) 7.2.2 Wall Pass Through Kozy Heat’s #800-WPT series, or wall thimble products that comply with the required 3 in (76 mm) top clearance to combustibles, must be installed for all horizontal vent runs Figure 7.1, Vertical Termination...

  • Page 21: Combination Venting

    7.5 Combination Venting MAX: 10 ft (3.05m) MIN: IMPORTANT: The vertical vent heat shield included with this 6” (152mm) HORIZONTAL VENT fireplace must be installed for every type of venting application. HEAT SHIELD The horizontal vent heat shield must be installed when 90°...
  • Page 22 7.5.2 LP Gas Applications MAX: 4 ft (1.22m) MIN: IMPORTANT: The vertical vent heat shield included with this 6” (152mm) fireplace must be installed for every type of venting application. 90° ELBOW The horizontal vent heat shield must be installed when HORIZONTAL VENT HEAT SHIELD incorporating minimum horizontal venting.

  • Page 23: 800-1 Series Direct Vent Termination Kit(S)

    7.6 #800-1 Series Direct Vent Apply a liberal bead of exterior sealant around outer edge of termination box (A), placing assembly through the wall-pass Termination Kit(s) through in exterior wall. Place screws through the four holes (B), securing it in place. IMPORTANT: The vertical vent heat shield included with this fireplace must be installed for every type of venting application.

  • Page 24: Vent Heat Shield Assembly Installation

    7.7 Vent Heat Shield Assembly Installation IMPORTANT: The vertical vent heat shield MUST be installed for every type of venting application. The horizontal vent heat shield must be installed when incorprating minimum horizontal venting. VENT STAND-OFF TAB LP GAS LOCATION NOTE: There are (6) screw holes located in front of the flue outlet to offset the vent heat shield assembly in front of the NATURAL GAS LOCATION...

  • Page 25: Vent Terminal Clearances

    7.8 Vent Terminal Clearances 7.8.1 Vertical Vent Cap Termination WARNING: This gas appliance must not be connected to a chimney serving any other appliance. LOWEST DISCHARGE OPENING APPROVED CAP MINIMUM *12” (.30 m) APPROVED VENT PIPE ROOF PITCH = x/12 H - MINIMUM HEIGHT FROM ROOF TO LOWEST DISCHARGE OPENING Figure 7.14, Vertical Vent Cap...
  • Page 26 7.8.2 Vent Cap Clearances WARNING: This gas appliance must not be connected to a chimney serving any other appliance. AREA WHERE TERMINAL IS NOT PERMITTED Figure 7.15, Vent Cap Locations Canadian installations US installations Clearance above grade, veranda, porch, deck, or balcony 12 in (30 cm) 12 in (30 cm) Clearance to window or door that may be opened...

  • Page 27: Fireplace Setup

    8.0 FIREPLACE SETUP 8.1 Glass Frame Assembly 8.3 #C46-500 Log Set Installation WARNING: Do not operate this fireplace with the glass removed, CAUTION: Do not place logs directly over burner port holes. cracked, or broken. Replacement of the glass assembly Improper log placement may affect flame appearance and #C46-057T, should be done by a licensed or qualified service cause excessive soot to build upon the logs and glass.
  • Page 28 Figure 8.1, Base Logs Figure 8.2, Logs C46-5, C46-6, C46-8 Figure 8.3, Logs C46-7, C46-9, C46-10, C46-11 FIREPLACE SETUP 31...

  • Page 29: Control Board Removal And Installation

    8.4 Control Board Removal and Installation WARNING: If burner and/or pilot have been burning, use appropriate protection to avoid burns or damage to personal property before removing any components. DO NOT OPERATE THIS APPLIANCE WITHOUT THE SEALING GASKET (LOCATED UNDER THE CONTROL BOARD) IN PLACE. IF GASKETING IS DAMAGED, IT MUST BE REPLACED.

  • Page 30: Electrical Information

    9.0 ELECTRICAL INFORMATION WARNING: Do not use this fireplace if any part has been under with the National Electrical Code, ANSI/NFPA 70, or the Canadian water. Immediately call a qualified service technician to inspect Electrical Code, CSA C22.1. this appliance and to replace any part of the control system and 9.2 Wiring Requirements any gas control which has been under water.

  • Page 31: Operating Instructions

    10.0 OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. This appliance is equipped with an ignition device which phone.

  • Page 32: Setup Proflame

    10.1 Setup Proflame 2 IFC Module • 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 Set the main ON/OFF rocker switch in the OFF position. off, provided CPI mode is turned on.

