Harman Castlewood 42 Quick Start Manual

Models: Outdoor Woodburning Castlewood 42

Owner’s Manual

Installation and Operation

CAUTION

DO NOT DISCARD THIS MANUAL

• Important operating

and maintenance instructions included.

• Read, understand and follow these

instructions for safe installation and operation.

WARNING

If the information in these instructions is not followed exactly, a

 re may result causing property damage, personal injury, or death.

• Do not store or use gasoline or other  ammable vapors and liquids in the vicinity of

this or any other appliance.

• Do not over re. Over ring will void your warranty.

• Comply with all minimum clearances to combustibles as speci ed. Failure to comply may cause house  re.

DO NOT

DISCARD

• Leave this manual with

party responsible for use and operation.

WARNING

HOT SURFACES!

Glass and other surfaces are hot during

operation and cool down.

Hot glass will cause burns.

• Do not touch glass until it is cooled

• NEVER allow children to touch glass

• Keep children away

• CAREFULLY SUPERVISE children in same room as

appliance.

• Alert children and adults to hazards of high

temperatures.

High temperatures may ignite clothing or other  ammable materials.

• Keep clothing, furniture, draperies and other combustibles away.

Installation and service of this  replace should be performed by quali ed personnel. Hearth & Home Technologies suggests NFI certi ed or factory-trained professionals, or technicians supervised by an NFI certified

professional.

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

WARNING

Fire Risk

• For use with solid wood fuel or decorative

gas appliance only.

• Do not install unvented gas logs.

Read this manual before installing or operating this replace.

Please retain this owner’s manual for future reference.

Congratulations!

Congratulations on selecting a Outdoor Lifestyles wood burning replace. The Outdoor Lifestyles replace you have

selected is designed to provide the utmost in safety, reliability and efciency.

As the owner of a new replace, you’ll want to read and carefully follow all of the instructions contained in this owner’s manual. Pay special attention to all cautions and warnings.

This owner’s manual should be retained for future reference. We suggest you keep it with your other important documents

and product manuals.

The information contained in this owner’s manual unless noted otherwise, applies to all models and gas control systems.

Your new Outdoor Lifestyles wood burning replace will give you years of durable use and trouble-free enjoyment. Welcome

to the Outdoor Lifestyles family of replace products!

Homeowner Reference Information

We recommend that you record the following pertinent

information about your replace:

Model Name: Date purchased/installed:

Serial Number: Location on replace:

Dealership purchased from: Dealer phone:

Notes:

Listing Label Information/Location

The model information regarding your specic replace can be found on the rating plate located on the smoke shield of the replace.

Serial

Number

Grate Fireplace

Model

FIREPLACE NO.

OUTDOOR FIREPLACE INTENDED FOR USE WITH HEARTH & HOME TECHNOLOGIES INC. LISTED FIREPLACE PARTS. SEE INSTALLATION AND OPERATING INSTRUCTIONS FOR THIS MODEL. ONLY HEARTH & HOME TECHNOLOGIES INC. GLASS DOOR KITS CAN BE INSTALLED ON THIS UNIT.

FIREPLACE ALSO FOR USE IN MANUFACTURED HOMES

FAN KIT MODEL NO.

DO NOT OVERFIRE. USE ONLY: SOLID WOOD FUEL OR LISTED DECORATIVE GAS APPLIANCE. DO NOT USE A FIREPLACE INSERT OR OTHER PRODUCTS NOT SPECIFIED FOR USE WITH THIS PRODUCT. IF DOORS ARE USED OPERATE FIREPLACE WITH DOORS FULLY OPEN OR CLOSED ONLY. WHEN BURNING A DECORATIVE GAS APPLIANCE IN THE FIREPLACE, ADJUST DAMPER TO THE FULLY OPEN POSITION.

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

WARNING: RISK OF FIRE DAMAGE. REPLACE GRATE WITH HEARTH & HOME TECHNOLOGIES INC.

YES

IF INSTALLATION OR OPERATING INSTRUCTIONS ARE MISSING CONTACT: HEARTH & HOME TECHNOLOGIES INC., 1915 W. SAUNDERS ST., MT. PLEASANT, IA 52641.

MODEL NO.

CLEARANCE TO COMBUSTIBLES:

WARNING! THIS FIREPLACE HAS NOT BEEN TESTED WITH AN UNVENTED GAS LOG SET. TO REDUCE THE RISK OF FIRE OR INJURY, DO NOT INSTALL AN UNVENTED GAS LOG SET INTO FIREPLACE.

