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)
M
x T
L
1.28
T
(inches) = 0.43* x 1”
M
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
r
M
L
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
2
HR °F or a thermal resistanc e
2
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
M
K
= K value of desired material
M
T
= Minimum listed thickness
L
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
k
ALTERNATIVE FLOOR PROTECTION MATERIALS
Listed Values Min. Thick
Material k
(per inch)r (per inch)
T
L
Millboard 1.28 0.78 1”
Alternative Values Min. Thick
Materials k
(per inch)r (per inch)
T
L
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.
L
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:
2
π
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-
PAGE 9
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 system.
13. Pull the insert slightly forward to its des ired position;
attach the face shield using the surround clips and
hardware as shown. The fiberglass ins ulation strips
should be secured along the top and sides (s tep 3).
Assemble the gold-tone trim using the 2 ins ide corner brackets. Attach trim to the face shield and
stove.
Push the unit back until face shield insulation is compressed against the fireplace f ront, forming a tight seal.
Test for air leaks by holding a candle around edge
of face shield to see if smoke is pulled into fireplace.
* Note: Preferred method of attaching connec tor to flue
outlet is to install two L-Brackets (1” angle br acket, 3/4”
wide) on opposite sides of the flue outlet: Use selftapping screws to secure in place. Cut a ½” (height) and
¾” (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 m achine screws. Seal around connection with furnace cement.
PAGE 10
INSTALLATION
POSITIVE FLUE CONNECTION FOR MASONRY FIREPLACE
A Professional should inspect chim ney prior to installation to
determine if any repairs are necess ary or if a chim ney reline
is necessary.
The fireplace dam per mus t 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
This can be achieved by using a filler plate. A filler plate ca n
be made by making a cardboard pattern to f it 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 screw s.
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.
(Or) Install 6" flex pipe to achieve the same result.
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).
PAGE 11
PROCUCT FEATURES AND CONTROLS
ASH DRA WER
The large ash drawer located below the fuel door is designed
to make cleaning easier by containing the ashes in a rem ovable drawer.
CAUTION: Do not operate the stove w ith th e 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 Operation Section – Blower System on page 15.
PRIMARY AIR CONTROL
The primary com bustion air delivery is controlled by the primary air control draft module (T he 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 f uel, the amount of heat and
burn times desired, the type of installation are all variables
that will affect the control se tting. The sam e control settings
in a variety of installations will produce different results. You
will need to try different settings so you can learn how muc h
heat to expect and how long the fire will burn
Lower Higher
.
CATALYTIC BYPA SS DAMPER CONTROL
The bypass damper control handle is loc ated on the front of
the insert (see above illustration). By pushing in or pulling out
the handle, the operator can route the exhaust either through
the catalytic combustor (pushed in) or directly 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.
CATALYTIC COMBUSTOR
How it works: From 5 to 30 percent of the c hemical energy
contained in every log escapes up the chimney when wood
is burned in a conventional stove. The catalytic co mbustor is
designed to make use of this energy, converting it into useful
heat as it lessens chimney creosote build-up and air pollution. The catalytic combustor cons ists of a durable temper ature resistant ceram ic composition, which is ex truded into a
cellular, or honeycomb, configuration. After extrusion, this
ceramic monolith is fired and then covered with a noblemetal 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
CAUTION: 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.
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.
PRIMARY AIR CONTROL
This appliance is equipped with a control for the com bustion air, located above the fuel door. Sliding the control to
the right increases the burn rate, to the lef t decr eas es 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 spec ified
safe distances.
Lower Higher
GLASS
The Glass is a super heat resistant ceramic that withstands continuous temperatur es up to 1390° F. T his 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 inside 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. A
short, hot fire (15 - 20 minutes) will help clean off muc h of
the normal buildup (see Troubleshooting). A commercial
glass cleaner designed for fireplace inserts is recommended for cleaning.
The glass should be cleaned thoroughly with glass
cleaner and a soft cloth BEFORE the f ireplace insert
is burned.
DOOR GASKET
The door gasket must be k ept in good condition. Do not
leave the stove burning with the door ajar or open. Leaving 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).
PROVIDE ADEQUATE AIR FOR COMBUSTION
In well insulated and weather tight homes, it may be difficult to establish a good draft up your chim ney. The poor
draft is caused by a shortage of air in the house. To provide 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 installation you have and how long you wish the fire to burn are
all variables that will affect the control s etting. The sam e
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 muc h heat to expect and how long the fire will burn. 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 tem perature to c om pletely cure. We recommend 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 manufactur er recommends thr ee burn cycles to
cure the paint. The first two burns s hould be low heat, approximately 250°F., for 20 minutes eac h, using paper and
light kindling.
