kozy heat 911-XXL Installation instructions

WARNING: If the information in these
instructions are not followed exactly, a fire or
explosion may result causing property damage,
personal injury or loss of life.
Model #911-XXL
Direct Vent Gas Fireplace Insert
INSTALLATION & OPERATING
MANUAL
U.S. PATENT #5,931,154
U.S. PATENT #6,004,493
U.S. PATENT #6,029,655
Do not store or use gasoline or other flammable vapors
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 electrical switches; do not use the
phone in your building.
‚Immediatelycallyourgassupplierfromaneighbor’s
phone. Follow the gas supplier’s instructions.
‚If you cannot reach your gas supplier, call the fire
department.
-Installationandservicemustbeperformedbyaqualified
installer, service agency or the gas supplier.
This appliance may be installed in an aftermarket
permanentlylocated,manufactured(mobile)home,where
not prohibited by local codes.This appliance is only for
use with the type(s) of gas indicated on the rating place.
This appliance is not convertible for use with other
gases, unless a certified kit is used.
IMPORTANT:
READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION.
FAILURE TO INSTALL THIS FIREPLACE INSERT CORRECTLY CAN
CAUSE SERIOUS STRUCTURAL AND FIRE HAZARDS AND MAY VOID
YOUR WARRANTY.
www.kozyheat.com
October 2006

INDEX
FireplaceInsertSpecifications ...................................................... 1
SafetyRequirements.............................................................. 1
RequirementsofExistingFireplace .................................................. 2
FireplaceInsertComponents ....................................................... 3
PreparingTheExistingFireplace .................................................... 4
GasLineInstallationRequirements-Minimum/MaximumPressures ..................... 4-5
InsertPreparation.............................................................. 6-7
RemovetheGlassAssembly ............................................ 6
Remove the Millivolt Board ............................................. 6
RemovetheAirDuct .................................................. 7
Installing the Insert ........................................................... 7-13
RestrictorInstallation ................................................. 7
Co-LinearVentSystem ................................................ 8
InstalltheVentSystem................................................ 9
PositiontheInsert&SecuretheAirDuct ................................ 10
Replace the Millivolt Board ............................................ 11
LogInstallation ................................................................. 12
Assemble&AttachtheShroud .................................................. 13-15
CompletetheFanInstallation ..................................................... 16
Complete the Installation -
Initial Lighting / Seasonal Heat Dump Adjustment /
ReplacetheGlassAssembly/ReplacetheLowerGrill ............................... 17
Thermostat-RemoteControl-WallSwitchInstallation ................................ 18
Lighting&ShutdownProcedures ................................................ 19-20
Manifold(outgoing)&Inlet(incoming)PressureCheckProcedures ....................... 21
MaintenanceRequirements ....................................................... 22
Troubleshooting.............................................................. 23-24
GasConversionKit ........................................................... 25-26
ReplacementParts .............................................................. 27
WarrantyPolicy .............................................................. 28-29

Page 1
MODEL JACKSON XXL
DIRECT VENT GAS BURNING FIREPLACE INSERT
INSTALLATION & OPERATING INSTRUCTIONS
IMPORTANT:
READ THIS MANUAL BEFORE INSTALLING AND USING THIS FIREPLACE
This fireplace has been tested to and complies with ANSI Z21.88-2002CSA 2.33-2002 “VENTED GAS FIREPLACE HEATERS” by
OMNI-Test Laboratories, Beaverton, Oregon for U.S. Installations only. Installation must conform with local building codes or in
the absence of local building codes, with the National Fuel Gas code, ANSI Z223.1 NFPA 54 - Current Edition.
SPECIFICATIONS:
Height (top of firebox): 25 1/4" Height (top of air duct): 27 1/2"
Width: 38 1/4" Back Width: 26 1/4" Depth: 16 1/8”
NOTE: Minimum existing opening width required: 38 1/2"
Donotusethisfireplaceifanyparthasbeenunderwater.
Immediatelycall a qualifiedservice techniciantoinspect
this appliance and to replace any part of the control
systemandanygas controlwhichhasbeenunderwater.
WARNING: DO NOT REPLACE THIS BURNER WITH ANY
OTHER SIZED BURNER. REPLACEMENT WITH AN
UNAUTHORIZEDBURNERCANRESULTINTEMPERATURES
EXCEEDING THE LIMITS FOR THIS FIREPLACE AND VOID
YOUR WARRANTY.
DUETO HIGH TEMPERATURES, THISFIREPLACE SHOULD
BE LOCATED OUT OF TRAFFIC AND AWAY FROM
FURNITURE AND DRAPERIES
The efficiency rating of this appliance is a product
thermal efficiency rating determined under continuous
operatingconditionsandwasdetermined independently
of any installed system.
YOUNG CHILDREN SHOULD BE CAREFULLY SUPERVISED
WHENTHEYAREINTHESAMEROOMASTHISFIREPLACE.
CHILDRENANDADULTSSHOULD BEALERTEDTOTHE
HAZARDS OF HIGH SURFACE TEMPERATURE AND
SHOULD STAY AWAY TO AVOID BURNS OR CLOTHING
IGNITION.
CLOTHINGOROTHERFLAMMABLEMATERIALSHOULD
NOT BE PLACED ON OR NEAR THE APPLIANCE.
COMMONWEALTH OF MASSACHUSETTS INSTALLATIONS
WARNING: This Product Must Be Installed By A Licensed Plumber Or
GasFitterWhenInstalledWithinTheCommonwealthofMassachusetts.
IMPORTANT: Installation of a CO detector is required in the fireplace
room.

