Lexington Home Brands AI42DV User's Manual
Contents
1. INSTALLING LOGS AND ROCK WOOL EMBER MATERIAL IN FIREBOX 1 Open front door of firebox 2 Carefully remove seven 7 logs from wrapping 3 Place rear log 1 against back of firebox Line up holes in bottom of log with two 2 mounting pins in bottom of firebox See Figure 16 4 Line up the holes in the bottom of the left base log 2 with pins on the left side of insert Install left base log See Figure 19 Rear Log 1 Left Front Log 2 TL we pi T Figure 18 Installing Rear Log 1 Figure 19 Installing Left Log 2 20 48D0139 LOG PLACEMENT 5 Place right base log 3 to the right of rear log 1 See Figure 20 6 Place left center log 4 on top two pins next to left base log 2 Line up hole in bottom left center log 4 with pin on burner See Figure 21 Right Base Figure 20 Installing Right Log 3 we Left Center Log 4 Right Center Log 5 Figure 21 Installing Left Center Log 4 7 Set right center log 5 on two pins to the left of right base log See Figure 22 Figure 22 Installing Right Center Log 5 Continued on page 22 48D0139 21 LOG PLACEMENT 8 Place one end of right top log 6 on cutout of right base log 3 Line up hole in bottom or right top log 6 with pin on right center log 5 See Figure 23 9 Lay top Y log 7 across rear log 1 and left2. It is normal for inserts fabricated of steel to give off some expansion and or contraction noises during the start up or cool down cycle Similar noises are found with your furnace heat exchanger or car engine It is not unusual for your Lexington Forge insert to give off some odor the first time it is burned This is due to the curing of the paint and any undetected oil from the manufacturing process Please ensure that your room is well ventilated OPEN ALL WINDOWS DURING INITIAL BURN OFF CURING PHASE Burn your insert for a least six 6 hours on HIGH the first time you use it Place fan in the OFF position during this time 48D0139 11 VENT INSTALLATION Read all instructions completely and thoroughly before attempting installation Failure to do so could result in serious injury property damage or loss of life Operation of improperly installed and maintained venting systems could result in serious injury property damage or loss of life O Z Z lt Failure to follow these instructions will void the warranty INSTALLATION PRECAUTIONS Consult local building codes before beginning the installation The installer must make sure to select the proper vent system for installation Before installing vent kit the installer must read this insert manual and vent kit instructions Only a qualified installer service person should install venting system The installer must follow these safety rules Wear gloves a
3. DUE TO HIGH TEMPERATURES THE APPLIANCE SHOULD BE LOCATED OUT OF TRAFFIC AND AWAY FROM FURNITURE AND DRAPERIES CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE TEMPERATURE AND SHOULD STAY AWAY TO AVOID BURNS OR CLOTHING IGNITION YOUNG CHILDREN SHOULD BE SUPERVISED WHEN THEY ARE IN THE SAME ROOM AS THE APPLIANCE CLOTHING OR OTHER FLAMMABLE MATERIAL SHOULD NOT BE PLACED ON OR NEAR THE APPLIANCE KEEP THE ROOM AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS READ BEFORE INSTALLING SAVE THESE INSTRUCTIONS CONTENTS CONGRATULATIONS You have purchased a state of the art gas appliance featuring the Lex Fire Burn System available exclusively on Lexington Forge gas appliances The Lex Fire Burn System sets a new standard for flame appearance through innovative log design burner technology and ember placement Each element effecting combustion and flame appearance was carefully scrutinized and strategically balanced during the design process to provide a product that was truly BORN TO BURN Important Safety Information 3 Product Features eee enne 5 Code ADDFIOVOL scssscxk kn RR ark a Su RR ROPERA Eu ARRA RC R 5 Pre Installation Information Installing Above 2000 Feet 6 Orifice Sizes Pressures and BTUS 6 Insert Dimensions enne
4. 6 Fireplace and Insert Dimensions 7 General Installation Information 8 Clearances 0 cccececccceccccecccccccccueacsueaveceaees 8 InstallatiOle zu ccna seseiesescatcacet gaemeaseaewexesentenee ee 9 Insert Clearances emm 9 Mantel Clearances nmm 9 Hearth Requirements 9 Insert Placement eene 10 Zero Clearance Metal Fireplace REQUIFEMENTS cccccceecseeseeeeeeseeteeeeeeaeees 11 Vent Installation 12 Installation Precautions 12 Vent Requirements eeeeeeeee 13 Altitude Considerations 13 Vent Configurations tiani vo babct ER 14 Manifold Removal and Installation 15 Insert Installation Check Gas IV 0G rS 16 Installing Gas Piping to Insert Burner System Location 2 2 ccc ccccceccececccccccccecuecccacucecueeeneaees 16 Checking Gas Pressure 18 Electrical Installation 19 Electrical Wiring 19 Remote Wall Switch 19 Log PIdcenmellb eue oc iiu ves ad eceont cetanecncentenes 20 Surround and Trim Installation 24 Installing Facing asacissnuccitenpd mde TR ORO Mte 24 Assemblin
5. We recommend that you install a sediment trap drip leg in supply line as shown in Figure 15 Locate sediment trap drip leg where it is within reach for cleaning Install in piping system between fuel supply and burner system Locate sediment trap drip leg where trapped matter is not likely to freeze A sediment trap traps moisture and contaminants This keeps them from going into the burner system gas controls If sediment trap drip leg is not installed or is installed wrong burner system may not run properly Approved Flexible Gas Line Supplied with Appliance Tee Joint Pipe Nipple Cap Sediment Trap Drip Leg Natural Gas From Gas Meter 4 5 W C to 10 5 W C Pressure Propane LP From External Regulator Minin 11 W C to 13 W C Pressure m Figure 15 Gas Connection 48D01 39 CHECKING GAS PRESSURE l 18 Check gas type The gas supply must be the same as stated on the appliance s rating decal If the gas supply is different from the fireplace STOP Do not install the appliance Contact your dealer immediately Install and attach 30 762mm flex line provided with on this appliance to 2 gas line After completing gas line connection purge air from gas line and test all gas joints from the gas meter to the fireplace for leaks Use a soap and water solution or a gas sniffer To adjust flame height turn HI LO knob to HI to get maximum pressure to burner Turn HI LO knob to LO to get minimum pressu
