Lennox International Inc. BV4000C User's Manual
Contents
1. FART TOVE INSTALLATION AND OPERATION MANUAL BY LENNOX HEARTH PRODUCTS EPA CERTIFIED CATALYTIC WOOD BURNING FIREPLACE INSERT RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE MODEL BV4000C THIS APPLIANCE MUST BE INSTALLED BY A QUALIFIED TECHNICIAN READ MANUAL THOROUGHLY BEFORE INSTALLATION Beaverton Tested amp Listed By Cc OMNI Test Laboratories Inc P N 775006M Rev J 04 01 IMPORTANT WARNINGS CAUTION Read this manual thoroughly before starting installation For your safety follow the installation op eration and maintenance instructions exactly without deviation Failure to follow these instructions may result in a possible fire hazard and will void the warranty If this appliance is not properly installed a house fire may result Contact local building or fire officials about restrictions and installation inspection in your area If utilizing an older chimney it must be inspected for adequate serviceability Refer to the heading Chimney Inspection on page 6 Install only in masonry fireplaces built to UBC chapter 37 standards or listed factory built fire places The minimum clearances must be maintained for all combustible surfaces and materials including furniture carpet drapes clothing wood papers etc Do not store firewood within this clearance space This appliance requires a non combustible heat resistant approved fireplace hearth or hearth ex tension2. 3 The house is too air tight ventilation is needed 4 nsufficient vertical height to chimney to achieve adequate draft ODORS 1 Creosote accumulation in firebox brush out on next cleaning 2 Chimney downdraft when stove is not operating close primary air control 3 Catalytic combustor not functioning 4 Paint curing on first several burns DIRTY GLASS Poor draft conditions Long burn periods at low draft settings Burning wet pitchy or spongy wood Poorly arranged logs too close to glass A Draft problems If installing into a larger flue it may be necessary to use a full length liner to achieve adequate draft for the appliance A draft gauge should read a minimum of 05 W c inches water column not to exceed 07 w c for optimum performance see draft re quirements page 6 PAGE 20 TROUBLESHOOTING CATALYST PLUGGING 1 Burning materials that produce a lot of char and fly ash Do not burn materials such as garbage gift wrap card board etc 2 Burning wet pitchy woods or burning large loads of small diameter wood with the combustor in the operation posi tion without light off taking place Burn proper fuel only Do not close bypass until temperatures are high enough to initiate light off CATALYST DEACTIVATION 1 Burning large quantities of trash pressure treated lum ber or painted woods etc will deactivate the catalyst Burn proper fuels only See Catalyst Replacement
3. 0 78 x Ti fM inches 2 0 78 x 1 2 33 Answer using r 0 34 x 1 034 3 8 3 8 thickness Micore will be required At times it is important to know what combination of materials are acceptable for use as floor protection The R values are used to determine acceptable combina tions of materials because R values are additive where r and k values are not R value 1 rxthickness of material used k ALTERNATIVE FLOOR PROTECTION MATERIALS Listed Material Alternative Materials n Wonderboard 1 1 2 3 7 8 3 7 8 9 3 4 Marble 11 0 009 85e 3 8 Uso U S Gypsum Johns Manville PAGE 5 Example Given that the required R value for a suitable floor protector used must be equal to or greater than R r x 0 78 x 1 0 78 PLANNING YOUR INSTALLATION CHIMNEY INSPECTION The existing fireplace should be inspected by a local fire marshal or qualified installer for adequate serviceability prior to installing this appliance Factory built fireplace If any portion of the chimney system shows signs of structural or mechanical weak nesses such as cracks leaky joints corroded or warped surfaces Look for obvious bulges in the lining which may indicate the need to replace that section use a bright flashlight Any faulty portion must be re paired or replaced prior to installing this appliance Also inspect the attic to see that the ch
4. ASH DRAWER The large ash drawer located below the fuel door is designed to make cleaning easier by containing the ashes in a remov able drawer CAUTION Do not operate the stove with the ash dump cover off as this will produce extreme temperatures within the stove overfiring and could cause damage to the appliance or other property such damage is not covered by the manufacturers warranty Replace the ash dump gasket if it becomes frayed or damaged BLOWER SYSTEM The 250 CFM room air circulation blower system comes equipped with a variable speed control rheostat The blower system can be operated manually or set to operated automatically so the blowers will turn on when the insert is hot and turn off when the insert is cool See Care and Op eration Section Blower System on page 15 AS POWER CORD RHEOSTAT SPEED CONTROL ON OFF SWITCH AUTO OR MANUAL MODE PRIMARY AIR CONTROL The primary combustion air delivery is controlled by the pri mary air control draft module The control handle is located above the fuel door The heat output can be controlled by sliding the handle to a higher or lower heat output setting see following illustrations The fuel the amount of heat and burn times desired the type of installation are all variables that will affect the control setting The same control settings in a variety of installations will produce different results You will need to try different settings
5. Contact your local municipal or provincial fire authority for information on how to handle a chimney fire Have a clearly understood plan for handling a chimney fire CATALYST REPLACEMENT The normal expected life of a catalytic combustor is 10 000 to 12 000 hours if appliance is operated correctly and proper fuels are used If the catalyst has been deac tivated it should be replaced Symptoms of deactivation include noticeably darker smoke exiting chimney and less heat output If these symptoms remain after normal maintenance or a major cleaning soak in heated vine gar water solution see page 19 the catalyst probably needs replacement Also if the catalyst is broken and or missing large pieces it should be replaced Note The catalyst does not need to be glowing to be working It will glow at times but it can work very effec tively at temperatures well below the 1000 F level at which it will begin to glow CLEANING BLOWERS The blowers require inspection and cleaning annually to remove lint dust etc If there are pets in the dwelling the blowers should be cleaned at least twice a year To ac cess remove blower cover remove the two 24 hex head screws then inspect propellers replace if cracked bro ken or melted and vacuum out lint dust and debris PAGE 18 MAINTENANCE CATALYTIC COMBUSTOR This appliance has been designed with a catalytic com bustor which will improve its overall performance Re mov
6. It may take a week or two to learn but your patience will be rewarded by the warmth and pleasant satisfaction that only a wood fire can provide PAGE 13 CARE AND OPERATION BREAK IN PERIOD Your fireplace insert finish is a high temperature paint that requires time and temperature to completely cure We rec ommend that you ventilate the house during the initial burns The paint emits non toxic odors during this process KEEP YOUR HOUSE WELL VENTILATED DURING THE CURING PROCESS TO PREVENT ACTIVATION OF YOUR HOME SMOKE DETECTOR The paint manufacturer recommends three burn cycles to cure the paint The first two burns should be low heat ap proximately 250 F for 20 minutes each using paper and light kindling After each 20 minute burn allow the appliance to cool completely The third burn should be at least medium high or about 450 F for 45 60 minutes The paint will become soft and emit non toxic haze during these burns Keep the area well ventilated As the paint cures it will become slightly lighter in color Eventually the entire surface will become an even color Once the paint has been softened and cooled two or three times it will harden Do not turn on a blower during the curing process Do not place anything on the fire place insert surface until the paint is completely cured Do not attempt to repaint the fireplace insert until the paint is completely cured If the surface later becomes stained or marred it ma