Page 2
CAUTION: THIS FIREPLACE INSERT IS APPROVED FOR INSTALLATION IN MASONRY AND FACTORY-BUILT SOLID FUEL
BURNING FIREPLACES.
CAUTION: THIS APPLIANCE MUST NOT BE CONNECTED TO A CHIMNEY FLUE SERVING A SEPARATE SOLID-FUEL
BURNING APPLIANCE.
THE EXISTING FIREPLACE MUST MEET THE FOLLOWING REQUIREMENTS:
1. The existing fireplace & chimney must be clean and in good working order and constructed of non-combustible materials.
2. A gas line must be able to be installed to the insert.
3. Any chimney cleanouts must fit properly.
4. Existing Chimney: - Class ‘A’ metal chimney: Co-linear 3” x 4” venting - 8” minimum inside diameter.
- Masonry Chimney: Co-linear 3" x 4" venting - 6" x 8" minimum inside diameter.
Chimney height: Height of existing chimney must be at least: 11 ft.
Maximum height of existing chimney: 40 ft.
To Determine the length of your existing chimney:
A) Remove the chimney cap.
NOTE: It is helpful to have two people complete the next step in determining chimney height.
B) With one person at the fireplace and the other person at the top of the chimney, measure from the base of the fireplace to the top of
the chimney. Subtract 24” for the height of the insert. This is the total length of co-linear flexible aluminum you will require.
MEASUREMENT FROM BASE OF FIREPLACE TO TOP OF CHIMNEY: ____
LESS: -24”
TOTAL CHIMNEY LENGTH REQ.: ____
5. The minimum inside dimensions of the existing fireplace must be:
Height: 28” Front Width: 38 1/2”
Depth: 16 1/2” Width at minimum depth location: 26 3/4"
NOTE: The refractory / firebrick may be removed to achieve minimum opening size requirements.
6. Minimum clearance from door frame to side wall: 4 1/2"
Minimum clearance from door frame to a combustible mantel: 16” Mantel depth: 10"
MINIMUM OPENING DIMENSIONS
38 1/2"
28" 26 3/4"
16 1/2"

Page 3
FIREPLACE COMPONENTS:
Check the assembly diagram below to ensure you have all the necessary components to properly install
this fireplace insert.
This insert includes the following:
1. Fireplace Insert.
2. Spring-loaded latch glass assembly.
3. Millivolt board with burner cover.
4. 150 CFM fan with limit switch and speed control.
5. Co-linear air duct.
6. Log set (See page #14).
Figure A
WARNING: Failure to position the parts in accordance with these diagrams or failure to
use only parts specifically approved for this appliance may result in
property damage or personal injury.
Additional components which are necessary for proper installation are:
1. Vent System:
Part #815-CL: For use with minimum 6” x 8” I.D. masonry or 8” I.D. Class ‘A’ metal chimneys - Includes 12 ft.
compressed,expandableto25ft.co-linear3”x4” flexiblechimney,andterminationcap. Ifyourexistingchimneyishigher
than 25 ft. above the fireplace, an extension kit (Part #510) must be used to properly extend the 3” intake and 4” exhaust
up to a maximum of 40 ft.
2. Shroud - 3 pc & 4 pc.: A standard shroud, 48" wide x 32" high is available for this insert and will fit most applications.
Customshroudsmaybeorderedonanon-returnablebasis. Whenorderingacustomshroud,pleasespecifytheexisting
fireplace front opening height and width.
3. Blank Shrouds - 3 & 4 pc. blank shrouds are available for on-site custom fit applications and are sized to the opening
afterthe inserthasbeen installed. The interior perimeterisproperlysizedto fitontotheinsert. Theouter perimetermust
be cut, formed and finished (painted).
4. Upper & Lower Grill set - Several grill set options are available. Contact your dealer for more information.

