kozy heat KZK-038 User manual

KZK-038 1Rev. 2 — May 2023
Komfort Zone Kit #KZK-038
For use with Bellingham 38 (#BHM-38), and Nordik 41 DV (#NDK-41-DV)
English and French installation manuals are available
through your local dealer. Visit our website
www.kozyheat.com.
Les manuels d’installation en français et en anglais sont
disponibles chez votre détaillant local. Visitez
www.kozyheat.com.
READ ALL THESE STEPS BEFORE STARTING INSTALLATION. LEAVE THESE INSTRUCTIONS WITH THE APPLIANCE.
This kit must be installed by a qualied installer, service agency, or gas supplier at the me of the heater installaon.
These instrucons must be used in conjuncon with the installaon and operaon manual provided with the appliance.
Please read all appliance owner’s manual completely before performing any procedures in these instrucons.
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.
IMPORTANT: Failure to read and follow these instrucons
may create a possible hazard and will void the replace
warranty.
1.0 Introducon............................................................. 3
1.1 Kit Contents ............................................................. 3
1.2 Suggest Conguraons............................................ 4
1.3 Dimensions and Overview....................................... 6
1.4 Air Duct Run............................................................. 7
2.0 Framing and Clearances ........................................... 8
2.1 Clearance to Sprinkler ............................................. 8
2.2 Framing.................................................................... 9
3.0 Facing and Finishing............................................... 12
3.1 Non-combusble Requirements ........................... 13
3.2 Finish Requirements.............................................. 15
3.3 Hearth and Mantel Clearances.............................. 18
4.0 Fireplace Preparaon & Installaon....................... 20
4.1 Bellingham 38........................................................ 20
4.2 Nordik 41 DV.......................................................... 22
This oponal convecon duct kit redistributes the warm air ow away from the replace opening to a more desirable
locaon using natural convecon without the use of a fan. The warm air ow may be relocated to a posion higher up the
wall, out the sidewalls, or even to an adjacent room. The result is much cooler wall temperatures above the replace
opening for locang televisions, artwork, etc.
P.O. BOX 557 204 INDUSTRIAL PARK DRIVE
LAKEFIELD, MINNESOTA USA 56150-0577

KZK-038 2Rev. 2 — May 2023

KZK-038 3Rev. 2 — May 2023
1.1 Kit Contents
ALL kit contents must be installed.
• (1) 40" plenum kit: KZK-038
• (1) plenum discharge trim: KZK-038DT
• (2) plenum support brackets
• (8) 6" collars - (4) to aach to the boom of the plenum;
(4) to aach to the unit where the cover plates are re-
moved.
1.0 Introducon
Figure 1.1 - #KZK-038 Figure 1.2 - #KZK-410-6
• (1) KZK-410-6 (sold separately) is used for a 10' vent run. If
you are mounng the plenum above the replace 10' (3m)
or less, use (1) KZK-410-6 kit.
• KZK-CPL6 (sold separately) is (6) 6" couplers that connect
(2) KZK-410-6. You will only need (4) 6" couplers for installa-
on. If you are mounng the plenum above the replace
between 10' to 20', you will need (2) KZK-410-6 kit and (1)
#KZK-CPL6 coupler kit.

KZK-038 4Rev. 2 — May 2023
1.2 Suggested Conguraons
• When installing the #KZK-038, take in consideraon the replace venng and the plenum tube conguraon.
• The #KZK-038 plenum can be installed so it discharges heat into either the room the Bellingham 38 is installed or an
adjacent in-door room behind the appliance.
• The “Rear Wall Outlet” allows the air discharge of the plenum to go into a seperate room.
Figure 1.3 - Bellingham 38 Suggested Plenum Conguraons
Bellingham 38

KZK-038 5Rev. 2 — May 2023
Figure 1.4 - Nordik 41 DV Suggested Plenum Conguraon
Nordik 41 DV
• The #KZK-038 plenum can only discharge into the same room that the Nordik 41 DV is installed.
• Figure 1.5 shows two common conguraons.
• The plenum discharge must be placed in the same room as the appliance.

KZK-038 6Rev. 2 — May 2023
1.3 Dimensions and Overview
Figure 1.5 - KZK-038 Dimensions

KZK-038 7Rev. 2 — May 2023
1.4 Air Duct Run
IMPORTANT: The air duct pipe cannot run horizontally without a vercal rise.
IMPORTANT: The 1/2" clearance around the air duct pipes must be maintained.
Use #KZK-410-6 UL181 Class 0 Air Duct piping to connect the plenum(s) to the unit.
Hussong Mfg. Co., Inc. requires pipes to be listed as UL181 Class 0 Air Duct to connect the plenum(s) to the unit.
Maximum Vent Run: 20’ (6m)
Figure 1.6 - Bellingham 38 Horizontal Run
Bellingham 38
Figure 1.7 - Nordik 41 DV Horizontal Run
Nordik 41 DV

