FPI U35-NG, U35-LP Owners & Installation Manual
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U35 Gas Insert
MODELS: U35-NG Natural Gas U35-LP Propane
Owners & Installation Manual
WARNING:
Improper installation, adjustment, alteration, service or main
tenance can cause injury, property damage, or loss of life
Refer to this manual. For assistance or additional informatio
consult an authorized installer, service agency or the ga
supplier.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapours an
liquids in the vicinity of this or any other appliance.
Installation and service must be performed by an authorize
installer, service agency or the gas supplier.
Tested by:
908-172d
FPI FIREPLACE PRODUCTS INTERNATIONAL LTD. 6988 Venture St., Delta, BC Canada, V4G 1H4
Installer: Please complete the details on the back cover
and leave this manual with the homeowner.
Homeowner: Please keep these instructions for future reference.
FOR YOUR SAFETY
What to do if you smell gas:
Do not try to light any appliance
Do not touch any electrical switch
do not use any phone in your build
ing.
Immediately call your gas supplie
from a neighbour's phone. Follow
the gas supplier's instructions.
If you cannot reach your gas sup
plier, call the fire department.
05/04/05
FPI GAS FIREPLACE INSERT
TO THE NEW OWNER
Congratulations! You are the owner of a state-of-the-art Gas Insert by FPI.
The U35 Gas Insert has been designed to provide you with all the warmth and charm of a fireplace, at
the flick of a switch. The U35-NG and U35-LP have been approved by Warnock Hersey for both safety
and efficiency. As it also bears our own mark, it promises to provide you with economy, comfort and
security for many trouble free years to follow. Please take a moment now to acquaint yourself with these
instructions and the many features of your FPI Fireplace.
2 U35 FPI Direct Vent Gas Insert
TABLE OF CONTENTS
FPI GAS FIREPLACE INSERT
Page
Unit Dimensions ................................................................... 2
Safety Label ......................................................................... 4
INSTALLATION REQUIREMENTS
For Your Safety ...................................................................... 5
Gas Pressure Testing ........................................................... 5
Specifications ........................................................................ 5
Installation into a Solid Fuel Burning
Fireplace or Factory Built Fireplace ............................... 5
General Safety Information....................................................5
Installation Checklist .............................................................6
Materials Required ................................................................6
Minimum Fireplace Dimensions .......................................... 6
Clearances to Combustibles................................................7
Combustible Mantel Clearances .......................................... 7
INSTALLATION
Gas Connection .................................................................... 8
Venting ......................................................................... 8
Flue Liner Installation ............................................................ 8
Gas Pressure Test ................................................................ 9
SIT Valve Description ........................................................... 9
Gas Insert Aeration System .................................................. 9
Optional Brick Panel.............................................................. 9
Log Installation ................................................................... 1 0
Faceplate & Trim .................................................................10
Standard Flush Door ........................................................... 1 1
Optional Flush Trim ............................................................. 1 1
Flush Louvers ...................................................................... 11
Optional Bay Door ............................................................... 12
Optional Bay Trim ................................................................ 1 2
Bay Louvers ....................................................................... 12
Double Screen Door ........................................................... 1 2
Kensington Front ................................................................. 13
Full Screen Front .................................................................15
Wiring Diagram ................................................................... 17
Optional Remote Control .................................................... 17
Optional Wall Thermostat ................................................... 17
Final Check ....................................................................... 18
Page
OPERATING INSTRUCTIONS
First Fire ....................................................................... 18
Operating Instructions......................................................... 18
Lighting Procedure ..............................................................18
Shutdown Procedure...........................................................18
Copy of Lighting Instruction Plate ....................................... 19
Automatic Convection Fan Operation ................................. 19
Normal Operating Sounds of Gas Appliances ................... 1 9
MAINTENANCE
Maintenance ....................................................................... 20
General Vent Maintenance .................................................. 20
Log Replacement................................................................20
Glass Gasket.......................................................................20
Steel or Gold Plated Trim .................................................... 2 0
Door Glass ....................................................................... 21
Flush Glass Replacement ..................................................21
Bay Glass Replacement ..................................................... 21
Fan Maintenance ................................................................. 2 1
Valve Removal..................................................................... 22
Valve Installation ................................................................. 2 3
REPLACEMENT PARTS LIST
Parts List ....................................................................... 2 4
WARRANTY
Warranty ....................................................................... 31
U35 FPI Direct Vent Gas Insert
3
SAFETY LABEL
This is a copy of the labels that accompany
each U35 Gas Insert. We have printed a copy
of the contents here for your review. The
safety label is located on a plate inside the base
of the unit visible when the bottom louver is
opened.