7. page 19 CATALYST SUBSTRATE CRACKING 1 Normal operation as long as combustor remains intact If cracking causes large pieces to fall out re place combustor 2 Mishandling or abuse Handle with care 3 Warped housing see Overfiring this page CATALYST SUBSTRATE 1 Extreme thermal shock Combustor is being worked too hard 2 Excessive draft Correct installation See Draft He quirements page 6 CATALYST PEELING Extreme Temperatures over firing at combustor surface can cause the catalyst to peel Some minor peeling does not affect function Severe peeling would close cell openings and cause a plugging problem If peeling is severe replace com bustor Do not overfire appliance See Overfiring this page TAR AND LIQUID CREOSOTE LEAKING FROM METAL FLUE JOINTS 1 No chimney cap on chimney Install cap 2 Metal flue assembled improperly Top flue sections should be inserted into lower flue sections DENCE SMOKE LEAVING CHIMNEY 1 Water vapor on cold still days water vapor may be mis taken for smoke Water vapor is normal and should be of little concern 2 Wet pitchy woods being burned Burn dry seasoned wood only 3 Bypassin open position Close bypass 4 Combustor not functioning See Catalyst Replacement page 19 OVERFIRING If any part of the appliance glows it is overfiring Other symptoms may include Cracking warping or burning out of components catalytic combustor may deteriorate gold d
8. 12 Depth 16 FRONT VIEW OF FIREPLACE e 22 uz M CATALYTIC TEMPERATURE PROBE Install temperature probe prior to installing insert To install the Catalytic Temperature Probe locate the plug on the top right hand side of the bypass control rod Remove the plug install the sleeve and place probe in sleeve It may be necessary to bend the flange on the plug so it won t interfere with the probe temperature indicator INSPECTION PLUG INSERT SLEEVE SMALL A SILVER PART AND PROBE INTO THIS HOLE 4 iat d The Catalytic Temperature Probe is provided so you can monitor the temperature of your Catalytic Com bustor Once you have established a fire and the Catalytic Temperature Probe indicates the tempera ture of your Catalytic Combustor is between 500 600 F approximately 20 25 minutes close the By pass Damper Control Depending on the type and size of the fuel load as well as the length of time the stove has been burning your Catalytic Combustor should operate between 1000 18007 F INSTALLATION INSTALLATION STEPS 1 Remove all ashes from the fireplace 2 Remove all materials inside the insert and set them aside 3 Remove the three piece surround assembly face shield and attach insulation material provided using a nonflam mable adhesive i e RTV Silicone rated 570 F 4 Use a large piece of cardboard or other protective material and place it in fr
9. ma chine screws Seal around connection with furnace ce ment PAGE 10 INSTALLATION POSITIVE FLUE CONNECTION FOR MASONRY FIRE PLACE A Professional should inspect chimney prior to installation to determine if any repairs are necessary or if a chimney reline is necessary The fireplace damper must be secured in the open position If this is not possible it will be necessary to remove the damper Installation into a masonry fireplace requires as a minimum of a flue extension past the header This can be accomplished by one of the following methods Install 6 smoke pipe if the chimney is located directly above the insert flue L I Use an offset adapter see page 25 to handle offsets This part is available through your dealer A preferable installation is the positive flue connection a positive seal between the flue extension and the chimney This can be achieved by using a filler plate A filler plate can be made by making a cardboard pattern to fit the fireplace throat Lay the pattern on 22 gage steel add 2 inches to each side and cut Snip corners and bend front lip up and sides and back down Cut an opening for the flue Attach filler plate with masonry screws The starter pipe extends through the filler plate past the damper and into the chimney system Small air leaks should be sealed with high temp fiberglass or ceramic insulation PAGE 11 PROCUCT FEATURES AND CONTROLS
10. much combustion air to be pulled into the firebox which results in hotter burns Too little draft below 05 W C l will not allow enough combustion air delivery to maintain a fire well or cause performance problems such as smoking this may result in improper operation of appliance i e will not maintain fire well unless catalytic bypass is left open or with fuel door left open see Operation Overfiring Caused From Improper Operation Never burn the appliance with the fuel door open or ajar the ash dump cover off or the ash drawer open Never burn the stove with the bypass handle in the open position once the fire has been established or the air control in the high position for extended periods Overfiring Caused From Improper Maintenance Strictly adhere to all maintenance requirements at frequent intervals as prescribed in this manual in cluding cleaning of flue and fireplace insert Should the fuel door ash dump or glass gaskets become worn or damaged they should be replaced Overfiring Caused From Improper Fuel This appliance is approved for use with natural dry well seasoned wood only consult your dealer for approved fuels in your area Do not burn garbage particleboard scraps or pressed logs using bonding agents because they can produce conditions that will deteriorate metal Green or uncured wood does not work well as fuel and can cause increased creosote buildups Do not overload or use kindling wood or mill ends as
11. of generating the heat the fireplace insert was designed to provide Green wood does not burn easily Attempting to burn green wood often results in a lot of smoke and very little fire Time is the most important factor in seasoning wood Ideally the moisture content should be reduced to 11 2096 although very few of us will be able to check that figure There are several steps that should be taken to ensure that that you come close to these figures SEASONING GUIDE Softwoods 6 months to 18 months Hardwoods 12 months to 24 months Logs that are 5 diameter across or larger should be split in half three pieces if over 8 inches and four pieces when over a foot across f the tree was fell 2 to 4 years ago it still needs to be cut split and seasoned for 6 to 24 months de pending on the wood WOOD STORAGE Wood to be seasoned should be stacked in an area open enough to ensure good air circulation on both sides leaving adequate space between woodpiles to walk comfortable Do not stack wood against a wall or building It helps to elevate the woodpiles off the ground two 2 x 4 s running lengthwise beneath the woodpile works well This allows air to flow un der the bottom logs Wood that is kept outdoors either covered with a tarp or not covered at all will not burn well until it has been in an en close space for one to two months SMALL AREA PAINT TOUCH UP The stove body is painted with a quality high temperature st
12. or NEC ANSI NFPA 70 latest edition Do not route the power cord under or in front of the appliance WIRING DIAGRAM WHITE R LOC NES x wa HET POWER FLOW DIAGRAM LOWER V RHEOSTAT ON OFF SWITCH 110 VAC 60Hz FAN DISC 39v 18 N33H9 Z LIHAA PAGE 15 POWER CORD CARE AND OPERATION BYPASS DAMPER CONTROL The operating handle of your bypass damper control is lo cated on the front of the stove flue collar By moving the by pass damper control the operator can route the fire either through the catalytic combustor pushed in or directly up the flue pulled out When starting a fire or refueling the bypass damper control should be pulled out Once the fire is estab lished it should be pushed in SECONDARY AIR TUBE BYPASS DAMPER CONTROL dE 4a AUF UE A Oa a a as i aaa a aaa a a aa a2 2a rrr ONING STOPS NING CATALYTIC COMBUSTOR ASSEMBLY CATALYTIC COMBUSTOR RETAINING CLIP CATALYTIC TEMPERATURE PROBE The catalytic temperature probe monitors the tempera ture of your catalytic combustor Once you have estab lished a fire and the catalytic temperature probe indi cates the temperature of your catalytic combustor When it reaches a temperature between 500 to 600 de grees approximately 20 25 minutes close the bypass damper control Depending on the type and size of the fuel load as well as the length o
