Sourcefy 24-3003 ODS Pilot Assembly Instruction Manual

1. Introduction and Overview

The Sourcefy 24-3003 ODS Pilot Assembly is a crucial replacement component designed for vent-free gas heating appliances. This assembly integrates an Oxygen Depletion Sensor (ODS) with a pilot light and thermocouple. Its primary function is to ensure safe and efficient operation by continuously monitoring oxygen levels in the room and verifying the presence of a pilot flame. If oxygen levels drop below a safe threshold or the pilot flame extinguishes, the ODS system automatically shuts off the gas supply to prevent hazardous conditions.

2. Important Safety Information

WARNING: Improper installation, adjustment, alteration, service, or maintenance can lead to injury or property damage. Always refer to this manual and the original appliance manufacturer's instructions. For assistance or additional information, consult a qualified installer, service agency, or the gas supplier.

• This product must be installed by a qualified service technician in accordance with all local codes and the appliance manufacturer's instructions.
• Always turn off the gas supply to the appliance and disconnect power before performing any service, maintenance, or installation.
• Ensure adequate ventilation when operating gas appliances to prevent oxygen depletion.
• Do not tamper with or bypass the ODS safety system. It is designed for your safety.
• Use only genuine replacement parts.

3. Product Description and Components

The Sourcefy 24-3003 Pilot ODS Assembly is specifically designed for use with Propane (LPG) gas. It is commonly found in various vent-free heating products, including infrared space heaters, vent-free gas log sets, blue flame wall heaters, and pedestal stoves.

Key components of the assembly include:

• Pilot Burner: Provides the small flame that ignites the main burner.
• Oxygen Depletion Sensor (ODS): Monitors ambient oxygen levels.
• Thermocouple: A safety device that generates a small electrical current when heated by the pilot flame, keeping the gas valve open. If the pilot flame goes out, the thermocouple cools, and the gas valve closes.
• Igniter Electrode: Produces a spark to light the pilot flame.

Figure 1: Overview of the Sourcefy 24-3003 ODS Pilot Assembly. This image shows the complete pilot assembly, including the pilot burner, ODS sensor, thermocouple, and gas inlet connection.

4. Compatibility

The Sourcefy 24-3003 ODS Pilot Assembly is specifically designed to fit and function with the following Kozy-World heater models:

• Kozy-World Model KWP192
• Kozy-World Model KWP196

Always verify the model number of your appliance before purchasing and installing replacement parts.

Figure 2: Sourcefy 24-3003 ODS Pilot Assembly with its coiled thermocouple. This view highlights the copper thermocouple tubing, which is essential for the safety mechanism.

5. Installation Instructions

Installation of the Sourcefy 24-3003 ODS Pilot Assembly should only be performed by a qualified service technician. Refer to the specific installation instructions provided by the manufacturer of your Kozy-World heater (KWP192 or KWP196) for detailed steps. The following is a general overview:

1. Preparation: Ensure the heater is completely cool. Turn off the gas supply to the appliance at the main shut-off valve and disconnect any electrical power.
2. Access: Remove the outer casing or access panels of the heater to expose the existing pilot assembly.
3. Disconnection: Carefully disconnect the gas line, thermocouple, and igniter wire from the old pilot assembly. Note their positions for reassembly.
4. Removal: Unmount and remove the old pilot assembly.
5. Installation of New Assembly: Mount the new Sourcefy 24-3003 ODS Pilot Assembly in the same position as the old one.
6. Reconnection: Reconnect the gas line, thermocouple, and igniter wire to the new assembly. Ensure all connections are secure and tight. The thermocouple tip must be properly positioned within the pilot flame path.
7. Leak Test: Turn on the gas supply and perform a leak test on all gas connections using a non-corrosive leak detection solution. Bubbles indicate a leak. Correct any leaks immediately.
8. Test Operation: Restore electrical power (if applicable) and follow the heater's lighting instructions to ignite the pilot and main burner. Observe the pilot flame and main burner operation.
9. Reassemble: Once proper operation is confirmed, reattach all access panels and the outer casing.

Figure 3: Angled view of the Sourcefy 24-3003 ODS Pilot Assembly, showing the mounting bracket and various connections. This perspective helps in understanding the physical orientation for installation.

6. Operating Instructions

Once correctly installed, the ODS Pilot Assembly operates automatically as an integral part of your heater's ignition and safety system. There are no direct user operating controls for the pilot assembly itself.

• Always follow the lighting and operating instructions provided in your Kozy-World heater's user manual.
• Ensure the pilot flame is stable, blue, and consistently engulfs the tip of the thermocouple. A weak or yellow pilot flame may indicate an issue.
• If the pilot light does not stay lit after following the heater's lighting procedure, or if the main burner does not ignite, refer to the Troubleshooting section of this manual and your heater's manual.

7. Maintenance

Regular inspection and maintenance can help ensure the longevity and safe operation of your ODS Pilot Assembly.

• Annual Inspection: It is recommended to have a qualified service technician inspect the pilot assembly and the entire heating appliance annually.
• Cleaning: Periodically inspect the pilot assembly for any accumulation of dirt, dust, lint, or debris. Gently clean the pilot burner, ODS sensor, and thermocouple with a soft brush or compressed air. Ensure the pilot orifice is clear.
• Flame Appearance: Observe the pilot flame. It should be a strong, steady blue flame. Yellow or flickering flames may indicate a problem with gas pressure, air mixture, or a partially blocked orifice.
• Replacement: Do not attempt to repair a faulty ODS pilot assembly. If it is determined to be defective, it must be replaced with a new, genuine Sourcefy 24-3003 ODS Pilot Assembly.

8. Troubleshooting

If you experience issues with your heater's pilot assembly, consider the following common troubleshooting steps. Always ensure the gas supply is off before inspecting components.

• Pilot Light Does Not Stay Lit:
  • No Gas Supply: Check if the main gas supply valve to the appliance is fully open.
  • Thermocouple Position: Ensure the thermocouple tip is fully engulfed by the pilot flame. Adjust if necessary.
  • Dirty Pilot Orifice: A clogged pilot orifice can cause a weak flame. Clean gently with a fine wire or compressed air.
  • Faulty Thermocouple: If the thermocouple is old or damaged, it may not generate enough voltage to hold the gas valve open. This component may need replacement.
  • ODS Sensor Activation: The ODS sensor may be detecting low oxygen levels. Ensure the room has adequate ventilation. If the issue persists, the ODS sensor itself might be faulty.
• Main Burner Does Not Ignite (Pilot is Lit):
  • Thermostat Settings: Verify that the heater's thermostat is set to a temperature higher than the current room temperature.
  • Gas Valve Issue: The main gas valve may not be opening. This could be due to electrical issues or a faulty valve.
  • Appliance Specific Issues: Consult your Kozy-World heater's instruction manual for further troubleshooting steps related to the main burner.

If these steps do not resolve the issue, contact a qualified service technician.

9. Specifications

10. Warranty Information

The Sourcefy 24-3003 ODS Pilot Assembly comes with a 6 Months Unlimited Warranty from Sourcefy. This warranty covers defects in materials and workmanship under normal use.

For warranty claims or further details regarding the warranty policy, please contact Sourcefy customer support directly.

11. Support and Contact

For technical assistance, product inquiries, or customer support regarding your Sourcefy 24-3003 ODS Pilot Assembly, please visit the official Sourcefy store or contact their customer service department.

Sourcefy Official Store: Visit Sourcefy on Amazon

Please have your product model number (24-3003) and the model of your heater (KWP192 or KWP196) available when contacting support.