kozy heat JOR-30 Installation And Operation Manual Download | Manualshive

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Summary of Contents for JOR-30

Page 1: ...n this manual for future reference English and French Installation Manuals Available Through Your Local Dealer or Visit Our Website at www kozyheat com 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 any electrical switch do not use any phone in your building...

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Page 3: ...ability but customer safety as well We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your Kozy Heat gas fireplace Jim Hussong Dudley Hussong President Board Chairman Read this manual before installing or operating this appliance Please retain this owner s manual for future reference Homeowner Reference Information We recommend that you record t...

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Page 5: ... KIT INSTRUCTIONS Conversion Kit Instructions 12 13 GLASS FRAME ASSEMBLY SCREEN FRONT Glass Frame Assembly Screen Front Removal Installation 14 INSTALLATION Approved Venting 14 Combustion Air Venting Options 14 Air Duct Removal 15 Kozy Heat 816 CL Co Linear Vent System 15 Run Vent System Through Existing Chimney 16 Connect Vent System to Air Duct 17 SHROUD INSTALLATION Shroud Installation 17 LOG S...

Page 6: ...bstructed Due to high temperatures the appliance should be located out of traffic and away from furniture and draperies The glass front or any part removed for servicing the appliance must be replaced prior to operating the appliance Work should be done by a qualified service technician Clean glass only when cool and only with non abrasive cleansers WARNING DO NOT OPERATE APPLIANCE WITH THE GLASS ...

Page 7: ...Refractory brick lining Log set IPI control system with remote control Engineer designed burner system Co linear vent system 3 combustion air 3 exhaust Innovative vent connection system Automatic fan kit 1 110 CFM Minnesota Energy Code compliant to 50 pascals FEATURES STANDARD FEATURES SAFETY FEATURES Brick refractory in various colors Standard size or custom sized shrouds Decorative doors in vari...

Page 8: ... appliance or equipment The sign shall read in print no less the one half inch 1 2 in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the ...

Page 9: ...240 149 SPECIFICATIONS PARTS DIAGRAM 1 Fireplace insert 2 Air chute 3 Module panel assembly 4 Valve access panel 5 Control board assembly 6 Burner base 7 Burner top 8 Glass frame assembly 9 Refractory brick lining 10 Fan kit 11 Floor Protector Kit sold separately 5 1 4 7 6 8 2 3 9 10 11 WARNING Failure to position components in accordance with these diagrams or failure to use only parts specifical...

Page 10: ...7 SPECIFICATIONS MINIMUM CLEARANCES TO COMBUSTIBLES Figure 7a 3 76mm Combustible Material ...

Page 11: ...y and termination cap Other approved venting ICC Selkirk American Metals Simpson Dura Vent RLH Security Metal Fab Approved caps listed on page 14 Shrouds Standard shrouds are available for this insert and will fit most applications Custom shrouds may be ordered on a non returnable basis When ordering a custom shroud please specify the existing fireplace front opening height and width or Blank Shro...

Page 12: ...m 1 Remove and discard existing chimney cap 2 Position one person at fireplace and another person at top of chimney Measure from fireplace base to top of chimney Subtract 19 3 4 501mm height of insert This is the total length of co linear flexible aluminum you will require MEASUREMENT FROM FIREPLACE BASE TO TOP OF CHIMNEY _________________ LESS 19 3 4 501mm HEIGHT OF INSERT 19 3 4 501mm TOTAL CHIM...

Page 13: ...ve been installed wired and mounted in a removable electrical box panel on right side of fireplace WIRING SCHEMATIC Figure 10a NOTE If wiring to pre installed electrical box is desired wiring should be run prior to permanently positioning insert and connecting vent system If this fireplace insert is being installed in minimum opening dimensions wiring may need to be completed after fireplace inser...

Page 14: ...e with the requirements of the provincial authorities having jurisdiction and in accordance with the requirements of the ANSI Z223 1 installation code CAUTION Installation of the gas line must only be done by a qualified person in accordance with local building codes if any If not follow ANSI 223 1 Commonwealth of Massachusetts Installation must be done by a licensed plumber of gas fitter NOTE A l...

Page 15: ... alignment of sensor and hood outlet is critical for proper ignition 4 Attach pilot assembly to pilot bracket with screws previously removed WARNING This conversion kit shall be installed by a qualified service agency in accordance with the manufacturers instructions and all applicable codes and requirements of the authority having jurisdiction If the information in these instructions is not follo...

