Lennox BV4000C User Manual

EPA CERTIFIED

CATALYTIC

WOOD BURNING

FIREPLACE

INSERT

INSTALLATION AND OPERATION

MANUAL

RETAIN THESE

INSTRUCTIONS

FOR FUTURE

REFERENCE

MODEL BV4000C

THIS APPLIANCE MUST BE INSTALLED BY A QUALIFIED TECHNICIAN.

READ MANUAL THOROUGHLY BEFORE INSTALLATION.

P/N 775006M, Rev. J, 04/01

IMPORTANT WARNINGS

CAUTION: Read this manual thoroughly before starting installation. For your safety, follow the installation, operation 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.

1. If utilizing an older chimney, it must be inspected for adequate serviceability. Refer to the heading Chimney Inspection on page 6.

2. Install only in masonry fireplaces, built to UBC chapter 37 standards or listed factory built fireplaces.

3. 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.

4. This appliance requires a non-combustible heat resistant approved fireplace hearth or hearth extension. 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 (see floor protection on page 5 for additional infor mation).

5. Minim um ceiling height must be 7 feet (measured from base of appliance to ceiling).

6. DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE CONNECTED TO ANOTHER APPLIANCE.

7. Do not connect this appliance to air ducts or any air distribution system.

8. Do not install appliance in a sleeping room.

9. PREVENT CREOSOTE FIRE: Inspect and clean chimney frequently. Under certain conditions of use, creosote buildup may occur rapidly. Inspect chimney connector and chim ney twice monthly and clean if necessary. Using green or inadequately seasoned wood can greatly increase creosote buildup. Use dry wood to minimize creosote buildup.

10. USE SOLID WOOD FUEL ONLY: This appliance is approved for burning dry seasoned natural wood only.

11. Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or sim ilar liquids to start or "freshen up" a fir e in this heater. Keep all such liquids well away from the heater while it is in use.

12. DO NOT OVERFIRE: If heater or chimney connector glows, you are overfiring. Overfiring this appliance could cause a house fire. Overfiring is a condition where the appliance is operated at temperatures above its design capabilities. Overfiring can be caused by improper installation, improper

operation, lack of maintenance or improper fuel usage. Damage caused from overfiring is NOT covered under the manufacturers limited warranty.

13. 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 primary 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.

14. Us e a metal container with a tight fitting lid to dispose of ashes.

15. 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 fireplace insert is operating (see Ventilation on page

6).

16. CAUTION: HOT WHILE IN OPERATION. An appliance hot enough to warm your home can severely burn anyone touching it. Keep children, clothing and furniture away. Contact may cause skin burns. Do not let children touch the applianc e. Train them to stay a safe distance from the unit.

17. Once the fire is established, never burn the appliance with the bypass open, except when refueling the appliance.

18. CATALYTIC COMBUSTOR: Do not operate this appliance without the catalytic combustor assembly (this consists of ceramics, gasket and a housing) properly installed. Burning of metal foils , coal, plastic garbage, diesel oil and sulfur will make the catalyst in the combustor inactive. T he combustor is fragile; handle carefully. The per formance of the catalytic device or its durability has not been evaluated as part of the certification.

19. Build fires directly upon the brick hearth inside the fireplace insert. Do not use grates, irons or any other method to elevate the fire.

20. SAVE THESE INSTRUCTIONS.

21. See the listing label located on the back of fireplace (or see Safety/Listing Label on page 26).

PAGE 2

TABLE OF CONTENTS

Important Warnings ................................................. 2

Testing / Listing, EPA, Using this Manual ............... 3

Planning Your Installation......................................4-7

Installation .......................................................... 8-11

Product Features and Controls ............................. 11

Care and Operation ..........................................13-16

Recommended Fuel............................................... 17

Maintenance......................................................17-19

Troubleshooting................................................. 20-21

Specifications ......................................................... 22

Replacement Parts List ..................................... 23-24

Optional Accessories.............................................. 25

Safety / Listing Label and EPA Label..................... 26

Service / Maintenance Log..................................... 27

CONGRATULATIONS ON THE PURCHASE OF YOUR NEW WOOD BURNING FIREPLACE INSERT MANUFACTURED 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 ref lects their concern for aesthetics, ef ficien cy and ou r env ironment. 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 selecting a Lennox Hearth Products insert as the answer to your home heating needs.