13. should be 3 8 in diameter and about three inches in length Side View P di Leveling Bolt 12 Reaching over the top of the insert install the starter pipe in the stove flue or attach the positive flue connection to the insert See Note SLIDE FAR ENOUGH IN TO ATTACH PIPE INSTALLATION SURROUND ASSEMBLY NOTE Do not face seal over chimney cooling air system on superior brand or any brand fireplace which is designed with the chimney cooling air sys tem 13 Pull the insert slightly forward to its desired position attach the face shield using the surround clips and hardware as shown The fiberglass insulation strips should be secured along the top and sides step 3 Assemble the gold tone trim using the 2 inside cor ner brackets Attach trim to the face shield and stove Push the unit back until face shield insulation is com pressed against the fireplace front forming a tight seal Test for air leaks by holding a candle around edge of face shield to see if smoke is pulled into fire place Note Preferred method of attaching connector to flue outlet is to install two L Brackets 1 angle bracket 3 4 wide on opposite sides of the flue outlet Use self tapping screws to secure in place Cut a Y height and 4 width notch in the front of connector pipe liner or adapter that will attach to flue outlet Install connector into flue outlet and secure to angle brackets using
14. so you can learn how much heat to expect and how long the fire will burn PRIMARY AIR CONTROL DRAFT MODULE Lower Higher DAMPER BYPASS HANDLE AW PRIMARY AIR CONTROL HANDLE CATALVTIC BVPASS DAMPER CONTROL The bvpass damper control handle is located on the front of the insert see above illustration Bv pushing in or pulling out the handle the operator can route the exhaust either through the catalvtic combustor pushed in or directiv up the flue pulled out When starting a fire or refueling the handle should be pulled out Once the fire is established it should be pushed in CATALVTIC COMBUSTOR How it works From 5 to 30 percent of the chemical energv contained in everv log escapes up the chimnev when wood is burned in a conventional stove The catalvtic combustor is designed to make use of this energy converting it into useful heat as it lessens chimney creosote build up and air pollu tion The catalytic combustor consists of a durable tempera ture resistant ceramic composition which is extruded into a cellular or honeycomb configuration After extrusion this ceramic monolith is fired and then covered with a noble metal catalyst When wood smoke contacts this catalyst chemical changes occur that causes the smoke to ignite at temperatures around 600 F Normally smoke will ignite and burn only at temperatures around 1000 F PAGE 12 CARE AND OPERATION FUEL DOOR CAUT
15. 0 Surround Kit Small 28 EE ht X 36 wd SKL 4000 Surround Kit Small 32 ht X 48 wd Ee OA4000 66 OFFSET ADAPTER Installations requiring offsets can be handled using an offset adapter it aligns starter pipe with flue With the use of this kit the power cord and blower sys tem can be transferred to the 1 1 2 to Tp right side of insert as shown in o illustration to the right A L I GOLD DOOR KIT This 24 karat Gold plated door is nearly maintenance free requiring only an occasional wipe down to remove Actual Appearance fingerprints It will never tarnish as brass doors do The gold cures to a very hardened durable finish and will Wal maintain a beautiful gold luster for manv vears C AV a For the location of the nearest Dealer for optional parts contact Lennox Hearth Products 1110 West Taft Avenue Orange CA 92865 PAGE 25 SAFETY LISTING LABEL EPALABEL CONTACT YOUR LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION IN YOUR AREA Listed Fireplace Insert Accessory FOR USE WITH SOLID WOOD FUEL ONLY EARTRESTOVE BY LENNOX HEARTH PRODUCTS PREVENT HOUSE FIRES Install and use only in accordance with manufacturer s installation and operating instructions and your local building codes DO NOT connect this unit to a chimney flue serving another appliance Approved for installation in listed zero cleara
16. 110 West Taft Avenue Orange WA 92865 PAGE 23 COMPONENT DIAGRAMS Model BV4000C CATALYTIC DAMPER COMPONENTS CATALOG PART QTY DIMENSIONS SECONDARY AIR TUBE FB 1 7 9x4 1 Regular BYPASS DAMPER CONTROL a FB 2 4 9x4 1 W Notch FBIO 1 412 x1 1 4 Regular FB11 1 412 x4 3 8 Regular Log Er FB7 2 9x21 8 Regular FB29 1 9x1 Regular FB9 1 19x I W Notch CATALYTIC COMBUSTOR NOTE ALL BRICK ARE 1 1 4 THICK ASSEMBLY CATALYTIC COMBUSTOR SIDES RETAINING CLIP LEFT RIGHT j PRIMARY AIR CONTROL DRAFT MODULE BACK PART CATALOG 11493 L FB10 Gold Door Frame DAMPER ASSEMBLY Push Rod Screws Damper Blade Glass Assembly N kA x Glass Channel Insulation ANS Retainer Damper Blade channel is welded Channel to damper PAGE 24 OPTIONAL ACCESSORIES Model BV4000C Accessories CORD CHANGEOVER KIT Catalog f Description Model Notes The blower system can be easily transferred to the other pera orange over side of the stove along with the power cord by installing this cord changeover kit This kit consists of a reversed right and left panels with cord hole switch and rheostat open 70K99 Touch up spray je kit E la OZ TSPK B ings on the right panel Power cord blower assem bly and controls come stan dard on the left side of insert as shown in illustration to the left SKS 400
17. 16 17 18 19 20 21 operation lack of maintenance or improper fuel usage Damage caused from overfiring is NOT covered under the manufacturers limited warranty NEVER LEAVE AN UNATTENDED FIREPLACE INSERT BURNING ON HIGH Operation of the fireplace insert with the primary air control at its highest burn rate setting for extended periods can cause dangerous overfiring conditions The pri mary air control should only be positioned at the highest setting during start up procedures and for short durations When leaving the fireplace insert unattended ensure that the primary air control is set to the low or medium low range Use a metal container with a tight fitting lid to dis pose of ashes Burning any kind of fuel uses oxygen from the dwelling Be sure that you allow an adequate source of fresh air into the room where the fire place insert is operating see Ventilation on page 6 CAUTION HOT WHILE IN OPERATION An ap pliance hot enough to warm your home can se verely burn anyone touching it Keep children clothing and furniture away Contact may cause skin burns Do not let children touch the appliance Train them to stay a safe distance from the unit Once the fire is established never burn the appli ance with the bypass open except when refueling the appliance CATALYTIC COMBUSTOR Do not operate this appliance without the catalytic combustor assembly this consists of ceramics gasket and a housing properly i
18. 3 Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec DO NOT REMOVE THIS LABEL Made in U S A Manufactured by Lennox Hearth Products Model Bayview 4000 CATALYST EQUIPPED MEETS EPA PARTICULATE MATTER SMOKE CONTROL REQUIREMENTS FOR CATALYTIC WOOD HEATERS BUILT ON OR AFTER JULY 1 1990 SEE CATALYST WARRANTY ILLEGAL TO OPERATE WHEN CATALYST 15 NOT WORKING SEE OWNER S MANUAL FOR OPERATION AND MAINTENANCE SMOKE Grams Per Hour EFFICIENCY 50 60 70 80 90 100 Wood heaters with higher efficiencies cost less to operate NOT TESTED FOR EFFICIENCY THE VALUE INDICATED IS FOR SIMILAR CATALYST EQUIPPED WOOD HEATERS HEAT OUTPUT 6 600 to 40 900 Btu Hr Use this to choose the right size appliance for your needs ASK DEALER FOR HELP This wood heater will achieve low smoke output and high efficiency only if properly operated and maintained See owner s manual PAGE 26 SERVICE AND MAINTENANCE LOG Service Service Service Date Technician Description LENNOX HEARTH PRODUCTS 1110 West Taft Avenue Orange CA 92865