Page 16: ...m open LP Both venturis 5 8 16mm open 2 Re install front burner into fireplace pull bracket forward until orifice is properly seated inside burner venturi tighten bracket nut 3 Install back top burner Burner venturi extends through center opening on front bottom burner and sits down over back burner orifice Ensure pilot assembly sits above burner Align holes in both burners and secure with screws ...

Page 17: ... 1 ea side Insert glass latch tool here Latch tab To Install Align tabs on back of frame with slots on insert set into position To Remove Lift frame up and out of slots SCREEN FRONT sold separately APPROVED VENTING MANUFACTURER APPROVED CAPS Kozy Heat 816 CL Vent System ICC TM IVT TM SVT Selkirk 4DT VC American Metals 4DVC Simpson Dura Vent 46DVA VCH Security 3PDVCV Metal Fab 4DVT HS C33U99 RLH HS...

Page 18: ...ly different than one shown INSTALLATION 1 Remove refractory panels secured at top with clips 1 ea side 2 Remove 3 screws securing baffle to firebox back wall Pull baffle forward and down to remove 3 Remove access plate secured with 2 screws from firebox ceiling 4 Locate and remove nuts securing air duct top to firebox 2 nuts reached through access holes 2 inside air duct 5 Remove air duct top Acc...

Page 19: ... at sides of termination cap 3 From inside existing fireplace CAREFULLY pull ropes down until exhaust pipe and combustion air intake if using full connection method are into existing fireplace STUB VENTING From inside existing fireplace insert a minimum of 4ft 1 22m of combustion air pipe end without collar past the damper opening and into existing fireplace See illustration at lower right 4 We st...

Page 20: ... duct Slide combustion intake pipe over collar Secure with 3 self tapping screws provided To ensure an air tight seal apply additional sealant around joint 4 Slide insert into fireplace opening Check for level If necessary leveling bolts are included in components packet and are threaded through bottom of insert into nuts located on each corner of insert Remove insert install leveling legs as nece...

Page 21: ...Use a steel or stiff bristle nylon brush to distribute Rock Wool Embers onto logs and burner J1 J7 J6 J2 J3 J5 J4 J8 J9 J10 Install J9 J10 logs aligning with notches in lower logs as shown below Figure 18c Figure 18b Figure 18a NOTE Log numbers are located on bottom of each log Refer to following instructions and illustrations for proper placement CAUTION Do not place logs directly over burner por...

Page 22: ...eplace models Figure 19a IMPORTANT THIS SYSTEM REQUIRES ELECTRICITY 120V AND OR BATTERIES TO OPERATE USING BATTERY BACK UP WILL OPERATE BURNER ONLY FAN AND LIGHT COMPONENTS WILL NOT FUNCTION ON BATTERY BACK UP POWER THIS SYSTEM IS GROUND TO FIREBOX CHASSIS ...

Page 23: ...OR LOW LIMIT SCREW STEP MOTOR WIRE HARNESS MAIN VALVE INTERNAL SOLENOID CONNECTION PILOT INTERNAL SOLENOID CONNECTION PILOT ADJUSTMENT SCREW INLET PRESSURE SCREW OUTLET MANIFOLD PRESSURE SCREW GAS VALVE IGNITER PILOT FLAME SENSOR PILOT ASSEMBLY Figure 20a ...

Page 24: ...N OFF SWITCH LEARN BUTTON MAIN CONTROL MODULE VALVE STEP MOTOR TERMINAL COMMUNICATION LINK TO EXTENSION MODULE AC ADAPTOR CONNECTION EXTENSION MODULE COMMUNICATION LINK TO CONTROL MODULE FAN CORD PLUG IN BACK UP BATTERY PACK AC ADAPTOR COMMUNICATION LINK TO LIGHT KIT not available in all models NON OPERATIONAL Figure 21a ...

Page 25: ...ONTROL INFORMATION CHILD PROOF ICON LIGHT LEVEL FLAME HEIGHT FAN SPEED BATTERY LIFE ICON THERMOSTAT MODE ICON SET TEMPERATURE visible only in THERMO MODE MANUAL ON OFF ROOM TEMPERATURE CONTINUOUS PILOT Figure 22a ...

Page 26: ...x located under firebox on right side of fireplace Ensure duplex box coveris installed with flange to top The IPI gas control system has the option of a continuous standing pilot feature This allows you to change from a spark to pilot system to a standing pilot system during cold weather conditions By having the pilot on continuously the firebox will remain warm and a draft is established in the v...