Sincerely, All of us at Lennox Hearth Products

TESTING/LISTING

Model BV4000C has been tested to UL Standards; UL1482 for installation into residential applications . T he listing laboratory is OMNI Environmental Services, Beaverton, Oregon.

EPA CERTIFICATION

This fireplace insert has been tested to rigorous emissions standard, and has been certified by the Environmental 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. T he Homeowner’s Care and Operation Instructions inc luded here will assure you have many years of dependable and enjoyable service from your appliance.

PAGE 3

PLANNING YOUR INSTALLATION

QUESTIONS TO ASK LOCAL BUILDING OFFICIAL

A correct installation is c ritical and im perative f or reducing fire hazards and perilous conditions that can arise when wood burning appliances are improperly installed. The installer must follow all of the manufacturers’ instructions.

The installation of a wood burning appliance m ust conform to local codes and applicable state and federal requirements. Familiarity with these requirements before installation is essential. Impor tant considerations to discuss with local building officials include:

1. Applicable codes (i.e. Uniform Mechanic al Code, State or Regional Codes.)?

Electrical codes: The blower system has a flexible 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 Instructions: 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.

SMOKE DETECTORS

Since there are always several potential sources of fire in any home, we recommend installing smoke detectors. If possible, install the sm oke detector in a hallway adjacent to the room (to reduce the pos sibility of occasional false activation from the heat produced by the fireplace insert). If your local code requires a smok e detector be installed within the same room, you mus t follow the requirements of your local code. Check with your local building department for requirements in your area.

2. Local amendments?

3. Is a permit required - cost?

(You may wish to contact your insurance company to ask if they require this).

4. Rooms where the installation is not allowed?

PAGE 4

PLANNING YOUR INSTALLATION

FLOOR PROTECTION

This appliance requires a heat resistant noncombustible approved fireplac e hearth or hearth extension. 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 m ust be mortared or grouted to form a continuous noncombustible surface (See Using Alternate Material As Floor Protector on this page).

This protected area must extend a m inimum of 16" to the front of the fuel door opening and 8" beyond both sides of the fuel door opening

HEARTH PROTECTION

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

TM (inches) = K

material (per inch)

x T

1.28

(inches) = 0.43* x 1”

1.28

Answer using k = 0.34 x 1” = 0.34 = 3/8” 3/8” thickness Micore will be required.

Using the r formula: TM (inches) = 0.78 x T

TM (inches) = 0.78 x 1”

2.33*

Answer using r = 0.34 x 1” = .034 = 3/8” 3/8” thickness Micore will be required.

USING ALTERNATE MATERIAL AS A FLOOR PROTECTOR/HEARTH EXTENSION

The alternate material used as a hearth extension m ust be constructed of a durable noncombustible material having an equal or better insulating value (lower k value) of k = 1.28 BTU/IN FT that equals or exceeds r = 78 HR °F FT

HR °F or a thermal resistanc e

IN/BTU. W ith these values, determine the minimum thickness/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 cas es , if the k value is less or the r value higher, a thinner m aterial 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: T

= Thickness of material in inches

= K value of desired material

= Minimum listed thickness

Example: Micore CV230 is to be used for the floor pr otection. How thick must this material be?

At times it is important to know what combination of materials are acceptable for use as floor pr otection. T he “R values” are used to determ ine acceptable combinations of materials because “R values” ar e additive where r and k values are not.

“R value” = 1 = r x thickness of material used

ALTERNATIVE FLOOR PROTECTION MATERIALS Listed Values Min. Thick Material k

(per inch)r (per inch)

Millboard 1.28 0.78 1” Alternative Values Min. Thick Materials k

(per inch)r (per inch)

Wonderboard 1.92 0.56 1 1/2” Common brick 5.00 0.20 3 7/8” Cement mortar 5.00 0.20 3 7/8” Ceramic tile 12.5 0.08 9 3/4” Marble 11.0 0.09 8 5/8” Micore CV230

0.43 2.33 3/8” (U.S. Gypsum) Ceraform 126

0.27 3.70 1/4” (Johns-Manville)

Example: Given that the required “R value” for a suitable floor protector used must be equal to or greater than: “R” = r x T

= 0.78 x 1” = 0.78.

