LG GC3 User's Manual
Contents
1. een Hmmm mmm 15 PitoT ADJUSTMENT cachet s cen ORE b EUR Gl e e aus chy ue Co e UE ARE XN DRE VERRE RA 15 MiLLivoLT CONTROL SYSTEM c esee m mI mI mn mmn 16 MAINTENANCE amp SERVICING c ccecccsccenccccceccencceusuccessneucusscennceescucessceeunuecers 17 19 MAINTENANCE GHEGKEIST 226 acu rera DE peace Mecano dat decis ae oett er adu aC bodes cout 17 GLASS MANTENAN O Ea corse ctrca Creuse na Er cave ae ink dau an Dvd EO E Oe odd 17 LASS DOOR REMOVAL a evERRU EN RE NUCRE Ci Rye ERE EE HR 17 2145 Door CLEANING AND REPAIR eee mmm mm mm mmm 18 BLOWER WIRING DIAGRAM c cessere mH mI n nemen heme nnn 18 REMOVAL sr lees FER x EE E KS 18 ELECTRICAL REQUIREMENTS 52 oio e eret even TT 18 FuEL CONVERSION amp CASSETTE INSTALLATION e esee mnm mmn nnn 19 TROUBLESHOOTING cox EUM E ER e cau cone US DURAN nee E VES 20 HEPLACEMENT PARTS Ree oe Ves ete etes esee vino Ee aD EV U deor ances NDA aidaa 21 IUSERT EABELS is ccuatsconesnacuas RKREEXRRR KURIER E Y RfeRU I T T A ra S SING CR 22 23 PRODUCT REFERENCE INFORMATION eee eee eren nmn 24 Cautions amp SAFETY FOR YOUR SAFETY do not install or operate your Fire star gas insert without first reading amp understanding this manual A2. 26 3 4 26 1 4 11 3 8 33 1 7 Figure 2 Minimum FiREPLACE Cavity Figure 3 Minimum FiREPLACE PENING REQUIRED A 29 3 4 Front Opening B 19 Height 19 Rear Width D 15 1 4 Fireplace Depth A CAUTIONS e The fireplace in which this gas insert is to be installed must be thoroughly cleaned if it has been used to burn wood or synthetic logs Have the chimney and all inside surfaces of the fire place brushed and vacuumed so that no soot embers or loose combustion deposits can be drawn into the heat circulation blower and blown into the living area If any portion of the chimney system shows signs of structural or mechanical weaknesses such as cracks leaky joints corroded or warped surfaces the faulty portion must be repaired or replaced prior to installing this appliance The factory built firebox must accept the insert without modification other than removing bolted or screwed together pieces such as baffles smoke shelf deflectors ash lips glass door screen or door tracks log grates refractory or masonry lining and damper assemblies Any fireplace component whichis removed must be retained so they can be reinstalled to restore the fireplace to its original operating condition The removal of any part must not alter the integrity of the outer shell of the pre engineered fireplace cabinet any
3. 3 Check inlet pressure and adjust pilot if necessary 4 Be sure wire connections from thermopile are tight at gas valve terminals and at vent safety snap switch 5a Either rocker switch or thermostat wires may be grounded Remove wires from valve terminals If pilot stays lit trace switch wiring for a ground May be grounded to insert or gas supply 5b Check open circuit millivolt output of thermopile Reading should be greater than 325mV Also check thermopile wire for kinks that can cause loss of mV Replace faulty thermopile if wire is okay and reading is less than 325mV 6 Turn valve knob to ON and thermostat if installed to 90 Millivolt meter should read greater than 100 mV If reading is OK and burner does not turn on replace gas valve qualified service technician only 1 See Lighting Instructions 2 Disconnect rocker switch and thermostat wires at terminals 1 and 3 on valve Jumper across from 1 to 3 with pilot lit If burner comes on either rocker switch thermostat or wiring is not functioning If not jumper wires across switch wires at gas valve If burner comes on wires are faulty or connections are bad 3 Check thermopile with millivolt meter see Maintenance and Servicing recheck symptom 2 4 Check burner for stoppage and remove REPLACEMENT PARTS LIST PART H5952 H5953 H5951 H5843 H5950 H5860 H5844 H5842 H5519 75145 H5874 H5877 H5996 H5997 H5866 H5934 H5740 H5863 H5985 H5
4. CO poisoning and possible death Insert must be vented to the outside in accordance with the current edition of the National Fuel Gas Code ANSI Z223 1 latest edition also known as NFPA 54 The insert must not be connected a chimney flue serving a separate solid fuel burning appliance This gas insert requires a 4 diameter B vent or listed flex alu minum or stainless chimney liner extending the entire length of the chimney to ensure proper operation The vent should terminate with a chimney cap or rain cap Chimney should be sealed around cap to prevent air and rain from entering chimney Adhere to vent manufacturer s instructions for installation and vent termination A minimum flue height of 12 feet is recommended The insert must be installed so the draft hood is in the same atmospheric pressure zone as the combustion air inlet to the appliance FLue CONNECTION This insert has a detachable flue collar to ease installation To detach flue collar lift removable vent trivet from top of insert unscrew draft tube retaining screw See Figure 5 and slide draft tube and flue collar to the rear Attach flue collar with 3 sheet metal screws or a B vent connector to vent pipe previously installed in chimney As the insert is pushed into fireplace guide draft tube and flue col lar into guide brackets until draft tube retaining screw can be reinstalled in its original hole Draft Tube Retaining Screw Figu
5. MUST NEVER be attached to a chimney serving a separate solid fuel burning appliance Each gas appli ance MUST USE a separate vent system Common vent systems are PROHIBITED This appliance uses room air for combustion It is im perative that provisions for adequate combustion and ventilation air be made This appliance is NOT designed to and will not operate in a negative pressure Contact your dealer if you suspect such a situation exists Mobile home installations must conform with the Mobile Home Construction and Safety Standard Title 24 CFR Part 3280 or when such a standard is not applicable the Standard for Mobile Home Installations ANSI A225 1 latest edition The appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 latest edition Your Lennox gas insert must be equipped for the proper fuel type amp altitude at which it will be operated Any operation outside the parameters outlined in this manual may result in a hazardous condition amp will void the warranty Please carefully read the sections pertain ing to these subjects and or be sure your appliance is properly equipped Do not use this insert if any part has been under water Immediately call a qualified service technician to inspect the appliance amp to replace any part of the control system amp any gas control which has been
6. THEY ARE FRAGILE DO NOT FORCE THE PANELS INTO THE FIREBOX AS THEY WILL BREAK IF FORCED 1 Open and remove glass door see Front Door Remov al 2 The longest panel goes in the rear of the firebox Tilt the top of the panel forward insert the bottom of the panel in the brick panel retainer and push the panel to the up right position 3 Install the side panels by sliding the top of the panel into the top side brick retainer and then dropping the bottom of the panel into the bottom retainer The rounded edge on the side brick panels goes toward the front 3 Piece Brick Panel Set Figure 8 Loc INSTALLATION INSTRUCTIONS CAUTION If the logs are not properly installed your insert will not function properly Part list Rear log Right Front log Left Front log and Top Twig 1 Remove the logs from the box and carefully unwrap them The logs are fragile so handle them with care 2 Place the rear log with the charred surface forward on the two rear locating pins see Figure 9 3 Place the left front log with the charred surface forward see Figure 10 on the two left front locating pins Next place the right front log with the charred surface forward on the two right front locating pins Continued on Page 10 Figure 9 Right Front Log Figure 10 NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE 9 Loc IusraLLATION Continuen GC3 4 Position the top twig with the charred end forward on
7. When installing these appliances into a fac tory built fireplace or heat form the air flow within and around the fireplace shall not be altered by the installation of the insert i e DO NOT BLOCK louvers or cooling air inlet or outlet ports circulating air chambers in a steel fireplace liner or metal heat circulator WARNING THIS FIREPLACE HAS BEEN ALTERED TO ACCOMMODATE A FIREPLACE INSERT AND SHOULD BE INSPECTED BY A QUALIFIED PERSON PRIOR TO RE USE AS A CONVENTIONAL FIREPLACE Codes amp Approvals CERTIFICATION Gas appliances must be tested and certified by a nation ally recognized testing and certification laboratory to ANSI American National Standard Institute gas appliance safety standards This insert has been tested and certified by OMNI Test Laboratories to ANSI 721 88 2005 Standard for Vented Gas Fireplace Heaters and UL 307B Gas Burning Heating Appliances for Manufactured Mobile Homes It has met all necessary ANSI Standards and is fully certified for installation in any community If there are any questions or if you need further substantiation either write to or call your Lennox Hearth Products dealer If you have further questions please contact Lennox Hearth Products New York City New York MEA Installation of these fireplaces are approved for installa tion in New York City in the US state of New York MEA 138 07 E CommonweattH Or MassacHusETTS REQUIREMENTS Installation of these firep
