Archgard 60-1600I User Manual

CHALET 1600I

CHALET 1600I

WOOD

Fireplace

Insert

Users’ Installation

Shown with optional nickel door (10-0203)
and brushed nickel fan inlay (40-1103)

Operation and
Maintenance Manual

PRIOR TO FIRST FIRE: Remove all labels from glass. Clean fingerprints from plated

surfaces with a glass cleanser and soft cloth to prevent permanent staining.

CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE

TEMPERATURES, ESPECIALLY THE INSERT GLASS, AND SHOULD STAY AWAY TO AVOID

BURNS OR CLOTHING IGNITION. KEEP ALL SMALL PARTS AWAY FROM CHILDREN WHILE

ASSEMBLING SINCE THEY CAN CAUSE A CHOKING HAZARD.

Homeowner: Please keep these instructions for future reference.

Installer: Please complete the details on the back cover

and leave this manual with the homeowner.

7116 Beatty Dr
Mission, BC V2V 6B4
Canada

200-0258 SEPT 2013

Chalet 1600I 2

TABLE OF CONTENTS

Important Safety Notes

Rating Plate Label

Dimensions

Specifications

Clearances

COMPONENT INSTALLATION / MAINTENANCE AND OPERATION METHODS

Door Installation and Assembling

Air Tube And Ceramic Baffle Installation and Removal

Blower / Fan Installation

Blower Operation & Diagram 13

Face Plate Installation and Assembling 14

First Fire And Operation of Insert 15

Brick Removal And Installation 19

Door And Glass Maintenance 20

Paint 21

INSERT INFORMATION FOR INSTALLATIONS

11

12

13

4

5

6

6

7

Venting Requirements 9

Precautions For Installation 8

Installation Methods 10

TROUBLESHOOTING / SAFETY / CHIMNEY AND WOOD

Troubleshooting 16

Creosote & Chimney Fires 17

Safety Equipment 17

Chimney Maintenance 18

wood 18

Ash Disposal 19

ACCESSORY / PARTS REPLACEMENT

Accessory & Replacement Parts List 22-23

Archgard Warranty 24

Warranty Registration Card 25

Notes 26

Installation Information 27

Chalet 1600I 3

ARCHGARD CHALET 1600I WOOD FIREPLACE INSERT

Surround

Trim

6” Flue

Adapter

Kit

Chalet 1600I

Blower

Congratulations on choosing a state-of-the-art Archgard Hearth Product!

The hand crafted Archgard CHALET 1600I WOOD Fireplace Insert has been designed to provide

you with comfort, security and economy for many years of trouble-free enjoyment.

It has been our experience that the overall enjoyment of your new appliance will be greatly

enhanced by becoming familiar with its installation, operation and maintenance. Prior to installation,

we ask that you take a few moments to read this manual.

We wish you and your family many years of enjoyment in the warmth and comfort of this hearth

appliance.

Thank you for choosing Archgard Industries!

Chalet 1600I 4

IMPORTANT SAFETY NOTES

1. When installing your insert, particular attention
should be paid to fire protection. If this room
heater is not properly installed, a house fire may
result. To reduce the risk of fire, follow the in­stallation instructions. Contact local building,
fire officials or the authority having jurisdiction
about restrictions, installation, inspection and
permit requirements in your area.

2. CAUTION: 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.

3. DO NOT BURN GARBAGE OR FLAMMABLE FLU­IDS SUCH AS GASOLINE, NAPHTHA OR ENGINE
OIL. Do not burn treated wood, or salt laden
(driftwood, etc.) wood. Burning materials other than
wood (including charcoal) under adverse conditions
may generate carbon monoxide in the home, result­ing in illness or possible death.

4. Your insert should burn dry, standard firewood only.

The use of cut lumber, plywood, “mill ends”, etc. is

not recommended as this fuel can easily overheat
your wood insert. Chemically treated fire logs must
not be burned in your wood insert.

5. Do not store any fuel within space heater installation
clearances or within the space required for charging
and ash removal. Do not place wood, paper, furni­ture, drapes or other combustibles near the appli­ance.

6. During operation, if any part of the insert starts to
glow, the insert is in an over-fired condition. Close
the air control completely by pushing it in until the
glowing has stopped. OVERFIRING VOIDS YOUR
WARRANTY and can be hazardous!

