kozy heat Z-42 User manual

Z42 DECEMBER 2011
Z42 REV-11
www.kozyheat.com
DONOT
DISCARD
ZERO CLEARANCE FACTORY BUILT FIREPLACE
WARNING: READ INSTRUCTIONS CAREFULLY BEFORE INSTALLATION. FAILURE TO INSTALL
THIS FIREPLACE CORRECTLY CAN CAUSE SERIOUS STRUCTURAL AND FIRE HAZARDS AND MAY
VOID YOUR WARRANTY.
INSTALLER: LEAVE THIS MANUAL WITH THE APPLIANCE.
CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.
INSTALLATION AND OPERATION MANUAL
Z-42-CD shown with accent grills

INTRODUCTION
Read this manual before installing or operating this appliance.
Please retain this owner’s manual for future reference.
PAGE 1
Homeowner Reference Information
We recommend that you record the following information about your fireplace.
Model Name:______________________________ Date purchased/installed:___________________________
Serial Number:____________________________ Location on fireplace:_______________________________
Dealership purchased from:__________________ Dealer Phone:____________________________________
Notes:_____________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
CONGRATULATIONS!
We welcome you as a new owner of a Kozy Heat gas fireplace. Kozy Heat products are
designed with superior components and materials and assembled by trained craftsmen who
take pride in their work. The burner and valve assembly are 100% test-fired and the complete
fireplace is thoroughly inspected before packaging to ensure that you receive a quality product.
Our commitment to quality and customer satisfaction have remained the same for over 30
years. We offer a complete line of gas and wood fireplaces, unique cabinets and stylish
accessories to compliment any décor. Adding a fireplace is one of the best ways to increase the
value of your home and we are proud to offer a network of dealers throughout the country to
help make your experience everything you imagine. We pride ourselves in being dedicated to
not only function and reliability, 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

TABLE OF CONTENTS
INTRODUCTION
Introduction and Homeowner Reference Information 1
TABLE OF CONTENTS
Table of Contents 2
SAFETY INFORMATION
Safety Information 3
FEATURES
Features 4
SPECIFICATIONS
Fireplace Dimensions 5
Clearance to Combustibles 5
Installation Overview 6
Placement Clearance Requirements 6
Placement Illustration 7
TYPICAL INSTALLATION OPTIONS
Typical Installation Options 8
FRAMING
Wall Enclosure Rough Opening 9
Hearth Extension 9
COMBUSTION AIR PIPE INSTALLATION
Combustion Air Pipe Installation 10
Combustion Air Pipe Venting Configurations 11
CHIMNEY
Chimney Location Illustrations 12
Chimney Requirements 13
Approved Chimney Systems 13
Anchor Plate Installation 13
Chimney Installation 14
OPTIONAL FAN INSTALLATION
Optional Fan Installation 15-16
Fan Shield Installation 15
FIREBRICK INSTALLATION
Firebrick Installation 17
PAGE 2
FIREPLACE FRAMING & FACING
Fireplace Framing & Facing 18
Mantel Projection Chart 18
COMPLETE THE INSTALLATION
Upper Grill Installation 18
Upper Grill Removal 18
Lower Grill Installation 18
Lower Grill Removal 18
Arched Door Model Spring Handle Installation 18
Cast Iron Door Model Spring Handle Installation 18
DOOR SEAL ALIGNMENT & ADJUSTMENT (Arched Door Model)
Checking the Seal 19
Hinge Adjustment 19
Latch Adjustment 20
DOOR SEAL ADJUSTMENT (Cast Door Model)
Door Seal Adjustment 21
FIREPLACE OPERATION
Fireplace Operation 22
Ash Disposal 22
MAINTENANCE REQUIREMENTS
Creosote Information 23
Glass Information 23
Broken Glass Removal & Replacement - Arched Door Model 23
Broken Glass Removal & Replacement - Cast Iron Door Model 23
OPTIONAL #970 HEAT DUCT KIT INSTALLATION
Optional #970 Heat Duct Kit Installation Instructions 24-28
ALTERNATE FLOOR PROTECTION MATERIAL WORKSHEET
Alternate Floor Protection Material Worksheet 29
TROUBLESHOOTING
Troubleshooting 30
REPLACEMENT PARTS
Replacement Parts 30