After each 20-minute burn, allow the appliance to cool
completely. The third burn should be at least m edium 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 becom e slightly lighter in color.
Eventually the entire surface will becom e 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 fireplace 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 m ay be lightly sanded and touched
up with spray paint from the same paint manufacturer
(See Maintenance – Small Area Paint T ouch- 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 m edium to high f iring
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 temperatures. 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 com bustor going 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 recomm end 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 temperatures and proper amounts of volatiles for the catalyst
to operate properly.
When re fueling a hot stove with the catalyst still operating,
no refiring step is necessary. Just open the bypass, s et the
primary air control to high, open the door approximately 1/2
inch, and wait for about thirty seconds. Load the f uel, c lose
the door, close the bypass and set the primary air control to
normal operation. Tem peratures 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 dum p cover (in c enter of firebox floor) is in place and the ash drawer is closed.
2. Open the bypass damper control by pulling it out (toward you). In the "OPEN" position the draft air will bypass the catalytic combustor and mak e s tar ting the f ire
easier.
3. Set the primary air control lever on "HIGH". The
"HIGH" setting will maximize your primar y 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 k indling is
ignited and burning on its own, close the fuel door.
The upper fire should help preheat the chimney
and create an effective draf t while the lower f ir e ignites 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 damper
hook and close the bypass by pushing the control rod
in (catalytic temperature probe should read 500600°F, takes approxim ately 20 - 25 minutes to reach
this temperature).
7. When the fire is well-es tablished slide the air contr ol
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" f or about one
minute. Open the fuel door about 1/2" and hold in this position 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 operating 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 (f an 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 click s). When the insert warms
up (110° F), the blower will automatically turn on (adjust rheostat dial to the desired speed setting). W hen
the insert cools down (90° F), the blowers will automatically turn 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.
WARNING: This appliance is equipped with a blower
system which has a flexible electrical power cord
with a three-prong (grounding) plug for your protection against shock hazard and should be plugged
directly into a properly grounded three-prong receptacle 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 system has a flexible electrical cord that must be electrically
grounded per local codes or NEC, ANSI/NFPA 70-latest
edition. Do not route the power cord under or in front of
the appliance.
CAUTION: Burning the insert at a high burn rate for
extended periods without running the blowers can
cause excessive temperatures resulting in overfiring damage to the appliance. Excessive heat will
cause the propellers on the blowers t o melt. If this
occurs, replace propellers and review these instructions 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.
PAGE 15
CARE AND OPERATION
BYPASS DA MPER CONTROL
The operating handle of your bypass damper control is located on the front of the stove f lue collar. By moving the bypass damper control, the operator can route the fire either
through the catalytic combustor (pushed in) or dir ectly up the
flue (pulled out). When starting a fire or refueling, the bypass
damper control should be pulled out. Onc e the fire is es tablished, it should be pushed in.
CATALYTIC TEMPERATURE PROBE
The catalytic temperature probe monitors the tem perature of your catalytic combustor. Once you have es tablished a fire and the catalytic temperature probe indicates the temperature of your catalytic combustor.
When it reac hes a temperatur e between 500 to 600 degr ees (approximately 20 - 25 minutes), cl ose th e b ypas s
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 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 partic leboard
or pressed logs using bonding agents as they can produce
conditions which will deteriorate metal or dam age the catalyst. 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 k indling wood or m ill
ends for primar y 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 f rom overf iring is not cover ed 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 wellseasoned 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 80%, which
must be reduced to less than 20%. Wood properly seasoned
is then capable 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 sm oke and ver y little fire. Tim e
is the most im portant factor in seasoning wood. Ideally the
moisture content should be reduced to 11-20%, although
very few of us will be able to check that figure. T here are
several steps that should be taken to ens ure that that you
come close to these figures.
SMALL AREA PAINT TOUCH-UP
The stove body is painted with a quality high-temperature
stove 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 gr it sand paper and lightly
sand the blemish so that the edges are “feathered” or
smooth to the touch between the painted and bare surfaces. 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 ins tead. Mask off
surfaces you do not want painted. Paint lightly over the
bare surface firs t 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 replaced if damaged (crumbling or excessively cracked).