7. WARNING: Do not operate with insert door open. It
can over fire your appliance, gas and flame may be
drawn out of the fireplace stove opening, creating
risks from both fire and smoke.

8. WARNING! Never draw outside combustion air

from a wall, floor or ceiling cavity or from any
enclosed space such as an attic or garage or
carport.

9. Check your chimney system thoroughly when in­stalling into an existing masonry chimney. Seek
professional advice if in doubt about its condition.

10. Comply with all minimum clearances to combusti­bles as shown in this manual.

11. Build fire on brick firebox floor. Do not use grates,
andirons or other methods to support fuel.

12. HOT WHILE IN OPERATION! Keep children, pets,
clothing and furniture away. Contact can cause skin
burns.

13. Do not operate without fully assembling all compo­nents. Doing so will void your warranty, and could

present a serious safety hazard.

14. Solid fuel-burning appliances shall be installed in
such a manner as to provide ventilation and com­bustion air supply to allow for the proper combustion
of fuel, chimney draft and the maintenance of safe
temperatures.

15. The controls of your unit or the air supply passages
should not be altered to increase firing for any rea­son.

16. If you burn the unit too slowly or at too low a setting
your unit will not be operating as efficiently as it can.
An easy rule of thumb says that if your glass is
clean, then your flue is clean and your exhaust is
clean. Burn the insert hot enough to keep your glass
clean and you won't need to clean your flue as of­ten.

17. Check you chimney twice a month for creosote ac­cumulation and sweep as required.

18. Burning wet or green, unseasoned wood, could
cause excessive creosote accumulation in the flue
pipe and chimney. This could result in a chimney
fire. Store wood in a dry location.

19. Do not permit creosote or soot build-up in the chim­ney system. Check and clean chimney at regular
intervals. Failure to do so can result in a serious
chimney fire.

20. Ashes should be disposed of carefully, using a
metal container.

21. Do not install in a mobile home.

22. Do not connect to any air distribution duct or sys­tem.

23. Do not connect this unit to a chimney flue already
serving another appliance.

24. This appliance must be connected to a chimney and
terminate to the outside of the building envelope.
Never vent to another room or inside a building.

25. Do not operate if the gasket on the door is missing
or damaged. Use only manufacturers approved
parts.

26. Do not operate with broken glass. Use only manu­facturers approved replacement parts.

27. Do not use “Black” or “Galvanized” pipe in your flue
system.

28. For further information refer to NFPA 211 (USA),
CAN/CSA-B365 (Canada) or any other appropriate
local codes.

Chalet 1600I 5

YOUNG CHILDREN SHOULD BE CAREFULLY SUPER­VISED WHEN THEY ARE IN THE SAME ROOM AS THE

APPLIANCE.

EMISSIONS FROM BURNING WOOD OR GAS COULD

CONTAIN CHEMICALS KNOWN TO THE STATE OF

CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR

OTHER REPRODUCTIVE HARM.

READ ALL INSTRUCTIONS BEFORE INSTALLING AND USING THIS APPLIANCE. FAILURE TO FOLLOW IN­STRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.

SAFETY NOTE: If this insert is not properly installed, a house fire may result. For your safety, follow the installation in-

structions. Contact your local building or fire officials, or any other authority having jurisdiction about restrictions and per­mit/inspection requirements in your area.

WHEN LOCATING YOUR INSERT: Consider safety and the fact that the insert will need a chimney. It is a good idea to
plan your installation on paper, using exact measurements for clearances and floor protection before actually beginning
the installation.

These installation instructions describe the installation and operation of the Archgard CHALET 1600I WOOD Fireplace

Insert. This insert meets the U.S. Environmental Protection Agency’s 1990 particulate emission standards. It is also

listed by Lab Test Laboratories, Inc. to UL Safety Standard 1482 and ULC S628. It also meets the requirements of (UM)
84-HUD.

SAFETY LABEL

A copy of the label that accompanies each Archgard Chalet 1600I WOOD Fireplace Insert , is printed here for your con­venience.

NOTE: Archgard units are constantly being improved. If there is a conflict between the label on the unit and the one
printed here, the label on the unit is the correct one. The safety label is attached to the side of the unit.

This unit has been approved for use in Washington State ,USA.