Page 4
A) PREPARE THE EXISTING FIREPLACE
WARNING: CUTTING ANY SHEET-METAL PARTS OF THE FIREPLACE, IN WHICH THIS GAS
FIREPLACE INSERT IS TO BE INSTALLED, IS PROHIBITED.
1) The refractory, glass doors, screen rails, screen mesh and log grates may be removed from the
fireplace before installing this gas fireplace insert.
2) Any smoke shelves, shields and baffles may be removed if attached by mechanical fasteners.
3) If necessary, remove the firebrick on the sides and back of the existing fireplace to obtain at least the
minimum opening requirements listed on page #2.
4) The fireplace flue damper can be fully blocked open or removed for installation of this gas fireplace
insert.
5) Trim panels or surrounds shall not seal ventilation openings in the fireplace.
6) Remove the existing chimney cap from the chimney.
7) Clean the chimney and inside of the fireplace to prevent creosote smell from entering the home.
8) Place ‘THIS UNIT HAS BEEN MODIFIED’ label in the bottom of the firebox so it will be visible if this
gas fireplace insert is removed.
B. RUN THE GAS LINE
CAUTION: Installation of the gas line must only be done by a qualified person in
accordance with local building codes.
This fireplace insert is equipped with a 3/8" flexible gas line connection 18" long.
CAUTION: The manual shut off valve and millivolt board flexible gas line must not extend outside the insert
cavity. See the WARNING label affixed to the flexible gas line for additional installation instructions
and warnings.
1. Run the gas line into the fireplace, preferably through the side or back, 2” from the bottom of the fireplace.
See Figure B-1 on page #5.
If installing this gas fireplace insert into a factory-built fireplace and the factory-built fireplace has no access
holes(s) provided, an access hole of 1 ½" or less may be drilled through the lower sides or bottom of the
firebox in a proper workmanship like manner. This access hole must be plugged with non-combustible
insulation after the gas supply line has been installed.
A flexible connector should then be attached to the previously run gas line to the point where the manual
shut off valve and millivolt board flexible gas line will connect.
IMPORTANT: An accessible shut off valve (included with this fireplace insert) must be installed up stream from
the regulator.
IMPORTANT: DO NOT RUN THE GAS LINE IN A MANNER THAT WOULD OBSTRUCT THE OPERATION
OF THE FAN OR POSITION OF THE SPEED CONTROL.

Page 5
Figure B-1
2. This fireplace insert is designed to accept either a 3/8" or 1/2" gas line approved for gas appliances. Consult
local building codes to properly size the gas supply line leading to a 3/8" reduction.
3. Connect the manual shut off valve to the previous run gas line.
4. The gas line will be connected to the millivolt board later in this manual.
IMPORTANT:
ALL CONNECTIONS WHETHER FIELD OR FACTORY MADE MUST BE CHECKED FOR LEAKS.
NOTE: This appliance and its individual shut off valve must be disconnected from the gas supply piping system
during any pressure testing of that system at test pressures in excess of 1/2 psi.
NOTE: This appliance must be isolated from the gas supply piping system byclosing its individual manual shut off
valve during any pressure testing of the gas supplypiping systems at test pressures equal to or less than1/2
psi.
Pressure check taps for both the manifold (outgoing) and inlet (incoming) pressures are located in front of the gas
valve. The right pressure tap is the manifold pressure and the left pressure tap is the incoming pressure. Follow
instructions on page #21 for checking these pressures.
NATURAL GAS:
The minimum inlet gas supply pressure: 5.0 in. W.C.
Recommended inlet gas supply pressure: 7.0 in. W.C.
The maximum inlet gas supply pressure: 10.5 in. W.C.
Manifold Pressure: 3.5 in. W.C.
Manifold Pressure (lo setting): 1.7 in. W.C.
Orifice size (0-2000 ft): 30 Input rating: 42,000 BTU/Hr.
Minimum Input rating: 29,500 BTU/Hr.
LP GAS:
The minimum inlet gas supply pressure: 11.0 in. W.C.
Recommended inlet gas supply pressure: 11.0 in. W.C.
The maximum inlet gas supply pressure: 13.0 in. W.C.
Manifold Pressure: 10.0 in. W.C.
Manifold Pressure (lo setting): 6.5 in. W.C.
Orifice size (0-2000 ft): 47 Input rating: 42,000 BTU/Hr.
Minimum Input rating: 30,000 BTU/Hr.
For high altitude installations, consult the local gas distributor or the authority having jurisdiction for proper rating methods.