6. connection All joints on valve and control body NOTE Remove any excessive pipe compound from the connections Excessive pipe compound can set off electronic sniffers LIGHTING PILOT M The control has an interlock device that does not allow the lighting of the insert up to the moment the safety device of the flame has not interrupted the gas flow After that period of time when the magnet is closed it is possible to start the lighting operation The gas control knob is designed to be operated by hand DO NOT use any tools during this operation Damaged knobs may result in serious injury WARNING 1 Depress and turn knob counterclockwise z to pilot position O D 2 Depress fully and hold pilot gas knob The elec tronic ignitor will automatically ignite the pilot Keep knob fully depressed for a few seconds Release R N Loy PpILO7T and check that pilot continues to burn If the pilot does not stay lit repeat steps 1 and 2 Figure 33 Pilot Position If the knob does not pop out to its original position when released turn off gas to appliance and contact qualified service technician WARNING 28 48D0139 OPERATING INSTRUCTIONS LIGHTING BURNER MAIN BURNER SWITCH The ON OFF REMOTE switch for the main burner can be found on the right side of insert surround This switch allows you to turn on and to turn off the main burner without using the gas valve knob Make sure the button
7. gas connections The gas control inlet is Figure 14 External Regulator with Vent Pointing 3 3 NPT Down Propane LP Only 16 48D0139 Only persons licensed to work with gas piping may make the necessary gas connections to this appliance O z z lt CAUTION INSERT INSTALLATION A manual shutoff valve is factory installed upstream of the appliance Union tee and plugged s NPT pressure tapping point should be installed upstream of the appliance See Figure 15 NOTE The gas line connection may be made using 1 2 rigid tubing or an approved flex connector Since some municipalities have additional local codes it is always best to consult your local authorities and the current edition of the National Fuel Gas Code ANSI 2223 1 NFPA54 In Canada CAN CGA B149 1 or 2 Installation Code A listed manual shutoff is factory installed upstream of appliance Union tee and plugged s NPT pressure tapping point should be installed upstream of the appliance See Figure 15 IMPORTANT The main gas valve is for turning on or shutting off the gas to the insert Check your building codes for any special requirements for locating equipment shutoff valve to inserts Apply pipe joint sealant lightly to threads This will prevent excess sealant from going into pipe Excess sealant in pipe could result in clogged burner system valves CAUTION Use pipe joint sealant that is resistant to liquid petroleum LP gas
8. must have electricity INSTALLATION PLANNING Plan for the installation of your insert This includes determining the size of fireplace in which unit is to be installed length of venting to be used and finishing details and whether any optional accessories 1 e wall switch or remote control are desired Consult your local building code agency to ensure compliance with local codes including permits and inspections 6 48D0139 FIREPLACE AND INSERT DIMENSIONS i A SF Fireplace Opening ig B y Top Figure 2 External Insert Dimensions L Fireplace opening height O Firebox width at insert depth N M Fireplace opening width P Firebox depth at insert back height Q N Depth of insert Q Insert back height Al42 FIREPLACE MINIMUM OPENING A255 G4imm J 2 6l mm Kasim 0 1 2287 T2mm G 1977 489mm 48D0139 T GENERAL INSTALLATION INFORMATION The following factors should be taken into consideration e This insert should have sufficient access for its safe operation and maintenance e The flow of combustion and ventilation air must not be obstructed e Minimum clearances to combustibles such as mantels must be maintained See Figures 3 and 4 pages 10 and 11 e Never obstruct the front opening of the insert e Do not install in the vicinity where gasoline or other flammable liquids may b
9. 0 feet Canada In this testing heater with standard orifice burns correctly with just an air shutter adjustment If you need to resize orifice for use at high altitude contact your Lexington Forge dealer Maximum 1 805mm l Offset Failure to adjust air shutter properly may lead to improper combustion which can create a safety hazard Consult your dealer or installer if you suspect an improperly adjusted air shutter Figure 6 Venting Unit uirga it 4 and 3 UL Termination Kit T centered on unit 1777 Gas Liner Al42TK43 SEY gt scone ENS E Apply high temperature silicone to lines on both ends and secure with two 2 screws Figure 7 Connecting Exhaust Pipe to Heater 48D0139 13 VENT INSTALLATION VENT CONFIGURATIONS CI Termination Kit part AIA2TK43 Exhaust Exhaust Inlet La g 4 100mm Exhaust Any cracks or a UL 1777 Gas Liner damage inside 3 75mm Inlet chimney must be repaired Recommended block off plate non combustible metal Prevents odors from chimney entering room The block off plate Al42AK43 must seal intake to the chimney space so that air is drawn down chimney for combustion air Block off Plate Suggestion Paint fireplace cavity with latex paint to eliminate possibility of AIAZAKAS odors from fireplace non combustible circulating into the room materials Inlet Z C meta
10. DJUSTING THE AIR SHUTTER The venturi of the burner is equipped with an air shutter The opening of the venturi has been set at 4 for Natural Gas and fully open for Propane installation at sea level The rear burner on Natural Gas Models may be adjusted for high altitude as follows To increase air mixture push up the adjustment rod located beneath the insert This opens the shutter more and will stop sooting See Figure 41 e To decrease air mixture pull down the adjustment rod located beneath the insert This closes the shutter Flames will be more yellow See Figure 42 Air Shutter Rod Figure 41 Push Adjustment Rod Up to Open Air Shutter Air Shutter 4 d Adjustment Pd Rod Figure 42 Pull Adjustment Rod Down to Close Air Shutter 48D0139 31 GLASS REPLACEMENT Make sure the glass panel edges do not touch any metal parts during thermal expansion Always use gloves when handling broken glass P e lt O WARNING 1 Put on gloves Remove frame from insert by releasing two clamps on bottom of insert and lifting the door up and off the unit See Figure 43 2 Remove the s rope from around glass frame See Figure 43 3 Using a 16 socket remove hex nuts from glass retaining brackets Remove retaining brackets See Figure 44 4 Carefully remove broken glass Wrap new glass pane with 4 gasket Make sure you have 4 overlap on each side Place new glass in frame