ASH REMOVAL A ND DIS POSA L
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.
Scrape 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.
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. If the tree was fell 2 to 4 years ago, it still
needs to be cut, split, and seasoned for 6 to 24 m onths depending on the wood.
WOOD STORAGE
Wood to be s easoned 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 under 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 enclose space for one to two months.
PAGE 17
Proper Disposal of Ashes:
Ashes should be placed in a metal container with a tight
fitting lid. The closed container of ashes s hould be placed
on a noncombustible floor or on the ground, well away
from all combustible m aterials, 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.
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 gas ket (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 dum p
cover. Should these gaskets becom e f rayed 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 replacing 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 stov e (such damage is not covered 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 safely 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 recommended. 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 (protective gloves are recommended).
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 RE MOVAL
What is Creosote - When wood is burned slowly, it pro-
duces tar and other organic vapors, which com bine with expelled moisture to form creosote. T he creosote vapors condense in the relatively cool chimney flue of a slow-burning
fire. As a result, creosote res idue accumulates on the flue
lining. When ignited this creosote makes an extrem ely 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 reosote deposits.
PAGE 18
To inhibit the build up of creosote, adjust the primary air
control to a medium- high or high setting f or a 10-m inute period each day. Do not attempt to burn out heavy creosote
accumulations in this m anner. This must be removed f rom
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 m onthly during the heating season to determine if a creos ote 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: M ake sure the bypass damper is in the
open position prior to chimney cleaning.
In the event of a ch imney fire - Mak e sur e the fuel door is
securely closed. Adjust the prim ary air control to the lowest
(most closed) s etting. Call the fire department im mediately.
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.
Contact your local municipal or provincial fire authority for
information on how to handle a chim ney 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 c orrectly
and proper fuels are used). If the catalyst has been deactivated, it should be replaced. Symptoms of deactivation
include – noticeably darker smoke exiting chimney and
less heat output. If these symptoms remain after norm al
maintenance or a major cleaning (soak in heated vinegar/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 ver y effectively 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 access, remove blower cover (rem ove the two ¼” hex head
screws), then inspect propellers (replace if c racked, broken or melted) and vacuum out lint, dust, and debris.
MAINTENANCE
CATALYTIC COMBUSTOR
This appliance has been designed with a catalytic combustor, which will improve its overall performance. Removing the combus tor assembly for cleaning and reinstallation is simple and convenient. Cleaning the combustor helps reduce buildup of as h and retarding chem icals. 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 s uff icient f or m ost users .
Reinstall the combustor according to the following instructions.
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 combustor from the rinse water and gently shake out excess
water. It is unlikely that you will notice a visible difference 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 baff le as s hown in
illustration (ceramic honeycom b to the back and louvered slots to the front). Push it back into the tunnel
baffle until it hits the positioning stops. Mak e 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 secondary air tube as illustrated. Make sure that 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
TROUBLESHOOTING
* SMOKES OUT FUEL DOOR WHEN OPEN
1. The primary air control is closed.
2. 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.
3. Excess creos ote will not only restrict your draft but it
will create a risk of a creos ote fire. Strictly adhere to
maintenance requirements as outlined in this manual. If excess creos ote 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.
4. 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.
5. Chimney diameter too large or too small to provide
adequate draft.
6. The house is too airtight (usually takes 20 to 30 m inutes for problem to appear as stove lowers air pressure in house). Crack a window open or provide an
outside source of air near insert.
7. Insufficient vertical height to chimney to achieve
adequate draft.
8. The combustor is plugged from engaging too soon
(remove combustor and clean, see Maintenance
section, page 19).
* DOES NOT PRODUCE ENOUGH HEAT
1. Using green or insufficiently cured wood.
2. Excessive draft.
3. High ceilings (heat rises quick ly, but can be recirculated by a well-placed ceiling fan with a winter/summer switch).
4. The area to heat, is too large (square foot heating
estimates are based on "average" climates and
home design.)
5. There's an obstruction in the chimney.
6. The chimney or chimney cap is restricted by creosote
preventing enough draw to sustain a "HIGH" heat
rate.
7. Combustor light off has not occurred.
* BACKPUFFING
1. Downdraft in the chimney (may need a special
wind cap).
2. The catalytic com bustor is too hot (avoid bur ning
soft, pitchy woods, or large amounts of smalldiameter wood).