Page 6
C. REMOVE THE FOLLOWING ITEMS FROM THE FIREPLACE INSERT:
1. GLASS ASSEMBLY: Figure C-1
A) Locate the spring-loaded latches securing the
glass assembly (under the firebox).
B) While holding onto the glass frame, pullthe latch
handlesout to release from the clips on the glass
assembly.
C) Pull the bottom of the glass assembly out
releasing the tabs at the back of the glass
assembly from the slots in the firebox face, then
lift up off the tabs at the top of the firebox.
D) Set aside where it will not be broken.
E) Remove the log package and bottom refractory
from inside the firebox and set aside for
installation later in this manual.
2. MILLIVOLT BOARD.
A) Loosen and remove the (2) nuts securing the
burner cover. Remove the burner cover by lifting
the front of the cover up, then carefully slide the
burnertubeofftheorifice.Removeentireassembly
from the firebox. Figure C-2.
B) Remove the pilot shield. Figure C-3.
Figure C-2
C) Loosen and remove the (2) 1/4" nuts securing the millivolt board to the firebox bottom. Lift the board
off the studs and remove from the firebox. Figure C-3.
IMPORTANT: BE CAREFUL NOT TO DAMAGE THE GASKET UNDER THE BOARD.
Figure C-3
NOTE: The millivolt board is secured with (2) nuts at the factory. After the millivolt board is properly installed it
must be secured with 8 nuts as shown above (6 additional nuts are included in the components packet).
The burner / cover assembly is then placed over the millivolt board and secured with 2 nuts.
1/4" NUTS SECURING BURNER COVER
Pilot Shield
1/4" NUTS SECURING BURNER

Page 7
3. REMOVE THE AIR DUCT. Figure C-4.
A. Pull the lower end of the air duct out of the (4)
mounting holes at the back and lift the air duct
(manifold) up from the top of the firebox and
set aside.
Figure C-4
D. INSTALLING THE INSERT
IMPORTANT: ALL STEPS IN SECTION ‘A) PREPARE THE EXISTING FIREPLACE’ MUST BE
COMPLETED BEFORE CONTINUING WITH THIS INSTALLATION.
1. Restrictor Installation
The restrictor plate included in this fireplace
components packet can be installed as either a large
orsmallrestrictor,depending on yourspecificventing
configuration.
There are several factors which can affect proper draft
of the vent system and the burner operation of a
fireplace. Installing a restrictor may be necessary to
resolve the problem, even though it may not be
required under ‘normal conditions’.
IMPORTANT: DO NOT INSTALL IF THE VENTING
CONFIGURATION IS AT THE MINIMUM
REQUIREMENTS!
Therestrictorincludedis sized asthe‘large’restrictor,
Figure D-1. To reduce the size to the ‘small’ restrictor,
simply bend the section without the tabs off at the
perforation and discard. Figure D-2.
Figure D-1
Large Restrictor
Figure D-2
Small Restrictor
Remove this
section.
To install the restrictor, refer to Figure D-3 and bend the tabs ‘up’ far enough (approximately 180-degrees) so that
when positioned into the exhaust pipe, will create tension to hold itself in place. Do not over bend the tabs! Slide
the restrictor into the exhaust pipe with the tabs pointing toward you. Access to the exhaust pipe can be gained
by removing the nuts securing the exhaust baffle at the back of the firebox.
Figure D-3 Install with the
tabs pointing
TOWARD you.