8. amp ILLUSTRATIONS ARE NOT TO SCALE 15 16 Donotsplice any millivolt wires Refer to Table 3 to determine the proper gage of wire for the thermostat or wall switch connections This table refers to the total length of the wire out to the switch and back The thermostat must be a millivolt type A 24 volt furnace thermostat will not work Never hook up household current 120 Volts to the millivolt system It is not recommended to hook up any more than two switches to the insert for example a rocker switch anda wall thermostat Additional switches may affect the system resistance and increase the chance of the burner not ignit ing Follow the instructions included with the thermostat or remote control for wiring The thermostat remote control and rocker switch will turn the burner on and off independently Be sure to set the rocker switch to the OFF position when using the thermostat or remote control and set the thermostat or remote control to the lowest temperature when you wish to use the rocker switch only otherwise one may override the other If a re mote thermostat is to be used with the insert do not place the receiver under the firebox Thermostat Wire Table 3 Wirinc DIAGRAM Gas Valve MiLLuivoLr SYSTEM This insert operates on a millivolt control system As such no addition power supply is needed for the insert to operate The pilot assembly contains a Thermopile that wh
9. any dam ages caused by an inoperable inadequate or unsafe condition as a result of any improper operation service or installation procedures whether direct or indirect INSTALLER THESE INSTRUCTIONS ARE TO REMAIN WITH THE HOME OWNER NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE Orifice Size Altitude Adjustment For altitudes above 2 000 feet the orifice should be de rated by 4 for every 1 000 feet to maintain the proper ratio of gas to air Improper orifice sizing may result in damage and unsafe conditions Changing the orifice should only be done by a qualified service technician Contact your Lennox Hearth Products dealer for proper orifice sizes see Page 21 and 24 for more information The Firestar Insert e Mustconform with all local state and national installation codes In the absence of local codes the installation must conform with National Fuel Gas Code ANSI Z223 1 latest edition also known as NFPA 54 Refer to the National Fuel Gas Code and local zoning and code authorities for details on installation requirements Must conform with the Manufactured Home Construc tion and Safety Standard Title 24 CFR Part 3280 or when such a standard is not applicable the Standard for Manufactured Home Installations ANSI A225 1 latest edition for manufactured mobile home installations Must be vented directly to the outside in accordance with the latest edition of the National Fuel Gas Code and must neve
10. fan wiring diagram below for reference Remove the glass door log set and brick pan els All of these items are fragile so handle them with care Remove the two allen head screws at the left and right front of the air control panel and lift the panel out Next remove the nine allen head screws around the outside of the panel fastened to the back wall of the firebox Rotate the top of this panel toward the front remove the two wires connected to the fan and then lift the panel with the fan attached out of the firebox To reinstall the fan repeat these steps in the reverse order ELECTRICAL REQUIREMENTS This gas insert operates without an outside power source however the fan blower requires a 120 Volt electrical service outlet The blower must be electrically grounded in accor dance with local codes In the absence of local grounding codes the National Electrical Code ANSI NFPA 70 latest edition The blower is equipped with athree pronged ground ing plug for your protection against electrical shock hazard and should only be plugged into a properly grounded three prong receptacle DO NOT CUT OR REMOVE THE GROUND ING PRONG FROM THE PLUG FOR ANY REASON e See Millivolt Control Schematic Figure 19 for information on thermostat and On Off switch e See Blower Wiring Diagram Figure 21 for information on the wiring and electrical requirements for the blower Pan Snap Switch Speed Control Wire Red Snap Sw
11. igniter will not light pilot after repeated tries Pilot will not stay lit after carefully following lighting instructions Pilot burning but no flame on main burner with valve knob ON rocker switch and thermostat ON 1 Improper log or ember placement 2 Improper air shutter setting 3 Not enough combus tion air 4 Incorrect gas pres sure 1 Normal operating noise 2 Obstructed orifice Opening 3 Defective regulator 1 Achange in gas pressure 2 Improper ember placement 1 No gas supplied to unit or air in line 2 Defective igniter no spark at electrode 3 Defective or mis aligned electrode at pilot spark at electrode 1 Vent Safety Snap Switch shut down 2 Improper Flame impingement 3 Low gas inlet pres sure 4 Defective thermopile 5 Bad connection 6 Defective automatic valve operator 1 Pilot has gone out 2 Rocker switch thermostat or wires defective 3 Thermopile may not be generating sufficient millivolts 4 Plugged burner orifice 1 See Log Set Installation on Pages 9 4 10 If there is soot in one specific location the rockwool below this location needs to be adjusted This can be done by pulling embers forward slightly If the flames have soot tails the shutter will need to be opened 2 If sooting continues open air shutter see Air Shutter Adjustment on Page 12 3 Check for debris obstructing air flow in valve compartment under insert or in front
12. minimum distance from the top of the insert to a combustible may be reduced to 16 with a mantel shield See owner s manual for shield dimensions CAUTION HOT WHILE IN OPERATION DO NOT TOUCH KEEP CHILDREN CLOTHING FURNITURE GASOLINE AND OTHER LIQUIDS HAVING FLAMMABLE VAPORS AWAY KEEP BURNER AND CONTROL COMPARTMENT CLEAN SEE INSTALLATION AND OPERATING INSTRUCTIONS ACCOMPANYING APPLIANCE DO NOT OPERATE THE APPLIANCE WITH GLASS REMOVED CRACKED OR BROKEN REPLACEMENT OF THE PANEL S SHOULD BE DONE BY A LICENSED OR QUALIFIED PERSON WARNING IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE REFER TO THE OWNER S INFORMATION MANUAL PROVIDED WITH THIS APPLIANCE FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR GAS SUPPLIER DATE OF MANUFACTURE 2007 2008 2009 2010 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC OOOOOOOOOOOOOO000 Part No 36226 Rev A 5 2007 DO NOT REMOVE OR COVER THIS LABEL IGN 07 2410 Lighting Label EE For Your SAFETY READ BEFORE OPERATING WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE INJURY OR LOSS OF LIFE CAUTION HOT WHILE IN OPERATION DO NOT TOUCH KEEP CHILDREN FURNITURE GASOLINE AND OTHER LIQUIDS WITH FLAMMABLE VAPORS AWAY NEVER OPERATE UNIT WITH GLASS DOOR OFF OR ATTEMPT TO OPEN THE DOOR WHILE HOT
13. under water e Due to high temperatures the insert should be located out of traffic areas amp away from furniture amp draper ies e Children amp adults should be alerted to the hazards of high surface temperature amp should stay away to avoid burns or clothing ignition Young children should be carefully supervised whenthey are in the same room as the Lennox gas insert Clothing or any other flammable material should not be placed on or near the insert Never use solid fuels such as wood paper cardboard coal or any flammable liquids etc in this appli ance Any grill panel or glass removed for service MUST be replaced prior to operating the insert Do not operate appliance with the glass front removed cracked or broken Replacement of the glass should be done by a qualified service technician DO NOT USE abrasive cleaner on the glass door assem bly DO NOT ATTEMPT to clean the glass door when it is hot Gold amp nickel plated surfaces must be cleaned with glass cleaner amp a clean soft cloth before firing the first time orfingerprints will remain permanently NEVER use brass polish to clean gold or nickel this will remove the plating When opening the lower door on the face while the insert is burning pull at the far left or far right vent openings because the door is hot during operation Lennox Hearth Products its employees or any of its representatives assume no responsibility for
14. way Any parts removed must be replaceable If any components are removed from or altered from the existing fireplace a Warning Label see Page 4 must be affixed inside the fireplace firebox so that it shall be visible upon removal of the fireplace insert Note RTV high temperature silicone is an approved adhesive to affix the label Insert Dimensions Width of insert behind Surround Panels 26 3 4 Rear height 18 7 8 Flue center line from back of surround with 11 3 8 standard draft hood Flue collar diameter OD 3 15 16 NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE Insert depth into fireplace 13 5 8 Minimum CLEARANCES TO COMBUSTIBLES The letters below C through H correspond to Figure 4 showing minimum clearances required from the appliance to combustibles and the minimum projection of the hearth extension 6 5 to Side Facing 3 4 or less D 11 to Side Wall E 24 to Mantel more than 3 4 F 14 5 to Top Facing maximum thickness 3 4 HEARTH PROTECTION G Minimum Hearth Protection from Front of Insert H Vertical Distance from Insert Bottom to Combustible Material Insert bottom is the metal lip below the lower gold trim bar Note Hearth protection to be min 3 8 10mm thick non combustible or equivalent with a k factor of 84 INSERT LEVELING The FireStar insert comes with four 3 8 X 3 leveling bolts two for use at the rear and two at the fro
