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kozy heat CALLAWAY 40 - User Manual

kozy heat CALLAWAY 40
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HUSSONG MANUFACTURING CO., INC.
INSTALLATION AND
OPERATION MANUAL
ͷ Do not store or use gasoline or other
ammable vapors and liquids in the vicinity
of this or any other appliance.
ͷ 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.
Leave the building immediately.
Immediately call your gas supplier from
a neighbors phone. Follow the gas
suppliers instructions.
If you cannot reach your gas supplier,
call the re department.
ͷ Installation and service must be performed
by a qualied installer, service agency or
the gas supplier.
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly
could result in serious injury, death, or
property damage.
This appliance may be installed in
an aftermarket, permanently located,
manufactured home (USA only) or mobile
home, where not prohibited by local codes.
This appliance is only for use with the type
of gas indicated on the rating plate. This
appliance is not convertible for use with other
gases, unless a certied kit is used.
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.
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
.
DANGER
HOT GLASS WILL
CAUSE BURNS
DO NOT TOUCH GLASS
UNTIL COOLED
NEVER ALLOW CHILDREN
TO TOUCH GLASS
A barrier designed to reduce the risk of burns
from the hot viewing glass is provided with this
appliance and shall be installed for the protection
of children and other at-risk individuals.
CALLAWAY 40
Model #CLW-40
Direct Vent Gas Fireplace
Hussong Mfg. Co., Inc.
CLW-40 Report No: 19-472
Rev. 3, November 2021
Starting Serial Number: 20 800334 26

Table of Contents

Questions and Answers

  • M
    Mary Perez DDSAug 13, 2025
    What to do if the main burner flame will not light on my Kozy Heat Indoor Fireplace?
    • R
      Rebecca HoffmanAug 13, 2025
      If the main burner flame doesn't light, make sure the ON/OFF rocker switch is in the ON position. Check the gas supply line for multiple shut-offs and ensure the gas supply is turned on. Consult a plumber or gas supplier if the gas supply is low, and check/refill the propane tank if necessary. Inspect for faulty or incorrect wiring. Remove any blockage from the main burner orifice. Ensure the pilot flame is properly directed to ignite the burner. Replace the remote control batteries. Verify the remote control is powered ON and thermostat operation is turned OFF.
  • A
    Adam WalkerAug 17, 2025
    What to do if pilot will not light on my kozy heat CALLAWAY 40 Indoor Fireplace?
    • S
      Stephanie ThomasAug 17, 2025
      If the pilot light won't ignite, first ensure that electrical power to the appliance is restored or use a battery back-up. If using a battery back-up, check that the batteries are fully charged. Next, check the wiring connections using the wiring schematic to ensure they are secure and correct. Finally, check the remote shut-off valves from the appliance to ensure the gas supply is turned on.
  • T
    thomas86Aug 21, 2025
    Why does my kozy heat CALLAWAY 40 pilot and burner extinguish while in operation?
    • W
      wheelerdavidAug 21, 2025
      Several factors can cause the pilot and burner to extinguish during operation. First, check the propane tank and refill if necessary. Also, ensure correct installation of the glass assembly. Check and adjust the vent cap installation if needed, and remove any debris blocking the vent cap. Ensure the horizontal venting has a ¼” (6mm) rise per foot (30cm). Check the exhaust vent pipe for leaks and repair if necessary. Finally, excessive draft may require a restrictor to be installed or modified.
  • G
    George TateAug 25, 2025
    What to do if pilot will not stay lit on my Kozy Heat Indoor Fireplace?
    • J
      jmorrisAug 25, 2025
      If the pilot light won't stay lit, first check the propane tank and refill it if necessary. Low gas pressure could also be the cause, so consult a plumber or gas supplier to check for issues like a bent line or low line pressure. Verify the pilot flame envelopes the top of the flame sensor and extends far enough onto the burner for ignition. To adjust the pilot flame, turn the pilot adjustment screw on the gas valve clockwise to decrease the flame and counterclockwise to increase it. Finally, ensure the pilot adjustment screw is sealed, but do not over-tighten it.
  • A
    Amanda KempAug 28, 2025
    Why is there soot on the glass of my kozy heat CALLAWAY 40 Indoor Fireplace?
    • J
      Jason AdamsAug 28, 2025
      Soot appearing on the glass can be due to several reasons. Check the media placement. The venturi air shutter may need adjustment to allow more air into the gas mix. Also, check the vent cap installation and remove any debris if necessary.
  • M
    Mary ArmstrongAug 31, 2025
    Why is the flame blue and lifting off burner on my kozy heat CALLAWAY 40 Indoor Fireplace?
    • F
      Frederick MeyerAug 31, 2025
      If the flame is blue and lifts off the burner, the venturi air shutter may need to be closed slightly to allow less air into the gas mix. Check the vent cap installation. Inspect the vent system for blockages or leaks, repairing pipes or removing debris as needed.
  • C
    Christopher GonzalesSep 4, 2025
    What to do if my kozy heat CALLAWAY 40 Indoor Fireplace has no reaction to command?
    • J
      Jeffery LeeSep 4, 2025
      If your fireplace isn't responding to commands, try these steps: * Replace the batteries in the battery back or remote control. * Reprogram the remote control to the IFC module. * Reset the IFC module if a maximum number of failed ignitions or flame restorations has been reached.
  • R
    Robert DunnSep 8, 2025
    Why is the pilot flame always on, or will not extinguish on my Kozy Heat Indoor Fireplace?
    • D
      duane02Sep 8, 2025
      If the pilot flame is always on or won't extinguish, the control system may be set to CPI mode. Set the control system to IPI mode.