  • Page 33: Ifc Module Ignition Sequence

    10.6 IFC Module Ignition Sequence The IFC module will try (2) times for ignition, each lasting approximately (60) seconds, with approximately (35) seconds between each attempt. With the system in OFF position, press the remote control ON/OFF key. Approximately (4) seconds after this key is depressed, the IFC module will generate sparks to the pilot hood.

  • Page 34: Remote Control Operation

    PROFLAME 2 TRANSMITTER LCD DISPLAY KEY LOCK TRANSMISSION LOW BATTERY ALARM THERMOSTAT OFF/ON/SMART ROOM BLUE BACK TEMPERATURE LCD DISPLAY CPI MODE SET POINT TEMPERATURE/LEVEL/STATE FLAME ON SPLIT FLOW ON/OFF KEY THERMOSTAT KEY LIGHT ON UP/DOWN ARROWS MODE KEY 10.8 Remote Control Operation 10.8.3 Pilot Ignition Selection (IPI/CPI) This system has the option of a continuous (standing) pilot.

  • Page 35: Smart Thermostat

    10.8.4 Turn ON the Appliance ROOM TEMPERATURE With the system in the OFF position, press the remote control ON/OFF key to turn ON the appliance. A single ‘beep’ will emit from the IFC module to confirm reception of the command. The LCD screen will display all active icons, and the IFC module will start the ignition sequence.

  • Page 36: Fan Speed Control

    10.8.8 Split Flow Control 10.8.11 Remote Control Low Battery Detection The secondary burner is controlled by the split flow. To activate Remote control battery lifespan depends on various factors this function, including battery quality, number of ignitions, changes to room thermostat set point, etcetera.

  • Page 37: Adjustment

    11.0 ADJUSTMENT 11.1 Pressure Testing 11.1.2 Manifold Pressure Test Light pilot. NOTE: The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any Loosen manifold (OUT) pressure tap by turning screw pressure testing of the system at test pressures in excess of ½ counter-clockwise.

  • Page 38: Flame Appearance Adjustments

    11.2 Flame Appearance Adjustments 11.2.1 Burner Venturi WARNING: To avoid property damage or personal injury, allow the fireplace ample time to cool before making any adjustments. NOTE: Venturi settings have been factory set. Refer to Table 11.3. Burner flame appearance is affected by several factors, including Figure 11.4, Back Burner Venturi altitude, venting configuration, and fuel quality.

  • Page 39: Restrictor

    11.3 Restrictor This fireplace is shipped with the restrictor set in the open position. After installation, it may be necessary to make adjustments to this setting. Allow the fireplace to burn for 15 minutes before making any adjustments. Follow Table 11.5 below. Table 11.5, Restrictor Adjustment Guidelines Flame Appearance Draft Problem...

  • Page 40: Troubleshooting

    12.0 TROUBLESHOOTING ATTENTION: Troubleshooting must be performed by a qualified • Verify all connections between the wire harnesses and the technician. system components are proper and positive. Before proceeding with the steps in the following troubleshooting • Verify the communication link is established between the guide, remote control and the IFC module.
  • Page 41 Issue Cause Solution Pilot and burner No LP gas in tank Check LP (propane) tank. Refill if necessary. extinguish while in operation Incorrect glass frame Refer to 8.1 Glass Frame Assembly, on page 30. assembly installation Incorrect vent cap installation Adjust if necessary Vent cap blockage Remove debris if necessary...

  • Page 42: Maintenance

    13.0 MAINTENANCE 13.2 Fans ATTENTION: Installation and repair shall only be done by a qualified service person. The appliance should be inspected CAUTION: Label all wires prior to disconnection when servicing before use by a qualified service person. This appliance is controls.

  • Page 43: Replacement Parts List

    14.0 REPLACEMENT PARTS LIST Replacement parts are available through your local dealer. Contact your local dealer for availability and pricing. CONTROL BOARD AND PARTS Control Board - NG C46-150 Valve Step Motor - LPG 700-504-1 Control Board - LPG C46-151 18 in. Flexible Gas Line - Black 700-213B S.I.T.

  • Page 44: Limited Warranty

    Hussong Manufacturing Co., Inc. warranties to the original all times, according to the operating instructions furnished. purchaser of this Kozy Heat Fireplace, that it is free of defects in This warranty is limited to defects in material and workmanship. It materials and workmanship at the time of manufacture.

  • Page 45: Lifetime Warranty

    Hussong Manufacturing Co., Inc. to repair and glass panel of this Kozy Heat Fireplace will not be defective in or replace the defective component. The foregoing warranty is material or workmanship under normal use and service for as long exclusive and in lieu of all other expressed warranties.

This manual is also suitable for:

Car-46

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