15. 5 102 MIN INLET PRESSURE IN WC 50 105 UNIT FACTORY EQUIPPED FOR 0 2000 FT 0 610 M ELECTRICAL RATING 115 VAC 60 HZ LESS THAN 2 AMPS DANGER RISK OF ELECTRICAL SHOCK DISCONNECT POWER BEFORE SERVICING UNIT IF ELECTRICALLY CONNECTED CONNECTIONS AND GROUNDING MUST BE IN ACCORDANCE WITH LOCAL CODES IF ANY IF NOT FOLLOW THE CURRENT NATIONAL ELECTRICAL CODE ANSI NFPA 70 CHIMNEY USE WITH B VENT CHIMNEY OR LISTED SINGLE WALL GAS VENT FLEX CHIMNEY LINER FOR ALTITUDES ABOVE 2 000 FT 610 M DE RATE THE APPLIANCE BY FOUR 4 FOR EVERY 1 000 FT 405 M WARNING OPERATION OF THIS APPLIANCE WHEN NOT CONNECTED TO A PROPERLY INSTALLED AND MAINTAINED VENTING SYSTEM OR TAMPERING WITH THE BLOCKED VENT SHUTOFF SYSTEM CAN RESULT IN CARBON MONOXIDE CO POISONING AND POSSIBLE DEATH MINIMUM FIREPLACE SIZES REQUIRED 29 75 Front Opening 19 00 Opening Height MINIMUM CLEARANCES 19 00 Rear Width 15 25 Fireplace Depth INSERT HEARTH PROTECTION Non Combustible Hearth Extension H Vertical Distance from Insert 4 Bottom to Combustible Material G Minimum Hearth Protection 17 Distance from Fireplace Facing Insert bottom is the metal lip below the lower gold trim bar Note Hearth protection to be min 3 8 thick non combustible or equivalent CLEARANCES TO COMBUSTIBLES 14 5 to Top Facing max thickness 3 4 24 to Mantle more than 3 4 6 5 to Side Facing 3 4 or less 11 to Side Wall The
16. 986 H5905 75146 H5875 H3106 H5881 H5930 H5940 H5744 H5995 5981 5982 H6000 H5880 H5949 H5939 75147 H5745 H5999 H5954 H5937 H5864 H3107 H5998 H5882 79254 H5993 H5994 DESCRIPTION 33 NG Main Burner Orifice 35 NG High Elevation Main Burner Orifice 50 LP High Elevation Main Burner Orifice 2 Bottom Trim Piece 49 LP Main Burner Orifice 4 Piece Log Set Air Control Burner Pan Baffle Plate Baffle Plate Holder Brackets Black Door w Glass Blower Power Cord Blower Speed Control Blower Speed Control And Housing Includes 2 Rivets Blower w Mounting Bracket Brick Panel Set Burner Tube Cassette Assembly NG For LP Installations Also Order LP Conversion Kit Volcanic Stone Decorative Gold Bar On Lower Stove Body Decorative Nickel Bar On Lower Stove Body Door Rope Per Foot Order 8 Ft for each door Gold Door w Glass Heat Sensed Blower Snap Switch Left hand Side Door Mounting Brackets amp Blower Speed Control Installed LP Pilot Assembly Includes Thermopile Electrode And Wire LP Pilot Orifice LP Regulator Main Burner On Off Rocker Switch Main Burner On Off Switch Wires Main Door Decorative Gold Bars Each 2 Per Stove Main Door Decorative Nickel Bars Each 2 Per Stove Middle Bay Glass W glass Tape Installed NG Pilot Assembly Includes Thermopile Electrode And Wire NG Pilot Orifice NG Regulator Nickel Door W glass Piezo Igniter Rheostat Wire Robertshaw Main Gas Control Val
17. A This appliance is equipped with a piezo ignition device to light the pilot When lighting the pilot follow these instructions exactly B BEFORE LIGHTING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS DO NOT try to light the appliance DO NOT touch any electric switch do not use any phone in the building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use any tool If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion DO NOT use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS IE CAUTION YOUR COUNTRY GAS STOVE MUST ALWAYS BE OPERATED WITH GLASS DOOR IN PLACE STOP Read the safety information above before proceeding 1 Open the right side door Make sure gas supply shut off cocks are open and ON OFF Rocker Switch is OFF 2 Turn off all electrical power to the appliance 3 Push in Gas Cock Dial slightly and turn cloc
18. Connect Terminal 1 Gas Valve Thermopile Wire Brown Connect to Terminals 1 amp 2 On Gas Valve Figure 19 NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE Thermostat Thermostat Wire Red TH1 On Off Switch Thermostat Wire White TH2 On Off Switch Wire Black 002 Connect Terminal 3 Gas Valve Maintenance amp Servicing MAINTENANCE CHECKLIST Should Only Be Performed by a Qualified Service Techni cian Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 1 Annual inspection should be made and the following checks performed a With unit cool remove glass and inspect burner for dirt soot and lint accumulations and remove if necessary If excessive soot accumulation is present on burner have a qualified serviceman adjust burner for proper combustion b Clean any deposits from inside glass with gas fireplace glass cleaner NEVER attempt to remove or clean glass when the unit is hot c Check that chimney and its outlet are open and free from soot blockage or debris d Inspect the pilot system for proper flame See instruc tions on page 15 e Check the Millivolt system as per Table 4 on page 16 f The appliance area must be kept clear and free of com bustible materials gasoline and other flammable vapors and liquids g Chec
19. FICE DMS 0 2 000 FT 0 610 M Unit factory equipped for 0 2000 FT 0 610 M PackAciNG List To install a Firestar insert an insert body and surround flange kit are required Insert Body Packaging List 1 Insert Body with Burner Cassette and trivet 1 Set of Refractory Brick Panels 3 pieces H5866 1 Log Set H5860 1 Lower front 2 filler panel 1 Fasteners 6 slotted 1 4 truss screws 4 speed nuts 6 spring clips 4 3 8 x 3 leveling bolts 2 socket head screws 1 Installation and Operation Manual Surround Kits One Required 29 X 41 Black Trim 75072 29 X 48 Black Trim 75073 33 X 41 Black Trim 75074 33 X 48 Black Trim 75075 Surround Kit Contents 1 Top Surround 2 Side Surrounds 3 Black Trim Pieces 2 Elbowed Trim Fasteners Firestar GC3 LP GAS 39 000 22 600 3 5 10 0 10 5 13 0 37 INSERT DIMENSIONS See Figures 1 2 and 3 showing insert dimensions and mini mum fireplace firebox dimensions to aid you in determining proper fit into existing fireplace 23 3 4 I 11 3 8 2 10 1 2 1 13 3 4 4 h apie 24 3 4 Equipped from the factory with a 2 filler Contact your dealer for additional information Figure 1 41
20. LENNOX INSTALLATION AND OPERATION MANUAL HEARTH PRODUCTS B Vent Gas Fireplace Insert Retain These Instructions For Future Reference PIN 775 225M Rev A 06 2007 A French manual is available upon request Order P N 775 225CF Ce manuel d installation est disponible en francais simplement en faire la demande Num ro de la pi ce 775 225CF In the Commonwealth of Massachusetts Installation must be performed by a licensed plumber or gas fitter See Table of Contents for location of additional Commonwealth of Massachusetts requirements MERIT senses oe Firestar GC3 OMNI Test Laboratories Inc Report No 050 S 07b 5 A WARNINGS e Hot Do not touch The glass and surfaces of this appliance will be hot during operation and will retain heat for a while after shutting off the appliance Severe burns may result 7 7 e Carefully supervise children in the same room as appliance e Suitable for installation into masonry or factory built fireplaces These appliances may he installed in an after market permanently located manufactured 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 certified kit is used Lennox gas burning appliances are designed for use as a supplemental heater They are not intended for continuous use as a primary heat source WARNI
21. NG If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e DO NOT light any appliance e NOT touch any electrical switches DO NOT use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow your gas supplier s instructions If your gas supplier cannot be reached call the fire department Installation and service must be performed by a quali fied installer service agency or the gas supplier AVERTISSEMENT Assurez vous de biensuivre les instruc tions donn es dans cette notice pour r duire au minimum le risque d incendie ou d explosion ou pour viter tout dommage mat riel toute blessure ou la mort POUR VOTRE S CURIT Ne pas entreposer ni utiliser d essence ni d autres vapeurs ou liquides inflammables a proximit de cet appareil ou de tout autre appareil POUR VOTRE S CURIT Que faire si vous sentez une odeur de gaz Ne pas tenter d allumer d appareil Ne touchez aucun interrupteur Ne pas vous servir des t l phones se trouvant dans le bati ment Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur Si vous ne pouvez rejoindre le fournisseur de gaz appele