3 The house is too air tight (ventilation is needed).
4. Insuffic ient 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
1. Poor draft conditions.
2. Long burn periods at low draft settings.
3. Burning wet, pitchy or spongy wood.
4. Poorly arranged logs (too close to glass).
* Draft problems; If installing into a larger flue,
it may be necessary to use a full length liner
to achieve adequate draft for the app liance. A
draft gauge should read a minimum of .05"
w.c. (inches water co lumn) not to exceed .07"
w.c. for optimum performance (see draft re-
quirements, page 6).
* DOES NOT MAINTAIN A FIRE
1. Soft wood does not burn as long or as well as seasoned hardwood resulting in a short burn time.
2. Wood size too small. Burns at too rapid a rate.
3. The gasket seal on the fuel door, as h dump cover or
glass is leaking air. Repair or replace it if necessary.
4. There is an obstruction in the chimney.
5. The stove was not up to normal operating tem perature before the bypass damper control was pushed
closed.
6. Excessive draft.
PAGE 20
TROUBLESHOOTING
CATALYST PLUGGING
1. Burning m aterials that produc e a lot of char and fly ash.
Do not burn materials such as garbage, gif t wrap, cardboard, etc.
2. Burning wet pitchy woods or burning large loads of small
diameter wood with the combustor in the operation position (without light-off taking place). Bur n proper f uel only.
Do not close bypass until temperatures are high enough
to initiate light off.
CATALYS T DE A C TIV A TI ON
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, page
19.
CATALYST SUBSTRA TE CRACKING
1. Normal operation, as long as combustor remains
intact. If cracking c auses large pieces to f all out, replace combustor.
2. Mishandling or abuse. Handle with care.
3. Warped housing (see Overfiring, this page).
CATALYST SUBSTRA TE
1. Extreme thermal shock. Combustor is being worked
too hard.
2. Excessive draft. Correct installation. See Draft Re-
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 s evere, r eplace c ombustor. Do not overfire appliance. See Overfiring, this page.
TAR AND LI QUID CREOSOTE LEA KIN G FROM METAL
FLUE JOINTS
1. No chimney cap on chimney. Install cap.
2. Metal flue assembled im properly. 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 smok e). W ater vapor is norm al and should be
of little concern.
2. Wet, pitchy woods being burned. Burn dry seasoned
wood only.
3. Bypass in open position. Close bypass.
4. Combus tor 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 doors
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 excessive 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 Imprope r Installa tion
The venting system must satisfy the draft Requirements
of the appliance. The appliance is merely one component
of a larger system. The other equally im portant component is the venting system, which is necessary for
achieving the required flow of com bustion air to the fire
chamber and for s afely removing unwanted combustion
byproducts from the appliance. If the venting system’s design does not promote these ends, the system may not
function properly, which may create performance problems as well as may be a safety hazard. To ensure that all
installation requirements have been met as outlined in the
installation manual. The chim ney should be clean and in
good repair. A draft test should be performed to determine if the draft requir ements of the appliance ar e being
met. A draft gauge should read between .05 and .07
inches water column (W .C.I.) . Exces sive draf t (above .07
W.C.I.) will allow too much combustion air to be pulled
into the firebox, which results in hotter burns. Too little
draft (below .05 W .C.I.) will not allow enough com bustion
air delivery to maintain a fire well or cause perf ormance
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 Imprope r 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 th e a ir c on tro l 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 including 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 Imprope r Fuel
This appliance is approved fo r 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 f uel, and
can cause increased creos ote buildups. Do not overload
or use kindling wood or mill ends as primary fuel.
PAGE 21
SPECIFICATIONS - Model BV4000C
Approx. sq. ft
heat capacity up to ~ 2000 Sq. Ft.
Maximum log length 18"
Flue size 6"
Width w/standard surround 42"
Width at fireplace opening 22.5"
Width at rear of firebox 22.5"
Depth into Fireplace 16"
Depth (overall) 25"
Height 21"
Height w/standard surround32"
Back of Stove to
Center of Flue 5 1/2"
Approx. burn time 8 - 10 hours
Note: Dimensions shown are approximations only (+/- ¼”)
Fuel capacity 70 lbs. (approx.)
Firebox size (cubic feet) 2.4 c.f.
Maximum Burn Rate 56,800 BTU
EPA BTU Range 6,500 to 40,900
BTU
EPA Efficiency 72%
Emissions Rate (grams/hour ) 1.9 gph
Approx. weight with brick 390 lbs.