• If this appliance is installed directly on carpeting, tile or other combustible material other than wood flooring, the appliance shall be
installed on a metal or wood panel extending the full width and depth of the appliance.
• Combustible flooring 16” (406 mm) in front of and 8” (203mm) to each side of the fuel opening must be insulated with non-combustible
floor protection with a minimum insulation R-value of 0.8.
• Do not store clothing, furniture or combustibles within 36” (914mm) of the fireplace.
• The chimney should be inspected monthly during the heating season to determine if creosote buildup has occurred. If creosote has
accumulated, it should be removed to reduce the risk of a chimney fire. We recommend a professional chimney cleaner inspect and
clean the chimney at least once annually.
• Children and adults should be alerted to the hazards of high surface temperatures and should stay away to avoid burns or clothing
ignition.
• Young children should be carefully supervised when they are in the same room as the appliance. Toddlers, young children and others
susceptible to accidental contact burns. A physical barrier is recommended if there are at risk individuals in the house. To restrict access
to a fireplace or stove, install an adjustable safety gate to keep toddlers, young children and other at risk individuals out of the room and
away from hot surfaces.
• 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.
• Do not operate this appliance with the glass/frame assembly removed, cracked or broken. The glass assembly, shall only be replaced as
supplied by Hussong Mfg. Co., Inc. Replacement of the glass assembly must only be performed by a licensed or qualified service person.
DO NOT SUBSTITUTE MATERIALS.
• Do not strike or slam glass assembly.
• Do not burn waste paper.
• Except when loading, the fireplace must be operated with the door / doors closed.
• Do not obstruct room air inlet and outlet grills. This may cause the fireplace to overheat.
• Burn only dry seasoned wood. Extremely hard woods, such as oak or ash can require up to two years of drying time to be sufficiently dry.
• It is recommended that smoke detectors be installed in your home as required by local building codes or the authority having jurisdiction.
• Some fuels, such as charcoal, may generate carbon monoxide, a dangerous, odorless gas. Exposure to carbon monoxide may cause serious
illness or death.
• For further information on using your fireplace safely, obtain a copy of the National Fire Protection Association publication “Using coal &
Wood Stoves Safely.” NFPA No. HS-10
SAFETY INFORMATION
This fireplace has been tested and listed by Intertek Testing Services (Warnock Hersey) to UL 127-2008, CAN/ULC S610-M98 Safety Standards for
U.S. and Canadian installations. This fireplace installation must conform with local building codes, or in the absence of local codes, with the NFPA
211 Standard for Chimneys, Fireplaces, and Vents.
IMPORTANT: BEFORE INSTALLING THIS FIREPLACE, THE AUTHORITY HAVING JURISDICTION SHOULD BE CONSULTED TO DETERMINE
IF A PERMIT IS REQUIRED.
INSTALLATION AND REPAIR SHOULD BE PERFORMED ONLY BY A QUALIFIED INSTALLER.
WARNING: THIS FIREPLACE HAS NOT BEEN TESTED WITH ANY GAS COMPONENT. TO REDUCE THE RISK OF FIRE OR INJURY, DO NOT
INSTALL ANY GAS COMPONENT, INCLUDING AN UNVENTED GAS LOG SET INTO THIS FIREPLACE.
WARNING: DO NOT CONNECT THIS FIREPLACE TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.
PAGE 3
MOBILE HOME INSTALLATIONS:
WARNING: DO NOT INSTALL IN A SLEEPING ROOM.
WARNING: THE STRUCTURAL INTEGRITY OF THE MOBILE HOME FLOOR, WALL, AND CEILING / ROOF MUST BE MAINTAINED.