PAGE 5

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 chim ney system shows signs of str uctural or mechanical weak nesses, such as: cracks, leaky joints, corroded or warped surfaces. Look f or obvious bulges in the lining, which may indicate the need to replace that section (use a bright flashlight. Any faulty portion must be repaired or replaced prior to installing this appliance. Also, inspect the attic to see that the chimney 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 f lue system is dirty or has some obstruction in it, clean it. A dirty chimney can cause your insert to smoke when refueling, and can res ult in a chimney fire. An oversized chimney may result in less than optimum perform ance. 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 inser t which were determined in a laboratory testing and must be maintained.

Minimum Clearance to Combustibles

Stove top to mantel: 32" Stove top to trim: 24" Stove side to trim: 9" Stove side to sidewall: 17"

DRAFT REQUIREMENTS

The appliance is mer ely one component of a larger system. The other equally important com ponent is the venting system. This is neces sary for achieving the required flow of combustion air to the f ire chamber and for safely removing unwanted combustion byproducts f rom the appliance. If the venting system's design does not prom ote these ends, the system may not function properly. Poorly functioning venting systems may create performance problems as well as be a saf ety 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 appliance. The combus tion 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 FIREPLA CES

This appliance is approved for installation into a listed f ac tor y built solid fuel burning fireplace. The fireplac e firebox must accept the insert without modification other than removing bolted or screwed together pieces such as smoke shelf/deflectors, ash lips, screen or door tracks and damper assem blies, that must be reinstalled to restore the fireplace to its original operating condition if the insert is removed and not r eplaced. T he rem oval 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 dam per mus t be secured in the open position. This appliance requires the use of a 6” diameter flex or rigid, UL1777 listed 2100° HT liner or equivalent. The liner must extend fr om the flue outlet of the appliance to termination. Do not face seal over fireplace chimney co o li n g a i r s ys t e m s . O ffsets c an be handled with an offset adapter (it aligns starter pipe with fireplace flue). F or 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.

MASONRY FIREPLACES

This appliance is approved for installation into a masonry fireplace built to UBC Chapter 37 standards. Do not rem ove brick or mortar f orm the m asonry fireplace to accom modate this appliance.

Venting Requirements for masonry fireplace:

The fireplace dam per mus t be secured in the open position. As a minimum , a flue extension pas t 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 r ecom mended) . 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.

FIREPLACE CHIMNEY MAXIMUM SIZE TO ENSURE PROPER DRAFT

The fireplace insert f lue size is 6 inches diameter, 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:

x r

= Area (π = 3.1416, r = 1/2 diameter)

PAGE 7

To calculate area of square or rectangle: Width x Depth = Area

Notes: ! 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.I. for optimum performance.

! T his appliance is appro ved f or all heatf orm style

fireplaces (masonry fireplace with a metal firebox liner).

Measure fireplace size to make certain the insert will fit before considering the i nstallation.

INSTALLATION

FIREPLACE INSTALLATION

BV4000C MINIMUM FIREPLACE DIMENSIONS

Approx. minimum Height: 21” dimensions into fireplace Width: 22 ½”

Depth: 16”

CATALYTIC TEMPERATURE PROBE Install temperature probe prior to installing insert.

To install the Catalytic Temper ature Probe locate the plug on the top, right-hand side of the bypass c ontrol 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.

PAGE 8

The Catalytic Temperature Probe is provided so you can monitor the temperature of your Catalytic Combustor. Once you have established a fire and the Catalytic Temperature Probe indicates the temperature of your Catalytic Combustor is between 500° 600° F (approximately 20 - 25 minutes) c lose the Bypass 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 - 1800° 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 surr ound assembly (face shield) and attach insulation material provided using a nonflammable adhesive (i.e. RTV Silicone, rated 570° F).

4. Use a large piece of cardboard or other protective material and place it in front of the fireplace to protect floor or carpet during installation.

5. Remove the insert from its wood pallet by removing the screws.

6. Prepare chim ney connection system as specified f or masonry 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 ex tending 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 c ompletely 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.

cluded with the hardware) located at the sides of the insert clockwise until insert is level. The leveling bolts should be 3/8" in diameter and about three inches in length.

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.

11. If the floor of the fireplace is lower than the hearth, turn the adjusting bolts secured with 2 nuts (not in-

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