11. ERI eee O om ee eee x d 3 i n y 0 Y i0 N j T o EN A Loo od 2 T d oy bo 0v 0 oo 1 od 0 Oond AE oo uid iN S Aen 8 Remove any excess slack in flex line Attach vent termina tion Figure 13 Excess Slack Taken Slack in Flex Vent 1 ard N eX ean 0 Q9 ef ONC 12 2 2 9 mis E E SN 3 e ine Erg LA i ae Uo pem Oe ne R Re a ee ce Oro u s V of s Uo E Or V b e Out of Flex Vent 9 Replace Manifold baffle and Bracket brick liner Nut Insert C L r ra DET ES eee Figure 12 Pulling On Figure 13 Sliding Insert Excess Flex Vent Into Place 48D0139 15 INSERT INSTALLATION CHECK GAS TYPE Use proper gas type for the insert you are installing If you have conflicting gas type do not install insert See dealer where you purchased the insert for proper insert according to your gas type INSTALLING GAS PIPING TO INSERT LOCATION A qualified installer or service person must connect appliance to gas supply Follow all local codes For propane LP units never connect insert directly to the propane LP supply This burner system requires an external regulator not supplied Install the external regulator between the burner system and propane LP supply CAUTION INSTALLATION ITEMS NEEDED Before installing insert and burner system make sure you have the items listed below e External regulator supplied by installer Piping check local codes e Sealant resistant to propane LP
12. Fasten retaining brackets back into place with 16 nuts 8 Replace s rope Make sure the joint is at the bottom and there is no gap 9 Slide door back down onto insert and fasten two clamps See Figure 43 YS Gasket Glass Frame Figure 43 Removing Door from Hinges y Retaining Brackets Hex Nuts not all shown Glass Figure 44 Replacing Glass Inside of Frame Shown NOTE Use only original Lexington Forge replacement parts 32 48D0139 MAINTENANCE MAINTAINING YOUR HEATER S APPEARANCE Fingerprints or other marks left on optional gold or nickel surface may become etched in place if they are not wiped clean prior to turning stove on Clean gold or nickel with a 50 50 vinegar and water solution and soft cloth soft cloth NOTE Make sure heater is cool before cleaning Using cleaners other than a 50 50 vinegar and water solution may leave a film that becomes permanently etched into the gold or nickel YEARLY SERVICE PROCEDURE Thermocouple Failure to inspect and maintain heater may lead to improper combustion and a potentially dangerous situation A qualified technician should do the following once a year 1 Check pilot flame Flame should touch approximately s of the top of ther mopile and touch top of thermocouple See Figure 45 If not contact dealer for service 2 Turn gas control knob to OFF position to shut off gas to heater See step To Turn Off Gas page 29 Let heater cool f
13. LEXINGTON FORGE DIRECT VENT GAS INSERT INSTALLATION AND OPERATING INSTRUCTIONS MODEL ASHTON AI42DV WARNINGS IF THE INFORMATION IN THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING Improper installation adjustment alteration services or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier 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 This appliance may be installed in an aftermarket permanently located manufactured home where not prohibited by local codes Aftermarket Completion of sale not for purpose of resale from the manufacturer
14. absence of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 Do not obstruct the flow of combustion and ventilation air in any way Provide adequate clearances around air openings into the combustion chamber along with adequate accessibility clearance for servicing and proper operation Do not use insert if any part has been exposed to or under water Immediately call a qualified service person to arrange for replacement of the unit Do not operate insert if any log is broken Do not operate the insert with glass door removed cracked or broken 48D0139 PRODUCT FEATURES anp CODE APPROVAL PRODUCT SPECIFICATIONS e This appliance has been certified for use with either natural or propane gas See appropriate data plates e This appliance is not for use with solid fuels e The appliance is approved for bedroom or bedsitting room installations e The appliance must be installed in accordance with local codes if any If none exist use the current installation code ANSI Z223 1 NFPA 54 in the USA CAN CGA B149 in Canada e This appliance is mobile home approved A 3 e The appliance must be prop Off Pilot On zc A erly connected to a venting Knob SS system Hi Lo Knob Optional Remote Receiver Valve On Off Remote Switch Figure 1 Al42DV Insert The efficiency rating of this appliance is a product thermal efficiency rating determine
15. all fingerprints from facing Slide one door onto hinges Repeat for other door See with a 50 50 vinegar and water Figure 32 26 solution before lighting the heater Any fingerprints left on the facing will be permanent when heater is lit Upper Magnetic Bracket Doors Magnetic E Bracket Hinges Figure 32 Installing Doors 48D0139 OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instruction exactly a fire or explosion may result causing property damage personal injury or loss of life O z z lt A This appliance is equipped with a pilot piezo ignition system Follow these instructions exactly to light pilot B BEFORE OPERATING smell all 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 e Turn off all gas to the appliance e Open windows e Do not attempt to light any appliance e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f 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 tools 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 resu
16. center logs 4 Place Y log 7 on two 2 pins provided See Figure 24 Right Top Log 6 Pin on Right Cutout on Right Center Log 5 Base Log 3 Figure 23 Installing Right Top Log 6 Top ub d Figure 24 Installing Y Log 7 22 48D0139 LOG PLACEMENT 10 Break up rock wool ember material into dime sized pieces Place evenly across burner surface and mesh of grate See Figures 25 and 26 Do not exceed 1 depth of coverage Lightly cover the airspace between logs and burner with small pieces rock wool for a better burner flame and glow See Figure 26 Also use additional small pieces of rock wool to lightly cover the airspace in front of burner See Figure 27 Rock Wool Rock Wool Rock Wool Figure 27 Installing rock Wool in Air Space Between Logs and Burner 48D0139 23 SURROUND AND TRIM INSTALLATION INSTALLING FACING 1 Line up surround with unit opening 2 Attach surround to unit with four 4 Surround Top of screws provided See Figure 26 E 3 Install magnetic L bracket to bottom of surround with two 2 screws and 2 nuts provided See Figure 26 ASSEMBLING OPTIONAL TRIM 1 Lay out trim and L brackets on floor See Figure 29 2 Put trim together at 45 angles to form a corner Insert L bracket into slots in back of trim Tighten screws with flat head screwdriver See Figure 27 Make