FEATURES
• EPA/WA Certified/Non-Catalytic (EPA emissions rate 3.34g / hr.)
• High quality lifetime glass
• Arched glass valance (Z42)
• Large burning area
• Air-seal 10 ga. steel door (Z42)
• Twin air-seal cast iron doors (Z42-CD)
• Zero Clearance to stand-offs
• Air-wash system (keeps viewing area cleaner)
• (2) heat duct knock-outs for optional ducting (#970 kit required)
• Decorative grills in various styles and finishes
• Decorative screen doors in various styles and finishes (Z42 only)
• Automatic fan kit with variable speed control ( (2) 100 CFM)
• 44” (1118 mm) lintel iron
• 6” flexible heat duct kit
• 4” non-closure air vent
• Finish material trim kits
• Tested by Intertek Testing Services (formerly Warnock Hersey)
• Sealed combustion chamber
• EPA certified
• Non-catalytic
• Uses 100% outside air for combustion
• U.S. and Canadian approved
• Fireplace Weight (as packaged for shipment)
Z42: 515lbs. (233.6kg)
Z42-CD: 534lbs. (242.2kg)
STANDARD FEATURES
OPTIONAL FEATURES
WEIGHT
SAFETY FEATURES
PAGE 4

SPECIFICATIONS
FIREPLACE DIMENSIONS
LETTER KEY A B C D E F G H
DESCRIPTION Height Width Depth Glass Frame
Height Glass Frame Width Stand-off Height Front to Flue Center Back to Flue Center
FIREPLACE
DIMENSIONS
INCHES 38 42 25-15/16 18-3/16 31-11/16 3-5/8 18-1/4 7-11/16
MILLIMETERS 965 1067 658 463 805 92 463 196
CLEARANCE TO COMBUSTIBLES
♦ Fireplace to back wall……………………………….0” (0mm)
♦ Fireplace to sidewalls………………………………..0” (0mm)
♦ Duct boots to framing……………………………….0” (0mm)
♦ Top stand-off to header……………………………..0” (0mm)
♦ Fireplace bottom to inside top of enclosure……..72” (1.83m)
WITHIN ENCLOSURE AREA EXPOSED AREA
♦ Wallboard to faceplate top edge/ sides………….0” (0mm)
♦ Fuel door opening to sidewall..………………..8” (203mm)
♦ Fireplace face top to 8” (203mm) mantel…..12” (305mm)
♦ Front of fireplace……………………………..36” (914mm)
♦ Air duct vent to ceiling………………………….2” (51mm)
NOTE: Even though minimum clearances from back and side walls is 0”, 1/4” (6mm) space is recommended for heat expansion.
PAGE 5
B. 42”
(1067mm)
E . 31-11/16”
(805mm)
H. 7-11/16”
(196mm)
G 18-1/4”
(463mm)
7-15/16”
(202mm) 16”
(407mm)
A. 38”
(965mm) D. 18-3/16”
(463mm)
F. 3-5/8”
(92 mm)
12-1/16”
(307mm)
16”
(406mm)
3-1/8”
(80mm)
5-7/8”
(149mm) C. 25-15/16”
(658mm)
9-15/16”
(252mm)
Figure 5a

1. If masonry (optional) will be used, prepare foundation for the masonry load. A lintel is required to support the added weight above the
fireplace.
2. Frame an opening for the fireplace, allowing for vent installation and type of installation (corner, flat wall application).
3. Install optional hearth.
4. Install optional heat duct venting.
5. Install any electrical wiring.
6. Install fireplace into framing.
7. Attach combustion air pipe.
8. Install chimney.
9. Install desired facing material.
10. Install mantel.
11. Install optional fan.
12. Install firebrick.
13. Install door components and grills.
14. Install any optional decorative accessories.
• Location of doors and windows on all floors of the home in relation to the fireplace and chimney must be considered and be in
compliance with applicable codes, if any.
• This fireplace must be installed on a level surface capable of supporting the fireplace and venting.
• Fireplace must be placed directly on wood or non-combustible surface (not linoleum or carpet) extending the entire depth and width of
fireplace.
• Metal sealing strips must be used under fireplace and hearth extension.
• The height of the enclosure must be a minimum of 72” (1.83m). This measurement is from fireplace bottom to inside top of enclosure.
• Due to high surface temperatures, fireplace should be located out of traffic and away from furniture and draperies.
• Please be aware of the large amount of heat this fireplace will produce when determining a location.
See illustration on following page.
INSTALLATION OVERVIEW
NOTE: The qualified installer should follow the procedure best suited for the installation.
PAGE 6
IMPORTANT: Combustible flooring 16” (406mm) in front of and 8” (203 mm) to each side of the fuel opening must be insulated with
non-combustible floor protection with a minimum insulation R-value of 0.8.
Manufactured hearth materials will usually have a published R value (resistance to heat) or k value (conductivity of heat).
Use the following formula to convert a k value to an R value.
R = 1/k x inches of thickness. See complete formula on page 29.
PLACEMENT CLEARANCE REQUIREMENTS

