kozy heat ALPHA-36S Installation And Operation Manual
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kozy heat ALPHA-36S Installation And Operation Manual

Direct vent gas fireplace
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HUSSONG MANUFACTURING CO., INC.
ALPHA-36S
Model #ALP-36S
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. • ALP-36S
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: 0216GF037S • Rev. 01, February 2015
Installation and
Operation Manual
Portland
Oregon USA
US

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  • Page 1 Installation and Operation Manual HUSSONG MANUFACTURING CO., INC. ALPHA-36S Model #ALP-36S 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 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

    TABLE OF CONTENTS TABLE OF CONTENTS ..............5 8.2 Venting Requirements ..............25 8.3 Use of Elbows .................25 1.0 INTRODUCTION ..............7 8.4 Restrictor Assembly and Installation .........25 1.1 Appliance Certification ..............7 8.5 Vertical Terminations ..............26 1.2 Requirements for the Commonwealth of Massachusetts ..7 8.6 Combination Venting ..............27 2.0 SPECIFICATIONS ..............

  • Page 7: 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 8: Specifications

    2.0 SPECIFICATIONS 2.1 Appliance Components Part Number Description AL36-L-150 Control Board Assembly 700-203 Manual Gas Shut-off Valve AL36-L-135 Burner Assembly AL36-HP Hearth Plate AL36-500 Log Package AL36-CAD Component Access Doors AL36--057T Glass Frame Assembly AL36-LKT Light Kit AL36-028 Fan Kit (2) - 75 CFM 600-002 Double Receptacle Assembly 700-408...

  • Page 9: Appliance Dimensions

    2.3 Appliance Dimensions Table 2.1, Physical Dimensions Glass Frame Back to Vent Description Height Width Back Width Depth Opening Width Stand-off Height Height Center Inches 41-11/16 46-1/2 46-1/2 23-3/8 38-1/4 5-5/16 9-3/8 Millimeters 1059 1182 1182 ⁄ ” (99mm) ¾ ”...

  • Page 10: Safety Barrier Dimensions

    2.4 Safety Barrier Dimensions 2.4.1 Safety Barrier Installation For models #AL36A-DSFS, #AL36A-MSFS, #AL36R-DSFS, WARNING: A barrier designed to reduce the risk of burns from #AL36R-MSFS the hot viewing glass is provided with this appliance and shall be installed for the protection of children and other at-risk Locate (2) magnets on the upper trim and (2) magnets on the individuals.

  • Page 11: Framing

    3.0 FRAMING 3.1 Appliance Placement TOP STAND OFF BRACKETS AS SHIPPED Considerations WARNING: Due to high temperatures, the appliance should be located out of traffic and away from furniture and draperies. FIRE HAZARD: Do NOT install this appliance directly on carpeting, vinyl, or any other combustible material other than wood.

  • Page 12: Clearances To Combustibles

    3.3 Clearances to Combustibles Table 3.1, Minimum Appliance Clearances to Combustible Material Top of unit face to framing 5-5/16 in 135 mm From unit left and right side stand-offs 0 in 0 mm From unit back stand-offs 0 in 0 mm From bottom stand-offs 0 in 0 mm...

  • Page 13: Wall Enclosure Rough Opening

    3.4 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 14: Recess Construction

    3.5 Recess Construction WARNING: All clearances to venting must be maintained. Mounting a television above a fireplace has become a common practice. Television surface temperatures are affected by mantel depth, ceiling heights, and wall and mantel construction material. Most television manufacturers specify in their instructions that a television should not be installed on, near, or above a heat source.

  • Page 15: Floor Support And Protection

    3.6 Floor Support and Protection • The fireplace must be placed directly on a wood or non- combustible surface (not linoleum or carpet) extending the entire depth and width of the fireplace • If this appliance is to be installed directly on carpeting, tile, or other combustible material other than wood flooring, this appliance shall be installed on a metal or wood panel extending the full width and depth of the appliance.