17. ch Shutoff Valve Venturi 12 Burner Gasket 13 Hi Lo Knob Extension 14 Knob Extension ON OFF 15 Ignitor Battery Module 16 Ignitor Wire Harness 17 ON OFF Wire Harness 18 3 8 Union 19 Nipple 10 5 x3 8 Grommet 20 21 Adjuster Rod 22 Disk Bracket 23 Rear Log 24 Left Log 25 Right Log 26 Left Center Log 2 Right Center Log 28 Right Top Log 29 Y Log Giooo oone25com EC D aja PRP RMP BP RM RPK NN QO I O anaes Available Not Shown Rear Brick Liner Left Brick Liner Right Brick Liner Glass Flame Deflector Vent Connector MA Blower Parts Blower Right Blower Left Blower Snap Disc Speed Control Blower Wire Harness ome et 48D0139 3 D0117 48D0154 h 48D0147K 49K 43D0094 45D0077 45D0078 48D0163 26D4500 48D0162 45D0241 48D0109 48D0109 48D0029 48D0029 48D0006 48D0007 48D0008 48D0151 48D0152 48D0153 48D0009 48D0010 48D0011 48D0012 48D0004 48D0022K 48D0113 33D0700 45D0240 23D6100 26D0746 26D0619 3 D0118 48D0156 48D0146K 49K 20H2049 41D0048 43D0094 45D0077 45D0078 48D0163 26D4500 48D0162 45D0241 48D0006 48D0007 48D0008 48D0151 48D0152 48D0153 48D0009 48D0010 48D0011 48D0012 48D0004 48D0022K 48D0113 33D0700 45D0240 23D6100 26D0746 26D0619 or failure to use only parts specifically approved with this applianc
18. d under continuous operating condi tions and was determined independently of any installed system Thermal Efficiency up to 80 CODE APPROVAL These appliances have been tested by CSA and found to comply with the established standards for VENTED GAS FIRE PLACE HEATERS in the USA and Canada as follows LISTED VENTED GAS FIREPLACE HEATER TESTED TO ANSI Z21 88 2002 CSA 2 33 2002 STANDARDS ATTENTION MASSACHUSETTS RESIDENTS This Lexington Forge product must be installed by a licensed gas fitter 48D0139 5 PRE INSTALLATION INFORMATION INSTALLING ABOVE 2000 FEET e Inthe USA the appliance must be derated 4 for every 1 000 ft above 2 000 ft elevations e In Canada these appliances are certified for altitudes of 0 2000 ft and must be de rated by 10 percent for installations between 2000 and 4 500 ft derate an additional 4 for every 1 000 ft above 4 500 ft elevations ORIFICE SIZES PRESSURES AND BTUs NATURAL GAS PROPANE GAS Manifold Press W C 33 Manifold Press W C 10 Maximum Supply Pressure 10 5 Maximum Supply Pressure I5 Minimum Supply Pressure 4 5 Minimum Supply Pressure 11 Model Number Al42 NATURAL PROPANE Max Btu hr Input 42 000 40 000 Min Btu hr Input 29 000 28 000 Orifice sizes as shipped Front 44 Front 55 Rear 43 Rear 55 The ASHTON AIA2 is equipped with a variable output gas control NOTE Ashton Al42 model insert works without any electrical supply Optional blower
19. der any circumstances Any parts removed for servicing must be replaced prior to operating insert Turn insert off and let cool before servicing installing or repairing Only a qualified service person should install service or repair the insert Have burner system inspected annually by a qualified service person You must keep control compartments burners and cir culating air passages clean More frequent cleaning may be needed due to excessive lint and dust from carpeting bedding material pet hair etc Turn off the gas valve and pilot light before cleaning insert Have venting system inspected annually by a qualified service person If needed have venting system cleaned or repaired See Cleaning and Maintenance page 30 Keep the area around your insert clear of combustible materials gasoline and other flammable vapor and liq uids Do not run insert where these are used or stored Do not place items such as clothing or decorations on or around insert Continued on page 4 3 IMPORTANT SAFETY INFORMATION Continued from page 3 12 13 14 15 16 D 18 19 Do not use this insert to cook food or burn paper or other objects Never place anything on top of insert Do not use any solid fuels wood coal paper cardboard etc in this insert Use only the gas type indicated on rating plate This appliance when installed must be electrically grounded in accordance with local codes or in the
20. e may result in property damage or personal injury 3 TROUBLESHOOTING O z z lt Turn appliance OFF and allow to cool before servicing Only a qualified service person should service and repair the heater Note All troubleshooting items are listed in order of operation OBSERVED PROBLEM POSSIBLE CAUSE REMEDY Spark ignitor will not light the pilot after repeated pressing of spark ignitor Pilot will not stay lit Burner will not light when valve and burner switch are both on Glass fogs up Blue flames Sooting 38 1 Battery needs replacing 2 Defective ignitor Misaligned spark electrode Defective thermocouple Loose thermocouple Air in gas line No gas Defective switch Defective thermopile Thermostat set too low defective Normal condition Normal during start up Flame impingement Replace battery 2 Check connections to ignitor Replace ignitor if ignitor connections are good but there is no spark Check for spark arcing from the elec trode to pilot Adjust and retighten Check for proper connection of thermo couple to rear of valve Bleed line Contact dealer Check shutoff valve and gas supply LPG tank Check switch connections Jump wires at switch Check connections to valve Contact dealer Turn up thermostat to start unit Check thermostat connections Allow appliance to warm up Glass
