Kozi BayWin User manual

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BayWin®Pellet Burner
* INSTALLATION * OPERATION * SERVICE * PARTS *
CAUTION:
Read all instructions carefully before starting the
installation or operating the heater. Failure to
follow these instructions could result in property
damage, bodily injury or even death. Contact local
building or fire officials about restrictions and
installation inspection requirements in your area.
Save this manual for future reference.
OWNER’S MANUAL
Manufactured By:
APR Industries Ltd.
1354 Waverley Street
Winnipeg, Manitoba, R3T 0P5
Canada
Lithoid in Canada
Rev July 2004
WWW.KOZISTOVES.COM

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CAUTION: Stove has moving parts. Disconnect power
before servicing.

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Table Of Contents
I. Installation and Operation Manual ................................................... 4
1. Preamble: Instructions for Safe Installation and Operation ................................................... 4
2. Clearance to Combustible Walls ................................................................................................ 5
2.1 Non-Combustible Floor Protector .................................................................................... 5
2.2 Free Standing Stove .......................................................................................................... 6
2.3 Free Standing Installed in an Alcove ................................................................................ 6
2.4 Insert Installed in an Alcove ............................................................................................. 6
2.5. Insert Installed in a Masonry/Factory Built Fireplace ..................................................... 6
2.6 Other Clearances and Recommendations ......................................................................... 6
3. Electrical Requirements ............................................................................................................. 7
4. Fuel Requirements ...................................................................................................................... 8
5. Venting System ............................................................................................................................ 8
5.1 Exhaust Vent Pipe Requirements ..................................................................................... 8
5.2 Exhaust Vent Termination Requirements ......................................................................... 9
5.3 Combustion Air Intake Requirements ............................................................................ 10
6. Location of the Heater .............................................................................................................. 11
7. Typical Installation Configurations .........................................................................................11
8. KOZIKOZI
KOZIKOZI
KOZI BayWin ® Pellet Insert Additional Considerations .................................................. 13
8.1 KOZI BayWin® Pellet Insert Additional Requirements .............................................. 13
8.2 Surround Assembly ........................................................................................................ 14
8.3 KOZI BayWin® Pellet Insert Installation .................................................................... 14
8.4 KOZI BayWin® Pellet Insert Removal ....................................................................... 15
8.5 Operation and Maintenance ............................................................................................ 15
9. Mobile Home Additional Installation Requirements ............................................................. 15
9.1 Combustion Air Intake Requirements ............................................................................ 15
9.2 Exhaust Vent Requirements ........................................................................................... 16
9.3 Other Installation Requirements ..................................................................................... 16
9.4 Typical Mobile Home Installation Configuration ........................................................... 16
9.5 Recommendations for Mobile Home Installation ........................................................... 17
II. Understanding Your Pellet Burning Heater ................................. 18
1. Component Description ............................................................................................................ 18
1.1 General Overview ...........................................................................................................18
1.2 Exhaust Fan .................................................................................................................... 18
1.3 Burn Pot .......................................................................................................................... 18
1.4 Circulation Fan ............................................................................................................... 18
1.5 Trouble Shooting Module Status Lights ......................................................................... 19
1.6 Auger Cycle Timer ......................................................................................................... 19
1.7 High Temperature Manual Reset Thermal Disk ............................................................. 19
1.8 Pressure Switch ............................................................................................................... 19
2. Heater Operation ...................................................................................................................... 19
2.1 Circulation Fan Speed Control ....................................................................................... 20
2.2 Start Button ..................................................................................................................... 20
2.3 Feed Control ................................................................................................................... 20
2.4 Damper Control .............................................................................................................. 20
2.5 Starting (lighting) your Heater for the First Time ........................................................... 20
2.6 Starting (lighting) your Heater ........................................................................................ 21
2.7 Stopping your Heater ...................................................................................................... 22
2.8 Adjusting your Heater ..................................................................................................... 22
III. Maintenance ................................................................................... 22
IV. Trouble Shooting Guide ................................................................ 25
V. Diagrams and Parts List ................................................................. 27
1. KOZIKOZI
KOZIKOZI
KOZI BayWin® Circuit Diagram ......................................................................................... 27
2. Stove Cross Section ................................................................................................................... 28
3. Equipment Compartment ......................................................................................................... 29
4. Parts List .................................................................................................................................... 30
5. Accessories List ......................................................................................................................... 31
VI. Warranty ......................................................................................... 31