NOTE: FPI units are constantly being improved. Check the label on the unit and if
there is a difference, the label on the unit
is the correct one.
For the State of Massachusetts, installation
and repair must be done by a plumber or
gasfitter licensed in the Commonwealth of
Massachusetts.
For the State of Massachusetts, flexible
connectors shall not exceed 36 inches in
length.
For the State of Massachusetts, the appliances individual manual shut-off must be a
t-handle type valve.
4 U35 FPI Direct Vent Gas Insert
INSTALLATION
IMPORTANT:
SAVE THESE
INSTRUCTIONS
The FPI Gas Fireplace must be installed in accordance with these instructions. Carefully read
all the instructions in this manual first. Consult
the building authority having jurisdiction to determine the need for a permit prior to starting the
installation.
NOTE: Failure to follow the instructions could
cause a malfunction of the heater which could
result in death, serious bodily injury, and/or
property damage. Failure to follow these instructions may also void your fire insurance
and/or warranty.
FOR YOUR SAFETY
This appliance requires air for proper combustion. Always provide adequate combustion and
ventilation air. Follow instructions and information in CAN/CGA B149 (in Canada) or the National Fuel Gas Code ANSI Z223.1 (in the USA),
regarding requirements for combustion and ventilation air.
GAS PRESSURE
TESTING
The appliance must be isolated from the gas
supply piping system by closing its individual
manual shut off valve during any pressure
testing of the gas supply piping system at test
pressures equal to or less than
1/2 psig. (3.45 kPa).
SPECIFICATIONS
At pressures over 1/2 psig, the pipe to the unit
must be disconnected.
Gas Input Capacity:
Natural Gas 35,000 Btu/h
Propane 35,000 Btu/h
Min. Input (Fan Off)
Natural Gas 17,500 Btu/h
Propane 17,500 Btu/h
Max. Output
Fan On Fan Off
Natural Gas 26,800 Btu/h 26,300 Btu/h
Propane 27,500 Btu/h 27,000 Btu/h
Fuels: Approved for use with both natural gas,
and propane. Approved as is for use at 0' to
4,500' (0-1370m).
Electrical: 120V A.C. system.
Circulation Fan: Variable speed, 127 CFM.
Log Set: Ceramic fibre, 3 per set.
Vent System: 3" co-linear aluminum flex.
The efficiency rating of the appliance is a
product thermal efficiency rating determined
under continuous operating conditions and
was determined independent of any installed
system.
INSTALLATION INTO A
SOLID FUEL BURNING
FIREPLACE OR
FACTORY BUILT
FIREPLACE
The U35 Gas Inserts have been tested and
approved to be vented into any masonry fireplace or approved solid fuel burning factory
built fireplace that will allow the insert to physically fit into the firebox. Refer to page 6 for
minimum fireplace clearances.
If the factory built fireplace* height is too
low for your Insert, you may remove the
smoke baffle plate and damper from the
factory built fireplace as long as these
items are saved and are reinstalled in
the event that the Insert is removed.
NOTE: Any alterations made to the listed
solid fuel burning factory built fireplace
may void the listing of the fireplace.
*Check with your local inspector before commencing with this installation.
BEFORE YOU START
Safe installation and operation of this appliance requires common sense, however, we
are required by the Canadian Safety Standards and ANSI Standards to make you aware
of the following:
General Safety Information
1) The appliance installation must conform
with local codes or in the absence of
local codes, with CAN/CGA B149 (in
Canada) or the National Fuel Gas Code
ANSI Z223.1 in the U.S.A. This appliance
should be installed by a qualified gas
fitter technician only.
2) Installation and repair should be done
by a qualified service person.
3) The appliance should be inspected
before use and at least annually by a
professional service person. More
frequent cleaning may be required
due to excessive lint from carpeting,
bedding material, animal hair, etc. It is
imperative that control compartments,
burners and circulating air passageways of the appliance be kept clean.
4) See general construction and assembly
instructions. This appliance may only be
installed in a vented, noncombustible fireplace.