22. Natural Gas L P Natural Gas L P 0 10 UP 3 3 1 2 3 g 1 3 cm 1 0 cm 1 3 cm 1 0 cm 1 2 Vo 5 g 1 2 1 3 cm 1 3 cm 1 6 cm 1 3 cm 1 2 Ye 3 4 Yo 1 3 cm 1 3 cm 2 0 cm 1 3 cm 3 4 1 2 3 4 2 0 cm 1 3 cm 2 3 cm 2 0 cm V 1 2 7 8 3 q 2 0 cm 1 3 cm 2 3 cm 2 0 cm 10 40 40 100 100 150 150 200 Table 2 NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE 11 12 Propane LP Naturat Gas SUPPLIES Your Firestar gas insert is equipped from the factory for use with natural gas only as specified on the Safety Listing label attached to the appliance This appliance can only be Operated using propane gas LP if a certified fuel conver sion kit provided by Lennox Hearth Products is installed by a qualified service technician Also check the orifice size on the label attached to your control panel It must be the correct size for the fuel and altitude Do not run propane tank dry Running the tank dry may cause a hazardous condition due to pressure drop in empty tank Solid fuel is NOT to be used with this unit SHUTTER ADJUSTMENT The main burner has an adjustable air shutter located at the end of the burner as it inserts over the orifice It is located behind the right side door and beneath the control valve The shutter adjustment has been set at the factory to ensure proper safe combustion and flame pattern Only
23. TALLATION iis sro ey aa es uer qul aera 9 LOG NSTAUEATIUNS aux RR EROS EF Ree pua EPRE V Ea SAEI C RE IRTPARTS 9 SURROUND PANELS INSTALLATION eeeeee enn mm me nm nennen nennen nnn 10 LOWER FRONT FILLER PANEL eeseeeeeeeeen m mI Hm heme nemen nennen nnn nnn 11 GAS LINE NSTALLATION es 11 Gas PRESSURE REQUIREMENTS eene m mI n mm nm nennen nennen nnn 11 GAS SUPPLY LINE SIZING fo cu ous eoram recu D eu spese vp T aea 11 LP amp NATURAL Gas SUPPLIES sees Hmm m mmm mmn nnn 12 AIR SHUTTER ADJUSTMENT icio ox ER WRFE EU CE DONEC EERCXXEEOKERE DeKE TRE RERVER CERE EFE 12 OPERATING INSTRUCTIONS v annie o Ex Re Ewan xw Ea E EE dew VEX CEDERE ck dE WERKE MER ER WE nenne 13 16 PRE LIGHTING CHECKLIST circo E ce ER ERE ERE U CK EX ule bkork DX KE CM DE EUN NE ERRE ean 13 LIGHTING INSTRUCTIONS crate ehe pex m e nC tases CURE AUC 13 FLAME amp BEHAVIOR rera ris sae Duda resa rec uuu eria pu voc ER Ya Ra Fer simak enn 14 REPLACING BURNER RIFICES eese mm m meme mnn 14 PAINT BURN cere Ene nrbe aee cri v orba ese satt cen te bra oca esa 15 QUIET OPERATION ERE TIL 15 BLOWER i esee ores tueantur ea eminet cuts cut he bia att 15 ON OFF Switch AND THERMOSTAT
24. a qualified gas technician should adjust the air shutter as an incorrect adjustment could cause a hazardous condition Closing the air shutter will cause the flames to take on a yellow color Closing it too far will cause improper burning and the flames will turn orange and sooty Opening the air shutter will cause the flames to burn cleaner becoming transparent and bluish Caution The air shutter should never be closed to such an extent to create sooting on the viewing glass logs or heat exchanger If soot begins to form after burning the air shutter should be opened gradually until the sooting condition stops Open the shutter a small amount at a time until the sooting ceases See Flame Colorand Behavior and Maintenance proper pilot flame 1 Remove glass door see Glass Door Removal on page 17 Carefully remove the log set and set aside 2 Using a 5 32 allen wrench remove the allen head screw on left side of the air control panel as shown in Figure 15a then lift out air control panel as shown in Figure 15b 3 Using a 5 32 allen wrench remove the screw which secures burner tube assembly as shown in Figure 15c Then lift out burner tube assembly as shown in Figure 15d 4 Using a phillips screwdriver loosenthe air shutter setscrew just enough so air shutter can be rotated by hand read note below See Figures 15e and 15f 5 Reinstall components by reversing steps 1 4 6 Locate the air shutter behind the
25. ale iron pipe coupling ora shut off valve After connecting the gas line all joints in the line and connections at the valve should be checked for leaks Gas Pressure REQUIREMENTS A MAJOR CAUSE OF OPERATING PROBLEMS WITH GAS APPLIANCES IS IMPROPER GAS PRESSURE The most important item to check during the initial installation and the first thing to check when operating problems occur is gas pressure This appliance will not function properly unless the required gas pressure is supplied See Table 1 for gas pressure requirements Two pressure taps are provided on the insert s valve to check gas pressures The taps are located below the on off pilot knob see Figure 14 The left tap is the inlet supply pressure side To check inlet pressure with the insert burning insert a small phillips screwdriver into the tap and turn a half turn counter clockwise Cover the tap with the line from a manometer and check the pressure Close tap gently but securely after completing the check The manifold outlet tap is to the right of the inlet tap To check manifold pressure with the insert burning at the high burn setting insert a small phillips screwdriver into the tap and turn a half turn counter clockwise Cover the tap with the line from Inlet A e the manometer and check Pressure is B the pressure Again close Tap Pressure Tap the tap gently but securely Iu s Flame Height after completing the check Outlet Adjus
26. cation 3 Open side doors and install the side flanges by lining up the holes in the tabs on the side flanges in front of the holes on the flange brackets Note that the larger tab on side flange goes at the bottom and the front leveling bolts need to be raised to at least two inches to accommodate the length of the side flanges Next insert two slotted 1 4 truss screws for each side flange and secure loosely 4 Fasten top flange with the remaining two truss screws Tighten all six truss screws after shifting flanges to eliminate space between side and top flanges 5 Install two spring clips approximately five inches from each end of each of the three gold trim pieces The spring clips should be installed in the channel of the trim with the curved end to the front toward the rounded surface of the trim 6 Place the longest trim piece with the rounded surface out along the edge of the top flange with the spring clips slightly behind the flange Pull the trim forward com pressing the spring clips and slide the trim down onto the flange 7 Insert the elbowed retainer in the mitred end of the side trim pieces and fasten with flat screwdriver Insert the other end of the retainer in the end of the already installed top flange and slide side trim onto the edge of the side flange compressing spring clips in the process Repeat the same steps for the other side trim Fasten the elbowed retainer securely in the top flange making a nice mitre
27. d corner Top Flange Mounting Holes oooooooooo Figure 13 Side Flange Mounting Holes 10 NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE Lower Front 2 FiLLER PANEL The FireStar insert comes with a 2 panel to fill the space be tween the insert bottom and the hearth extension If the hearth elevations necessitate the insert may be installed directly on the hearth without the leveling bolts or filler panel To install the panel insert the four tabs on the top of the panel into the corresponding slots in the insert bottom Open the insert side doors remove the two socket head screws from the hardware bag and install them using a5 32 hex wrench through the insert bottom into the filler panel A tall adjustable filler panel is also available Gas LiNE INSTALLATION After leveling position the insert in the fireplace holding it about six inches out from its final location Caution Specific Hearth Requirements apply see Clearances and Specifications The Firestar gas insert must be connected to the gas line in accordance with local codes and or the National Fuel Gas Code Z223 1 latest edition also known as NFPA 54 Included in the manual package is an 8 gas nipple Locate the threaded gas inlet on the lower left of the insert Thread the 8 gas nipple into the inlet with a teflon sealer or equivalent Attach the gas supply line to this hard pipe The hard pipe can receive a 3 8 inch fem
28. d off independently of each other Be sure to set the rocker switch to the off position when using the thermostat and set the thermostat to the lowest temperature when you wish to use the rocker switch only otherwise one may override the other Follow the instructions included with the thermostat for wiring Solder all connections as good wire connections are critical in millivolt system Check with your insert dealer for the proper length and size of the thermostat wire Both factors effect the function of the thermostat Pitot ADJUSTMENT All pilots are burned and checked at the factory prior to shipment NOTE If upon initial insert installation the pilot flame flickers or will not remain lit most likely the pilot is fine but there is air in the gas line or the gas pressure is too low Pilot adjustment is not normally required but should it be necessary it should be done only by a qualified service technician The pilot adjustment screw is located to the left of the ON OFF PILOT control knob With a flat bladed screwdriver remove the pilot adjusting cover to access the pilot adjusting screw Adjust pilot screw to the properly sized flame as shown in Figure 18 The flames should completely surround the thermopile and extend across the main burner ports Be careful not to back the adjusting screw out of its threads Replace the cover and check for gas leaks Millivolt Pilot Gas Pilot Hood Figure 18 Igniter NOTE DIAGRAMS