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I. Installation and Operation Manual
This heater is suitable for both mobile home and conventional home installation. Read all
instructions carefully before starting installation. Save this manual for future reference.
1. Preamble: Instructions for Safe Installation and Operation
1. Read these instructions carefully. Failure to follow them could cause a
malfunction of the heater resulting in damage to the heater, property,
bodily injury and even death.
2. Familiarize yourself with the heater operation. (Refer to the “Under-
standing you Pellet Burning Heater” section) If you are unsure, ask
your dealer to explain how to operate the heater properly.
3. The burn pot of this heater is designed for premium grade wood pellets.
Pellets with too much fines and saw dust must be screened before use.
DO NOT use wet pellets. Refer to the “Fuel Requirements” section for
more information.
4. Oil the circulation fan motor bearings every 6 months. See the “Mainte-
nance” section for more details.
5. Check with the local code authority regarding restrictions or installation
requirements.
6. This heater requires a floor protector beneath the heater and extending a
minimum of 6 inches (150mm) in front of the heater. This is to catch
any spillage, which may occur during opening and closing of the
doors.
7. Use only UL/ULC listed Type Pl or Type L venting for the exhaust
system. This heater is designed to use 3-inch (76 mm) vent pipe. Avoid
long runs and too many bends. It may be necessary to increase the size
of the vent pipe to 4 inches (102 mm) if long runs and too many bends
in the venting system are unavoidable. For details see the “Venting
System” section.
8. Combustion of wood pellet fuel deposits ash in the heater and venting
system. These ashes must be removed from the heater regularly
(approximately once a week, more frequently for high ash content
fuels). Refer to the “Maintenance” section for more information.
9. The heater must be turned OFF and allowed to cool completely before
cleaning. Make sure there are no hot ashes or embers present. Use a
brush and scoop to remove all of the ashes and place them in a metal
container.

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10. This heater is POWER VENTED. The vent pipes have positive
pressure during operation. It is IMPERATIVE that all joints in the
venting system be sealed to prevent any leakage of exhaust gases
inside the house. All joints must be sealed using high temperature
silicone sealer (RTV). Aluminum tape is not an adequate sealant.
11. Store all pellet fuel at a safe distance (at least 36 inches / 1 meter) away
from the heater and in a sealed metal container.
12. Use of outside combustion air is highly recommended and is manda-
tory in mobile home installations. Connect the air intake of the heater
to the exterior of the building with a non-combustible metal pipe with a
minimum diameter of 2 inches (50 mm) (Use APR Part No AK100).
Use of plastic pipes is not permitted. Where outside air cannot be used
in conventional homes, APR Part No CV100 (Check Valve) must be
used.
13. This appliance is wired and grounded according to the CSA C22.1
code for Canada and the NFPA 70 code for the USA. Also, this heater
meets the fuel burning appliance installation codes NFPA 211 in the
USA and CSA B365 in Canada.
14. Do NOT operate the heater with the door open. Make sure the door is
closed tightly during operation. Inspect the gaskets of the door
periodically to make sure they are in good condition.
15. Replace broken or defective components only with parts provided by
the manufacturer. See WWW.KOZISTOVES.COM or contact your
local dealer to find out how to purchase replacement parts.
16. Follow this manual carefully for proper installation. If you are
uncertain, call your dealer. Most dealers have qualified and trained
installers. We highly recommend the use of their services.
2. Clearance to Combustible Walls
Figure 1. KOZI pellet stove with a non-
combustible floor protector.
The following is a list of all minimum clearances to
combustibles for both the free standing stove as well as the
insert version.
2.1 Non-Combustible Floor Protector
A. Depth of Floor Protector 32 inches (815 mm)
B. Width of Floor Protector 27 inches (680 mm)
C. Floor Protector to Front of Unit 6 inches (150 mm)
D. Width of Unit 25 inches (635 mm)
E. Depth of Unit 25 inches (635 mm)