19. ION When opening the door do not extend it beyond its normal travel Overextending the door to a further open position can put excessive stress on hinge area of door and hinge pins and may result in breakage TO OPEN ROTATE HANDLE 90 DEGREES CLOCKWISE DOOR HANDLE DOOR HANDLE ASSEMBLY The door handle assembly opens and securely latches the fuel door closed To open the door rotate the coil handle to the 9 00 position until door releases To close and latch hold the coil handle in the 9 00 position close the door then rotate the handle to the 6 00 position See illustration above GLASS The Glass is a super heat resistant ceramic that with stands continuous temperatures up to 1390 F This tem perature is well beyond the temperatures in which you operate your fireplace insert This unit is designed to provide a flow of air over the in side of the glass where along with high heat helps keep it clean When operating the fireplace insert on low for extended periods of time the glass may get dirty short hot fire 15 20 minutes will help clean off much of the normal buildup see Troubleshooting commercial glass cleaner designed for fireplace inserts is recom mended for cleaning The glass should be cleaned thoroughly with glass cleaner and a soft cloth BEFORE the fireplace insert is burned DOOR GASKET The door gasket must be kept in good condition Do not leave the stove burning with the door ajar or op
20. TU IN HR F or a thermal resistance that equals or exceeds r 78 HR F FT IN BTU With these values determine the minimum thick ness material required using the formula and the table shown here see chart Alternative Floor Protection Materials Note Any noncombustible material having a thickness of 1 whose k value is less than 1 28 or whose r value is more than 78 is acceptable If the alternate material used has a higher k value or lower r value will require a greater thickness of the material used In some cases if the k value is less or the r value higher a thinner mate rial may be used Methods of determining floor protection equivalents To determine the thickness required for any material when either the k or r values are known Thickness of material in inches Ku K value of desired material Ti Minimum listed thickness Example Micore CV230 is to be used for the floor pro tection How thick must this material be Millboard The following formulas give the means of determining minimum thickness required of alternate materials Using the k formula Desired Thickness k value of desire Minimum thickness of the alternate material per inch x of Listed material k value of listed Material material per inch Im inches Km X Ti 1 28 inches _0 43 x 1 1 28 Answer using k 0 34 x 1 2 0 34 3 8 3 8 thickness Micore will be required Using the r formula inches
21. This protected area must extend a mini mum of 16 to the front of the fuel door opening and 8 beyond both sides of the fuel door opening see floor protection on page 5 for additional infor mation Minimum ceiling height must be 7 feet measured from base of appliance to ceiling DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE CONNECTED TO ANOTHER APPLIANCE Do not connect this appliance to air ducts or any air distribution system Do not install appliance in a sleeping room PREVENT CREOSOTE FIRE Inspect and clean chimney frequently Under certain conditions of use creosote buildup may occur rapidly Inspect chimney connector and chimney twice monthly and clean if necessary Using green or inadequately seasoned wood can greatly increase creosote buildup Use dry wood to minimize creosote buildup USE SOLID WOOD FUEL ONLY This appliance is approved for burning dry seasoned natural wood only Never use gasoline gasoline type lantern fuel kerosene charcoal lighter fluid or similar liquids to start or freshen up a fire in this heater Keep all such liquids well away from the heater while it is in use DO NOT OVERFIRE If heater or chimney con nector glows you are overfiring Overfiring this ap pliance could cause a house fire Overfiring is a condition where the appliance is operated at tem peratures above its design capabilities Overfiring can be caused by improper installation improper 2 13 14 15
22. allowed PAGE 4 SMOKE DETECTORS oince there are always several potential sources of fire in any home we recommend installing smoke detectors If possible install the smoke detector in a hallway adja cent to the room to reduce the possibility of occasional false activation from the heat produced by the fireplace insert If your local code requires a smoke detector be installed within the same room you must follow the re quirements of your local code Check with your local building department for requirements in your area PLANNING YOUR INSTALLATION FLOOR PROTECTION This appliance requires a heat resistant non combustible approved fireplace hearth or hearth exten sion If a hearth extension is used it must be a 3 8 minimum UL approved hearth pad or equivalent If the floor protection is to be stone tile brick etc it must be mortared or grouted to form a continuous non combustible surface See Using Alternate Material As Floor Protector on this page This protected area must extend a minimum of 16 to the front of the fuel door opening and 8 beyond both sides of the fuel door opening HEARTH PROTECTION TOP VIEW OF INSERT 8 MIN 36 MIN USING ALTERNATE MATERIAL AS A FLOOR PROTEC TOR HEARTH EXTENSION The alternate material used as a hearth extension must be constructed of a durable noncombustible material having an equal or better insulating value lower k value of k 1 28 B
23. applications The listing laboratory is OMNI Environmental Services Beaverton Oregon EPA CERTIFICATION This fireplace insert has been tested to rigorous emis sions standard and has been certified by the Environ mental Protection Agency PACKAGING LIST This appliance is packaged with an accessory package which contains the following One Installation and operation instructions manual One Warranty One Catalytic combustor temperature probe and sleeve One Damper Hook USING THIS MANUAL Please read and carefully follow all of the instructions found in this manual Please pay special attention to the safety instructions provided in this manual The Home owner s Care and Operation Instructions included here will assure you have many years of dependable and enjoyable service from your appliance PAGE 3 CONGRATULATIONS ON THE PURCHASE OF YOUR NEW WOOD BURNING FIREPLACE INSERT MANU FACTURED BY LENNOX HEARTH PRODUCTS When you purchased your new insert you joined the ranks of thousands of concerned individuals whose answer to their home heating needs reflects their concern for aesthetics efficiency and our envi ronment We extend our continued support to help you achieve the maximum benefit and enjoyment available from your new insert It is our goal at Lennox Hearth Products to provide you our valued customer with an appliance that will ensure you years of trouble free warmth and pleasure Thank you for sele
24. ay from all combustible materials pending final disposal If the ashes are disposed of by burial in soil or other wise locally dispersed they should be retained in the closed container until all cinders have thoroughly cooled PAGE 17 MAINTENANCE DOOR GLASS GASKET AND ASH DUMP GASKET A 3 4 spun fiberglass gasket provides the seal around the fuel door and a flat spun fiberglass rope gasket 1 8 x 1 provides the seal around the glass A cerawool pad 4 1 4 x 4 1 4 x 1 2 provides the seal for the ash dump cover Should these gaskets become frayed or damaged they should be replaced with the same size and type as the original gasket Contact your dealer for ordering Use high temperature silicone sealer as an adhesive for re placing door and ash dump gaskets The glass gasket has a self adhesive backing WARNING The gaskets must be kept in good condition Do not leave the stove burning with the door or ash dump cover off This will cause excessive heat build up in the unit and could ignite surrounding combustibles as well as damage the stove by overfiring it Overfiring is a condition where excessive temperatures are reached beyond the design capabilities of the stove such damage is not cov ered by the manufacturer s warranty SERVICING GLASS CAUTION Be careful not to abuse door assembly by striking or slamming it If the door assembly or glass is broken or damaged they must be replaced before heater can be safel