Page 8
2. INSTALL THE VENT SYSTEM
NOTE: The 4” exhaust pipe and 3” combustion air intake pipe will extend 25 ft. An optional extension kit (Part #510)
is available to extend the #815-CL kit up to a maximum of 40 ft.
A. Carefully extend the 3” combustion intake and 4” exhaust pipes and extension kit (if used)
to equal the total chimney length required.
B. 1. Slide the 3" intake pipe (end without the collar) onto the collar on the termination cap and
secure with 3 self-tapping screws (provided).
2. Place a bead of sealant around the inner edge of the 4" exhaust pipe (end without the
collar) and slide onto the corresponding collar on the termination cap. Secure with 3 self-
tapping screws (provided). Apply additional sealant around the joint to ensure a seal.
C. If an extension kit is being used, it must be connected as follows:
Exhaust extension: Apply a liberal bead of sealant (provided) around the exhaust adaptor (male)
extensionpipe and slide into thefemaleconnector ontheendofthe4”exhaustpipealreadyattached
to the chimney termination plates. Secure with 3 self-tapping screws, (provided). To ensure an air-
tight seal, additional sealant should be applied at the point of connection.
Combustion intake extension: Apply a liberal bead of sealant (provided) around the male end of
the extension kit and slide into female end of the 3” combustion intake pipe attached to the chimney
termination plates. Secure with 3 self-tapping screws (provided). To ensure an air-tight seal,
additional sealant should be applied at the point of connection.
FIGURE D-4

Page 9
:
3. RUN THE VENT SYSTEM THROUGH THE EXISTING CHIMNEY
ˆOPTIONAL: We recommend wrapping the first 3 ft. of the vent system below the termination cap with non-faced
fiberglass insulation (secure with wire) before running it through the existing chimney. This will prevent cold air from
coming down the existing chimney.
NOTE: If there are offsets in the existing chimney, it may be easier to place a weighted rope around the end of
the 4” pipe and another weighted rope around the 3” pipe to guide them through it.
DO NOT ATTEMPT TO TIE ONE ROPE AROUND BOTH
PIPES.
A. Guide the rope, if used, and flexible pipes down the
existing chimney.
B. To secure the chimney termination cap to the
existing chimney, apply a liberal bead of sealant
(provided) around the top of the existing chimney. Set
the termination cap into position.
OPTIONAL: Secure the termination cap to the existing
chimney with the 2" self-tapping screws and anchor
straps provided. Screw holes are located at the sides of
the termination cap.
C. From inside the opening, grasp the ropes and
CAREFULLY pull the ropes until the 3” combustion air
intake and 4” exhaust pipe is down into the existing
fireplace.
ˆOPTIONAL: We recommend placing non-faced
fiberglass batting insulation between the pipes and
existing chimney to prevent heat loss up the chimney.
( SEE FIGURE D-5)
Figure D-5
4. CONNECT THE VENT SYSTEM TO THE AIR DUCT
A. Place the air duct into the existing fireplace opening.
B. Place a bead of sealant (provided) around the 4”
exhaust pipe and slide it inside the 4” collar on the
duct. Secure with (3) ½" self-tapping screws,
provided. Apply additional sealant around the joint to
ensure an air tight seal.
C. Apply a liberal bead of sealant (provided) around the
3” collar on the air duct. Slide the 3” combustion
intake pipe over the collar and secure with (3) ½"
self-tapping screws, provided. To ensure an air-tight
seal, apply additional sealant around the joint.
FIGURE D-6

Page 10
E. POSITION THE FIREPLACE INSERT:
1. Slide the insert in the fireplace opening.
2. If necessary, level the insert by threading the
leveling bolts (included in the components
packet) into the nuts mounted in the bottom
of the insert behind the lower grill.
See Figure E-1.
Figure E-1
3. Place the air duct onto the fireplace by aligning the studs located on each side of the 4" exhaust duct
on the air duct to the two holes in the fireplace top and aligning the (4) mounting studs at the lower
end of the air duct, (around the combustion air intake), into the (4) mounting holes at the lower end
of the firebox back. Set into position.
NOTE: THE AIR DUCT BACK AND SIDES SHOULD BE ON THE ‘OUTSIDE’ OF THE FLANGES AT THE BOTTOM,
OTHERWISE A RATTLING NOISE MAY OCCUR DURING FAN OPERATION.
Figure E-2
4. Locate the baffle with seasonal heat dump inside
firebox and note the (2) access holes on each side
of the heat dump. Secure the air duct to the
fireplace with (2) 1/4” nuts through the access
holes (A). IMPORTANT: Make sure the gasket is
properly seated in place.
Figure E-3
5. Secure the lower end of the air duct to the
firebox by placing a 1/4" nut onto each mounting
stud (B) around the intake duct and tighten (4
total). IMPORTANT: Make sure the gasket is
properly seated in place.
Figure E-4