  • Page 16: 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 17: 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 18: 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 19: 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 20: Mantel Requirements

    5.2 Mantel Requirements NON-COMBUSTIBLE ZONE ¾ ” ⁄ ” (121mm) (770mm) 17” (432mm) 15” (381mm) 13” (330mm) 11” (279mm) 9” (229mm) ⁄ ” (99mm) ½ ” (12mm) THICK NON-COMBUSTIBLE SHOWN MANTEL OVERHANG DIMENSIONS ARE BASED ½ OFF TYPICAL ” (12MM) NON-COMBUSTIBLE FINISH MATERIAL.

  • Page 21: Facing Material Requirements

    5.3 Facing Material Requirements • Non-combustible material surrounding the fireplace face is required. The illustrations below reflect minimum non- WARNING: Maintain minimum clearances to combustible combustible material dimensions. materials from the appliance and vent system. • It is acceptable to pre-drill holes and use self-tapping screws •...

  • Page 22: 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 23: Termination Locations

    7.0 TERMINATION LOCATIONS 7.1 Vertical Vent Cap Termination WARNING: This appliance must not share or be connected to a chimney flue serving a separate solid-fuel burning 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 *If vent is closer than 12 in (.30 m), it must terminate at least 2...

  • Page 24: Minimum Termination Clearances

    7.2 Minimum Termination Clearances AREA WHERE TERMINAL IS NOT PERMITTED Figure 7.2, 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 12 in (30 cm) 9 in (23 cm) Clearance to permanently closed window (recommended to prevent condensation...

  • Page 25: Venting

    1 in (25 mm) 1 in (25 mm) 8.2.2 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 that pass through interior or exterior walls.

  • Page 26: Vertical Terminations

    8.5 Vertical Terminations VENTING DIAGRAM (VERTICAL TERMINATIONS) NOTE: Attic insulation shields may be insulated using unfaced (A) Stand-off Brackets (D) Vent Heat Shield (not applicable) (B) Stand-off Heat Shields insulation products listed as non-combustible per ASTM E 136. (E) Termination Cap (C) 90°...

  • Page 27: Combination Venting

    8.6 Combination Venting VENTING DIAGRAM (NG HORIZONTAL TERMINATIONS) (A) Stand-off Brackets (D) Vent Heat Shield 8.6.1 Natural Gas Installations (B) Stand-off Heat Shields (E) Termination Cap (C) 90° Elbow IMPORTANT: The horizontal vent heat shield must be installed when incorporating minimum horizontal venting. Refer to Section 8.8 on page 30.
  • Page 28 8.6.2 LP Gas Installations VENTING DIAGRAM (LPG HORIZONTAL TERMINATIONS) IMPORTANT: The horizontal vent heat shield must be installed (A) Stand-off Brackets (D) Vent Heat Shield when incorporating minimum horizontal venting. Refer to (B) Stand-off Heat Shields (E) Termination Cap Section 8.8 on page 30. (C) 90°...

  • Page 29: 800-1 Series Direct Vent Termination Kit(S)

    8.7 #800-1 Series Direct Vent insulation products listed as non-combustible per ASTM E 136. Termination Kit(s) Apply a liberal bead of exterior sealant around outer edge of IMPORTANT: The horizontal vent heat shield must be installed termination box (A), placing assembly through the wall-pass when incorporating minimum horizontal venting.

  • Page 30: Horizontal Vent Heat Shield Installation

    8.8 Horizontal Vent Heat Shield Installation IMPORTANT: The horizontal vent heat shield must be installed when incorporating minimum horizontal venting. Loosen, but do not remove the (2) attachment screws in front of the flue collar on the top of the fireplace. Bend the heat shield at perforation to a 90°...