25. bypass set the primary air control to high open the door approximately 1 2 inch and wait for about thirty seconds Load the fuel close the door close the bypass and set the primary air control to normal operation Temperatures within the firebox should be hot enough to maintain the catalytic operation HOW TO START AND MAINTAIN A FIRE 1 Check to ensure the ash dump cover in center of fire box floor is in place and the ash drawer is closed 2 Open the bypass damper control by pulling it out to ward you In the OPEN position the draft air will by pass the catalytic combustor and make starting the fire easier 3 Set the primary air control lever on HIGH The HIGH setting will maximize your primary combustion air 4 Build a fire directly on the firebrick covering the bottom of the stove a Place five or six loosely crumpled sheets of news paper in the stove b Add a small amount of dry kindling randomly on the top of the newspaper c Place a few more loosely crumpled newspapers on top of the kindling and light the bottom paper first then light the top paper Once the kindling is ignited and burning on its own close the fuel door The upper fire should help preheat the chimney and create an effective draft while the lower fire ig nites the kindling 5 When the kindling is burning well add increasingly larger pieces of wood until the fire is actively burning 6 When the fire is well established use the damp
26. cting a Lennox Hearth Products insert as the answer to your home heating needs Sincerely All of us at Lennox Hearth Products PLANNING YOUR INSTALLATION QUESTIONS TO ASK LOCAL BUILDING OFFICIAL A correct installation is critical and imperative for reduc ing fire hazards and perilous conditions that can arise when wood burning appliances are improperly installed The installer must follow all of the manufacturers in structions The installation of a wood burning appliance must con form to local codes and applicable state and federal re quirements Familiarity with these requirements before installation is essential Important considerations to dis cuss with local building officials include 1 Applicable codes i e Uniform Mechanical Code otate or Regional Codes Electrical codes The blower system has a flexi ble electrical cord that must be electrically grounded per local codes or per electrical codes In USA NEC ANSI NFPA 70 1987 In Canada CSA C22 1 WARNING Electrical Grounding Instruc tions 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 Local amendments Is a permit required cost You may wish to contact your insurance company to ask if they require this Rooms where the installation is not
27. en Leav ing the door ajar or open while the stove is burning will cause excessive heat build up in the stove overfiring and could ignite surrounding combustibles as well as damage the stove such damage is not covered by the manufacturers warranty PRIMARY AIR CONTROL This appliance is equipped with a control for the combus tion air located above the fuel door Sliding the control to the right increases the burn rate to the left decreases the burn rate You will generally want to set the control in the low or medium range The fireplace insert is safe burning on any setting as long as combustibles are kept at the specified safe distances Lower Higher PRIMARY AIR PROVIDE ADEQUATE AIR FOR COMBUSTION In well insulated and weather tight homes it may be diffi cult to establish a good draft up your chimney The poor draft is caused by a shortage of air in the house To pro vide the needed air crack a window on the windward side of the house USE CONTROL SETTINGS THAT WORK FOR YOU The fuel the amount of heat you want the type of instal lation you have and how long you wish the fire to burn are all variables that will affect the control setting The same control settings in a variety of installations will produce different results Familiarize yourself with your fireplace insert by trying different settings so you can learn how much heat to ex pect and how long the fire will burn
28. er hook and close the bypass by pushing the control rod in catalytic temperature probe should read 500 600 F takes approximately 20 25 minutes to reach this temperature 7 When the fire is well established slide the air control lever for the desired heat output REFUELING To refuel the stove open the bypass and move the primary air control to HIGH Let the fire LIVEN UP for about one minute Open the fuel door about 1 2 and hold in this posi tion about 30 seconds or until the stove is drafting well Open the door and add wood After refueling reset the primary draft control to the desired position and close the bypass when the catalytic temperature probe reaches op erating temperatures PAGE 14 CARE AND OPERATION BLOWER SYSTEM The Blower System consists of a ON OFF rocker switch a variable speed blower speed control switch rheostat a thermally activated switch fan disc and 2 axial blowers When starting a fire leave the blower system off until the insert is thoroughly heated approx 30 minutes after start up The blowers can be operated in one of the following manners AUTO Turn Rocker Switch to the OFF o position and the rheostat to the ON position rotate rheostat dial clockwise until it clicks When the insert warms up 110 F the blower will automatically turn on ad just rheostat dial to the desired speed setting When the insert cools down 90 F the blowers will auto matically tur
29. f time the stove has been burning your catalytic combustor should operate between 1000 to 1800 degrees When the blower is operating it will affect the temperature probe reading Turn the blower off for an accurate reading PAGE 16 MAINTENANCE BURN RECOMMENDED FUEL This appliance is approved for use with natural dry wood only Burning materials other than natural wood will shorten the life of the catalytic combustor Do not burn particleboard or pressed logs using bonding agents as they can produce conditions which will deteriorate metal or damage the cata lyst Green or uncured wood does not work well as fuel and can cause increased creosote buildups and plugging of the catalytic combustor The value of green wood as a source of heat is limited Do not overload or use kindling wood or mill ends for primary fuel as this may cause overfiring Overfiring is a condition where excessive temperatures are reached beyond the design capabilities of the fireplace insert The damage that occurs from overfiring is not covered under the fireplace insert warranty WHY SEASON WOOD The key to the success of a good fire that produces heat from a wood burning insert is the wood It needs to be well seasoned natural wood What does Well Seasoned mean When a tree is cut down the wood is green full of sap and moisture This moisture content can exceed 8096 which must be reduced to less than 2096 Wood properly seasoned is then capable
30. hapter 37 DO NOT remove brick or mortar from masonry fireplace to accom modate insert Use flue outlet with a direct connector Remove and clean behind unit frequently as creosote buildup may occur rapidly Materials in inches SIDEWALL 1 8 46 HEARTH y EXTENSION Front enclosure trim kit required for installation CAUTIO HOT WHILE IN OPERATION DO NOT TOUCH CONTACT MAY CAUSE SKIN BURNS KEEP CHILDREN CLOTHING FURNISHINGS AND COMBUSTIBLE MATERIAL A CONSIDERABLE DISTANCE AWAY SEE NAMEPLATE AND INSTRUCTIONS DO NOT OVERFIRE IF HEATER OR CHIMNEY CONNECTOR GLOWS YOU ARE OVERFIRING INSPECT AND CLEAN CHIMNEY AND CONNECTOR FREQUENTLY UNDER CERTAIN CONDITIONS OF USE CREOSOTE BUILDUP MAY OCCUR RAPIDLY DO NOT USE GRATE OR ELEVATE FIRE BUILD WOOD FIRE DIRECTLY ON HEARTH DO NOT BURN WITH FEED DOOR OR FLUE BYPASS OPEN FEED DOOR MUST BE CLOSED DURING FIRING EXCEPT WHEN ADDING FUEL OPEN FLUE DRAFT BEFORE OPENING FEED DOOR U S ENVIRONMENTAL PROTECTION AGENCY Certified to comply with July 1990 particulate emission standards This wood heater contains a catalytic combustor which needs periodic inspection and replacement for proper operation Consult owner s manual for further information It is against the law to operate this wood heater in a manner inconsistent with operating instructions in the owner s manual or if the catalytic element is deactivated or removed DATE OF MANUFACTURE 2001 2002 200