Page 27: ...batteries We recommend always using ALKALINE batteries to extend battery life and improve operational performance Before matching security codes make sure 120V AC is connected and powered to fireplace and hand held remote control is installed with 2 AA batteries It may be necessary to program main control module located on right side of firebox to LEARN the hand held remote control security code u...

Page 28: ...E This remote will operate the fan allowing for 6 different speed levels When the FAN button is pressed FAN level setting will flash on the LCD screen Press UP or DOWN buttons to select desired fan speed level If no adjustment is made within 7 seconds the control will exit function setting mode and LCD display will return to normal view LIGHTING MODE not operational in all models This remote will ...

Page 29: ...ture The FLAME ON and THERMO icons will appear on the LCD screen By pressing UP or DOWN buttons a new set temperature may be attained SET Temperature will only appear when THERMOSTAT MODE is activated but is implemented in all MODES with the exception of MANUAL MODE To exit THERMO mode press the MODE button This also shuts fireplace OFF SYSTEM OPERATION WITHOUT HAND HELD REMOTE This system is desi...

Page 30: ...TRACTION THIS IS NORMAL AND DOES NOT AFFECT THE PERFORMANCE OR LONGEVITY OF THE FIREPLACE 1 This appliance is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot by hand 2 BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU S...

Page 31: ... to access manual shut off valve located under firebox Turn manual shut off valve to OFF Power OFF Power ON Power OFF OFF OFF ON 1 4 1 3 2 5 3 2 Figure 28b Figure 28a WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use the phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If...

Page 32: ...orporated into the valve The pressure tap marked OUT measures outgoing pressure and the pressure tap marked IN measures incoming pressure Follow instructions below for proper testing procedures Refer to page 14 for proper NAT and LP manifold pressures NOTE The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of that syste...

Page 33: ...heck if pilot flame is actually present when valve is turned OFF if yes replace valve Replace pilot assembly Replace module Error Code Four beeps every two seconds Description of Fault Warns users that module s internal temperatures have exceeded 170 F 77 C How to Clear Module s internal temperatures must cool to below 160 F 71 C and then press ON button What to Check Are modules located in an una...

Page 34: ...ring first 15 minutes of operation If flames remain blue or become dark orange with evidence of sooting black tips the burner tube venturi may need adjustment BURNER TUBE VENTURI ADJUSTMENT GUIDELINES VENTURI POSITION FLAME COLOR VENTURI ADJUSTMENT Closed too far Dark orange flame with black tips Open venturi setting slightly Open too far Blue flames Close venturi setting slightly WARNING Burner t...

Page 35: ... IF VENT AIR INTAKE SYSTEM IS DISASSEMBLED FOR ANY REASON RE INSTALL PER INSTRUCTIONS PROVIDED WITH INITIAL INSTALLATION The flow of combustion and ventilation air must not be obstructed VENT SYSTEM FAN Clean glass only when cool and only with non abrasive cleansers WARNING DO NOT OPERATE APPLIANCE WITH GLASS FRAME ASSEMBLY REMOVED CRACKED OR BROKEN REPLACEMENT OF THE GLASS SHOULD ONLY BE PERFORME...

Page 36: ...ing for a beep from receiver when ON is pressed on hand held remote If you do not hear a beep ensure main control module has learned the hand held remote See above Ensure black lead from pilot assembly igniter is securely connected to terminal labeled I and red lead from flame rectification sensor is securely connected terminal labeled S on main control module Ensure black cap leads marked PILOT f...

Page 37: ... that in which the hand held remote was tested It may take up to 3 hours for the temperature inside a packaged transmitter and several minutes for an unpackaged transmitter to equalize with room temperature FIREPLACE WILL NOT RESPOND IN THERMO MODE Ensure hand held remote is within 20ft 6 096m operational range Make sure an ON or OFF command was not last sent from another transmitter These command...

Page 38: ... Flexible Gas Line Valve to Burner Connection 700 404 JOR Jordan IPI Valve Natural 700 244 Natural Gas Orifice 44 Back Burner 700 404 JOR 1 Jordan IPI Valve LP 700 253 Natural Gas Orifice 53 Front Burner 700 200 Pilot Assembly Natural Gas 700 253 LP Gas Orifice 54 Back Burner 700 200 1 Pilot Assembly LP Gas 700 261 LP Gas Orifice 61 Front Burner 700 801 8 PIN Primary Wire Harness Primary Wire Harn...

Page 39: ...t in material or workmanship at Hussong Manufacturing Co Inc s expense including reasonable labor costs to repair or replace the defective component if a factory pre authorization is given for the repair YEARS 2 10 Subject to the conditions requirements listed below beginning with the first day of the second year and continuing through the tenth year Hussong Manufacturing Co Inc will at its discre...