WARNING! TO AVOID THE RISK OF DAMAGING FIREPLACE MATERIALS AND INCREASING THE RISK OF SPREADING A FIRE DO NOT USE THE FIREPLACE TO COOK OR WARM FOOD.

MODEL NO.

CHIMNEY 2 IN. MIN.

RATED AT 115 VOLTS, 50/60 Hz.,

FIREBOX

MFG. DATE

IN. MIN.

AMP.

1 Listing and Code Approvals

A. Appliance Certication .........................4

2 Getting Started

A. Design and Installation Considerations ............5

B. Non-Combustible Materials .....................5

C. Combustible Materials .........................5

D. Tools and Supplies Needed .....................5

E. Inspect Fireplace and Components ...............6

F. Grate .......................................6

G. Firescreen ...................................6

H. Cooling Air ..................................6

I. Molded Brick Panel ............................6

3 Framing and Clearances

A. Selecting Fireplace Location ....................7

B. Clearances .................................9

C. Sidewalls/Surrounds .........................10

D. Frame the Fireplace .........................10

E. Chimney Requirements .......................11

4 Installation of Fireplace

A. Secure the Fireplace .........................12

B. Install Cooling Air Hoods ......................13

5 Chimney Assembly

A. Chimney Requirements .......................14

B. Assemble the Chimney Sections ................15

C. Using Offsets/Returns .........................16

6 Complete the Enclosure

A. Chimney Termination .........................17

B. Chase Top ..................................17

C. Install the Termination Cap .....................17

7 Installation of Molded Brick Panel

A. Install Hearth Molded Brick Panel ................19

B. Install Back Molded Brick Panel .................19

C. Install Side Molded Brick Panel .................19

D. Install Screens ..............................20

E. Mortar (Optional) .............................20

8 Accessories

A. Gas Log/Lighter Provisions ....................21

9 Finishing

A. Non-combustible Materials .....................22

B. Combustible Materials ........................22

C. Hearth Extension ............................22

D. Raised Hearth Extension Framing ...............23

E. Non-combustible Sealant ......................24

F. Finishing Material ............................25

G. Mantel .....................................26

10 Operating Instructions

A. General Information ...........................27

B. Grate ......................................27

C. Clear Space Near the Fireplace .................28

D. Firescreen ..................................28

E. Glass Doors .................................28

F. Wood Fuel ..................................29

G. Starting a Fire ...............................30

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

Table of Contents

11 Troubleshooting

A. Diagnostics and Problem Solving ................31

12 Maintenance and Servicing the Fireplace

A. Disposal of Ashes ...........................32

B. Chimney Inspection/Cleaning ..................32

C. Firebox Refractory ...........................32

D. Maintenance Task List ........................33

E. Chimney Fire ...............................33

13 Reference Materials

A. Fireplace Dimensions .........................34

B. Optional Components .........................35

C. Chimney Components ........................36

D. Termination caps .............................38

E. Service Parts List ............................39



F. Limited Warranty ............................41

G. Contact Information ..........................43

Listing and Code Approvals

A. Appliance Certication

This replace system has been tested and listed in accordance with UL 127 and CAN/ULC-S610-M87 standards by Underwriters Laboratories Inc. for installation and operation in the United States and Canada. This replace has been tested and listed for use with the optional components specied in this manual. These optional components may be pur-

chased separately and installed at a later date.

Outdoor Lifestyles is a registered trademark of Hearth & Home Technologies Inc.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to the owner’s information manual provided with this replace. For assistance or additional information consult a qualied installer, service agency or your

dealer.

Not intended for use as a primary heat source.

This replace is tested and approved as a decorative replace. It should not be factored as a primary heat

source in residential heating calculations.

WARNING

Fire Risk

• Do not install or operate damaged replace.

• Do not modify replace.

• Installation other than as instructed by Hearth & Home

Technologies Inc. is strictly prohibited.

• Do not operate the replace without fully assembling

all components.

• Do not overre.

• THIS FIREPLACE HAS NOT BEEN TESTED FOR USE

WITH UNVENTED GAS LOGS. TO REDUCE RISK OF

FIRE OR INJURY, DO NO INSTALL AN UNVENTED GAS LOG SET INTO THIS FIREPLACE

• Installation and/or use of any component part not approved by Hearth & Home Technologies.

Hearth & Home Technologies disclaims any responsibility

for, and the warranty and agency listing will be voided by the above actions.

WARNING

Fire Risk

• WARNING! TO AVOID THE RISK OF DAMAGING FIREPLACE MATERIALS AND INCREASING THE RISK OF SPREADING A FIRE, DO NOT USE THE

FIREPLACE TO COOK OR WARM FOOD.