29. e and behind the gas inlet eloow Then disconnect the thermostat red and white wires and rocker switch black wires at terminals 1 amp 3 Remove the socket head screw attaching the cassette body block plate and block plate located in the bottom right end of the firebox Remove the socket head screw fastening the pilot end of the cassette to the burner holder Remove the three socket head screws holding the cassette valve pilot assembly to the body of the insert The cassette can now be removed by rotating the valve for ward and out to the right Install new converted or serviced cassette in the reverse order of removal All parts and wires must be correctly reinstalled to ensure safe and proper operation of the unit Conversion Kit Please see instructions provided with conversion kit NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE 19 Troubleshooting NOTE When troubleshooting the gas control system be sure the external gas shut off valve located at the gas sup ply inlet is in the ON position IMPORTANT Call your gas supplier or plumber for additional help with any gas control problem Valve system troubleshooting should only be accomplished by a qualified service technician SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION 20 Thin black coating soot forms on the viewing glass logs or firebox Humming or whistling coming from insert A change in flame appear ance or burner operation Spark
30. e left side door is left in the on position The fan will not operate until the insert is warm 3 Once the fan comes on turn the knob to the desired speed No further adjustment is necessary the fan will come on automatically whenever the insert is warm 4 Ifyou do not wish to have the fan on turn the knob until it clicks into the OFF position Switch THERMOSTAT Your gas insert comes equipped with an ON OFF rocker switch used to turn the burner on and off while the pilot is on The switch is located behind the right side door to the right of the control valve This switch can be relocated to the hole provided in the top surround panel by pulling the two connectors off of the spades on the back of the switch Then unscrew the plastic nut on the back side of the switch and pull the switch forward through the hole Cut the wire tie holding the switch wire and feed the wire behind the side flange up to the switch hole in the top flange Care must be taken to ensure the wire is kept away from the heat of the firebox Reinsert the switch in the hole in the flange tighten the retaining nut and push the wire connectors back on the spades The spades may need to be carefully bent downward to provide clearance between the switch and the fireplace facing material Amillivolt wall thermostat or remote thermostat can be used to supplement the rocker switch The thermostat and rocker switch will turn the burner on an
31. eaners may damage glass NOTE BE CAREFUL NOT TO SPRAY COMMERCIAL GLASS CLEANER WITH AMMONIA ON GASKET AREA OF DOOR AMMONIA WILL DISSOLVE GASKET GLUE NOTE GOLD PLATED SURFACE MUST BE CLEANED WITH GLASS CLEANER AND SOFT RAG BEFORE FIRING THE FIRSTTIME OR FINGER PRINTS AND STAINS WILL REMAIN PERMANENTLY NEVER USE BRASS POLISH TO CLEAN GOLD THIS WILL REMOVE GOLD PLATING Front door glass replacement should be completed only by a qualified technician GLass Door CLEANING REPAIR Cleaning Do not remove or clean the glass door when hot A gas door glass cleaner available from your Lennox Hearth Products dealer or windex should be used with a soft cloth to clean the glass Do not use an abrasive cleaner Repair If the glass is broken in the glass door the entire door metal frame gasket and glass should be replaced as a unit This replacement unit is available from your Len nox Hearth Products dealer Do not use substitute parts or materials Caution Do not operate this insert with broken glass Wirinc DIAGRAM Snap Switch Connection Wire Black Figure 21 Bower Removat Unplug the power supply cord from the electrical outlet prior to removing the blower The fan can be accessed through the back wall of the firebox Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing See the
32. en heated by the pilot flame generates electricity millivolts mV 1 1000 of a volt that travels to terminal 1 From this terminal it travels through a black wire to the Vent Safety Snap Switch If this switch over heats through a flue blockage or vent pipe disconnection it will open stop the flow of mV and shut the insert off This switch will automatically reset close when it is cooled down to normal operating temperature During normal operation it is closed allowing the mV to flow back to the valve which opens so gas can flow through To check for proper operation use a multimeter and perform the system checks shown in Table 4 and refer to Figure 19 Check Test Meter Reading Should Be To Connect Thermostat Test Terminals Than Millivolt and System Checks Meter Connects Leads to Complete 100 MV System or More Greater 325 MV m qmm Thermopile Output System Resistance Valve Terminals e Valve Snap Switch Wire 582 Terminal 1 erminal 3 Terminal Snap Switch Wire Black SS1 Spark Electrode Pilot Hood Thermopile Inlet Pre Spark Electrode Wire TH TP TH Terminal 2 TP Vent Safety Snap Switch Piezo Igniter Off On Pilot Manifold Pressure Tap Flame Adjustment OPTIONAL Black connect to Piezo Igniter Burner Orifice Pilot Tube On Off Switch Wire Black 001
33. er flame appearance Burner Flame Appearance Soot at Soot above No Soot at Flame Tip Flame Tip Flame Tip Ports Burner Assembly Flame No Blue Flame Blue Flame Center Center PROPERLY BURNING FLAME IMPROPERLY BURNING FLAME Figure 17 RePLAcING Burner ORIFICES To change orifices first remove the cassette see Fuel Con version and Cassette Installation on page 19 Then unscrew orifice using an 3 4 open end wrench discard the old orifice and reinstall the new orifice REDUCING THE ORIFICE SIZE FOR HIGHER ALTITUDES MAINTAINS THE PROPER BTU INPUT TO AIR RATIO TOO LARGE AN ORIFICE WILL RESULT IN HIGHER BTU INPUTS THAN THE DESIGN ALLOWS MAY RESULT IN AN UNSAFE CONDITION AND MAY VOID YOUR WARRANTY For altitudes above 2 000 ft 610M the appliance should be derated by four 4 percent every 1 000 ft 305M To operate safely your Firestar gas insert must have the proper burner orifice size determined by the altitude at which it will be operated and other variables such as pres sure and valve tolerances If you have reason to believe your insert s orifice size may be incorrect for your altitude have it checked and remedied if necessary by a qualified service technician NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE Paint CURING This insert has been painted with Stovebright high tem perature metallic stove paint It leaves the factory dry to the touch but finishes c
34. er s Name Fuel Type Check one NATIONAL FIREPLACE INSTITUTE NFI CERTIFIED www nficertified org Lennox reserves the right to make changes at any time without notice in design materials specifications prices and also to discontinue colors styles and products Consult your local distributor for fireplace code information Printed in U S A Lennox Hearth Products 2007 P N 775 225M REV A 06 2007 Natural Gas L Propane Gas LP We recommend that our gas hearth products be installed and serviced by profes sionals who are certified in the U S by the National Fireplace Institute NFI as NFI Gas Specialists LENN X HEARTH PRODUCTS 1110 West Taft Avenue Orange CA 92865
35. heat output by turning the flame height knob clockwise 7 w for full flame and counterclockwise 4 w for reduced flame PILOT Set the blower to the desired air flow after it turns on when the appliance reaches operating temperature LIGHT TO TURN OFF GAS TO APPLIANCE REI 1 Turn off the ON OFF rocker switch and or thermostat if installed 2 Turn off electric power to the appliance if service is to be performed 3 Turn gas control knob clockwise w to OFF Do not force This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air See Installation and Operation Manual accompanying appliance WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage For assistance or additional information consult a qualified installer service agency or your gas supplier Operation of this appliance when not connected to a properly installed and maintained venting system or tampering with the vent safety shut off system can result in carbon monoxide CO poisoning and possible death SHUTDOWN PROCEDURE 1 To turn off the burner switch the rocker switch to OFF or adjust the thermostat to a setting below room temperature if installed The pilot will remain lit for future burner ignition For complete shutdown See TO TURN OFF GAS TO APPLIANCE above 23 24 WARRANTY Your gas appliance is co