2013 2014 2015

Chalet 1600I 6

23 3/4"
603mm

18 5/8"
473mm

6"
152mm

20"
508mm

23 3/8"
595mm

20 11/16"
525mm

15 7/16"
392mm

SEE NOTE A

NOTE A:
SURROUND DEPTH IS ADJ USTABLE.
12 7/16" TO 15 7/16" (316 mm TO 392mm)

O

6"
152mm

28"
711mm

SEE NOTE B

40"
1016mm

SEE NOTE B

NOTE B:
OPTIONAL 46" (1168mm) W X 3 2" (813mm) H SURROUND.

17 7/8"
454mm

DIMENSIONS

SPECIFICATIONS

MODEL

HEIGHT OF
BODY

WIDTH of
BODY

DEPTH of
BODY

E.P.A.
EMISSIONS

E.P.A.
OUTPUT
RATING

APPROXI­MATE
HEATING
AREA

DURATION
ON LOW
FIRE

INSERT
BODY
WEIGHT
WITH
PACKAGING

CHALET 1600I WOOD

FIREPLACE INSERT

18 5/8” (473 mm)

23 3/4” (603 mm)

23 3/8” (595 mm)

2.88 g/hr

63 %

800—1500 square feet

6—10 hours

300 lbs

Surround Panels

Standard

(width x
height)

Optional

(width x
height)

(1016 mm W x 711 mm H)

(1168 mm W x 813 mm H)

40” W X 28” H

46” W X 32” H

Chalet 1600I 7

Minimum Fireplace Size

Your fireplace opening requires the following minimum sizes:

Height Width Depth From back of adjustable faceplate to front of flue collar

18 3/4”

476.25 mm)

24”

(609.6 mm)

13”

(330.2 mm)

3 1/2” — 6 1/2”

(88.9 mm — 165.1 mm)

Minimum Clearances To Combustible Materials (Measured From Insert Body)

Side Wall to Insert

= A

8.5”

(216 mm)

Note 1: If insert to floor is less than 4” the unit requires 0.5” of k = 0.84 (Btu)(in)/(Ft2)(hr)(°F) thermal protection.

All floor protection must be non-combustible (i.e., metal, brick, stone, mineral fiber boards, etc.)

Any organic materials (i.e., plastics, wood paper products, etc.) are combustible and must not be used. The floor protection

specified includes some form of thermal designation such as R-value. (thermal resistance) or k-factor

PROCEDURE:

1. Convert specification to R-value

i. R-value given—no conversion needed. 1
ii. k-factor is given with a required thickness (T) in inches R = k x T

1
Iii. K-factor is given with a required thickness (T) in inches: R = K x 12 x T

Iv. R-factor is given with a required thickness (T) in inches: R= r x T

2. Determine the R-value of the proposed alternate floor protector.

i. Use the formula in step (1) to convert values not expressed as “R”

Ii. For multiple layers, add R-values of each layer to determine overall R-value.

3. If the overall R-value of the system is greater than the R-value of the specified floor
Protector , the alternate is acceptable.

EXAMPLE: The specified floor protector should be 3/4-inch thick material with a k-factor of 0.84. The proposed alternate is
4” brick with a r-factor of 0.2 over 1/8” mineral board with a k-factor of 0.29.

Step (a): Use formula above to convert specification to R-value.

1 1

R = k x T = 0.84 x 0.75 = 0.893
Step (b): Calculate R of proposed system.
4” brick of r = 0.2, therefore:

Total = brick +

R

Mineral board = 0.29 x 0.125 = 0.431

R R

Top of Insert to

Bottom of Mantle (12”)

= B

21”

(534 mm)

How to determine if alternate floor protection materials are acceptable.

1

R

mineral board = 0.8 +0.431 = 1.231 (continued on next page)

Side of Insert

to Mantle Leg

= C

8.5”

(216 mm)

(thermal conductivity).

Hearth Extension Front

Canada = 18” (450 mm)

USA = 16” (400 mm)

Hearth Extension Side

= D

Canada = 8” (200 mm)

USA = 8” (200 mm)

*see note 1

= E

Chalet 1600I 8

R

Total = brick + mineral board = 0. 8 + 0.431 = 1.231

Step ( c ): Compare proposed system total of 1.231 to specified R of 0.893. Since proposed system total is greater than
required , the system is acceptable.