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2.2 Free Standing Stove
Minimum clearance must be:
A. Side Wall to Unit 12 inches (300 mm)
B. Back Wall to Unit 1 inch (25 mm)
C. Corner to Unit 1 inch (25 mm)
2.3 Free Standing Installed in an Alcove
Alcove dimensions must be:
Minimum width 48 inches (1220 mm)
Minimum height 48 inches (1220 mm)
Maximum depth 30 inches (760 mm)
2.4 Insert Installed in an Alcove
Alcove dimensions must be:
Minimum width 48 inches (1220 mm)
Minimum height 38 inches (965 mm)
Maximum depth 30 inches (760 mm)
2.5. Insert Installed in a Masonry/Factory Built Fireplace
Minimum clearance must be:
D. Floor protector 6 inches (150 mm)
E. Combustible side wall to unit 12 inches (300 mm)
F. Mantle to unit 13 inches (330 mm)
G. Top facing to unit 13 inches (330 mm)
H. Side facing to unit 12 inches (300 mm)
Please refer to the “Typical Installation Configurations” section and Figure 2 for more
information. Please note the certification label supersedes any information contained in
this manual.
2.6 Other Clearances and Recommendations
1. This heater must be mounted on a non-combustible material, placed
underneath the heater and extending a minimum of 6 inches (150 mm)
in front of the heater.
2. A safety certification label has been attached to either the back of the
heater or inside the hopper lid. A diagram of a sample label is
provided to aid in the identification of the aforementioned clearances.
3. Clearances can ONLY be reduced by means approved by local building
or fire officials in your area.

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Figure 2 Certification Label
INSTALLATION COMMENT: We recommend sufficient space be
provided (minimum 20 inches/500 mm) on each side of the heater to
service the equipment area. If this is not possible, a provision must be
made to pull the heater out for service.
3. Electrical Requirements
1. This heater is an electrical appliance. The North American versions of this
appliance require 120 Volts, 60 cycle and 3 Amps of electrical power. The
European versions of this appliance require 230 Volts, 50 cycles and 2 Amps
of electrical power. All heaters with an electric igniter require an additional
300 watts of electrical power during the start up sequence.

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3. When installed in mobile home, the heater must be grounded to the
steel chassis of the home (unless this is not required by local code).
4. Fuel Requirements
This heater is designed for premium grade, 1/4 inch (6.35 mm) wood pellets. Pellets with
too much fines and saw dust must be screened before use. DO NOT use wet pellets. It is
very difficult to maintain a clean and efficient burn when using high moisture and/or
high ash content fuels. These “poor” fuels cause the burn pot to clog much more
frequently and do not provide the proper air flow for a clean, effective burn. “Poor”
fuels require more frequent cleaning; the ashtray must be emptied and the burn pot must
be cleaned on a weekly possibly daily basis. Please refer to the “Maintenance” section
for further instructions on cleaning your heater.
All pellet fuel should be stored in a clean dry place and at a safe distance (at least 36
inches / 1 meter) away from the heater. DO NOT place the fuel within the installation
clearances of the heater or within the space needed for ash removal and starting of the
heater.
5. Venting System
Before proceeding with the installation, the following sections should be reviewed:
Section 5: Venting System
Section 6: Location of the Heater
Section 7: Typical Installation Configurations
5.1 Exhaust Vent Pipe Requirements
KOZI pellet heaters have a negative pressure combustion chamber. A high pressure,
radial blade, fan pulls the air out of the burn chamber creating negative pressure
(vacuum) inside the burn chamber. Air from outside the heater then rushes through the
intake air tube, burn pot stand and burn pot to fill this vacuum. As this air passes through
the burn pot it is used to burn the pellets. A proper size ULC/UL listed type PL or L
venting should be used to provide the least resistance for movement of the combustion
air.
This KOZI pellet burner is certified for 3 and 4 inch exhaust venting. 3 inch venting is
sufficient for most direct vent installations. However, installations with several elbows,
long horizontal and/or vertical runs may add excessive resistance against the flow of air
which reduces the volume of air movement and creates burn problems. The use of 4 inch
venting will reduce this resistance. A simple technique called ‘EQUIVALENT VENT
LENGTH (EVL)’ can be used to determine whether 3 or 4 inch vent pipe should be used.
2. The heater comes with a 5 ft (1.5 M) long, grounded, electrical cord suitable
to plug into any standard residential electrical outlet. The electrical outlet
must be grounded.