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

Getting Started

A. Design and Installation Considerations

CAUTION

Check building codes prior to installation.

• Installation MUST comply with local, regional,

state and national codes and regulations.

• Consult insurance carrier, local building inspector, re ofcials or authorities having jurisdiction about restrictions, installation inspection, and permits.

When planning a replace installation, it is necessary to determine the following information before installing:

• Where the fireplace is to be installed. See Sections 3 and 4.

• The vent system conguration to be used. See Sections 5 and 6.

• Framing and nishing details. See Sections 3, 6 and 8.

• Whether optional accessories are desired. See Section 12.

Moisture Resistance:

This outdoor replace will shed moderate amounts of water, but is not waterproof. Water and condensing water vapor

may enter the chase under certain conditions.

The replace will not perform as an exterior wall. Moisture

penetration must be considered for construction that places

the replace in structure walls or on moisture sensitive sur-

faces.

When installed on exterior walls: Hearth & Home Tech- nologies recommends that the replace chase be constructed outside the structure’s weather envelope. Where the platform meets the wall, use a ashing detail similar to that required for attached decks. Chase platforms, including hearths should slope away from the structure at 1/8 in. to 1/4 in. per foot. The replace can be shimmed level.

When installed on surfaces where water may collect or cause damage: Hearth & Home Technologies recommends

that a drainage pan be placed under the unit. This can be

constructed of metal, adhesive polymer membrane (such as ice and water shield) or other suitable materials. A means of drainage out of the pan such as tubes or weep holes should be provided. A slope of 1/8 in. to 1/4 in. per foot towards the drain port is suggested. The replace can be shimmed level.

Hearths should slope away from the front of the replace and chase at 1/8 in. to 1/4 in. per foot. Spark strips must be

on top of any combustible hearth materials used for moisture management.

B. Non-Combustible Materials

Materials which will not ignite and burn, composed of any combination of the following:

- Steel -Iron

- Brick -Tile

-Concrete -Slate

-Glass -Plasters Materials reported as passing ASTM R 136, Standard Test Method for Behavior of Metals, in a Vertical Tube Furnance aat 750° C

C. Combustible Materials

Materials made of or surfaced with any of the following

materials:

-Wood -Compressed paper

-Plant bers -Plastic

Any material that can ignite and burn; ame proofed or not, plastered or un-plastered.

D. Tools and Supplies Needed

Before beginning the installation be sure the following tools and building supplies are available:

Reciprocating Saw Framing material

Pliers High temp caulking material

Hammer Gloves

Phillips screwdriver Framing square

Flat blade screwdriver Electric drill and bits

Plumb line Safety glasses

Level Tape measure

1/2-3/4 in. lenght, #6 or #8 self-drilling screws

Misc. screws and nails

Read all the instructions before starting the

installation. Follow these instructions carefully

during the installation to ensure maximum safety

and benit.

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

E. Inspect Fireplace and Components

WARNING

Fire Risk

Explosion Risk

Inspect fireplace and components for

damage. Damaged parts may impair safe

operation.

• Do NOT install damaged components.

• Do NOT install incomplete components.

• Do NOT install substitute components

• Carefully remove the replace and components from the

packaging.

The replace system consists of the following:

• Fireplace / Integral grate/dual cooling air inlet hoods, rescreen, and hearth refractory.

F. Grate

This replace is designed to be used with the grate supplied with this unit or one approved by HHT. The grate will deteriorate over time and will need occasional replace-

ment.

I. Molded Brick Panel

• The molded brick panels are shipped separately, but required to contain heat and provide an attractive interior.

• They will deteriorate over time and will need occasional replacement. Small hairline cracks and discoloration are

normal and do not affect safety.

• Mortar is not necessary but can be used to enhance the appearance.

Warning! Risk of Fire!

Use only the factory-supplied intergral grate.

Keep logs in place.

Allows proper air circulation around the re.

G. Firescreen

The rescreen is provided to control sparks. Keep it closed when the replace is in use.

WARNING!

SCREEN WILL NOT PREVENT BURNING MATERIALS FROM FALLING OUT.

SCREEN PULLS OR HANDLES MAY BE HOT

Risk of Fire or Burns!

H. Cooling Air

Cooling air is necessary to install the replace on a combustible surface and in a combustilbe enclosure. Two inlet hoods are provided and must be installled, to allow cooling air to be drawn into the enclosure. Ducting between the hoods and the replace is not necessary.

The complete structure must be noncombustible if the hoods

are not installed.

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

Framing and Clearances

WARNING

Fire Risk

Provide adequate clearances.