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Page 41: ...he time of this Lifetime Warranty or to accept on Hussong Manufacturing Co Inc s behalf any additional obligation of liability connected with the unit Hussong Manufacturing Co Inc may fully discharge all obligations with respect to this Lifetime Warranty by refunding the wholesale price of the defective component s It is expressly agreed and understood that this Lifetime Warranty is Hussong Manufa...

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Page 43: ...G WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to fireplace installation manual and this manual For assistance or additional information consult a qualified installer service agency or the gas supplier HOT GLASS WILL CAUSE BURNS DO NOT TOUCH GLASS UNTIL COOLED NEVER ALLOW CHILDREN TO TOUCH GLASS INSTALLER Leave this manual wit...

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Page 45: ... WIRING SCHEMATICS Wiring Schematics 4 OPERATING INSTRUCTIONS Control System Components 5 6 System Operations 7 10 Lighting and Shutdown 11 12 Pressure Testing 13 TROUBLESHOOTING Troubleshooting 14 15 CONVERSION KIT INSTRUCTIONS Conversion Kit Instructions 16 18 MAINTENANCE Maintenance 19 REPLACEMENT PARTS Replacement Parts 20 ...

Page 46: ...materials gasoline and other flammable vapor and liquids The flow of combustion and ventilation air must not be obstructed Due to high temperatures the appliance should be located out of traffic and away from furniture and draperies The glass front or any part removed for servicing the appliance must be replaced prior to operating the appliance Work should be done by a qualified service technician...

Page 47: ...RE LO 1 6 WC 40 kPa 6 4 WC 1 59 kPa ORIFICE SIZE 44 53 54 61 INPUT BTU hr kW 30 500 BTU hr 8 94 kW 33 500 BTU hr 9 82 kW MINIMUM INPUT BTU hr kW 20 500 BTU hr 6 01 kW 23 000 BTU hr 6 74 kW PART NUMBER DESCRIPTION JOR 100 Control Board Assembly 700 203 Manual Gas Shut off Valve JOR 135 Burner Assembly JOR H900 Firebrick Refractory Set JOR 500 Log Package JOR 057T Glass Frame Assembly 816 CL1 Co Lin...

Page 48: ...EQUIRES ELECTRICITY 120V AND OR BATTERIES TO OPERATE USING BATTERY BACK UP WILL OPERATE BURNER ONLY FAN AND LIGHT COMPONENTS WILL NOT FUNCTION ON BATTERY BACK UP POWER Figure 4a To Fan To Lights Pilot Assembly Not used Green yellow Green Orange ...

Page 49: ...TS Figure 5a Pilot Igniter Flame Sensor PILOT ASSEMBLY REMOTE CONTROL Figure 5c GAS VALVE Outlet pressure tap Stepper motor Pilot connection orange Main valve connection green Inlet pressure tap Pilot flame adjustment Figure 5b ...

Page 50: ...6 CONTROL SYSTEM COMPONENTS FAN CONTROL MODULE Figure 6a RECEIVER DFC CONTROL BOARD Figure 6c Figure 6b ...

Page 51: ... and set to the particular code of that transmitter 5 Push OFF button on transmitter The receiver will beep two 2 times to indicate the transmitter s command is again accepted 6 Move slider switch to REMOTE position 7 Turn On fan control module switching to ON position 8 The system is now initialized TURN ON THE APPLIANCE Press ON OFF key on transmitter The display will show all active icons on th...

Page 52: ...rt level To activate this function press the Thermostat Key The LCD display will change to show the room thermostat is ON and set temperature is now displayed To adjust set temperature press Up or Down arrow keys until desired set temperature is display on LCD screen SMART THERMOSTAT Transmitter Operation SYSTEM OPERATION Figure 8c Figure 8b Figure 8a REMOTE FLAME CONTROL The remote control has si...

Page 53: ...p Arrow Key to turn light kit on press Down Arrow Key to turn light kit off A single beep will confirm reception of the command 3 Use the installed dimmer switch to adjust brightness of lights ACCENT LIGHT KIT not available in all fireplace models SYSTEM OPERATION Figure 9b Figure 9c FAN SPEED CONTROL Fan speed can be adjusted through six 6 speeds To activate this function use Mode Key to index to...