Summary

1.0 INTRODUCTION

1.1 Appliance Certification

Details on appliance certification standards and laboratory.

1.2 California Proposition 65 Warning

Warning about chemicals causing cancer, birth defects, or harm.

1.3 Requirements for the Commonwealth of Massachusetts

Specific installation requirements for Massachusetts.

2.0 SPECIFICATIONS

2.1 Heating Specifications

Details on input ratings, manifold pressure, and orifice sizes.

2.1.1 Altitude Adjustment

Guidelines for adjusting input ratings based on altitude.

2.2 Electrical Specifications

Power requirements for the appliance.

2.3 Appliance Dimensions

2.4 Barrier Dimensions

2.4.1 Standard Safety Barrier

Information on the standard safety barrier for burn risk reduction.

2.4.2 Optional Surrounds

Details on optional surrounds and hearth finish considerations.

3.0 FRAMING

3.1 Installation Planning

Planning considerations for heat transfer kits, Komfort Zone, and Power Vent.

3.1.1 Appliance Placement Considerations

Guidelines for locating the appliance safely and correctly.

3.1.2 Moving the Appliance

Instructions for safely lifting and moving the fireplace.

3.2 Nailing Flange Assembly and Installation

3.3 Stand-off Assembly and Header Heat Shield

3.4 Clearances to Combustibles

3.5 Rough Framing

3.5.1 Rough-in Wall Enclosure

Guidelines for framing the wall enclosure for the fireplace.

3.5.1.1 TV Recess Construction

Guidelines for constructing a TV recess above the fireplace.

3.5.2 Rough-in Vent Termination

3.5.2.1 Requirements

Requirements for cold air transfer and compliance with codes.

3.5.2.2 Clearances

Minimum clearances for vertical and horizontal vent pipes.

3.5.2.3 Vertical Terminations

Instructions for vertical vent pipe terminations.

3.5.2.4 Horizontal Terminations

Requirements for horizontal vent pipe terminations.

3.5.2.5 Wall Pass Through Framing Instructions

Steps for framing wall pass-throughs for vent pipes.

3.6 Outdoor Covered Fireplace Installation

3.6.1 Safety Screen Barriers

Recommendations for safety screen barriers in outdoor installations.

3.6.2 Requirements

Building envelope, temperature, and wiring requirements for outdoor use.

3.7 Heat Management Preparation Overview

3.7.1 Exterior and Interior Heat Transfer Kit Cover Plates

Instructions for removing cover plates for heat transfer kits.

3.7.2 Vented Cavity and Komfort Zone Kits

3.7.2.1 Standoff Assembly Installation and Header Heat Shield Removal

3.7.2.2 Clearances to Sprinkler

3.7.2.3 Clearances to Combustibles

3.7.2.4 Rough-in Wall Enclosure

3.7.2.5 TV Recess Construction

3.8 Vented Cavity

3.8.1 Single Opening Vented Cavity Option

Details on single opening vented cavity with air discharge location.