21. e stored e These units can be installed in a bedroom See National Fuel Gas Code ANSI Z233 1 NFPA 54 current edition the Uniform Mechanical Code current edition and Local Building Codes for specific installation requirements IMPORTANT Your direct vent insert was designed to be installed in an existing wood burning fireplace The location and clearances are subject to local building codes INSERT APPLICATIONS Before installing the gas fireplace insert consider the functioning needs of the fireplace Confirm the size of the fireplace cavity the design of the chimney and the availablility of the gas supply and electricity for the insert fan IMPORTANT Your direct vent insert is designed to be only vented vertically with a minimum height of 10 feet When the unit is installed into a woodburning fireplace the minimum distance the mantel can be placed above the fireplace is governed by local building codes applicable to woodburning fireplaces Consult local authorities having jurisdiction for these clearances The underside of the mantel will become warm Use only finishes which are heat resistant and do not discolor CLEARANCES MINIMUM FIREPLACE SIZE CLEARANCES TO COMBUSTIBLES The dimensions shown in Figures 4 and 5 pages 10 and 11 are minimum clearances to maintain when installing this heater Follow these instructions carefully to ensure safe installation Failure to follow instructions exactly can create a fire hazard Mai
22. eliminate dust e This heater may be placed in a bedroom Please be aware of the large amount of heat this appliance produces when determining a location For tight fits you may remove the manifold oee Removing the Mainfold page 15 Minimum 35 889mm Minimum 231 2 597mm The insert protrudes 17 432mm into the fireplace The gas line should be installed prior to insert placement Use the leveling bolts for fireplaces with recessed floors Run the on off switch wires to the right behind the surround panels Run the power cord either side of the insert along the face Figure 4 Insert Placement 10 48D0139 INSTALLATION ZERO CLEARANCE METAL FIREPLACE REQUIREMENTS e The damper and grate must be removed e The smoke shelf internal baffles screen refractory and metal or glass doors may be removed if applicable Do not cut any sheet metal parts of the fireplace in which this gas fireplace insert is installed THIS IS STRICTLY PROHIBITED O Z Z lt e Do not remove or alter the insulation or any structured rigid frame members metal sides floor door frame face of the fireplace etc Insulation X AN AN fg s 2 S Shelf e Q D onc Ore OED SANA S o Masonry Lining or Refractory AN ofo S o A Grate 4 w o Masonry Lining or Refractory Figure 5 Metal Fireplace Zero Clearance Requirements IMPORTANT Please review the following carefully
23. g Optional Trim 24 ISO HEIC WA ensuite RUE eut EXER OR oa IEEE UmSIS 24 Installing On Off Switch 24 Filigree Installation 25 Door Installation 26 Operating Instructions 27 What To Do If You Smell Gas 27 Lighting Pilot for the First Time 2f AB re audio ro NOU NDERIT E RETE ROM 28 LIONUNG BUGT oues ecce ipee age erae tee veSa PERS ANE 29 To Turn Off Gas eeeemmHRH m 29 Adjusting Blower Speed 29 Cleaning Maintenance 30 Venting System suis turiitate arai 30 Cleaning E El RETE 30 Pilot and Burner Flames 30 Firebox Cleaning oauncteritint baa eUb Ca ED 30 Air Shutter Adjustment Natural Gas Only 31 Glass Replacement 32 MeiiriterndliC8 oieomieete xime reis pasecerons iN Ue Ia e ERES 33 Maintaining Your Heater s Appearance 33 Yearly Service Procedure 33 BIOWECN oc ccccccecscccccccscceccncececceneececceuesceanenneneanennees 35 Replacement Parts 36 Troubleshooting 38 Warranty saccos avena exea UE S EUnS uS Back Cover 48D0139 INSTALLER Please leave these inst
24. gas e Test gauge connection e Sediment trap optional but recomended Tee joint Pipe wrench e approved flexible gas line with gas connector if allowed by local codes not provided A CSA design certified equipment shutoff valve with s NPT tap is an acceptable alternative to test gauge connection Purchase the CSA design certified equipment shutoff valve from your dealer For propane LP connections only the installer must supply an external regulator The external regulator will reduce incoming gas pressure You must reduce incoming gas pressure to between 11 and 13 inches of water If you do not reduce incoming gas pressure burner system regulator damage could occur Install external regulator with the vent pointing down as shown in Figure 27 Pointing the vent down protects it from freezing rain or sleet SS CEP SS External Pe dem Use only new black iron or steel pipe Regulator Propane LP Internally tinned copper or copper Supply Tank i tubing can be used per National 7 4 Fuel Code section 2 6 3 providing K gas meets hydrogen sulfide limits e and where permitted by local codes xS Gas piping system must be sized to O provide minimum inlet pressure listed m late at the maximum flow rat Pointing on data plate at the maximum flow rate Down BTU hr Undue pressure loss will occur if the pipe is too small CU ENENENESS NS NS NS When using copper or flex connectors use only fittings o 2 approved for
25. h and up to fifteen 15 feet of 18 Ga wire may be used with this appliance Attach the wall switch in a junction box at the desired location on the wall See Figure 17 NOTE Extended lengths of wire may cause the fireplace not to function properly Longer length of wire is permitted if the wire is made out of larger gauge diameter wire Always check with local code E BATTERY OPTIONAL REMOTE l POWERED WALLSWITCH IGNITOR C ee l amp og i Ex xd ae eL l i OFF OPTIONAL REMOTE i WALL SWITCH o ON Do i Figure 17 Wiring Diagram for Wall Switch 48D0139 19 LOG PLACEMENT Before you begin This unit is supplied with seven 7 ceramic fiber logs Do not handle these logs with your bare hands Always wear gloves to prevent skin irritation from ceramic fibers After handling the logs wash your hands gently with soap and water to remove any traces of fibers The positioning of the logs is critical to the safe and clean operation of this heater Sooting and other problems may resultif the logs are not properly and firmly positioned in the appliance Never add additional logs or embellishments such as pine cones or vermiculite to the heater Only use the logs supplied with the unit Failure to position the parts in accordance with diagrams below or to use only parts specifically approved for this heater may result in property damage or personal injury WARNING