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The exhaust vent pipes are located on the exhaust side of the exhaust fan and are under
positive pressure. At least 3 screws are needed for securing all joints for connector pipes.
Care must be taken to ensure that all the joints are completely sealed to prevent any
leakage of exhaust fumes into the house. If you smell smoke, the venting has not been
properly sealed. Use only high temperature RTV silicone for sealing. Aluminum tape is
not considered an adequate sealant.
The venting of this heater is not allowed to pass through any closets, concealed spaces,
through a floor, ceiling or attic space. If the venting is to go through a wall or combus-
tible partition, the installation must conform to the Installation Code for Solid Fuel
Burning Appliance and Equipment CAN / CSA -B365. For more detailed venting
information, please refer to your venting manufacturer’s instructions.
5.2 Exhaust Vent Termination Requirements
1. The exhaust vent must terminate into an open space. Under no
circumstances is the vent allowed to terminate into closed or semi-
closed spaces. Venting into a garage, under a sun deck, porch or any
other space where the concentration of fumes may occur is prohibited.
To calculate EVL use the following formula:
for each 90° Elbow or T fitting = add 5 EVL
for each 45° Elbow = add 3 EVL
for each Horizontal run of vent = add 1 EVL per foot of horizontal venting
for each Vertical run of vent = add 1/2 EVL per foot of vertical venting
DO NOT USE MAKESHIFT MATERIALS OR MAKE COMPROMISES IN
THE INSTALLATION. IT IS A FIRE HAZARD.
DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST
VENTING SYSTEM OF THIS HEATER
DO NOT CONNECT THIS HEATER TO A CHIMNEY
FLUE SERVING ANOTHER APPLIANCE
YOU MUST USE APPROPRIATE 4” VENTING IF:
The EVL is 7 or more AND you are at or above an altitude of 3000 ft
OR
The EVL is 15 or more
OR
Your heater is an Insert
CAUTION: EVL CANNOT EXCEED 25ft (7.6 meters). Installations
using an EVL exceeding 25ft (7.6 meters) are not permitted.

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2. The exhaust vent must be at least:
* 4 feet (1.2 m) below
* 4 feet (1.2 m) horizontally from
* 1 foot (0.3m) above
any opening in the building such as doors, windows, ventilation air
intakes, etc.
3. The exhaust vent opening must be a minimum of:
* 12 inches (0.3m) from the ground
* 24 inches (0.61m) from any combustible surface i.e. fence, plant, etc.
* 7 feet (2.1 m) from any public walkway
4. The exhaust air is EXTREMELY HOT. Caution must be taken to avoid
contact with children, people, plants, animals, or any other object that
may be affected by heat. It is recommended to use a vertical pipe to
discharge the hot air at a safe elevation.
5. The vent terminal must have an end cap to protect against down-draft
and back-draft created by severe wind conditions.
5.3 Combustion Air Intake Requirements
There are 2 methods of supplying the heater with combustion air. They are as follows:
1. Room Air: Conventional homes may use room air for combustion
provided APR Part No: CV100 (Check Valve) is installed. For
installations where the exhaust pipe incorporates a minimum 3’ vertical
section immediately adjoining the heater, APR Part No: CV100 (Check
Valve) is optional. In this venting configuration it is highly recom-
mended that the total exhaust vertical rise be longer than the total
horizontal run.
2. Outside Air: All installations can be connected to the exterior of the
building using a non-combustible metal pipe, with a minimum 2 inch
(50mm) internal diameter or by using APR Part No: AK100 (Air
Intake Kit). A larger diameter air intake pipe may be required if the
length of intake exceeds 3’ (1 meter) or has several bends. Use of
plastic pipes are not permitted.
In some installations, outdoor combustion air may be needed to ensure proper perfor-
mance. If your heater burns poorly, experiences roll-out or back-drafts, outside combus-
tion air may be required.
The following restrictions apply to any and all installations:
1. Use of plastic pipes is not permitted under any circumstance.
INSTALL ALL VENTING AT CLEARANCES
SPECIFIED BY THE VENT MANUFACTURER