DEFINITIONS:

= ( ft ² )(hr)(°F) k = K X 12 K= ( ft ² ) (hr) (°F) r = =

R

R R

Btu

(Btu) (in)

( ft

R R

(Btu) (ft)

( ft ² ) (hr) (°F)

(Btu) (in)

1

k

B

A

C

D E

Hearth Protection

In the USA, the floor protection must be made of non-combustible material and must extend 16" in front and

8” beyond each side of the fuel loading and ash removal openings. Consult with your local inspector/

authority having jurisdiction or check the NFPA 211 or local codes.

In Canada, the floor protection must be made of non-combustible material and must extend 18" (450mm) in

front and 8” beyond each side of the fuel loading and ash removal openings. A 0.38 mm (0.015 in) thick

metal sheet or a grouted ceramic floor-tile surface installed in accordance with recognized Building Codes
shall be considered a durable pad. A floor pad shall not be placed on top of a carpet unless the pad is struc­turally supported to prevent displacement and distortion. Consult with your local inspector or check the
CSA B365.

All floor protection must be non-combustible (i.e. metals, brick, stone, mineral fiber boards, etc.). Any or­ganic materials (i.e., plastics, wood paper products, etc.) are combustible and must not be used.

Chalet 1600I 9

BEFORE INSTALLING AND USING THIS APPLIANCE.

The installation of Smoke and Carbon Monoxide detectors
along with a minimum of a five pound fire extinguisher is
highly recommended in any home. When you first fire up
your CHALET 1600I WOOD Fireplace Insert, you may
notice the smoke detectors operating more frequently.
This may be due to the curing of stove paint or oils from
manufacturing or fumes caused by accidentally leaving
the door open. Do not disconnect the detectors.

Consult local building or fire officials about restrictions and
installation inspection and permit requirements in your
area. Let your home insurance company know that you
plan to install this CHALET 1600I WOOD Fireplace Insert
in your home.

Please read this entire manual before you install and use
this CHALET 1600I WOOD Fireplace Insert in your home.
Failure to follow instructions may result in property dam­age, bodily injury or even death.

Install and use only in accordance with manufacturer’s

installation and operating instructions. CHALET 1600I
WOOD Fireplace Insert is designed to be installed into a
masonry or factory built zero-clearance fireplace. Have
the chimney and fireplace inspected and swept prior to
installing the Insert to be sure that the chimney/fireplace
meets requirements of the Standard of Chimneys, Fire-

places, Vents and Solid Fuel Burning appliances,
N.F.P.A. 211 (Latest Edition) or applicable National, Pro-

vincial, State or local codes. The installation shall conform
to CAN/CSA-B365, Installation Code for Solid-Fuel
Burning Appliances and Equipment. The factory built
zero-clearance fireplace and its chimney must be listed
per UL 127 or ULC S610 Standards.

WARNING: Under no circumstances is this heater to be
installed in a makeshift or temporary manner.

Do not connect the insert to a chimney system servic­ing another appliance.

The chimney damper may be removed or lock in the open
position to install the chimney liner. Check local codes
first.

A permanent metal warning label must be attached to
the back of the fireplace stating that the fireplace may
have been altered and may be unsafe to use without
the insert.

Do not use unlabelled parts, or substitute parts made for
another chimney system.

Install only to liner/chimney manufacturer's installation
instructions.

The chimney must be suitable for wood burning use.
Check for creosote build up or other obstructions.

The insert is very heavy and will require two or more peo­ple to move it into position. Be sure to protect your hearth

extension with a heavy blanket or carpet scrap during the
installation.

This fireplace insert must be installed with a continuous

chimney liner of 6” diameter extending from the fireplace

insert to the top of the chimney. The chimney liner must
conform to the Class 3 requirements of CAN/ULC-S635,
Standard for Lining Systems for Existing Masonry or Fac­tory-Built Chimneys and Vents, or CAN/ULC-s640, Stan­dard for Lining Systems for New Masonry Chimneys.

RECOMMENDED MINIMUM CHIMNEY HEIGHTS

The chimney must be at least 3 ft. (.9m) higher than the
highest point where it passes through the roof and at least
2 ft. (.6m) higher than the highest part of the roof or struc­ture within 10 ft. (3m) of the chimney, measured horizon­tally. These are code requirements and cannot guaran-
tee a suitable draft. We recommend using a minimum
total system height of 12 ft. (3.6m), measured from the
flue collar to the bottom of the chimney cap). And extend
2’ above the overall highest living space.