3.8.1.1 Single Opening Vented Cavity Option Alternative Installations

3.8.1.1 Single Opening Vented Cavity Option Alternative Installations (cont.)

3.8.1.1 Single Opening Vented Cavity Option Alternative Installations (cont.)

3.8.2 Top Vented Cavity Framing

3.8.2.1 Top Vented Cavity Option Alternative Installations

Alternative installations for top vented cavity with crown molding or overhang.

4.0 FACING AND FINISHING

4.1 Standard Installation Facing and Finishing Requirements

General requirements for facing and finishing standard installations.

4.1.1 Mantel and Hearth Requirements

Clearances and guidelines for combustible mantels and hearths.

4.1.2 Adjacent Sidewall Requirements

Minimum clearance requirements for adjacent sidewalls.

4.1.3 Facing Requirements

Requirements for non-combustible facing materials.

4.1.4 Finishing Recommendations

Recommendations for painting and drywall finishing.

4.2 #CW40-SCK Optional Skim Coat Kit

4.3 Finishing Guidelines for Optional Surrounds

4.4 Barrier Installation

4.4.1 Safety Barrier Screen (#CW40-ES)

Instructions for installing the safety barrier screen.

4.4.2 Optional Surrounds (CW40-RS, CW40-RS4, CW40-GS, CW40-MS)

Instructions for installing optional surrounds.

4.5 Vented Cavity and KZK Facing and Finishing Requirements

4.5.1 Mantel and Hearth Requirements

Mantel and hearth requirements for Vented Cavity/KZK.

4.5.2 Adjacent Sidewall Requirements

Sidewall clearance requirements for Vented Cavity/KZK.

4.5.3 Facing Requirements

Facing requirements for Vented Cavity/KZK.

4.5.4 Finishing Recommendations

Recommendations for drywall and paint for Vented Cavity/KZK.

4.5.4.1 Combustible Wall Finish

Guidelines for combustible wall finishes with Vented Cavity/KZK.

5.0 GAS LINE CONNECTION

5.1 Gas Conversion

Instructions for converting the appliance to propane.

5.2 Gas Line Installation

Guidelines for installing the gas line to the appliance.

6.0 NATURAL DRAFT TERMINATION LOCATIONS

6.1 Vertical Natural Draft Vent Termination

Requirements for vertical natural draft vent termination placement.

6.2 Minimum Natural Draft Vent Termination Clearances

7.0 VENTING

7.1 Approved Vent Systems

Lists of approved vent systems for the appliance.

7.1.1 Approved 5 x 8 Vent Systems

Approved 5"x8" vent systems and cap part numbers.

7.1.2 Approved 4” x 6-5;8″ Vent Systems

Approved 4"x6-5/8" vent systems and cap part numbers.

7.2 Venting Requirements

General requirements for combustion air and vent clearances.

7.3 Natural Draft Vent Restriction

7.4 Natural Draft Installation

7.4.1 Natural Gas and Propane Vertical Terminations

Configurations for vertical vent terminations.

7.4.2 Natural Gas and Propane Horizontal Terminations

Configurations for horizontal vent terminations.

7.4.3 Natural Gas and Propane Combination Venting

7.4.4 Natural Gas and Propane Maximum Vertical & Maximum Horizontal Combination Venting

7.5 Class A Chimney;Masonry Chimney Conversion

7.5.1 4 Flex Pipe Venting Configurations

Venting configurations for Class A/Masonry chimney conversion.

7.6 Coaxial to Co-Linear Chimney Conversion

7.6.1 Coaxial to Co-Linear Venting Configurations

Venting configurations for coaxial to co-linear chimney conversion.

8.0 FIREPLACE SETUP

8.1 Glass Frame Assembly

Instructions for removing and installing the glass frame assembly.

8.2 Burner;Perimeter Media Installation

Instructions for installing burner and perimeter media.

8.3 Control Board Removal and Installation

8.3.1 Control Board Removal

Steps for safely removing the control board.

8.3.2 Control Board Installation

Steps for safely installing the control board.