36. itch Connection Wire White Speed Control Connection Speed Control Connection Wire Speed control Connection Wire Black White Speed Control ConnectionWire White l Speed Control Connection Wire Black Main Power Cord Wire Black l Ground Wire Green NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE Fue Conversion amp CASSETTE INSTALLATION Converting your FireStar gas insert between natural gas and LP can be accomplished by either changing the Quick Change Cassette valve and pilot assembly or installing a conversion kit regulator burner orifice and pilot orifice Only a qualified service technician should perform the conversion as it requires discon necting the gas supply line and other procedures that should only be performed by a qualified technician Cassette Removal 1 Be sure the gas supply is off and fan power cord is discon nected before beginning the conversion Disconnect the gas supply from the insert being careful not to apply pressure to the valve in the process Remove the log set and brick panels see Brick Panel amp Log Installation Remove the burner by lifting the left end and pulling the burner gently through the block plate and past the pilot assembly Disconnect at the valve the two wire connectors from vent safety snap switch the uppermost black wire on terminal 1 and the black wire with the round connector located at the top of the valv
37. k glass gaskets once a year Gaskets must be tight Replace if necessary 2 The viewing glass should be cleaned periodically see Glass Maintenance 21455 MAINTENANCE Cleaning When cool the glass may be cleaned with a clean softcloth and Windex For cleaning white condensation from the interior glass use KEL KEM gas fireplace glass cleaner available from your insert dealer Use of caustic or abrasive cleaners may damage the glass DO NOT operate the insert with broken glass DO NOT clean door or glass when hot DO NOT abuse the glass door by striking or slamming it shut DO NOT use substitute materials if replacing the glass DO NOT spray commercial glass cleaner with ammonia on the door and glass gasket as it may dissolve the gasket glue Replacement Theglassinthe insert door cannot be replaced separately Should the glass be damaged the entire glass gasket and metal frame assembly must be replaced as a unit This replacement glass assembly is availablefrom your Lennox Hearth Products dealer The glass is neo ceramic and alternative types must not be used WARNING Do not operate appliance with the glass panel removed cracked or broken Do not remove glass door while the insert is hot Replacement of the glass door should be done by a qualified service technician Gass Door RemovaL refer to Figures 20a and 20b Caution Do not slam or strike glass door or damage may occur Do not remove the glass door while the inser
38. kwise w to OFF NOTE Dial cannot be turned from PILOT to OFF unless Dial is pushed in slightly Do not force 4 Wait five 5 minutes to clear out any gas If you smell gas STOP Follow B above If you don t smell gas continue 5 Locate the pilot by looking through the notch in the bottom right end of the front log Blue flame will be seen when the pilot is lit 6 Turn the gas control knob counterclockwise 4 w to the PILOT position 7 Push the knob all the way in and hold in that position Immediately light the pilot by pressing the ignitor button several times until pilot is lit Continue to hold the knob in for about 30 2s seconds after the pilot is lit Release knob and it will pop back out Pilot should remain lit If it lt OUTLET goes out repeat steps 4 8 holding knob in an additional 15 seconds after pilot is lit If knob does not pop out when released stop and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn the gas control knob to OFF and call your service technician or your gas supplier 8 After pilot is lit turn gas control counterclockwise A w to ON Knob can only be turned ON if the knob has popped out 9 To turn burner on turn ON OFF rocker switch to ON or set the thermostat to the desired temperature o e e above room temperature 10 Adjust the flame height and
39. l pilot is lit Continue to hold the knob in for about 30 seconds after the pilotis lit Release knob and it will pop back out Pilot should remain lit If it goes out repeat steps 4 8 holding knob in an additional 15 seconds after pilot is lit If knob does not pop out when released stop and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn the gas control knob to OFF and call your service technician or your gas supplier 8 After pilot is lit turn gas control knob counter clockwise to ON Knob can only be turned to ON if the knob has popped out 9 To turn burner on turn ON OFF rocker switch to ON or set the thermostat to the desired temperature above room temperature 10 Adjust the flame height and heat output by turning the flame height knob clockwise 7 w full flame and counter clockwise for reduced flame 11 Turn on the electric power to the appliance and set the blower to the desired air flow after it turns on when the appliance reaches operating temperature 13 14 TO TURN OFF GAS TO APPLIANCE Refer to controls shown in Figure 16 1 Turn off the ON OFF rocker switch and or thermostat if installed to its lowest setting 2 Turn off electric power to the appliance if service is to be performed 3 Push in gas control knob slightly and turn clockwise to OFF Do not force This appliance needs fresh air for safe opera
40. laces are approved for installation in the US state of Massachusetts if the following additional requirements are met Installation and repair must be done by a plumber or gas fitter licensed in the Commonwealth of Massachusetts The flexible gas line connector used shall not exceed 36 inches 92 centimeters in length The individual manual shut off must be a T handle type valve NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE Pre Installation FEATURES Installation Options Residential Vented Vertical Only Manufactured Mobile Home Natural Gas Or Propane LP Bedrooms Optional Wall mounted Or Remote Thermostat Electrical The fan motor requires 120 Volts AC for operation The fireplace is not dependent on the fan or an outside electrical supply to operate Millivolt Valve This insert is operated with a millivolt valve and therefore burns even during a power outage Fuel This insert comes from the factory equipped to burn natural gas at a specified elevation The insert can be converted to burn LP liquid propane by installing a conversion kit Only Lennox Hearth Products conversion kits can be used to convert from NG to LP or LP to NG Contact your Lennox Hearth Products dealer for details RATINGS NATURAL GAS 39 000 27 500 1 7 3 5 MAXIMIN INPUT BTUH 0 2 000 FT 0 610 M MANIFOLD PRESSURE IN WC MIN MAX INLET PRESSURE IN WC MAXIMUM HEAT OUTPUT BTUS HOUR STEADY STATE ORI
41. nt of the insert The two at the rear can be used to raise the back of the insert resting on the fireplace hearth The two at the front can be used to adjust the front of the insert on the hearth extension To install the bolts a 3 8 nut should be threaded onto the bolt followed by a 3 8 flat washer The bolt should then be installed from the under side of the insert into the captive nut in the bottom of the insert When the bolt is adjusted to the proper height the nut previously threaded onto the bolt can be snugged up to the insert bottom CLEARANCES Mantel Figure 4 The minimum distance from the top of the insert to a combustible may be reduced to 16 with a mantel shield The shield should be made from 18 gage or thicker sheet metal 7 by 33 The shield must be centered over the insert and spaced one inch below the mantel The shield can be fastened to and spaced from the mantel using four to six screws NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE Installation INSERT VENTING Refer to Figure 6 which shows a typical installation of this ap pliance into an existing solid fuel fireplace WARNING This appliance is equipped with a safety control sys tem designed to protect against improper venting of combustion products Operation of this heater when not connected to a prop erly installed and maintained venting system or tampering with the blocked vent shut off system can result in carbon monoxide
42. ny installation or operation of the appli ance deviating from that which is stated in this manual WILL void the warranty amp may be hazardous INSTALLATION amp REPAIR SHOULD ONLY DONE BY A QUALIFIED SERVICE TECHNICIAN DO NOT ATTEMPT TO SERVICE THE APPLIANCE YOURSELF The insert should be inspected 4 cleaned before use amp at least annually by a qualified service technician More frequent cleaning may be required due to exces sive lint from bedding material carpeting etc e It is imperative that control compartments burners 4 circulating air passageways of the room heater be kept clean e Adequate clearances around the combustion chamber and accessibility clearances for servicing amp proper operation must be maintained e Turn off the gas before servicing this appliance It is recommended that a qualified service technician per form an appliance check up at the beginning of each heating season All installations must conform with all local state amp national codes Inthe absence of local codes the instal lation must conform with National Fuel Gas Code ANSI 2223 1 latest edition also known as NFPA 54 Refer to the National Fuel Gas Code amp local zoning amp code authorities for details on installation requirements Your Firestar gas insert must be vented to the outside in accordance with the latest edition of the National Fuel Gas Code e This gas insert MUST be vented directly to the outside amp