26. is in the ON position to light the main burner See Figure 34 LIGHTING THE BURNER Depress and turn the knob counterclockwise K to the ON position See Figure 55 It will take less than four 4 seconds for the burner to ignite PILOT POSITION Depress and turn knob to pilot position to keep burner off while maintaining the pilot light See Figure 56 EE is a PILOT Figure 34 Figure 35 On Position Figure 36 Pilot Position On Off Remote Switch TO TURN OFF GAS BRENNEN Depress and turn knob clockwise A to OFF TN X KS position See Figure 37 Figure 37 Off Position FA ADJUSTING BLOWER SPEED N The internal blower helps transfer heat from heater into room It will not turn on until heater is up to temperature approxi Qp mately 10 minutes after starting R To turn blower off turn knob all the way counter clockwise K 0 One click clockwise turns blower to high speed Turning knob clockwise A from high position decreases speed of blower See Figure 36 Figure 38 Blower Knob 48D0139 29 CLEANING ano MAINTENANCE Make sure the gas valve knob is in the OFF position Wait at least five 5 minutes before start ing maintenance VENTING SYSTEM A qualified agency should examine the venting system annually CLEANING GLASS Clean the ceramic glass periodically Condensation will some times form on the glass during a cold startup This 1s normal for all gas fireplaces and inserts This c
27. l firebox Masonry Fireplace e co c sg x g ES 1 0 52h a 2 e op Z Figure 8 Inlet and Exhaust Reline Figure 9 Exhaust Only Reline NOTE You may use either reline configuration with a masonry or zero clearance fireplace 14 48D0139 VENT INSTALLATION MANIFOLD REMOVAL AND INSTALLATION The manifold is shipped attached to insert It may be removed to allow tight installation Mani fold may be loosened and rotated for desired pipe location Flex Vent Chimney Extra 3 Remove brick liner and baffle 914mm 2 Remove manifold Place manifold in fireplace 3 Route flex vent through chimney from above See Figure 10 Leave an extra 3 914mm at the top Flex Vent 4 Attach flex vent to manifold See Figure 11 Seal with silicone and attach with screws Manifold Vent L Termination i Bracket Nut Manifold Excess Flex Vent Chimney 5 Place manifold in an upright Figure 10 Placing Manifold Into Fireplace Figure 11 Attaching Flex Vent to Manifold 6 Slide insert into place Guide position Have someone pull on g the manifold over the insert the excess flex vent Figure 12 until it is fully in place Temporarily attach flex vent to Figure 13 top of chimney Leave some extra 7 Remove any slack from flex slack in flex vent vent Attach manifold to insert Figure 13 e SAEN ANSA EA A UT Uo Vo Vo f I o ho q 25 PRA oN
28. lt in a fire or explosion D Do not use this appliance if any part of it has been under water Immediately call a qualified service tech nician to inspect the appliance and to replace any part of the control system and any gas control that has been under water LIGHTING PILOT FOR THE FIRST TIME BEEN INITIAL LIGHTING Purge air from the supply line as follows e Open main shutoff valve e Unscrew main pressure test point Leave inlet test screw open until gas comes in e When gas is flowing tighten inlet screw immediately LEAK TESTING 1 Follow the pipe from the gas supply line connection to the gas valve Check connection for leaks with soap and water mixture Never use an open flame to check for gas leak 2 Next check for gas leaks at the burner thread inlet with soap and water mixture 3 Check the pilot for gas leaks with soap and water mixture Continued on next page 48D0139 2f OPERATING INSTRUCTIONS LIGHTING PILOT FOR THE FIRST TIME LEAK TESTING continued You may check for gas leaks with the following methods only If using a soap and water solution to test for leaks Soap and water solution DO NOT spray solution onto An approved leak testing spray control body e Electronic sniffer Check for gas leaks in each of the following locations Pipe from the gas supply line connection to the gas valve Burner thread inlet e Field made joints e Pilot e Factory made joints Each joint or
29. nd safety glasses for protection e Use extreme caution when using ladders or when on rooftops Be aware of electrical wiring locations in walls and ceilings The following actions will void the warranty on your venting system e Installation of any damaged venting component Unauthorized modification of the venting system nstallation of any component part not manufactured or approved by Lexington Forge nstallation other than permitted by these instructions This insert must be vented to the outside The venting system must NEVER be attached to a chimney serving a separate solid fuel burning appliance Each gas appliance must use a separate vent system Do not use common vent systems O z z lt 12 48D0139 VENT INSTALLATION VENT REQUIREMENTS e Make sure the exhaust pipe on heater connects to exhaust portion of cap Attach flex liners See Figure 7 Do not crimp or rupture liner when bending it into chimney offsets WARNING e The exhaust vent must reline the entire length of chimney and terminate above chimney top e Vent must meet all vent manufacturer s requirements when installed e Make sure you have the following before installing unit Maximum Height 4 and 3 UL 1777 Listed gas liner for air inlet and exhaust us 1 oad M h e Vertical termination kit AI42TK43 E v t ALTITUDE CONSIDERATIONS This heater has been tested at altitudes ranging from sea level to 4 500 feet USA 0 200
30. ntain the following minimum clearances for service and maintenance See pages 9 and 10 8 48D0139 INSTALLATION INSERT CLEARANCES No combustibles ie drapes doors may be within or swing within 36 of the front of the inset 13 330mm Maximum Depth ES S DE FAC NG Minimum A 11 279 Lm Pd 3 4 Maximum N Depth i Minimum Combustible 8 203mm Facing l 22 559mm Minimum 4412 305mm 2 813mm Minimum 42 8 203mm MANTEL CLEARANCES pu NOTE The combustible area above the facing must not protrude more than from the facing If it does it is considered a mantel and must meet the mantel requirements shown above HEARTH REQUIREMENTS The insert must be installed on a non combustible hearth extending a minimum of 12 from the fireplace opening local codes may require a larger hearth The hearth must also extend to both sides of the face see the table above for the exact width of the face Figure 3 Mantel Clearances 48D0139 9 INSTALLATION INSERT PLACEMENT e Insert must be placed within a code conforming masonry fireplace or a tested and listed zero clearance metal fireplace Repair any fireplace damage prior to installation e Because the insert uses a circulation blower clean the fireplace smoke shelf and chimney before installing Paint interior surface of the fireplace with latex paint to further