9.0 ELECTRICAL INFORMATION

9.1 Electrical Specifications

Power supply and grounding requirements for the appliance.

9.2 Wiring Requirements

Power and battery requirements for the IFC system module.

9.3 #600-TLK Top Light Kit

9.3.1 Install Light Kit

Instructions for installing the top accent light kit.

9.4 #SL42-028 Optional Fan Kit

10.0 OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

Critical safety warnings before operating the appliance.

OPERATING INSTRUCTIONS

Step-by-step guide for operating the fireplace.

TO TURN OFF GAS TO APPLIANCE

Procedure for safely turning off gas to the appliance.

10.1 Setup Proflame 2 IFC Module

10.2 Initialize the Control System

10.3 Reset the System for Manual Operation

10.4 Automatic Safety Restart

10.5 Backup Battery Operation

10.6 Control System 7 Day Timer Operation

10.7 IFC Module Ignition Sequence

10.7.1 Reset IFC Module after Lockout

Procedures to reset the IFC module after a lockout.

10.7.1.1 ON;OFF Rocker Switch

Resetting the IFC module using the ON/OFF rocker switch.

10.7.1.2 Remote Control ON;OFF Key

Resetting the IFC module using the remote control.

10.7.1.3 Cycling Flame

How to cycle the flame using the remote control.

10.8 Additional Diagnostic Information

10.9 Remote Control Operation

10.9.1 Temperature Display

How to change temperature display between °F and °C.

10.9.2 Key Lock

Function to lock the remote control keys.

10.9.3 Pilot Ignition Selection (IPI;CPI)

How to select between IPI and CPI pilot ignition modes.

10.9.4 Turn ON the Appliance

10.9.5 Turn OFF the appliance

10.9.6 Remote Control Flame Adjustment

10.9.6.1 Deactivate Flame Modulation

How to deactivate flame modulation.

10.9.7 Remote Control Thermostat Operation

10.9.7.1 Room Thermostat

How to use the remote as a room thermostat.

10.9.7.2 Smart Thermostat

10.9.7.3 Deactivate Remote Control Thermostat Operation

10.9.8 Fan Speed Control

10.9.9 Top Accent Light Kit

10.9.9.1 Deactivate Light Kit Modulation

How to deactivate light kit modulation.

10.9.10 Remote Control Low Battery Detection

11.0 ADJUSTMENT

11.1 Pressure Testing

Procedures for testing inlet and manifold gas pressures.

11.1.1 Inlet Pressure Test

Steps to test the incoming gas pressure.

11.1.2 Manifold Pressure Test

Steps to test the manifold gas pressure.

11.2 Burner Flame Adjustments

11.2.1 Burner Venturi

Instructions for adjusting burner venturi for optimal flame.

11.2.1.1 Venturi Adjustment

Specific steps for adjusting the venturi.

11.2.2 Vent Restriction (after installation)

11.2.2.1 Restrictor Plate Installation

How to install the restrictor plate.

11.2.2.2 Restrictor Plate Modification

How to modify or remove the restrictor plate.

12.0 TROUBLESHOOTING

Pilot will not light

Troubleshooting steps for when the pilot does not light.

Pilot will not stay lit

Troubleshooting steps for when the pilot does not stay lit.

Pilot flame always on, or will not extinguish

Troubleshooting steps for constant pilot flame.

Main burner flame will not light

Troubleshooting steps for when the main burner does not light.

Pilot and burner extinguish while in operation

Soot appears on glass

Flame burns blue and lifts off burner

No reaction to command

13.0 MAINTENANCE

13.1 Firebox

Annual maintenance for the firebox.

13.2 Fan (optional)

Maintenance for the optional fan kit.

13.3 Vent System

Annual inspection of the vent system.

13.4 Glass Assembly

Instructions for cleaning and inspecting the glass assembly.

13.5 Burner and Pilot System

14.0 REPLACEMENT PARTS LIST

LIMITED LIFETIME WARRANTY

kozy heat CALLAWAY 40 Specifications

General IconGeneral
ModelCALLAWAY 40
CategoryIndoor Fireplace
Width40 inches
Fuel TypeNatural Gas or Propane
Finish OptionsBlack
Log OptionsOak, Driftwood

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