KZK-038 8Rev. 2 — May 2023
2.0 Framing and Clearances
2.1 Clearance to Sprinkler
• In a situaon where a sprinkler head is installed within the proximity to a #KZK discharge opening, the diagram below
MUST be followed.
• The distance between a sprinkler head and discharge opening cannot be less than 60" (1524mm) in length at every point
from the origin of the discharge opening. You must also verify the sprinkler head sensor is set to the proper heat seng so
it does not acvate when the room heats up from the replace being operated normally.
• Please follow local building codes to determine what temperature seng is relevant for your installaon.
Figure 2.1 - Clearance to Sprinkler

KZK-038 9Rev. 2 — May 2023
2.2 Framing
Shown in this secon are the rough opening dimensions
and clearances for the plenum, unit installaon, and unit
installaon with a TV recess construcon.
Rough opening framing dimensions should allow for wall
covering thickness and facing materials. Please refer to
Secon 3.0 on page 12 for specic facing and nishing
opons.
Figure 2.3 & 2.4 show the minimum height of plenum
framing from the base of that specic replace.
Figure 2.2 - Plenum Framing
Figure 2.3 - Bellingham 38 Plenum Framing
Bellingham 38 Nordik 41 DV
Figure 2.4 - Nordik 41 DV Plenum Framing

KZK-038 10 Rev. 2 — May 2023
Figure 2.5 shows the minimum clearance between the top
of the plenum opening and the ceiling. This applies to all
models.
Figure 2.6 shows the minimum height of plenum framing
from the top nishing edge of the replace. This applies to
the Bellingham 38.
Figure 2.7 shows the minimum height of plenum framing
from the top of the replace. This applies to the Nordik 41
DV.
Figure 2.6 - Bellingham 38 Plenum Framing
Bellingham 38 Nordik 41 DV
Figure 2.7 - Nordik 41 DV Plenum Framing
Figure 2.5 - Minimum Clearance to Ceiling

KZK-038 11 Rev. 2 — May 2023
Figure 2.8 - Bellingham 38 Wall Enclosure Rough Opening
Bellingham 38
Nordik 41 DV
Figure 2.9 - Nordik 41 DV Wall Enclosure Rough Opening

KZK-038 12 Rev. 2 — May 2023
3.0 Facing and Finishing
See below for some replace specic nishing material informaon:
Bellingham 38
The Bellingham 38 are equipped only with a safety screen that ts inside the nishing edge. Finishing material, mantel pro-
jecons, and hearth projecons may bu up against the nishing edge.
• If you are purchasing the oponal rectangle surround (Part #BH38-RS) nishing material up to 1-1/4” in total thickness
can connue to be nished up to the replace nishing edge and the oponal surround can be installed over the top of
the nishing material. These oponal surrounds have a sloed bracket to secure the surround to the replace that al-
low this installaon over up to 1-1/4” thick nishing material.
• If you have combined thickness of nishing material over 1-1/4” we recommend bung the nishing material up
against the nishing edge and not using the oponal surround.
• The oponal surround must be able to be removed for service work. Ensure the nishing material does not inhibit this.
Nordik 41 DV
The Nordik 41 DV is supplied with a “Finishing Trim Kit”. It is highly recommended that this kit is installed and used with the
replace. The nishing trim kit provides a nishing edge for material to bu up against while providing the necessary clear-
ance for the safety screen barrier to be removed.
IMPORTANT: The B41-PSF2 and B41-FRSF2 (Figure 3.1) are ONLY approved for use when the Nordik 41 DV is installed with
the #KZK-038. The other (4) safety barriers shown in Figure 3.2 are approved in all installaon scenarios.
KZK Plenum
Secon 3.2 will provide informaon about nishing material around the KZK plenum.
Safety Barriers Approved for All Design Opons
(Standard or Kozy Zone Kit Installaons)
Figure 3.1 - Safety Barriers Group #1
Safety Barriers Approved for
Kozy Zone Kit Installaons ONLY
Figure 3.2 - Safety Barriers Group #2

KZK-038 13 Rev. 2 — May 2023
3.1 Non-Combusble Requirements
Figure 3.3 - Bellingham 38 Minimum Non-Combusble Finishing DImensions
Bellingham 38

KZK-038 14 Rev. 2 — May 2023
Figure 3.4 - Nordik 41 DV Minimum Non-Combusble Finishing DImensions
Nordik 41 DV

KZK-038 15 Rev. 2 — May 2023
3.2 Finishing Requirements
3.2.1 Finishing Opons - Plenum Air Discharge
Figure 3.5 applies to all replace models.
NOTE: It is not required to use the discharge trim (#KZK-038DT). You are allowed to run non-combusble nishing material
up to the air discharge opening. See Figure 3.5 for nishing opons. Finishing material must not block the opening and must
be run evenly along the plenum opening.
WARNING! RISK OF OVERHEATING AND FIRE! Ensure the KZK duct system is installed in accordance to this manual
Figure 3.5 - Plenum Air Discharge Finishing Opons