31. ondensation often attracts dust and lint to the surface of the glass The initial paint curing of the appliance can also leave a slight film on the glass This is a temporary problem Let glass cool before cleaning Do not clean glass when it is hot Damage could occur Z O lt O Your should clean the glass after the first two weeks of use After that you should clean the glass no more than two or three times a season Use a mild glass cleaner to clean the door Do not use abrasive cleaners They will damage the glass surface PILOT AND BURNER FLAMES Visually check pilot and burner flames periodically See Figure 39 for typical burner flame See Figure 40 for typical pilot flame Thermocouple Thermopile Figure 39 Typical Burner Flame Figure 40 Typical Pilot Flame FIREBOX CLEANING 1 Carefully remove log set and embers from combustion aia z Make sure that clearances to 2 Vacuum burner compartment thoroughly g combustibles leave enough room for 3 Vacuum any dust off logs a maintenance and service 4 Remove any lint from main burner and pilot 5 Carefully replace log set and embers in their correct Qo positions See pages 20 through 23 r Carefully reassemble and reseal 6 Replace door if it has been removed insert properly after any cleaning 7 Relight pilot See page 26 or servicing 8 Turn on main burners 30 48D0139 AIR SHUTTER ADJUSTMENT NATURAL GAS ONLY A
32. or 15 minutes Remove faceplate see instructions included with face plate and glass See page 32 3 Carefully remove log set If logs are severely deteriorated replace logs Check logs for sooting A small amount of soot along bottom of logs is normal If excessive sooting is found heater must be adjusted Contact dealer where you bought heater Figure 45 Before taking unit apart check pilot flame Flame should touch thermocouple and thermopile 4 Clean burner and burner ports Inspect the following See Figure 46 e Check burner ports for cracks warpage and corrosion e Make sure burner assembly is not warped or damaged e Check firebox and area around pilot to make sure there is no warping or damage If any problem is found do not use heater Contact your dealer for service Check walls and ceiling of firebox for deterioration Check burner ports Make sure burners are not warped or damaged Figure 46 Checking Burner Ports Burners Walls and Ceiling of Unit Continued on Page 34 48D0139 33 MAINTENANCE 5 34 Replace log set and rock wool per instructions on pages 20 23 Replace glass Make sure gasket along perimeter of glass contacts face of firebox and forms an airtight seal Realign if airtight seal is not formed Replace glass and glass frame if damaged Inspect area behind access door Clean if necessary Check gas control valve and all gas lines If damaged do not use heater Contact y
33. our dealer Start pilot and turn on main burner Flames should be orange yellow and not touch top of firebox If pilot or main burners do not burn correctly contact your dealer for service Monitor blower operation 48D0139 BLOWER BLO24 ACCESSORY PARTS LIST DESCRIPTION PART NUMBER Right Blower 1 33D0700 Left Blower 1 45D0240 PARTS NOT SHOWN Thermostat Bracket 45D0258K Thermostat 23D6100 Speed Control 26D0746 NOTE Unplug power cord before servicing The Wire Harness 41D0203 blowers are attached to insert bottom and back with Velcro To remove blower for servicing pull away from Velcro and disconnect wires Right Blower Left Blower Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation OFF after servicing Variable Fan 1 Control r White CAUTION Blower Motor 110 115 V A C Blower Plug Black C E White Blower E T Green Motor 48D0139 35 REPLACEMENT PARTS 48D0139 36 REPLACEMENT PARTS REPLACEMENT PARTS ARE AVAILABLE THROUGH YOUR RETAILER Al42 Description QTY Natural Burner Assembly 48D0073 Left Log Support Bracket 48D0025K Right Log Support Bracket 48D0027K WARNING Failure to position the parts in accordance with these diagrams Propane 48D0073 48D0025K 48D0027K SIT 820 Nova Valve Front Injector Rear Injector Tube Valve Burner Pilot Assembly Rocker Swit
34. re To check gas pressures at valve turn captured screw counter clockwise 2 or 3 turns and then place tubing to pressure gauge over test point Turn unit to high See Figure 16 After taking pressure reading be sure and turn captured screw clockwise firmly to reseal Do not over torque Check test points for gas leaks with a soap and water solution Pressure Test IN b Pressure pP d Test Sue HI LO Knob Pilot Adjustment f Screw Figure 16 Gas Pressure Check at Gas Valve Do not use open flame to check for gas leaks 48D0139 ELECTRICAL INSTALLATION ELECTRICAL WIRING This insert will work without any electrical supply Electricity is only needed if you install a remote wall mounted switch Electrical connections should only be performed by a qualified licensed electrician Main power must be off when connecting to main electrical power supply or performing service All wiring shall be in compliance with all local city and state codes 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 and Canadian Electrical Code CSA C22 1 WARNING Label all wires before disconnecting when servicing controls Wiring errors can cause improper and dangerous operation CAUTION Verify proper operation after servicing REMOTE WALL MOUNTED SWITCH A remote wall switc
35. rs from the date of purchase EXCLUSIONS Items that are not covered under this warranty include but are not limited to damage or chipping to any component surfaces gasketing refractory material or trim It does not cover installation or operational problems related to venting systems inadequate draft inadequate gas pressure adjustments to the appliance the cost of inspection components which have been altered or modified labor costs removal and re installation costs shipping to or from the factory or authorized service center shipping damage damage from improper use or neglect installation damage damage from unauthorized service incidental or consequential damage or negative pressure caused by mechanical systems such as furnaces fans clothes dryers etc TERMS This warranty shall be void if the appliance is not installed by qualified installer in accordance with the installation instructions provided with the appliance and state and local codes The warranty shall also be void if the appliance is not operated and maintained in accordance with the operating instructions supplied with the appliance All service work must be performed by an authorized service representative Any part or parts which we deem defective will be repaired or replaced at Lexington Forge s option through an authorized dealer or service provider This warranty is expressly in lieu of other warranties express or implied including the warranty of merchantabilit