  • Page 31: Fireplace Setup

    9.0 FIREPLACE SETUP 9.1 Hearth Plate and Component 9.3 Light Kit Access Doors CAUTION: Disconnect all electrical power from the fireplace before performing this task. 9.1.1 Install Hearth Plate and NOTE: To avoid damage and prolong the life of the halogen Component Access Doors bulbs, never touch with bare hands.

  • Page 32: Al36-500 Log Set Installation

    9.4 #AL36-500 Log Set Installation mounting pins on the burner. Push to seat. Position log #4 as shown below. CAUTION: Do not place logs directly over burner port holes. Improper log placement may affect flame appearance and Position logs #5 through #8 over the base logs as shown cause excessive soot to build upon the logs and glass.

  • Page 33: Firebox Liner Kit Installation

    9.5 Firebox Liner Kit Installation WARNING: RISK OF FIRE! Do not operate this fireplace without a firebox liner kit installed. • Firebox liner kits will provide insulation and are required to operate this fireplace. • If converting to LP (propane) gas, complete the conversion before installing firebox liner kit.

  • Page 34: Electrical Information

    10.0 ELECTRICAL INFORMATION 10.2 Wiring Requirements WARNING: Do not use this fireplace if any part has been under water. Immediately call a qualified service technician to inspect • The IFC System Module requires 120V of electricity and/or this appliance and to replace any part of the control system and batteries to operate.

  • Page 35: Operating Instructions

    11.0 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 36: Setup Proflame

    11.1 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 37: Ifc Module Ignition Sequence

    11.6 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 38: 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 ON/OFF KEY THERMOSTAT KEY LIGHT ON UP/DOWN ARROWS MODE KEY 11.8 Remote Control Operation 11.8.3 Pilot Ignition Selection (IPI/CPI) This system has the option of a continuous (standing) pilot.

  • Page 39: Smart Thermostat

    11.8.4 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 40: Fan Speed Control

    11.8.8 Fan Speed Control Fan speed can be adjusted through (6) speeds. To activate this function, Press the mode key to index to the fan control icon. Press the up or down arrow keys to turn on, off, or to adjust fan speed.

  • Page 41: Adjustment

    12.0 ADJUSTMENT 12.1 Pressure Testing 12.1.2 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 42: Burner Flame Adjustments

    12.2 Burner Flame Adjustments IMPORTANT: Slight adjustments to the venturi opening will create dramatic results. Adjust at slight increments until desired WARNING: To avoid property damage or personal injury, allow look is achieved. Always burn the fireplace insert for at least 15 the fireplace ample time to cool before making any adjustments.

  • Page 43: Restrictor Installation

    12.2.2 Restrictor REMOVE TAB(S) TO WARNING: To avoid property damage or personal injury, allow LARGE RESTRICTOR CREATE SMALL RESTRICTOR the fireplace ample time to cool before making any adjustments. WARNING: Improper vent installation may cause the burner flames to lift or “ghost.” Perform a visual check on flame appearance after restrictor adjustment to ensure proper performance.

  • Page 44: Troubleshooting

    13.0 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 45 Issue Cause Solution Pilot and burner No LP (propane) gas in tank Check LP (propane) tank. Refill if necessary. extinguish while in Incorrect glass assembly Refer to Section 9.2 Glass Frame Assembly on page 31. operation installation Incorrect vent cap installation Adjust if necessary.

  • Page 46: Maintenance

    14.0 MAINTENANCE 14.2 Fans ATTENTION: Installation and repair should only done by a qualified service person. The appliance should be inspected CAUTION: Label all wires prior to disconnection when servicing before use and at least annually by a professional service controls.

  • Page 47: Replacement Parts List

    15.0 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 AL36-L-150 Valve Step Motor - NG 700-504 Control Board - LPG AL36-L-151 Valve Step Motor - LPG 700-504-1 S.I.T.

  • Page 49: 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 51: Lifetime Warranty

    Kozy Heat Fireplace will not be defective in than those incurred by Hussong Manufacturing Co., Inc. to repair material or workmanship under normal use and service for as long or replace the defective component.

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