5) This appliance is Listed for bedroom installations when used with a Listed Millivolt
Thermostat. Some areas may have further
requirements, check local codes before
installation.
6) Always connect this insert to a vent system
venting to the outside of the building envelope. Never vent to another room or inside
a building. Make sure that the vent is properly sized and is of adequate height to
provide the proper draft.
7) Inspect the venting system annually for
blockage and any signs of deterioration.
8) Any glass removed for servicing must be
replaced prior to operating the appliance.
9) WARNING: Failure to position the parts
in accordance with the diagrams in
this manual or failure to use only parts
specifically approved with this appliance may result in property damage or
personal injury.
10)To prevent injury, do not allow anyone who
is unfamiliar with the operation to use the
fireplace.
11)Due to high temperatures, the appliance
should be located out of high traffic areas
and away from furniture and draperies.
Children and adults should be alerted to the
hazards of high surface temperatures, especially the fireplace glass and gold trims,
and should stay away to avoid burns or
clothing ignition. Young children should be
carefully 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.
Emissions from burning wood or gas could
contain chemicals known to the State of
California to cause cancer, birth defects or
other reproductive harm.
U35 FPI Direct Vent Gas Insert
5
INSTALLATION
INSTALLATION
CHECKLIST
Before installing vent system ensure that the
damper plate is open and secure to prevent the
damper plate from falling down and crushing
the liner.
The FPI Gas Insert is installed as listed below.
1) Check all clearances to combustibles, see
page 7.
2) Make the gas connection. See page 8.
3) Install the 3" flue liner to the sliding connec-
tor plate. See page 8.
4) Slide the unit half way into the fireplace.
5) Pull the vent connector plate through the
tapered brackets and fasten to the front
plate. See page 8.
6) Slide the unit fully into the fireplace.
7) Test gas pressure, page 9. Check aeration
system, page 9.
8) Install the optional brick panels. See page
9.
9) Install the log set. See page 10.
10)Assemble and install the faceplate and trim.
See page 10.
MATERIALS
REQUIRED
No electrical power supply is required for the
gas control to operate. A 120 Volt AC power
cord is hooked up to the fan. Plug the 3 wire
cord into a suitable receptacle. Do not cut the
ground terminal off under any circumstances. When connected with 120 volts, the
appliance must be electrically grounded in
accordance with local codes, current version
of the Canadian Electrical Code CSA C22.1 (in
Canada) or in the absence of local codes, with
the National Electrical Code ANSI/NFPA 70.
NOTE: This unit is equipped with a
heat sensor thermodisc which will prevent the blower from operating until the
unit reaches the correct temperature.
WARNING:
Electrical Grounding Instructions
This appliance is equipped with a
three pronged (grounding) plug for
your protection against shock hazard and should be plugged directly
into a properly grounded threeprong receptacle. Do not cut or
remove the grounding prong from
this plug.
MINIMUM FIREPLACE
DIMENSIONS
The minimum fireplace clearances & dimensionsfor the FPI gas fireplace insert are shown
in the following diagrams:
11)Install the glass front (flush or bay). See
pages 11 & 12.
12)Install both louvers (flush or bay). See
pages 11 & 12.
13)Install optional double screen door. See
page 12.
14)Install optional remote control or wall thermostat, pages 17 & 18.
15) Final check: Before leaving this unit with
the customer, the installer must ensure that
the appliance is firing correctly. This includes:
a) Clocking the appliance to ensure the
correct firing rate.
b) Adjusting the primary air, if required,
to ensure that the flame does not
carbon. See page 9.
c) Ensuring that the appliance is vent-
ing correctly.
Note: If you are installing the Molded Faceplate,
the minimum fireplace dimensions are as follows:
Width (at front): 34-1/2" (876mm)
Depth: 18" (457mm)
Height: 26-3/4" (679mm)
6 U35 FPI Direct Vent Gas Insert
MINIMUM CLEARANCES TO COMBUSTIBLES
From Unit
Sides A 8" / 203 mm
Ceiling B 34" / 834 mm
INSTALLATION
31-1/8" x 44-1/8" (791mm x 1121mm)
From Standard Surround
Sides D 1-15/16" / 49 mm
Ceiling E 28-7/8" / 733 mm
Max. Mantel Depth G 12" / 305 mm
Hearth Height H 0" / 0 mm
Hearth Depth I 16" / 405 mm
Hearth Width J 44" / 1118 mm
Min. Alcove Width K 48" / 1220 mm
Max. Alcove Depth L 36" / 915 mm
REGENCY BAY & FLUSH
COMBUSTIBLE MANTEL CLEARANCES
KENSINGTON FRONT
COMBUSTIBLE MANTEL CLEARANCES
Because of the extreme heat this fireplace emits, the mantel clearances are critical.