31. imney has proper clearance to combustible framing members Masonry fireplace The chimney should have no cracks loose mortar other signs of deterioration or blockage Any necessary repairs should be done by a qualified mason If the existing fireplace flue system is dirty or has some obstruction in it clean it A dirty chimney can cause your insert to smoke when refueling and can result in a chim ney fire An oversized chimney may result in less than optimum performance Installations into a large masonry chimney may require a liner to improve performance CLEARANCES WARNING It is very important that you observe the minimum clearances There are listed clearances for your fireplace insert which were determined in a laboratory testing and must be maintained Minimum Clearance to Combustibles otove top to mantel 32 otove top to trim 24 Stove side to trim 9 Stove side to sidewall 17 TOP VIEW OF INSERT 38 INSERT TO SIDE WALL INSERT TO 17 MIN SIDE TRIM 9 MIN COMBUSTIBLE WALL FIREPLACE HEARTH HEARTH PROTECTION 36 vin COMBUSTIBLE MANTLE AND TRIM INSERT TO MANTLE 32 MIN DRAFT REQUIREMENTS The appliance is merely one component of a larger sys tem The other equally important component is the vent ing system This is necessary for achieving the required flow of combustion air to the fire chamber and for safely removing unwan
32. ing the combustor assembly for cleaning and rein stallation is simple and convenient Cleaning the com bustor helps reduce buildup of ash and retarding chemi cals To clean the combustor a soft brush vacuum cleaner or pipe cleaner may be used Cleaning the combustor once a year preferably when your flue system is serviced is sufficient for most users Reinstall the combustor according to the following in structions The catalytic activity and effectiveness of a two to three year old combustor can be improved by following this Major Cleaning Procedure Soak the combustor in a hot cleaning solution of a 50 50 mixture of white vinegar and distilled water for 30 minutes Then rinse by soaking in hot distilled water After 15 minutes remove the com bustor from the rinse water and gently shake out excess water lt is unlikely that you will notice a visible differ ence in the combustor after this cleaning procedure The combustor unit is fragile in comparison to the rest of the stove so handle with care 1 Place the combustor on the tunnel baffle as shown in illustration ceramic honeycomb to the back and lou vered slots to the front Push it back into the tunnel baffle until it hits the positioning stops Make sure it is sitting flat against the bottom and the sides so that it does not tilt forward and jump the positioning Stops 2 Position combustor clip over the middle of the sec ondary air tube as illustrated Make sure that
33. ll arched 9 3 8 15 34 Requires welding Hinge pin 4 28 retrofit UNF Requires drilling and tap ping 0340 ELECTRICAL PARTS Blower assembly includes 2 blowers propellers mounting bracket amp termi nal block Catalog G6000 5 11 6 128 10300 10580 10267 10265 10266 G2000 7 11529 11531 10362 Catalog 4020 11573 Blower axial 13 1 4 J239 Includes propeller 5116 42amps 410 25 3 Blower propeller ij 11597 Harness wiring p Knob not included 28 Hheostat w connectors 2107 Hheostat knob 410 270 Rocker switch on off 11565 isc fan F110 20F 410 260 erminal block large U O U 2 m 2 U p JJ o Part Catalog 0907 Description Module spring handle Module assembly Req s 10 32 x 1 hex screw Blower cover louvered left Blower cover louvered right 00 00 B O N Oo 0 c JJ JJ O 2 U go 0 P JJ o Part Catalog BV4032 Description Surround Assembly 32 Standard x 42 Air intake housing gold trim Corner key surround trim L bracket nsulation Surround side nsulation Surround top 11817 02046 Requires 2 11843 00 IN NO Misc Parts Part Description Catalog 775005M Manual Installation Operation For the location of the nearest dealer for replacement parts contact Lennox Hearth Products 1
34. n off MANUAL Turn Rocker Switch to the ON position and adjust rheostat dial to the desired speed The Blower will have to be manually turned off by rotating the rheostat dial counterclockwise until it clicks POWER CORD RHEOSTAT SPEED CONTROL ON OFF SWITCH AUTO OR MANUAL MODE CAUTION Burning the insert at a high burn rate for extended periods without running the blowers can cause excessive temperatures resulting in overfir ing damage to the appliance Excessive heat will cause the propellers on the blowers to melt If this occurs replace propellers and review these instruc tions for proper operation Propeller Part Catalog 410 25 3 Some people prefer metal propellers which are available through Grainger stock 2C953 Be advised that these are noisier than standard plastic blades Overfiring damage is not covered under the 5 year prorated warranty WARNING This appliance is equipped with a blower system which has a flexible electrical power cord with a three prong grounding plug for your protec tion against shock hazard and should be plugged directly into a properly grounded three prong recep tacle per local codes or NEC ANSI NFPA 70 latest edition Do not cut or remove the grounding prong from the power cord plug BLOWER SPECIFICATIONS 115 Volt 60 Hz 2 axial blowers 42 amps each 125 CFM each Blower sys tem has a flexible electrical cord that must be electrically grounded per local codes
35. nce fireplaces Zero clearance installations require a full reline from the flue collar to the rain cap For flue collar offsets inZero clearance and masonry fireplace installations use only part 14 76 See manual for further information ELECTRICAL MOTOR RATING Aerovox Model 510625082 115V 5 Watts 60 Hz DANGER Risk of electrical shock Disconnect power before servicing unit Do not route power cord beneath heater Minimum Clearances to Combustible Manufactured by Lennox Hearth Products 1110 West Taft Avenue Orange CA 92865 Tested amp Listed By Beaverton Oregon USA OMNFTest Laboratories Inc REPORT NO SS 094 8 SERIAL NO MOD BAYVIEW 4000 OREGON DESIGN NO E S 08 TESTED TO UL 1482 TEST DATE March 31 1987 CATALYTIC COMBUSTOR Burning of metal foils coal plastic garbage sulphur and diesel oil will make the catalyst in the converter inactive The combustor is fragile handle carefully The performance of the catalytic device or its durability has not been evaluated as part of the certification NOTE Replace glass only with 5mm ceramic Install insert with a minimum of 17 clearance to combustible sidewall 9 to side and 24 to top trim 32 from top of insert to mantel Floor protector must be 3 8 minimum non combustible material or equivalent extending 16 in front of insert and 8 to both sides When used as an insert stove install only in a masonry fireplace built to UBC C
36. nstalled Burning of metal foils coal plas tic garbage diesel oil and sulfur will make the catalyst in the combustor inactive The combustor is fragile handle carefully The performance of the catalytic device or its durability has not been evalu ated as part of the certification Build fires directly upon the brick hearth inside the fireplace insert Do not use grates irons or any other method to elevate the fire SAVE THESE INSTRUCTIONS oee the listing label located on the back of fire place or see Safety Listing Label on page 26 TABLE OF CONTENTS Important Warnings 2 Testing Listing EPA Using this Manual 3 Planning Your Installation 4 7 IistallallOflr assess aus ast ii ada 8 11 Product Features and Controls 11 Care and Operation 13 16 Recommended 17 Maltitenatieo ia 17 19 TROUDIESHOOLING copas docct tee a eek 20 21 SPCCIICATIONS TR 22 Replacement Parts List 23 24 Optional 25 Safety Listing Label and EPA Label 26 Service Maintenance 09 27 TESTING LISTING Model BV4000C has been tested to UL Standards UL 1482 for installation into residential