Page 11
1/4" NUTS SECURING BURNER
F. REINSTALL MILLIVOLT BOARD INSTALLATION. See Figures F-1 & F-2.
NOTE: The millivolt board must be fitted with a gasket, (included) to seal the board. Make certain this
gasket is properly placed around the opening before installing the millivolt board.
1. Grasp the millivolt board with both hands and place into the fireplace, lining up the (8) mounting holes in the board to the
mounting studs on the bottom of the firebox. IMPORTANT: BE CAREFUL NOT TO DAMAGE THE GASKET UNDER THE
BOARD.
CAUTION: BEFORE SECURING THE BOARD INTO PLACE, MAKE CERTAIN THAT ALL OF THE WIRES (ATTACHED
UNDER THE BOARD) ARE CLEAR AND UNOBSTRUCTED.
WHEN INSTALLATION OF THE MILLIVOLT BOARD IS COMPLETE, CHECK TO ENSURE THAT THERE ARE NO
WIRES, FLEX LINES, ETC., TOUCHING THE FAN TERMINALS.
2. Attach the (8) nuts (you will use the 2 nuts previously removed & the 6 additional nuts included in the fireplace components
packet) and tighten, securing the board in place. Figure F-1.
3. Position the pilot shield behind the pilot assembly. Figure F-1.
Figure F-1
4. Place the burner cover assembly onto the board, properly
seatingtheburnertubeovertheorificeandaligningtheholes
in the mounting brackets attached to the cover to the
mounting studs on the millivolt board. Secure with the (2)
nuts previously removed. Figure F-2.
5. Connect the flexible gas line to the manual shut off valve.
6. Connect any remote control, wallswitch orthermostat wires,
if used.
IMPORTANT: CHECK ALL CONNECTIONS, WHETHER FIELD
OR FACTORY MADE, FOR LEAKS.
Figure F-2
Pilot Shield
1/4" NUTS SECURING BURNER COVER

Page 12
G. LOG INSTALLATION. See Figures G-1 - G-3.
This log set includes: (1) ‘S421’ log (1) ‘BC’ log (1) ‘BB’ log (1) XXL901 BOTTOM REFRACTORY PANELS
(1) ‘S423’ log (1) ‘S424’ log (1) ‘AP1’ log (1) Embers pkg.
(1) ‘BL’ log (1) ‘X5’ log
1. Position the left & right bottom refractory panels
onto front of the burner cover and as shown in
Figure G-1.
2. Place the ‘S421' log into position aligning the
notches in the bottom of the log to the mounting
brackets in the cover.
3. Place remaining base logs ‘BB’, & ‘BC’ into
position on the burner cover aligning th holes in
the bottom of the logs to the mounting studs as
shown in Figure G-1.
4. Place the ‘S423' & ‘S424' logs over the bottom
refractory panels, aligning the offset ends at the
center. Figure G-2.
5. Place rock wool ember material as desired onto
the logs and burner for additional glow.
NOTE: You will not use all the embers included in the
packet at this time. Save for future use.
6. Positionthe ‘BL’ and‘AP1' logs overthe baselogs,
as shown in Figure G-3.
7. Position the remaining top log ‘X5' in place as
shown in Figure G-3.
BC BB
S421
LEFT PANEL RIGHT PANEL
Figure G-1
S423 S424
Figure G-2
BL X5 AP1
Figure G-3
ATTENTION HOMEOWNER / INSTALLER:
TO ACHIEVE OPTIMUM GLOW AND FLAME
APPEARANCE, IT MAY BE NECESSARY TO
SLIGHTLY ADJUST THE VENTURI SHUTTER
POSITION AND/OR LOG POSITIONS.
WARNING:FAILURETOPOSITION THEPARTSIN
ACCORDANCE WITH THESE DIAGRAMS OR
FAILURE TO USE ONLY PARTS SPECIFICALLY
APPROVEDWITHTHISAPPLIANCEMAYRESULT
IN PROPERTY DAMAGE OR PERSONAL INJURY.