• Around air openings

• To combustibles

• For service access. Locate replace away from trafc areas.

A. Selecting Fireplace Location

This outdoor replace will shed moderate amounts of water, but is not waterproof. Water and condensing water vapor

may enter the chase under certain conditions.

The replace will not perform as an exterior wall. Moisture

penetration must be considered for construction that places

the replace against structure walls or on moisture sensitive

surfaces.

• Exterior Walls (see Figure 3.1)

Hearth & Home Technologies recommends that the

replace chase be constructed outside the structure’s weather envelope. Where the platform meets the wall, use a ashing detail similar to that required for attached decks. Chase platforms, including hearths, should slope away from the structure at 1/8 in. to 1/4 in. per foot. The replace can be shimmed level. Build the outside enclosure out of standard building materials, being careful to maintain the minimum air clearances specied in these installation

instructions.

Note:

• Illustrations and photos reect typical installations

and are FOR DESIGN PURPOSES ONLY.

• Illustrations/diagrams are not drawn to scale.

• Actual installation/appearance may vary due to

individual design preference.

• Hearth & Home Technologies reserves the right to

alter its products.

• Freestanding Installations (see Figure 3.2)

When installing this replace as a freestanding replace in

your yard, it must be enclosed to prevent impact damage to the replace.

• Porch and Patio Installations

The replace will not perform as an exterior wall. Hearth

& Home Technologies recommends that the replace chase be constructed outside the structure’s weather envelope. Where the platform meets the wall, use a ashing detail similar to that required for attached decks. Chase platforms, including heaths should slope away from the structure at 1/8 in. to 1/4 in. per foot. The replace can be shimmed level.

• The cooling air hoods MUST be used if installing in

a combustible enclosure. Ducting is not necessary

between the hoods and the replace.

• If replace is installed on cement and totally enclosed with

non combustilbe materials (i.e. metal studs, cement board, etc.) the cooling air hoods do not need to be installed.

• When Installed on Surfaces Where Water May Collect

or Cause Damage:

Hearth & Home Technologies recommends that a drainage

pan be placed under the unit. This can be constructed

of metal, adhesive polymer membrane (such as ice and water shield) or other suitable materials. A means of drainage out of the pan such as tubes or weep holes should be provided. A slope of 1/8 in. to 1/4 in. per foot towards the drain port is suggested. The replace can be shimmed level. Hearths should slope away from the front of the replace and chase at 1/8 in. to 1/4 in. per foot. Spark strips must be used on top of any combustible

hearth materials used for moisture management.

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

Note: If this surface is inside the building’s warm air enevelope...

...then this surface must be an exterior wall system.

1-1/2 [ ]

737

[ ]

28-1/2

724

[ ]

1-1/2

[ ]

1/2

[ ]

1344

[ ]

1369

[ ]

67-1/2

1714

[ ]

1-1/2

[ ]

1-1/2

[ ]

1/2

[ ]

Figure 3.1 Fireplace Locations

(Enclosed Fireplace)

FREESTANDING

INSTALLATION

Figure 3.2 Freestanding Fireplace Locations

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

1/2

[ ]

10 ft Min.

1346

[ ]

1372

[ ]

95-1/2

2424

[ ]

(Combustible Structure)

1/2

[ ]

B. Clearances

WARNING

Fire Risk

• Comply with all minimum clearances to combustibles as specied.

• Framing or nishing material used on the front of, or in front of, the appliance closer than the minimums listed, must be constructed entirely of noncombustible materials (i.e., steel studs, concrete board, etc.).

Failure to comply may cause re.

0 in. to level of standoffs

1-1/2 to side and back

Figure 3.3 Clearance to Combustible

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

0 in.

1/2 in to framing

C. Sidewalls/Surrounds

Note: Grid depicts 1 inch squares.

• Locate adjacent combustible sidewalls a minimum of 24 in. (610 mm) from replace opening.

• Mantle leg, surround, stub wall, whether combustible or non-combustible, may be constructed as shown in Figure 3.4.

FLUSH

FRONT

BRICK

FRONT

4 in.

[102 mm]

42 in.

22 3/8 in. [568 mm]

50° angle

[1067 mm]

52-7/8 in.

(1343 mm)

39° angle

19 3/4 in. [500 mm]

18 1/2 in. [470 mm]

24 in.

[610 mm]

Figure 3.4 Mantel Leg, Surround or Wall Projection (acceptable on both sides of opening)

24 in.

[610 mm]

D. Frame the Fireplace

Figure 3.4 shows typical framing using combustible materials (2x4 lumber shown). Cooling air hoods required If total structure is non-combustible, cooling air hoods are not necessary.