37. one of the holes in the secondary air tube is centered in the 1 2 hole on the clip You can feel with your fingertip 3 Tighten screw snugly but do not over tighten or you may spread the clip apart PAGE 19 al CATALYTIC B ful COMBUSTOR j ASSEMBLY fu DAMPER CATALYTIC COMBLIETOR RETAINING CUP f USE A 716 SOCKET TIGHTEN SNUG BUT DO NOT CVERTKSHTEN amp IR TUBE e ini SECONDARY a E TROUBLESHOOTING k on SMOKES OUT FUEL DOOR WHEN OPEN The primary air control is closed The chimney is too cool Set the primary air control on HIGH with the bypass damper control OPEN for a few minutes before opening the fuel door Excess creosote will not only restrict your draft but it will create a risk of a creosote fire Strictly adhere to maintenance requirements as outlined in this man ual If excess creosote has built up on the inside of the firebox sides and door burn a small hot fire at intervals that are more frequent with air control on HIGH for a few minutes Deposits may have built up in the chimney and are restricting the draft or the spark arrester on top of the chimney may be plugged Chimney diameter too large or too small to provide adequate draft The house is too airtight usually takes 20 to 30 min utes for problem to appear as stove lowers air pres sure in hou
38. ont of the fireplace to protect floor or carpet during installation 5 Remove the insert from its wood pallet by removing the screws 6 Prepare chimney connection system as specified for ma sonry or factory built fireplaces 7 Set the insert on the protective cardboard laid out in front of the fireplace centered in front of the fireplace opening 8 Masonry Fireplace Slide insert into the fireplace far enough to attach the starter pipe or positive flue connection a minimum of a 6 starter pipe extending past the header is required See note 9 Factory Built Fireplace Slide insert into the fireplace far enough to attach connector to flue outlet See note 10 Offsets can be handled using an offset adapter it aligns starter pipe with flue See Offset Adapter page 25 for or dering information Do not push insert in completely until surround assembly is installed Care should be used to ensure that this adjustable connector is oriented so it does not angle downhill when positioned on the flue outlet on top of insert CORRECT CORRECT Level or even slightly up at the outbound end is better WRONG WRONG This may produce a problem of smoking durmg refueling or poor chimney draw 11 If the floor of the fireplace is lower than the hearth turn the adjusting bolts secured with 2 nuts not in cluded with the hardware located at the sides of the insert clockwise until insert is level The leveling bolts
39. oors may turn color stove glass may develop a haze which will not come off with cleaning firebox baffle plate tunnel baffle may warp etc Overfiring of a fireplace insert is a condition where ex cessive temperatures are reached beyond the design capabilities of the appliance The damage that occurs from overfiring is not covered under the manufacturers limited warranty The following are a few conditions that should be evaluated and corrected if necessary if an overfiring condition is suspected Overfiring Caused From Improper Installation The venting system must satisfy the draft Requirements of the appliance The appliance is merely one component of a larger system The other equally important compo nent is the venting system which is necessary for achieving the required flow of combustion air to the fire chamber and for safely removing unwanted combustion byproducts from the appliance If the venting system s de sign does not promote these ends the system may not function properly which may create performance prob lems as well as may be a safety hazard To ensure that all installation requirements have been met as outlined in the installation manual The chimney should be clean and in good repair A draft test should be performed to deter mine if the draft requirements of the appliance are being met A draft gauge should read between 05 and 07 inches water column W C I Excessive draft above 07 W C l will allow too
40. ove paint Use only model TSPK B Stove Paint Catalog 70K99 Do not touch up your stove with any other paint Using one small piece of 320 grit sand paper and lightly sand the blemish so that the edges are feathered or smooth to the touch between the painted and bare sur faces Do not let the sand paper gum up with paint as this will cause scratches on the metal surface If there are any scratches use 600 grit sandpaper instead Mask off surfaces you do not want painted Paint lightly over the bare surface first as this will act as an undercoat Then paint over a larger area in smooth even strokes to blend See Break In Period on page 14 for information on curing the paint FIREBRICK The firebrick should be inspected periodically and re placed if damaged crumbling or excessively cracked ASH REMOVAL AND DISPOSAL CAUTION Make sure that the fire is out and the stove is cold before removing ashes Never burn your stove with the ash dump cover off Ashes can hold live embers for several days and must be disposed of with care ocrape ashes from the firebox through the ash dump opening into the ash drawer After emptying clean and replace the ash drawer NEVER place ashes in a cardboard box or any other combustible receptacle Proper Disposal of Ashes Ashes should be placed in a metal container with a tight fitting lid The closed container of ashes should be placed on a noncombustible floor or on the ground well aw
41. primary fuel PAGE 21 SPECIFICATIONS Model BV4000C Approx sq ft heat capacity Maximum log length Flue size Width w standard surround Width at fireplace opening Width at rear of firebox Depth into Fireplace Depth overall Height up to 2000 Sq Ft 18 6 42 22 5 22 5 16 25 21 Height w standard surround 32 Back of Stove to Center of Flue Approx burn time Fuel capacity Firebox size cubic feet Maximum Burn Rate EPA BTU Range BTU EPA Efficiency Emissions Rate grams hour Approx weight with brick Air Control Blower Assembly 2 blowers 125cfm each W speed control Rheostat Square feet heating capacity and burn time are approximations only They will vary de pending upon the level of insulation cli mate house design ceiling height ambient outside temperatures and how the stove is operated 5 1 2 8 10 hours 70 Ibs approx 2 4 c f 56 800 BTU 6 500 to 40 900 72 1 9 gph 390 Ibs Manual 250 75 110 volt Note Dimensions shown are approximations only Va 42 ________ gt PAGE 22 REPLACEMENT PARTS LIST Model BV4000C DOOR PARTS Door assembly cast black Door handle assembly Door handle coil spring Gasket door kit 34 rope Includes adhesive Gasket glass channel Requires 5 per foot Clip glass long bottom Requires 1 9 side Requires 8 Glass sma
42. reosote de posits To inhibit the build up of creosote adjust the primary air control to a medium high or high setting for a 10 minute pe riod each day Do not attempt to burn out heavy creosote accumulations in this manner This must be removed from the chimney by scraping or brushing to reduce the risk of a chimney fire Burn Approved Fuel Only This stove is approved for burning dry seasoned natural wood only Using green or inadequately seasoned wood may increase creosote buildup Inspection Frequency The chimney connector and chimney should be inspected at least twice monthly dur ing the heating season to determine if a creosote buildup has occurred If creosote has accumulated it should be removed to reduce the risk of a chimney fire Cleaning Remove the catalytic combustor and open the bypass damper prior to having your chimney cleaned should be done by a qualified chimney sweep See Maintenance Catalytic Combustor on page 19 for in structions on removing catalytic combustor IMPORTANT Make sure the bypass damper is in the open position prior to chimney cleaning In the event of a chimney fire Make sure the fuel door is securely closed Adjust the primary air control to the lowest most closed setting Call the fire department immediately After a chimney fire the complete chimney system should be checked by a qualified technician before further use Consult your dealer for suggestions on proper chimney care