Page 13
H. ATTACH THE SHROUD
Shroud assembly includes: (1) Shroud top (1) Set (1 left & 1 right) ‘inside fit’ brackets
(1) Shroud left side (12) Phillips head screws
(1) Shroud right side with on/off rocker switch mounting hole
Additional items needed: Rocker switch & wires from the fireplace components packet.
Upper grill (grill set sold separately).
ASSEMBLE THE SHROUD - Figures H-1 & H-2
1. Loosen and remove the nuts on the upper grill. Place the
upper grill rods through the holes in the shroud top piece
and secure with the nuts (A).
NOTE: The louvers on the upper grill should be in the
downward position. See Figures H-1 & H-2.
2. Securethe right and left shroud pieces tothetoppieceby
aligning the (2) holes in the side pieces to theholes in the
top piece. Secure with the screws (B) provided (2 ea.
side). NOTE: Screws are secured from the bottom.
3. Snap the rocker switch in place on the shroud.
4. Slideoneconnectorononeendofeachrockerswitchwire
to the rocker switch.
FigureH-2
ATTACH THE SHROUD
OUTSIDE FIT APPLICATIONS:
1. Attach the shroud to the insert by placing the tabs on the left
and right shroud pieces into the holes in the insert. The
shroud will set into place. Figure H-3.
Figure H-3
Screws are secured
from the bottom.
Figure H-1

Page 14
CONNECT THE ROCKER SWITCH WIRES TO THE VALVE
Refer to Figure N-1 page #24.
1. Slide the remaining connectors on the rocker switch wires to the top and bottom terminals marked ‘TH’ on the valve.
IMPORTANT: CHECK ALL CONNECTIONS, WHETHER FIELD OR FACTORY MADE, FOR LEAKS.
INSIDE FIT APPLICATIONS:
NOTE: INSIDE FIT APPLICATIONS REQUIRE THE ‘INSIDE FIT MOUNTING BRACKETS’, INCLUDED WITH THIS KIT, FOR
INSTALLATION.
1. Removetheglassassembly. Refertothefireplaceinstallation
manual if necessary.
2. Assemble the shroud, install the upper grill & on/off rocker
switch as described on page #12 of these instructions.
3. Referring to Figure H-4, use a tin snips to cut off the lower end
of all (4) mounting tabs on the shroud side pieces.
Cut lower end of
each tab at the
location shown.
Figure H-4
IMPORTANT- MOUNTING BRACKET ORIENTATION:
The bracket with the notched out section at the bottom is the
right mounting bracket. Figure H-5.
The flanges on both mounting brackets shroud should be
toward the side of the fireplace. Figure H-5.
4. Align the holes in the right mounting bracket to the
corresponding holes in the fireplace face. Figure H-6. NOTE:
Make sure the brackets are positioned as shown in Figure H-5.
5. Secure the bracket to the face through the top & bottom holes
with (2) of the screws provided (A). Figure H-6.
6. Repeat for left mounting bracket.
Secure brackets at top & bottom
holes with screws provided.
Notched
Out section
Figure H-5 - Note flange orientation
Figure H-6 A
A

Page 15
7. Position the tabs (lower end previously cut), on the shroud, 2
eachside, into the slotsinthefireplacefaceandaligntheoblong
holeson theleft&rightinsideflangeofthesideshroudpiecesto
theholesinthemountingbrackets. Securewiththeremaining(4)
screws (C), 2 each side. Figure H-7.
A
Figure H-7
C
C
CONNECT THE ROCKER SWITCH WIRES TO THE VALVE
Refer to Figure N-1 page #24 for wiring diagram, if necessary.
1. Slide the remaining connectors on the rocker switch wire to the top and bottom terminals marked ‘TH’ on the valve.
COMPLETE THE INSTALLATION:
1. Replace the glass assembly. Refer to Figure C-1, page #6, if necessary.
Completed Shroud Installation

Page 16
I. COMPLETE THE FAN INSTALLATION:
This insert comes complete with a fan, speed control and temperature limit switch assembly already installed. This fan is
equipped with a three-prong (grounding) plug attached to the end of the 8 ft. fan electrical cord for protection against shock
hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not remove the grounding prong
from the plug. Do not allow any excess fan cord to touch the firebox.
1. Attach the limit switch on the left side of the millivolt board under the firebox.
2. Plug fan cord into the nearest, properly grounded receptacle.
Note: The fan will not operate unless the speed control has been turned on. The fan will not turn on until sufficient heat is applied to the
thermostatic control switch. The fan will then turn on and off automatically as the fireplace heat and cools. Adjust fan to desired speed
while it is running.
NOTE: THIS FAN SYSTEM, WHEN INSTALLED, MUST BE ELECTRICALLY CONNECTED AND GROUNDED IN ACCORDANCE WITH LOCAL
BUILDING CODES, OR IN THE ABSENCE OF LOCAL BUILDING CODES, WITH THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70.
CAUTION: WHEN INSTALLATION OF THE MILLIVOLT BOARD IS COMPLETE, CHECK TO ENSURE
THAT THERE ARE NO WIRES, FLEX LINES, ETC., TOUCHING THE FAN TERMINALS.