• Observe all required air space clearances to combustible materials as shown in Figure 3.5.

2 in./51 mm minimum air space clearance to the enclosure.

28-3/8 in.

721 cm

Figure 3.5 Framing the Fireplace

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

74- 1/2 in. 1892 cm

53-7/8 in. 1368 cm

Metal framing stud to provide support and backing for wall material and mantel.

area to be covered with nonccombustible material.

E. Chimney Requirements

When planning your replace location, the chimney construction and necessary clearances must be considered. The replace system and chimney components have been tested to provide exibility in construction. The following gures are the minimum distances from the base of the replace.

• Minimum overall straight height is 10 ft If the replace is freestanding and a minimum of 10 ft from a combustible structure. See Figure 3.2.

• Chimney must extend 2 ft (.6 m) above any portion of the roof within 10 ft (3048 mm) of the chimney. Refer to Figure 6.2.

ft m

• Minimum height width offset/return 16 4.88

• Maximum height 90 27.43

• Maximum chimney length between an offset

and return

• Maximum distance between chimney

stabilizers

• Double offset/return minimum height 24 7.32

• Maximum unsupported chimney length

between the offset and return

• Maximum unsupported chimney height above

the replace

• Minimum overall straight height if replace is

freestanding

20 6.1

35 10.67

6 1.83

35 10.67

6.4 3.048

91/2 ft

* Transition section standard with unit and 1 foot section

required in addtion as minimum

or SLA10 (for Canada)

CAK8A required for Canada installation

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

Installation of Fireplace

Top piece must overlap

A. Secure the Fireplace

Position the Fireplace

This replace may be placed on either a combustible

or noncombustible continouous at surface. Follow the instructions for framing in Section 3.D. Slide the replace into position. Be sure to provide the minimum air clearance at the sides and back of the replace assembly. See Section 3.B.

WARNING

FIre Risk!

Prevent contact with sagging, loose

insulation.

Do NOT instal against vapor barriers or e x po se d

insulation.

Cooling Air Hoods must be installed if

instaling on a combustible surface.

Level the Fireplace

Level the replace side-to-side and front-to-back. Shim with noncombustible material, such as sheet metal, as necessary. Secure the replace (using the nailing anges located on either side of the replace) to the vertical framing.

Note: When elevating the fireplace above the hearth extension the front of the elevated platform must be protected with a protective metal hearth strip.

Important: To ensure proper t of the glass doors, check

the fireplace opening for square. Measure diagonal distances of the opening to make sure they are equal.

If they are not, continue to shim the replace until those

diagonals are equal.

• Place the Protective Metal Hearth Strips

1 in. (25 mm) overlap

Protective metal strips are placed 2 in. (51 mm) under the front of the fireplace and must extend beyond the front and sides of fireplace opening by 2 in. (51 mm).

Figure 4.1 Position the Protective Metal Hearth Strips

Included with your replace you will nd two metal hearth strips measuring approximately 26 in. x 4 in. (660 mm x 102 mm). These strips are used to provide added protection where the replace and the hearth extension meet when installed on a combustible service.

Slide each metal strip 2 in. (51 mm) under the front edge of the replace. The individual pieces must overlap each other by 1 in. (25 mm) minimum in the middle of the replace to provide continuous coverage of the oor. See Figure 4.1. These metal strips should extend from the front and sides of the replace opening by 2 in. (51 mm).

WARNING

Fire Risk!

• Metal hearth strips MUST be installed. Sparks or embers may ignite ooring.

bottom piece

Raised Platform

2 in.

(51 mm)

Floor

2 in.

Figure 4.2 Protect the Front of an Elevated Platform

(51 mm)

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

1 in. (25 mm) min.

overlap

B. Install Cooling Air Hoods

WARNING! Cooling air must be provided when install-

ing in combustible enclosure or on combustible surface.

• Locate cooling air hoods to prevent blockage from leaves, snow/ice, or other debris. Blockages could cause the unit to overheat.

• Recommended bottom of a 7-3/4” X 7-3/4” or 7-3/4” diameter hole 12” above bottom of unit

• Do Not place cooling air hood close to exhaust vent.

• The outside air hood can be painted to match/accent

the color of the structure.

Caution! Risk of Fire or Asphyxiation! Do not draw

outside air from wall, oor, or ceiling cavity, or enclosed

spaces such as an attic or garage.

Outdoor Lifestyles by Hearth & Home Technologies Inc. • 4070-300 Rev E • 11/25/13

+ 30 hidden pages