43. of lower venting 4 Have gas supplier check for correct gas pressure 7 W C natural gas 11 W C pro pane gas 1 See Quiet Operation on Page 15 The noise may be reduced by slightly turning down the flame Turning the flame down will reduce the heat output of the insert 2 If noise is excessive or is whistling have your gas supplier check the regulator and orifices and replace if necessary 3 If noise is excessive or is whistling have your gas supplier check the regulator and orifices and replace if necessary 1 Have your gas supplier check for correct gas pressure 7 W C 1 74 kPa natural gas 11 W C po C E 2 74 kPa LP gas NOTE NEVER BLOCK OR OBSTRUCT AIR INTAKE OR OUTLET VENTS 2 See Log Set Installation Instructions 1 Check gas supply To purge hold in gas cock on valve for 1 2 minutes and try again 2 Check for spark at electrode and pilot if no spark and electrode wire is properly con nected replace igniter and igniter wire 3 Using a match light pilot If pilot lights turn off pilot and trigger the igniter again If pilot lights an intermittent gas air supply may be the problem if longer purge will not light check gap between electrode and pilot should be 1 8 inch 3 mm to have a strong spark If OK replace pilot 1 Snap switch activated have venting system inspected for blockage down draft or bad snap switch 2 Check pilot flame adjustment see Maintenance section
44. push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D DO NOT use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part ofthe control system and any gas control which has been under water OPERATING INSTRUCTIONS Refer to controls shown in Figure 16 CAUTION Your Lennox gas INSERT MUST ALWAYS BE OPERATED WITH GLASS IN PLACE STOP Read the safety information above before pro ceeding 1 Openthelower door Make sure gas supply shut off cocks are open and ON OFF rocker switch is OFF If equipped with a thermostat set it to the lowest setting 2 Turn off all electrical power to the appliance 3 Push in gas cock dial slightly and turn clockwise to OFF NOTE Dial cannot be turned from PILOT to OFF unless dial is pushed in slightly Do not force 4 Wait five minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow above If you don t smell gas continue 5 Locate the pilot by looking over the top of the left front log A blue flame will be seen when the pilot is lit 6 Turn the gas control knob counter clockwise 10 the PILOT position 7 Push the knob all the way in and hold in that position Immediately light the pilot by pressing the igniter button several times unti
45. r be attached to a chimney serving a separate solid fuel burning appliance Uses room air for combustion It is imperative that provi sionsforadequate combustion and ventilation air be made This appliance is NOT designed to and will not operate in a negative pressure Contact your dealer if you suspect such a situation exists Has been certified for use with either natural gas or pro pane Is not for use with solid fuels Is approved for sitting rooms and or bedrooms Fireplace Requirements These heaters are designed to be installed into an existing masonry fireplace built to UBC 37 standards or factory built solid fuel wood burning fireplace listed to UL 127 standards only All exhaust gases must be vented outside the structure Combustion air is drawn from outside the structure When installing in a factory built fireplace the fireplace grate must be removed and the damper must be removed or secured open If the factory built fireplace has no gas access hole s pro vided an access hole of 1 1 2 inches 38 mm 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 a non combustible insulation after the gas supply line has been installed The installer must mechanically attach the marking supplied with the gas fireplace insert to the inside ofthe firebox of the fireplace into which the gas fireplace insert is installed IMPORTANT
46. re 5 Chimney Cap Storm Chimney Use With B vent Chimney Or Single Wall Gas Vent Flex Chimney Liner Listed To UL 1777 Or ULC S635 Figure 6 A WARNING Do not substitute the heat rated flex liner UL1777 or ULC 635 for the exhaust with any other type liner or a fire may result causing property damage personal injury or loss of life The following vent liner kits are available from Lennox Hearth Products see Figure 7 and table below Figure 7 VENT KITS Catt Mode Description Hogos VKBVI2 BVI 4 Dia x 25 Length H0906 H0907 VKBVI35 4 Dia x 35 Length NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE ZERO CLEARANCE FIREPLACE INSTALLATION This insert may be installed in a masonry or factory built zero clearance ZC fireplace When installing in a ZC fireplace the ZC grate must be removed and the ZC damper must be removed or secured open The ZC doors screen refractory or masonry lining baffles and smoke shelf may be removed if necessary to install the gas insert However do not cut or alter the fireplace components The removal of any parts to facilitate installation must not alter the integrity of the inner or outer shells of the fireplace cabinet See Fireplace Requirments on page 4 21485 Door Removat See page 17 for Glass Door Removal Instructions Brick LINER INSTALLATION HANDLE THE BRICK PANELS WITH CARE SEE FIGURE 8 AS
47. right side access door below valve then adjust the air shutter gap until the proper flame characteristics are achieved Note The setscrew for the air shutter is secured tightly from the factory so that it does not rotate from the factory setting during shipping Once you loosen the setscrew just enough so that it can be rotated by hand then reinstall the burner tube you will be able to access and adjust the air shutter from behind the right side panel below valve Figure 15b Figure 15 gi Figure 15d Figure 15e Remove Allen Head Screw Burner Tube Assembly Figure 15e Operating Instructions CHECKLIST Be sure to check these items before the initial lighting of the insert All packaging materials are removed from the firebox brick panels and logs are installed The insert gas label must correspond to the gas supply available that is natural gas for natural gas LP gas for LP gas Besure the gas pressure has been carefully checked see Gas Pressure Requirements Fingerprints or other marks are cleaned while the insert is cool from any gold or nickel surfaces with denatured alcohol and a soft cloth Marks left on these surfaces may become etched into the finish if not removed prior to burning the unit Check all gas fittings for leaks Remove all combustible materials from the area in front ofthe insert and ensure the vented areas of the insert face are unobst
48. ructed Check to ensure all clearances to combustibles are met see page 7 Make sure the glass door is in place and properly sealed before burning the appliance Ventilate the house to clear initial paint curing odors see page 15 Lighting Instructions The following is a copy of the operating and lighting instruc tions found with each insert FOR YOUR SAFETY READ BEFORE OPERATING WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE INJURY OR LOSS OF LIFE CAUTION HOT WHILE IN OPERATION DO NOT TOUCH KEEP CHILDREN FURNITURE GASOLINE AND OTHER LIQUIDS WITH FLAMMABLE VAPORS AWAY NEVER OPERATE UNIT WITH GLASS OFF OR ATTEMPT TO REMOVE THE GLASS WHILE HOT A This appliance is equipped with a piezo ignition device to light the pilot When lighting the pilot follow these instructions exactly B BEFORE LIGHTING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS DO NOT try to light the appliance DO NOT touch any electric switch DO NOT use any phone in the building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use any tool If the knob will not
49. t is hot Open both latches on the right and left side of the door they are centered on the sides of the front door see Figure 20a With the latches released rotate the catch part of each latch outward away from the front door The door will pivottoward you from the top hinging from the bottom as shown in Figure 20b On the bottom of the door there are tabs that slide into slots on the firebox Disengage the tabs on the door from the slots on the firebox by lifting up on the door until it stops and slide the door all the way to the left You can then remove the door straight out from the slots To reinstall door reverse the steps above Side Door Latches E Open the top door latches by pulling them forward and up Figure 20a Lift the glass door up and off the lower spring latch Figure 20b NOTE DIAGRAMS amp ILLUSTRATIONS ARE NOT TO SCALE 17 To remove the front door open the side doors release the front door latches on either side and rotate the top of the glass door forward and down until it stops Once it is all the way open lift it slightly move it to the left and pull it away from the insert Place door on a nonabrasive surface being careful not to damage door or glass When cooled the exterior glass may be cleaned with a clean soft cloth and windex For cleaning white condensation from the interior glass use KEL KEM gas fireplace glass cleaner available from your insert dealer Use of caustic or abrasive cl