43. res the use of a 6 diameter flex or rigid UL1777 listed 2100 HT liner or equivalent The liner must extend from the flue outlet of the appliance to termination Do not face seal over fireplace chimney cooling air systems Offsets can be handled with an offset adapter it aligns starter pipe with fireplace flue For more information on the offset adapter see pages 9 and 25 WARNING Do not substitute the heat rated 2100 HT liner with any other type line or a fire may result causing property damage personal injury or loss of life PAGE 7 MASONRY FIREPLACES This appliance is approved for installation into a masonry fireplace built to UBC Chapter 37 standards Do not remove brick or mortar form the masonry fireplace to accommodate this appliance Venting Requirements for masonry fireplace The fireplace damper must be secured in the open position As a minimum a flue extension past the fireplace header is required A preferred installation is a positive flue connection sealing the throat of the chimney This appliance requires the use of a 6 diameter flex or rigid single wall pipe minimum 24 25 MSG black or blued steel connector pipe stainless steel recommended Offsets can be han dled with an offset adapter it aligns starter pipe with fireplace flue For more information on the offset adapter see pages 9 and 25 FIREPLACE CHIMNEY MAXIMUM SIZE TO ENSURE PROPER DRAFT The fireplace insert flue size is 6 inches diame
44. se Crack a window open or provide an outside source of air near insert Insufficient vertical height to chimney to achieve adequate draft The combustor is plugged from engaging too soon remove combustor and clean see Maintenance section page 19 DOES NOT PRODUCE ENOUGH HEAT Using green or insufficiently cured wood Excessive draft High ceilings heat rises quickly but can be recircu lated by a well placed ceiling fan with a win ter summer switch The area to heat is too large square foot heating estimates are based on average climates and home design There s an obstruction in the chimney The chimney or chimney cap is restricted by creosote preventing enough draw to sustain a HIGH heat rate Combustor light off has not occurred DOES NOT MAINTAIN A FIRE Soft wood does not burn as long or as well as sea soned hardwood resulting in a short burn time Wood size too small Burns at too rapid a rate The gasket seal on the fuel door ash dump cover or glass is leaking air Repair or replace it if necessary There is an obstruction in the chimney The stove was not up to normal operating tempera ture before the bypass damper control was pushed closed Excessive draft BACKPUFFING 1 Downdraft in the chimney may need a special wind cap 2 The catalytic combustor is too hot avoid burning soft pitchy woods or large amounts of small diameter wood
45. ted combustion byproducts from the ap pliance If the venting system s design does not promote these ends the system may not function properly Poorly functioning venting systems may create performance problems as well as be a safety hazard i e an oversized chimney may result in less than optimum performance Installations into a large masonry chimney may require a liner to improve performance A draft test should read greater than 04 W C inches water column and less than 08 W C VENTILATION Ventilation is essential when using a solid burning appli ance The combustion process uses oxygen from inside the home and it may be necessary to open a window in a house that is well insulated PAGE 6 PLANNING YOUR INSTALLATION FACTORY BUILT FIREPLACES This appliance is approved for installation into a listed factory built solid fuel burning fireplace The fireplace firebox must accept the insert without modification other than re moving bolted or screwed together pieces such as smoke shelf deflectors ash lips screen or door tracks and damper assemblies that must be reinstalled to re store the fireplace to its original operating condition if the insert is removed and not replaced The removal of any part must not alter the integrity or outer shell of the pre engineered fireplace cabinet in any way Venting Requirements for factory built fireplace The fireplace damper must be secured in the open position This appliance requi
46. ter which is approximately 28 square inches the minimum The maximum flue size should be no more than 3 three times the cross sectional area of the size of the fireplace insert flue collar In this case that would be no larger than a 10 inch diameter stack area approx 85 sq inches Note Formulas for calculating area Calculating area of a circle T x Area T 3 1416 r 1 2 diameter To calculate area of square or rectangle Width x Depth Area Notes gt It may be necessary to use a full length liner to achieve adequate draft for the appliance A draft gauge should read more than 04 W C I but less than 08 W C l for optimum performance This appliance is approved for all heatform style fireplaces masonry fireplace with a metal fire box liner Measure fireplace size to make certain the insert will fit before considering the installation INSTALLATION FIREPLACE INSTALLATION CHIMNEY TERMINATION CAP ENSURE CHIMNEY Im T IS SOUND EA JT MASONRY FIREPLACE APPROVED LINER 6 DIA FLEX e mpr 1 OR RIGID 24 26 MSG BLACK OR i 1 grind STEEL PIPE OR 2100 HT _ FACTORY BUILT ZC FIREPLACE APPROVED LINER 6 DIAMETER B 2100 HT LINER ar REMOVE FIREPLACE DAMPER OR SECURE OPEN s 8 4000 MINIMUM FIREPLACE DIMENSIONS Approx minimum Height 21 dimensions into fireplace Width 22
47. y be lightly sanded and touched up with spray paint from the same paint manufacturer See Maintenance Small Area Paint Touch up Paint is available at your local authorized Lennox Hearth Products dealer Never attempt to paint a hot stove CATALYTIC COMBUSTOR During the start up of a cold stove a medium to high firing rate must be maintained for about 20 minutes The high firing rate will ensure that the stove the flue the catalyst and the fuel are all stabilized at proper operating tempera tures Even though it s possible to have temperatures in the stove reach 600 F within two or three minutes after the fire is started do not set the primary air control lever to the LOW position until approximately twenty minutes have passed Setting the primary air control on LOW too early could result in either the fire or the catalytic combustor go ing out At the end of a burn cycle it s possible that the hot embers remaining might not provide sufficient fuel value for the catalyst to retain its minimum operating temperature of 600 F During the refueling we recommend that the stove be refired for about 10 minutes with the bypass open to ensure a good draw is established and that the catalyst reaches 600 F The refiring will ensure sufficient tem peratures and proper amounts of volatiles for the catalyst to operate properly When refueling a hot stove with the catalyst still operating no refiring step is necessary Just open the
48. y operated Use only components provided by the manufacturer as replacement parts Cleaning Glass Ensure stove is cold prior to cleaning glass A commercial glass cleaner designed for stoves is recom mended Do not use abrasive cleaners Replacing Glass 1 Remove door from stove by lifting door up and off hinge pins Place the door on a flat protected towel clean flat surface with the inside of the door facing up Remove the glass clips by removing screws holding clips then carefully remove broken glass one piece at a time pro tective gloves are recommendeo 2 Clean area where the glass with gasket will be installed 3 Install new glass with gasket use only factory 5 mm glass with glass channel gasket Do not substitute Carefully reinstall glass clips Be very careful not to overtighten screws 4 Reinstall door CREOSOTE FORMATION AND NEED FOR REMOVAL What is Creosote When wood is burned slowly it pro duces tar and other organic vapors which combine with ex pelled moisture to form creosote The creosote vapors con dense in the relatively cool chimney flue of a slow burning fire As a result creosote residue accumulates on the flue lining When ignited this creosote makes an extremely hot fire Also creosote deposits tend to form in long runs of venting where gases become too cool prior to exhausting Note Single wall pipe cools rapidly therefore installations using this type of flue are more susceptible to c
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