Page 54: ...ransmitter mode button to adjust settings The thermostat and burner ON OFF operating functions will not work on the transmitter LOW BATTERY DETECTION TRANSMITTER Remote control battery lifespan depends on various factors including battery quality number of ignitions changes to room thermostat set point etc When transmitter batteries are low a Battery Icon will appear on the LCD display before all ...

Page 55: ...CTION THIS IS NORMAL AND DOES NOT AFFECT THE PERFORMANCE OR LONGEVITY OF THE FIREPLACE 1 This appliance is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot by hand 2 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SME...

Page 56: ...r to the appliance 5 Press hand held remote ON button TO TURN GAS OFF TO APPLIANCE 1 Press hand held remote OFF button 2 Turn OFF all electric power to appliance if service is to be performed 3 Manual shut off valve located behind lower grill Turn manual shut off valve to OFF WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your...

Page 57: ... CAN CAUSE DELAYED IGNITION 1 Loosen inlet IN pressure tap screw counter clockwise 2 Attach manometer using a 5 16 I D hose 3 Set IPI CPI switch to CPI setting 4 Light pilot Note manometer reading 5 Move receiver slider switch to ON Burner should light Check pressure to ensure it stays between the min and max recommended pressure settings 6 Set IPI CPI switch to IPI setting Move receiver slider sw...

Page 58: ... pressure Consult with plumber or gas supplier No LP in tank Check LP propane tank Refill if necessary Wiring disconnection Use wiring schematic in this manual to determine that all wiring connections are secure and correct Pilot flame not making contact with flame rectification sensor on pilot assembly This valve is equipped with a pilot flame adjustment screw Adjust as necessary Pilot adjustment...

Page 59: ...OFF BURNER Improper venturi setting Venturi may need to be closed slightly Improper vent cap installation Check for proper vent cap installation Blockage or vent system leaks NO REACTION TO COMMAND Receiver or transmitter batteries low Replace batteries No communication between remote control and receiver Reprogram transmitter to receiver Follow INITIALIZING THE SYSTEM FOR THE FIRST TIME as outlin...

Page 60: ...d orifice sizing IMPORTANT For high altitude installations Above 2000ft 610m US 4500ft 1372m Canada consult the local gas distributor or authority having jurisdiction for proper de rating methods CONVERT PILOT ASSEMBLY 1 Remove pilot hood by pulling it directly up from pilot bracket 2 Insert 5 32 4mm hex key into hexagon key way of injector turn counter clockwise to remove from injector journal 3 ...

Page 61: ...ot adjustment screw clockwise to decrease or counter clockwise to increase pilot flame 7 Turn fireplace off 8 Affix gas type sticker to label 9 Re install glass frame and screen front assemblies 10 Verify proper ignition and operation of fireplace 11 Complete and affix Gas Conversion label to outer wrap close to gas valve COMPLETE THE CONVERSION 1 Adjust burner tube venturis to correct setting by ...

Page 62: ...igh Correct pilot flame Figure 18b BURNER TUBE VENTURI ADJUSTMENT GUIDELINES VENTURI POSITION FLAME COLOR VENTURI ADJUSTMENT Closed too far Dark orange flame with black tips Open venturi setting slightly Open too far Blue flames Close venturi setting slightly TO ADJUST VENTURIS Figure 18c IMPORTANT SLIGHT ADJUSTMENTS TO BURNER VENTURI OPENING CREATE DRAMATIC RESULTS ADJUST AT SLIGHT INCREMENTS UNT...

Page 63: ...D FOR ANY REASON RE INSTALL PER INSTRUCTIONS PROVIDED WITH INITIAL INSTALLATION The flow of combustion and ventilation air must not be obstructed VENT SYSTEM FAN Clean glass only when cool and only with non abrasive cleansers WARNING DO NOT OPERATE APPLIANCE WITH GLASS FRAME ASSEMBLY REMOVED CRACKED OR BROKEN REPLACEMENT OF THE GLASS SHOULD ONLY BE PERFORMED BY A LICENSED OR QUALIFIED SERVICE PERS...

Page 64: ...s Orifice 61 Front Burner 700 558 GTMFS Wire Harness NCK JOR S Natural Gas Conversion Kit 700 130 Fan Control Module LCK JOR S LP Gas Conversion Kit 700 308 Transmitter JOR 135 Burner Assembly 700 296 51 Natural Gas Pilot Orifice 700 992 Pilot Igniter with wire 700 168 35 LP Gas Pilot Orifice 700 993 Pilot Flame Sensor with wire REFRACTORY PANELS Sandstone JOR H900 3 pc Refractory Panel Set JOR H9...

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