36. rt do not place propane LP supply tank s inside any structure Locate propane LP supply tank s outdoors To prevent performance problems do not use propane LP fuel tank of less than 100 Ibs capacity 3 Ifyou smell gas shut off gas supply do not try to light any appliance do not touch any electrical switch do not use any phone in your building e immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions 48D01 39 IMPORTANT SAFETY INFORMATION OWNER Please retain these instructions for future reference 4 10 11 Read this owner s manual carefully and completely before trying to assemble operate e Any change to this insert or its controls can be dangerous Improper installation or use of this insert can cause serious injury or death from fire burns explosions electrical shock and carbon monoxide poisoning Never install the insert e inarecreational vehicle where curtains furniture clothing or other flammable objects are less than 36 from the front top or sides of the insert e in high traffic areas e in windy or drafty areas This insert reaches high temperatures Keep children and adults away from hot surfaces to avoid burns or clothing ignition Insert will remain hot for a time after shutdown Allow surfaces to cool before touching Carefully supervise young children when they are in the room with insert Do not modify this insert un
37. ructions with the owner or service this insert O Z Z lt This insert is a vented product This insert must be properly installed by a qualified service person The glass door must be properly seated and sealed If this unit 1s not properly installed by a qualified service person with glass door properly seated and sealed combustion leakage can occur CARBON MONOXIDE POISONING Early signs of carbon monoxide poisoning are similar to the flu with head aches dizziness and or nausea If you have these signs the insert may not have been installed properly Get fresh air at once Have the insert inspected and serviced by a qualified service person Some people are more affected by carbon monoxide than others These include pregnant women people with heart or lung disease or anemia those under the influence of alcohol and those at high altitudes Propane LP gas and natural gas are both odorless An odor making agent is added to each of these gases The odor helps you detect a gas leak However the odor added to these gases can fade Gas may be present even though no odor exists Make certain you read and understand all warnings Keep this manual for reference It is your guide to the safe and proper operation of this insert 1 This appliance is only for use with the type of gas indi cated on the rating plate This appliance is not convertible for use with other gases unless a certified kit is used 2 For propane LP inse
38. sure there are no gaps at the 45 angle INSTALLING TRIM 1 Slide trim over surround See Figure 28 2 Attach a piece of double stick tape to bottom side of surround to keep bottom from flaring out See Figure 28 Y Q INSTALLING ON OFF SWITCH 1 After installing surround and trim disconnect the Magnets on off switch from wires leading from heater l Magnetic L Bracket 2 Insert switch into hole in upper right side of the trim dii due Figure 28 Installing D 3 Reattach wires See Figure 50 Surround and Trim Double Stick Tape E 7 Right Trim Top Trim e Sigo s L Brackets oide Trim Pieces On Off Switch Install in trim or install in surround if trim is not used Tape wires to back of surround with foil tape Ligure igni Y EAO AOON Nia c igure atin ON 29 Aligning Trim on Floor Figure 30 Installing On Off Switch 24 48D0139 FILIGREE INSTALLATION INSTALLING FILIGREE FACING 1 Line up four 4 screw holes on filigree facing with four 4 screw holes on surround See Figure 31 Remove all fingerprints from facing with a 50 50 vinegar and water solution before lighting the heater Any fingerprints left on the facing will be permanent when heater is lit 2 Attach filigree facing with four 4 screws provided See Figure 31 Screws Filigree Facing Figure 31 Installing Filigree Facing 48D0139 25 DOOR INSTALLATION INSTALLING DOORS Remove
39. will clear Additives in the gas may dirty glass Clean glass when cool Flames will yellow as appliance heats up Check log position Open shutters to increase primary air 48D0139 INSTALLATION RECORDS THE FOLLOWING INFORMATION MUST BE RECORDED BY THE INSTALLER FOR WARRANTY PURPOSES AND FUTURE REFERENCE LEXINGTON FORGE Model Name of Owner Name of Installer Address Address Name of Dealer Address Manufactured by LEXINGTON FORGE 149 Cleveland Drive Paris Kentucky 40361 U S A 48D0139 39 WARRANTY COVERAGE Lexington Forge warrants its products to be free of defects in material and workmanship and backs each product with a Limited Lifetime Warranty This warranty is to the original purchaser of a Lexington Forge product and is not transferable LIFETIME WARRANTY Covered under this warranty are the insert body combustion chamber door frame gold plating manufacturing defects only glass thermal breakage only heat exchange system and burner This coverage includes parts and reasonable labor during the first five years of ownership and parts only thereafter FIVE YEAR WARRANTY Ceramic fiber logs firebrick panels and secondary air tubes are covered for a period of five years from the date of pur chase TWO YEAR WARRANTY Gas valves pilot assemblies thermopiles thermocouples regulators electrical components cast iron grates and blowers are covered for a period of two yea
40. y of fitness for purpose and of all other obligations or liabilities Lexington Forge does not assume for it any other obligations or liability in connection with the sale or use of the appliance In states that do not allow limitations on how long an implied warranty lasts or do not allow exclusion of indirect damages those limitations of exclusions may not apply to you You may also have additional rights not covered in this Limited Warranty Lexington Forge reserves the right to investigate any and all claims against the Limited Warranty and decide upon the method of settlement Lexington Forge 149 Cleveland Drive Paris KY 40361 December 2003 P N 48D0139 Rev 5
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