Solving Common Problems

Common misconceptions about gas heaters are that "anyone" can install them and that they are "maintenance free." While gas heaters are easily installed, the installer should have sufficient knowledge to insure that the gas pressures are correct and that there are no gas leaks.

Gas Leaks

Gas leaks can occur during shipment and installation. A simple solution of soap and water dabbed on the fittings will bubble if a gas leak is present. Do not use an open flame to check for leaks as this could create a fire or explosion if a gas leak is present.

Most leaks only require tightening the connection. If the leak does not stop, you may need to replace that section or part.

Redoping threaded fitting can also stop leaks. If this does not work, the threads should be checked for damage.

Cutting new threads or reflaring the supply line tubes are additional options for qualified installers.

All gas leaks are serious and must be corrected before operating the heater.

Gas Pressure

Do not assume that the gas pressure is O.K., even if other appliances or heaters in line have been operating correctly. Always check the gas pressure. Too much gas pressure may severely damage the heater. Too little pressure could cause improper burning and other problems.

The regulators used on our Kozy-World natural gas heaters are set to produce a gas flow of 6.0 inches of water column. To accomplish this, the inlet pressure flowing into the regulator must be between 7.0 inches and 14.0 inches of water column.

Our LP gas heaters have a regulator setting of 10.0 inches of water column. To accomplish this rate of flow, the inlet pressure must be between 11.0 inches and 14.0 inches of water column pressure. Propane heaters require an external regulator which must be connected between the heater and the propane tank to reduce incoming pressure to a maximum of 14.0 inches of water column. (This regulator is not supplied with the heater.)

Damage caused to the heater's regulator by omitting this external regulator is not covered under warranty.

A 1/2 inch manual shut off valve with 1/8 inch NPT Plug/Tap for test connection is available from your retailer. Part #KW-5010. Water manometers with instructions are also available. Part # KW-5060.

Cleaning and Maintenance

IMPORTANT: All warranties are void unless proper cleaning and maintenance is performed. (See owner's manual for additional information.)

Dust and dirt may affect heater performance.

The heater draws air into it during normal combustion. In the process dust and dirt will also be drawn into the heater. How often the heater will need cleaning will depend on how and where the heater is used. At a minimum, it should be cleaned at least once a year, at the beginning of the heating season.

If the pilot light will not stay on, try cleaning it.

The gas orifice "opening" in the pilot is actually a tiny ruby about the size of a head on a pin. A tiny hole is drilled through the ruby.

If this tiny opening begins to close from an accumulation of dust, the pilot light won't stay lit.

To clean, follow these instructions:

1.	Be sure the heater has been turned off and is cool before cleaning.
2.	Use a can of compressed air, such as the type used to clean a computer, to blow dust out. Sometimes just blowing air back through the pilot will get rid of the dirt. Do not use excessive air pressure as this may dislodge the tiny ruby.
3.	If that fails to solve the problem carefully lift the metal strip on the pilot assembly. Blow out any dust from the hole beneath the strip. Check for correct operation. (Do not bend the metal strip.)
4.	If that fails, the pilot assembly should be removed and air blown through the assembly and gas line as shown below.

Oxygen Depletion Sensor Pilot Servicing

When yellow tip flames are present, clean the ODS pilot by loosening nut B from the pilot tubing. When this procedure is required, grab the nut A with an open end wrench.

Blow air pressure through the hole as indicated with arrows in figure 1. This will blow out foreign materials such as dust. Tighten nut B also by grabbing nut A. Always test for leaks after reassembling the pilot.

NOTE: A dirty pilot assembly is sometimes mistaken for a defective pilot/thermocouple. With proper maintenance pilot/thermocouple replacement is rarely required.

Additional Cleaning Tips

Controls, burners and the heater air passageways must be kept clean. Inspect before each use and perform noted maintenance at least once a year. More frequent cleaning may be necessary depending on the environment where used and the amount of use.

Use a vacuum cleaner or pressurized air to clean passageways inside the cabinet.

Wipe any dust from exterior with a soft cloth dampened with a mixture of mild soap and water.

White chalky deposits may form near the burner if the heater is installed in a dusty, humid environment. The condition is caused when the dust passes through the heater and the residue sticks on the surface. Some installations, especially below grade, may be helped by using a dehumidifier. Although these deposits may be unsightly, they should not cause a problem provided all burn surfaces are kept clear and open and frequent cleaning is performed