Combustible mantel clearances from top of unit are shown in the above diagrams.
Note: A non-combustible mantel may be installed at a lower height if the framing is made of metal studs covered with a non-
combustible board.
Mantel can be installed anywhere in shaded area or higher using the above scale.
Note: Ensure the paint that is used on the mantel and the facing is "heat resistant" or the paint may discolour.
U35 FPI Direct Vent Gas Insert
7
INSTALLATION
GAS CONNECTION
GAS CONNECTION WARNING:
Only persons licensed to work
with gas piping may make the
necessary gas connections to
this appliance.
1) If the appliance is to be installed into an
existing chimney system, thoroughly clean
the masonry or factory built fireplace.
2) The appliance is provided with an opening
on the left hand side of the control compartment. A 3/8" NPT gas supply pipe must be
brought near this inlet hole.
3) Locate the center point where the vent will
pass through the chimney above the appliance. Move the appliance into the exact
location where it is to be installed. Ensure
that the Insert is level.
In areas of consistently high winds, we recommend using the Simpson Dura-Vent System
(923GK adapter and 991 high-wind cap).
The Air Intake pipe must be attached to the inlet
air collar of the termination cap.
5) Install flashing.
6) Insert both liners into chimney, passing
through the damper opening.
7) Install termination cap.
8) Connect the marked end of the liner to the
inlet collar of the vent connector plate
marked with an "I", seal connection with
high temperature silicone. Secure with gear
clamp.
9) Connect the 2nd liner to the exhaust collar
marked with an "E", seal connection with
high temperature silicone. Secure with gear
clamp.
VENTING
THE APPLIANCE MUST NOT BE
CONNECTED TO A CHIMNEY FLUE
SERVING A SEPARATE SOLID FUEL
BURNING APPLIANCE.
This appliance is designed to be attached to
two 3" (76mm) co-linear aluminium flex running
the full length of the chimney. The flue length
must be a minimum length of 8 ' (2.44m) and a
maximum of 35' (10.7m). See chart below for
minimum distances from roof. Periodically check
that the vent is unrestricted.
Masonry chimneys may take various contours
which the flexible liner will accommodate. However, keep the flexible liner as straight as
possible, avoid unnecessary bending.
Part # Description
948-305 3" Flex - 35 ft.
946-529 Co-linear DV Vertical
Termination Cap
Alternate Approved Caps
980 Vertical Termination Cap
991 High Wind Cap
923GK 3" Co-linear Adaptor with flashing
FLUE LINER
INSTALLATION
1) Cut the flex liner as required.
2) Mark the end of one liner to indicate
Inlet.
3) Connect the other end of the above liner to
the inlet side of the termination adaptor,
seal connection with high temperature silicone. Secure with gear clamp.
4) Connect the 2nd liner to the exhaust side of
the adaptor, seal connection with high
temperature silicone. Secure with gear
clamp.
NOTE: 1) Final gas connection should be
made after unit is in place to avoid
damage to line when pushing the unit
into position.
2) Mill-pac may be used instead of
high temperature silicone and screws
may be used instead of gear clamps
at connections of liner to inlet and vent
collars.
8 U35 FPI Direct Vent Gas Insert
INSTALLATION
GAS PIPE
PRESSURE TESTING
The appliance must be isolated from the gas
supply piping system by closing its individual
manual shut-off valve during any pressure
testing of the gas supply piping system at test
pressures equal to or less than 1/2 psig.
(3.45 kPa). Disconnect piping from valve at
pressures over 1/2 psig.
The manifold pressure is controlled by a regulator built into the gas control, and should be
checked at the pressure test point.
Note: To properly check gas pressure,
both inlet and manifold pressures
should be checked using the valve
pressure ports on the valve.
1) Make sure the valve is in the "OFF" position.
2) Loosen the "IN" and/or "OUT" pressure
tap(s), turning counterclockwise with a 1/
8" wide flat screwdriver.
3) Attach manometer to "IN" and/or "OUT"
pressure tap(s) using a 5/16" ID hose.