KZK-038 16 Rev. 2 — May 2023
3.2.2 Combusble Wall Finish Requirements
• Figure 3.6 shows installaon of combusble wall nish up to 1" thick for the Bellingham 38. This combusble material
goes on top of any required non-combusble materials as required in Figure 3.3 on page 13.
• This 1" (25mm) combusble material is able to go down to the replace nishing edge.
• See Figure 3.5 on page 15 for up to 1" (25mm) thick combusble material installaon around the KZK air discharge
grille.
Figure 3.6 - Bellingham 38 Combusble Wall Finish and Surround
Bellingham 38

KZK-038 17 Rev. 2 — May 2023
• Figure 3.7 shows installaon of combusble wall nish up to 1" thick for the Nordik 41 DV. This combusble mate-
rial goes on any required non-combusble materials as required in Figures 3.4 on page 14.
• This 1" (25mm) combusble material is able to go down to the replace nishing edge.
• See Figure 3.5 on page 15 for up to 1" (25mm) thick combusble material installaon around the KZK air discharge
grille.
Figure 3.7 – Nordik 41 DV Combusble Wall Finish and Surround
Nordik 41 DV
Fireplace Enclosure Floor
Non-combusble material only
Fireplace Top
Combusble wall nish up to
1” (25mm) thick may be
installed over required
non-combusble material up
to the top nishing edge and
the boom of the air
discharge opening
Non-combusble Zone

KZK-038 18 Rev. 2 — May 2023
3.3 Hearth and Mantel Clearances
• The following drawings show the hearth and mantel clearances allowed for the Bellingham 38 and Nordik 41 DV.
• Figure 3.8 show the mantel and hearth projecons for the Bellingham 38 allowed when using this KZK-038. The
image below shows the mantel projecon starng at the top replace nishing edge and the hearth projecon
starng at the boom replace nishing edge.
Figure 3.8 - Bellingham 38 Combusble Hearth and Mantel Requirements
Bellingham 38

KZK-038 19 Rev. 2 — May 2023
Figure 3.9 - Nordik 41 DV Combusble Hearth and Mantel Requirements
• Figure 3.9 shows the mantel and hearth projecons for the Nordik 41 DV allowed when using this KZK-038. The im-
age below shows the mantel projecon starng at the top replace nishing edge.
• Combusble ooring can run underneath this appliance which would then allow an unlimited combusble hearth
projecon. The hearth projecon cannot be elevated (vercally) past the base of the replace / enclosure oor.
Nordik 41 DV

KZK-038 20 Rev. 2 — May 2023
4.0 Fireplace Preparaon & Installaon
4.1 Bellingham 38
All contents in this kit are required and must be installed.
The Kozy Zone Kit requires that the convecon bae, lo-
cated above the rebox inside the appliance metal cabinet,
to be removed to allow the hot airow to convect upwards
into the air ducts installed on the replace. You will also
remove the cover plates.
See addional requirements and installaon informaon in
the appliance manual.
1. Remove the convecon bae from the appliance. The
bae is secured by (4) screws right behind the upper
edge of the replace opening. There is a small bae
clip in the center where you remove (2) screws and
then the remaining (2) screws will involve (1) screw
being on each side of the convecon bae. Recycle
this panel as it is no longer needed. See Figure 4.1.
2. Remove (4) cover plates on top of the appliance (4
screws each).
3. Align the take o collars to the corresponding holes on
top of the appliance. Secure with screws previously
removed. Install the take o collars to the correspond-
ing opening(s) on the plenum(s). Use supplied screws.
Figure 4.2 - Bellingham 38 Air Flow with Convecon
Bae Removed
Figure 4.1 - Bellingham 38 Convecon Bae and
Cover Plates
4. Frame the rough opening of the replace and KZK plenum.
Refer to all pages of this KZK-038 manual and the Bellingham
38 manual. See previous pages of this manual for allowable
plenum posions and rough frame opening sizes.
5. Install stand-o assembly on top of the appliance. See Figure
4.3. Locate the stand-o assembly and header heat shield on
top of the replace, as shipped. Discard header heat shield.
Aach the stand-o assembly pieces as shown below and se-
cure with (4) screws.
6. Install the plenum(s) into the rough frame opening maintain-
ing minimum clearances to combusbles as listed (see previ-
ous pages). Fix the plenum to the framing using nails or screw
through the top mounng bracket.
NOTE: Mounng brackets are not intended to carry the weight of
the plenum and pipes. Provide support to the underside of the
plenum and ensure the plenum is level and its outlet is not distort-
ed.
7. Use metal strapping (all-around, not supplied) as required to
further secure the plenum to framing.
8. Aach the piping from all (4) plenum vent collars to all (4) re-
place vent collars. If you are mounng the plenum 10' or less
above the replace, use (1) #KZK-410 kit or UL-181 Class 0
approved air duct. If you are mounng the plenum between
10' to 20' above the replace then you will need (2) #KZK-410
kits and #KZK-CPL or UL-181 Class 0 approved air duct.
9. An upward slope must be maintained in horizontal secons of
pipes for proper convecon. Support horizontal secons every
24 inches.
10. Install the 15-3/8" x 7-3/4" air grilles provided with the kit us-
ing (2) screws.
If desired, the air grille may be painted. Use high temperature
paint (250°F).
Connue with replace installaon.