50. the pin in the top of the rear log and the pin in the top of the right front log see Figure 11 5 Place the volcanic stone one high in front of the front burner tube see Figure 12 Take care not to cover all the burners ports Any extra volcanic stone may be placed at the ends of the front logs off the burner Place small pinches of rockwool embers on top of the volcanic stone Top Twig Figure 11 Note The pilot flame can be viewed through the burned hole in the right front log Figure 12 N aet SURROUND INSTALLATION Install per the following instructions refer to Figure 13 The FireStar insert flanges are made of heavy 12 gage steel for durability and if desirable for the ease of making an inside fit in the fireplace See Packaging List for sizes available The side flanges extend 2 below the bottom of the insert and align with the 2 lower filler panel In those few instances when the elevation of the hearth necessitates 2 can be cut from the bottom of the side flanges and the insert placed directly on the hearth not using the leveling bolts or filler panel 1 Remove the speed nuts from the parts bag and install with the flat surface forward on the six holes in the flange brackets three on each side of the insert A flat bladed screwdriver may help in installing the nuts 2 Install all flanges and trim with the insert positioned in the fireplace but a few inches in front of its final lo
51. tion and must be installed so there are provisions for adequate combustion and ventilation air WARNING Improper installation adjustment alteration service or maintenance can cause injury or property dam age For assistance or additional information consult a qualified installer service agency or your gas supplier Operation of this appliance when not connected to a prop erly installed and maintained venting system can result in carbon monoxide CO poisoning and possible death SHUTDOWN PROCEDURE To turn off the burner turn the rocker switch to OFF or adjust the thermostat if installed to a setting below room temperature The pilot will remain lit for future burner igni tion For complete shutdown see TO TURN OFF GAS TO APPLIANCE above Robertshaw Gas Valve Gas Control Knob Off On Pilot Flame Height Control Knob Hi Lo Millivolt Pilot ON OFF Switch Gas Pilot Hood Piezo Igniter Igniter Figure 16 FLAME amp Your Firestar gas insert is designed for maximum heating efficiency Therefore upon lighting of the main burner the flames will be semi transparent or bluish After 10 20 minutes of operation the logs will heat up and the flames will become a yellow orange color Adjusting the insert to cause the flames to turn orange sooner may result in poor combustion sooting and a hazardous situation See Figure 17 showing prop
52. tment Checkthetapsforgasleaks Orifice with a gas leak test solution X retighten if necessary C Figure 14 If the pressure is not sufficient make sure the gas supply line is large enough the supply regulator is properly adjusted and the total gas load for the residence does not exceed the amount supplied The 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 psig The appliance must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig Check with your gas supplier or plumber Fuel Inlet Pressure Manifold Pressure Desired On Lo Fire hall nl Fas E id ced Ld Table 1 Gas Suppty Line Sizine The proper gas line diameter must be selected to run from the supply regulator to the insert Refer to the Table 2 for proper gas pipe diameters NOTE Some areas allow copper tubing check with local approval agencies and codes COPPER TUBING NOT ALLOWED IN MASSACHUSETTS IN NATURAL GAS INSTALLATIONS NEVER USE GALVANIZED OR PLASTIC PIPES Pipe Length Feet from Supply Regulator Schedule 40 Pipe Inside Diameter Black Pipe Tubing Type L Outside Diam eter Copper Do Not Use Copper in Massachusetts with Natural Gas
53. uring as the insert is used Fire the insert four successive times for ten minutes each time with a five minute cool down between each firing Ventilate the house during these first firings as the paint gives off car bon dioxide and unpleasant odors It is recommended that persons sensitive to an imbalance in the indoor air quality avoid the insert during the curing process Quiet OPERATION GAS NOISE The sound of gas flowing through the insert may be detectable while the unit is in operation This is a normal operating sound however if it is objectionable it can be reduced by turning down the flame Turning down the flame will reduce heat output BLOWER NOISE As the insert heats up the blower will come on to move hot air through the heat exchanger and into the room Adjust the fan speed with the fan control knob to the sound level and air flow desired BLower Your Firestar gas insert comes equipped with a 150 CFM blower with a variable speed control and an automatic temperature activated On Off snap switch Operation 1 Plug the blower power cord into a grounded three prong outlet This appliance is equipped with a three prong grounding plug for your protection against shock hazard and should be plugged directly into a properly grounded three prong receptacle Do not cut or remove the grounding prong from this plug 2 After the insert warms up the fan will come on if the speed control located at the bottom of th
54. ve LP Robertshaw Main Gas Control Valve NG Rock Wool embers Side Bay Glass W glass Tape Installed Each 2 Per Stove Snap Switch Wire Thermopile Top Trivet Vent Safety Snap Switch W bracket Vent Safety Snap Switch Wires 21 Safety Listing Label FIRESTAR mE Tested amp B 7 Manufactured by Usted By aie LENNOX gt enwoxseartiprooucts z US PO BOX 987 OMNI Test Laboratories Inc HEARTH PRODUCTS AUBURN WA 98071 USA PROPANE GAS O Report No 050 S 07 5 IF CONTROL PANEL CONTRADICTS THIS LABEL UNIT FUEL TYPE HAS BEEN CONVERTED VENTED GAS FIREPLACE HEATER FIREPLACE INSERT NOT FOR USE WITH SOLID FUEL TESTED TO ANSI Z21 88 1998 VENTED GAS FIREPLACE HEATERS THIS APPLIANCE MUST BE INSTALLED IN ACCORDANCE WITH LOCAL CODES IF ANY IF NOT FOLLOW THE CURRENT ANSI Z223 1 IN THE USA THIS APPLIANCE MUST BE INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTALLATION INSTRUCTION FOR INSTALLATION IN SOLID FUEL BURNING FIREPLACES ONLY MASONRY OR FACTORY BUILT THIS VENTED GAS FIREPLACE HEATER IS NOT FOR USE WITH AIR FILTERS THIS APPLIANCE NEEDS FRESH AIR FOR SAFE OPERATION AND MUST BE INSTALLED SO THERE ARE PROVISIONS FOR ADEQUATE COMBUSTION AND VENTILATION AIR RATINGS NATURAL GAS LP GAS MAXIMUM INPUT BTUH 0 2 000 FT 0 610 M 39 000 39 000 MINIMUM INPUT BTUH 0 2 000 FT 0 610 M 27 000 ORIFICE DMS 0 2000 FT 0 610 M 22600 53 MANIFOLD PRESSURE IN WC 3
55. vered by a limited warranty provided with appli ance Please read the warranty to be familiar with its coverage Retain this manual File it with your other documents for future refer ence PRODUCT REFERENCE INFORMATION We recommend that you record the following important information about your fireplace Please contact your Lennox Hearth Products dealer for any questions or concerns For the number of your nearest Lennox Hearth Products dealer please call 1 800 9 Lennox REPLACEMENT PARTS See Page 21 for a complete replacement parts list Use only parts sup plied from the manufacturer Normally all parts should be ordered through your Lennox Hearth Products distributor or dealer Parts will be shipped at prevailing prices at time of order When ordering repair parts always give the following information 1 The model number of the appliance 2 The serial number of the appliance 3 The part number 4 The description of the part 5 The quantity required 6 The installation date of the appliance If you encounter any problems or have any questions concerning the installation or application of this system please contact your dealer LENNOX HEARTH PRODUCTS 1110 West Taft Avenue Orange CA 92865 Visit us at www Lennox com Your Fireplace Insert s Model Number Your Fireplace Insert s Serial Number The Date On Which Your Fireplace Insert Was Installed The Type of Gas Your Fireplace Insert Uses Your Deal
56. z le service des incendies L installation et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz Table of Contents CAUTIONS amp SAFETY 55 o c va ER a t oec dev Wine Mare vnde as UU RE Va Pee 3 ORIFICE Size ALTITUDE ADJUSTMENT eee mm Hm mm mn mnn 4 FIREPLACE PEOUIREMENTS s con ER PRESE r e e eR eer Fen Da aa AEST Cra 4 CODES amp APPROVALS i0 conet Ded Ead AUD ALLE CLE EL C NICE eb Ue DELE 4 REQUIREMENTS Fon THE COMMONWEALTH OF MASSACHUSETTS een 4 PRE INSTAEEATION event ate Sta cat dese eun etu ECL ELO cd NEN at 5 7 FEATURES A Servei Dt M MU E iL aL E 5 PACKAGING LIST oro oe cv oko eR OX ER retin D PEE Oi OO NS Val wi EE Seed E ER 5 areca eyelet res DR ERR ee Leo 5 INSERT amp FIREPLACE DIMENSIONS eee mm mI mmm mnn 6 CLEARANCES TO COMBUSTIBLES c eee nmm nnns 1 INSERT LEVELING S o coh a ea ev ccv os E eevee co ur va eu Vea A eek dda wed dae eden adie 1 DSTALPATION eon e eec bordure OVER dey ERU UE T een ANE 8 12 VENTING NSTALLATION e orae eo exa mete ebat cete eben es usu 8 CONNECTION Uve Cos ord 8 ZERO CLEARANCE FIREPLACE INSTALLATION eese m m mmm mmn nnne nnn 9 BRICK LINER INS
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