4) Light the pilot and turn the valve to "ON"
position.
5) The pressure check should be carried out
with the unit burning and the setting should
be within the limits specified on the safety
label.
SIT Valve Description
1) Gas cock knob
2) Manual high/low adjustment
3) Pilot Adjustment
4) Thermocouple Connection - option
5) Outlet Pressure Tap
6) Inlet Pressure Tap
7) Pilot Outlet
8) Main Gas Outlet
9) Alternative TC Connection Point
CAUTION: Carbon will be produced if air
shutter is closed too much.
Note: Any damage due to carboning re-
sulting from improperly setting
the aeration controls is NOT covered under warranty.
Note: Aeration Adjustment should only
be performed by an authorized FPI
Installer at the time of installation
or service.
OPTIONAL
BRICK PANEL
1) Unwrap the brick pattern panels from the
protective wrapping.
2) Remove the glass front if it is already
installed (see manual).
3) Put the rear brick panel flat against the back
of the unit.
4) Before installing the side brick panels,
loosen the screws for the brick tabs enough
so that you can slide the brick tabs on to the
screws easily but that the tabs are secure.
For the location of the side brick tab screws
see diagram 1.
6) When finished reading manometer, turn off
the gas valve, disconnect the hose and
tighten the screw (clockwise) with a 1/8"
flat screwdriver.
snug, but do not over tighten.
Note: Screw should be
GAS INSERT
AERATION SYSTEM
The air shutter can be adjusted by moving the
adjusting wire up or down. The wire is accessed through the bottom louver opening.
Open the air shutter for a blue flame or close
for a yellower flame. The burner aeration is
factory set but may need adjusting due to either
the local gas supply or altitude.
Minimum Air Shutter Opening:
1/8" Natural Gas
1/4" Propane
Diagram 1
5) Remove the brick tabs and slide the side
brick panels into position. Install the brick
tabs. See diagrams 1 and 2.
Diagram 2
U35 FPI Direct Vent Gas Insert
9
INSTALLATION
LOG INSTALLATION
WARNING: Dangerous operating conditions may occur if these logs are not
positioned in their correct certified locations. Read the following instructions
carefully and refer to the attached diagram.
1) Remove the logs from the box and carefully
unwrap them. The logs are fragile, handle
with care. Do not force into position.
2) Place the rear log on the rear log support in
the back of the unit with the flat side of the
log facing the back of the unit. Carefully
push the log down onto the pins.
3) Sprinkle the vermiculite and ember combination on the sides of the firebox base.
4) Place the front logs in the unit, aligning the
holes on the underside of the logs with the
log support pins in the front of the unit.
Carefully push the logs down onto the pins.
(Hint: Install the front right side first.)
5) Test for pilot ignition.
6) Install the door and louvers.
NOTE: There are NO Rockwool or Large
Ember pieces used on the U35 Log
Set.
FACEPLATE & TRIM
INSTALLATION
1) Lay the faceplate panels flat, face down on
something soft so they don't scratch.
2) Take the top faceplate and align the holes in
it with the holes in the side panels. Using the
screws provided, attach from the top of the
panel (the holes in the top panel are slightly
larger than the holes in the side panel to
facilitate easier installation). Diagram 1.
Hint: Don't tighten the screws down completely at this point, continue on with
steps 3 and 4 and do a trial fit to the unit. Make
any necessary adjustments and when it fits
properly then tighten down the screws.
3) Using the connectors provided, join the left
side trim (with the ON/OFF switch) to the top
trim. Diagram 2. Connect the right side trim
to the top trim.
4) Place the trim on the assembled faceplate
panels, aligning the wire connections from
the switches with the notch on the left side
panel.
Rear View: Faceplate Assembly
Diagram 1
Rear View: Trim Assembly
Diagram 2
5) Connect the fan switch wires by taking the
black and red wires with the male ends (in
the grey harness) and connect them with
the wire connectors from the fan speed
control.
6) Connect the ON/OFF switch wires by taking the black and red wires with the female
ends and connect them to the ON/OFF
switch.
7) Tuck the wires into the faceplate to keep
them away from the insert using the clip
provided. Attach the clip to the rear of the
faceplate to ensure that the wires do not
touch the side of the unit.
Diagram 3.
8) The power cord should be run behind the
faceplate panel.
10 U35 FPI Direct Vent Gas Insert
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