Air Control Manual
Blower Assembly 250 cfm
(2 blowers, 125cfm each)
W/ speed control Rheostat 75 – 110 volt
~ Square feet heating capacity and burn time
are approximations only. They will v ary depending upon the level of insulation, climate, house design, ceiling height, ambient
outside temperatures and how the stove is
operated.
PAGE 22
REPLACEMENT PARTS LIST – Model BV4000C
DOOR PARTS
Part/
Catalog #
G6000 Door assembly, cast black
10300 Door handle assembly
85-11 Door handle, coil spring
86-128 Gasket door kit, ¾” rope Includes adhesive
10580 Gasket, glass channel
10267 Clip, glass long (bottom-
10265 Clip, glass modified (hinge
10266 Clip, glass standard Requires 5
G2000-7 Glass small arched 9 3/8
11529 Hinge pin 10 l 18 (original) Requires welding
11531 Hinge pin ¼-28 (retrofit)
10362 Torque plate (latch)
00340 Torque plate nut
ELECTRICAL PARTS
Part/
Catalog #
4020 Blower assembly (includes
Description Notes
Requires 5’
(per foot)
Requires 1
9”)
Requires 2
side)
*
x 15 ¾”
UNF
Requires drilling and tapping
Description Notes
2 blowers, propellers,
mounting bracket & terminal block)
11573 Blower, axial 13 1/4" (J239-
5116) .42amps
410-25-3 Blower, propeller
11597 Harness, wiring
528 Rheostat w/connectors Knob not included
02107 Rheostat, knob
410-270 Rocker switch, on/off
11565 Disc, fan (F110°-20F)
410-260 Terminal, block large
COMPONENT PARTS
Part/
Catalog #
00907 Module spring handle
11493 Module assembly Req's 10-32 x 1"
11807 Blower cover, louvered -
11809 Blower cover, louvered -
SURROUND & TRIM PARTS
Part/
Catalog #
Description Notes
left
right
Description Notes
BV4032 Surround Assembly – 32”
Includes propeller
hex screw
Standard
x 42”
11817 Air intake housing gold trim
02046 Corner key, surround trim
("L" bracket)
11843 Insulation. Surround side
11842 Insulation. Surround top
Misc. Parts
Part/
Catalog #
775005M M anual, Installation/Operation
Description
Requires 2
For the location of the nearest dealer for replacement parts, contact:
Lennox Hearth Products
1110 West Taft Avenue
Orange, WA 92865
PAGE 23
COMPONENT DIAGRAMS – Model BV4000C
CATALYTIC/DAMPER COMPONENTS
PRIMARY AIR CONTROL DRAFT MODULE
(PART/CATALOG #11493)
DAMPER ASSEMBLY
HANDLE ASSEMBLY (PART/CATALOG #10300)
DOOR ASSEMBLY (PART/CATALOG #G3000)
PAGE 24
OPTIONAL ACCESSORIES - Model BV4000C
Accessories
Catalog # Description (Model) Notes
14M73 Cord change over kit (CCOK-4000)
14M72 Gold Door Kit (DK100-G)
70K99 Touch-up spray paint kit, black
(TSPK-B)
14M70 (SKS-4000) Surround Kit, Small, 28”
ht. X 36” wd.
14M71 (SKL-4000) Surround Kit, Small, 32”
ht. X 48” wd.
14M76 Offset adapter, 6” to 6” diameter
(OA4000-66)
12 oz Spray
Can
OFFSET ADAPTER
Installations requiring offsets can be handled using an
offset adapter (it aligns starter pipe with flue).
Actual Appearance
CORD CHANGEOVER KIT
The blower system can be easily transferred to the other
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 openings on the right panel).
Power cord, blower assembly and controls come standard on the left side of insert
as shown in illustration to
the left
With the use of this kit, the
power cord and blower system can be transferred to the
right side of insert as shown in
illustration to the right).
GOLD DOOR KIT
This 24-karat Gold plated door is nearly maintenancefree, requiring only an occasional wipe down to rem ove
fingerprints. It will never tarnish as bras s doors do. The
gold cures to a very hardened durable finish and will
maintain a beautiful gold luster for many years.
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 / EPA LABEL
PAGE 26
SERVICE AND MAINTENANCE LOG
Service Service Service
Date Technician Description
PAGE 27
1110 West Taft Avenue
Orange, CA 92865
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