PAGE 7
PLACEMENT CLEARANCE REQUIREMENTS
Minimum enclosure height:
72” (1.83m)
Metal sealing strips
Minimum width:
48” (1219mm) Minimum depth:
16” (406mm)
Non-combustible floor protection
with minimum
insulation R-value of 0.8
Fuel door opening
to adjacent side wall
8” (203mm)
minimum
Fireplace face top to
8” (203mm) mantel
12” (305mm)
WARNING: FOLLOW ALL INSTRUCTIONS AND CLEARANCES AS OUTLINED THROUGHOUT THIS MANUAL.
DO NOT FILL SPACE DIRECTLY ABOVE FIREPLACE WITH ANY MATERIAL (EXCEPT WOOD FRAMING).
Do not install shelving or cupboards into this area.
Figure 7a

TYPICAL INSTALLATION OPTIONS
IMPORTANT: If this fireplace is installed on an exterior wall, it must be insulated the same as any other exterior wall to prevent cold air
from entering the home.
Combustion air pipes must be secured with screws to prevent separation and cold air transfer.
NOTE: All dimensions include 1/4” (6mm) side and back expansion space /
1/2” (13mm) sheathing. Sheathing is flush with fireplace front.
Adjust dimensions if sheathing is more than 1/2” (13mm) thick.
Must allow 6” (152mm)
for combustion air pipe.
Combustion
Air Pipe
8” (203mm) from door
to side wall
Combustion
Air Pipe
Combustion
Air Pipe
21-1/2”
(546mm)
26-1/4”
(667mm)
42-1/2”
(1080mm)
26-1/4
(667mm)
48-1/2”
(1232mm)
42-1/2”
(1080 mm)
26-1/4”
(667mm)
94-3/4”
(2407mm)
67”
(1702mm)
3”
(76mm)
PAGE 8
Figure 8a

FRAMING
Frame opening to fit fireplace. All required clearances must be maintained.
MINIMUM WALL ENCLOSURE DIMENSIONS: 42-1/2” (1080mm) wide x 38-1/4” (792mm) high x 26-1/4” (667mm) deep.
IMPORTANT: Allow a minimum of 6” (152mm) in framing width dimension for the combustion air pipe which will be installed after
fireplace has been inserted into framing. Please refer to illustration on previous page.
ENCLOSURE MUST BE A MINIMUM OF 72” (1.83 m) HIGH FROM BOTTOM OF FIREPLACE TO INSIDE TOP OF ENCLOSURE.
APPLIES TO BOTH RAISED AND NON-RAISED HEARTHS: Combustible flooring 16” (406mm) in front of and 8” (203mm) to
each side of fuel door opening must be insulated with non-combustible floor protection with a minimum insulation R-value of 0.8.
Manufactured hearth materials will usually have a published R value (resistance to heat) or k value (conductivity of heat).
Use the following formula to convert a k value to an R value.
IMPORTANT: Metal sealing strip (included with fireplace) must be used. Install sealing strip so it is centered under fireplace and hearth
extension the full width of fireplace. Sand-cement grout may also be used between hearth and an on-site constructed hearth
extension.
WALL ENCLOSURE ROUGH OPENING
CAUTION: The lower grill must be allowed to open completely. Do not position fireplace in such a manner that would obstruct this grill.
NOTE: If installing optional #600-1 Fan Kit, run electrical wiring at this time.
If installing optional #970 Heat Duct Kit, please refer instructions included with kit at this time.
Floor
Non-combustible
hearth extension
material
Metal sealing strips
Sand-cement grout
PAGE 9
R = 1/k x inches of thickness. See complete formula on page 29.
Figure 9a