Page 17
J. COMPLETE THE INSTALLATION
1. THIS STEP SHOULD ONLY BE DONE BY A QUALIFIED INSTALLER OR SERVICE TECHNICIAN:
A) Perform lighting and shutdown procedures as described on pages #19-20. This should be done prior to replacing the
glass so that any necessary adjustments can be made and proper operation and log position is verified.
2. SEASONAL HEAT DUMP ADJUSTMENT:
This fireplace insert has been manufactured with a heat vent damper located at the top inside the firebox. This allows infinite
control over the amount of heat emitted into the living area without affecting the flame height.
INSTALLER: Please install this fireplace insert with the heat vent damper in the closed position.
HOMEOWNER: This fireplace insert has been installed with the heat dump in the closed position and will operate at its peak
efficiency. The heat dump may be opened as much as necessary to maintain desired heat level.
TO ADJUST:
CAUTION: DO NOT ATTEMPT TO ADJUST THE HEAT DUMP OPENING IF THE FIREPLACE HAS BEEN IN OPERATION. ALLOW
AMPLE TIME TO COOL OR USE THE APPROPRIATE PROTECTION TO AVOID SERIOUS BURNS AND/OR PROPERTY DAMAGE.
A. Remove the glass assembly & open or close the damper as desired.
HEAT OUTLET HEAT OUTLET SHOWN
SHOWN IN IN PARTIALLY OPENED
CLOSED POSITION. POSITION.
3. REPLACE THE GLASS FRAME ASSEMBLY. Refer also to Figure J-1.
WARNING: DO NOT OPERATE THIS FIREPLACE
WITH THE GLASS ASSEMBLY REMOVED,
CRACKED, OR BROKEN. Replacement of the
glass assembly should be done by a licensed or
qualified service person.
A. Align the 3 slots in the top of the glass assembly over the 3
tabs on the fireplace (at the top).
B. Place the glass assembly so it is flush with the front of the
fireplace front.
C. While holding the glass assembly, pull the latches out and
secure over the glass latch clips on the bottom of the glass
frame locking it in place.
Figure J-1
4. INSTALL THE LOWER GRILL. Refer to Figure J-2.
A. Remove the (2) 1/4" nuts from the lower grill.
B. Place the bolts through the hinges in the lower grill opening.
C. Attach the 1/4" nuts.
D. Tighten both 1/4" nuts. Figure J-2

Page 18
K. THERMOSTAT - WALL SWITCH - REMOTE INSTALLATION (optional).
CAUTION: DO NOT connect high voltage (115 V) wire to the switch.
If desired, a thermostat (wireless available), wall switch or
remote control assembly may be used to turn the fireplace
‘OFF’ and ‘ON’. Only one of these may be installed.
Follow instructions included with each kit.
IMPORTANT:
High voltage (115v) is not required to operate
any of these systems.
OPTIONAL: Disconnect the ON/OFF rocker switch wires
from the top & bottom terminals on the gas valve. Refer to
Figure N-1, page #24.
NOTE: INSTALLATIONOFATHERMOSTATORWALL SWITCH SHOULD
ONLY BE DONE BY A QUALIFIED INSTALLER.
REMOTE CONTROL USERS:
Follow Instructions included with the remote control.
IMPORTANT:Aninsulated coverisincludedwiththeremote
control and must be placed over the receiver to protect it
from overheating.
WALL SWITCH / THERMOSTAT USERS:
Run low-voltage (thermostat) wire from the terminals on the
gas valve to the desired location of the thermostat or wall
switch.
Attach the appropriate connector to each wall switch /
thermostatwireandconnecttothetopandbottomterminals
marked ‘TH’ on the gas valve.
Remote Control Wiring Diagram
Figure K-2
Figure K-1
Thermostat Wiring Diagram
IMPORTANT: The on/off rocker switch on the shroud
must be in the ‘OFF’ position for proper operation of any of
these components.
If the rocker switch is ‘ON’, the fireplace burner will operate
until it is turned ‘OFF’ by the rocker switch. A wall switch,
thermostat,orremotecontrolwillnotturnthefireplace‘OFF’
when it has been turned ‘ON’ by the rocker switch.
Note: The fireplace must be turned ‘ON’ and ‘OFF’ by the
samemethod. Forexample:Ifthefireplaceisturned‘ON’by
the remote, it must be turned ‘OFF’ by the remote.