Lennox BV4000C User Manual

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INSTALLATION AND OPERATION

MANUAL

EPA CERTIFIED

CATALYTIC

WOOD BURNING

FIREPLACE

INSERT

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 information).

5.Minimum 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 chimney 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 similar liquids to start or "freshen up" a fire in this heater. Keep all such liquids well away from the heater while it is in use.

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

PAGE 2

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.Use 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 appliance. 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. The combustor is fragile; handle carefully. The performance 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).

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

TESTING/LISTING

Model BV4000C has been tested to UL Standards; UL1482 for installation into residential applications. The 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. The Homeowner’s Care and Operation Instructions included here will assure you have many years of dependable and enjoyable service from your appliance.

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 reflects their concern for aesthetics, efficiency and our environment. 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

PAGE 3

PLANNING YOUR INSTALLATION

QUESTIONS TO ASK LOCAL BUILDING OFFICIAL

A correct installation is critical and imperative for 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 must conform to local codes and applicable state and federal requirements. Familiarity with these requirements before installation is essential. Important considerations to discuss with local building officials include:

1.Applicable codes (i.e. Uniform Mechanical 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.

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?

SMOKE DETECTORS

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

PAGE 4

PLANNING YOUR INSTALLATION

FLOOR PROTECTION

This appliance requires a heat resistant noncombustible approved fireplace 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 must 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 minimum of 16" to the front of the fuel door opening and 8" beyond both sides of the fuel door opening

HEARTH PROTECTION

USING ALTERNATE MATERIAL AS A FLOOR PROTECTOR/HEARTH EXTENSION

The alternate material used as a hearth extension must be constructed of a durable noncombustible material having an equal or better insulating value (lower k value) of k = 1.28 BTU/IN FT2 HR ° F or a thermal resistance that equals or exceeds r = 78 HR ° F FT2 IN/BTU. With 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 cases, if the k value is less or the r value higher, a thinner material 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:

TM = Thickness of material in inches KM = K value of desired material

TL = Minimum listed thickness

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

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

 

 

material (per inch)

 

TM (inches) =

KM

x TL

 

1.28

 

 

 

 

 

TM (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 TL rM

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.

At times it is important to know what combination of materials are acceptable for use as floor protection. The “R values” are used to determine acceptable combinations of materials because “R values” are 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)

 

TL

Millboard

1.28

0.78

 

1”

Alternative

Values

Min. Thick

Materials

k (per inch)

r (per inch)

 

TL

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 TL = 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 chimney system shows signs of structural or mechanical weaknesses, such as: cracks, leaky joints, corroded or warped surfaces. Look for 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 flue system is dirty or has some obstruction in it, clean it. A dirty chimney can cause your insert to smoke when refueling, and can result in a chimney fire. An oversized chimney may result in less than optimum performance. 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 insert 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 merely one component of a larger system. The other equally important component is the venting system. This is necessary for achieving the required flow of combustion air to the fire chamber and for safely removing unwanted combustion byproducts from the appliance. If the venting system's design does not promote these ends, the system may not function properly. Poorly functioning venting systems may create performance problems as well as be a safety 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 combustion 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 FIREPLACES

This appliance is approved for installation into a listed factory built solid fuel burning fireplace. The fireplace 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 assemblies, that must be reinstalled to restore the fireplace to its original operating condition if the insert is removed and not replaced. The removal 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 damper must 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 from the flue outlet of the appliance to termination. Do not face seal over fireplace chimney cooling air systems. 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.

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 remove brick or mortar form the masonry fireplace to accommodate this appliance.

Venting Requirements for masonry fireplace:

The fireplace damper must be secured in the open position. As a minimum, a flue extension past 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 recommended). 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 flue 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:

π x r2 = Area (π = 3.1416, r = 1/2 diameter)

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.

!This appliance is approved for all heatform style fireplaces (masonry fireplace with a metal firebox liner).

!Measure fireplace size to make certain the insert will

fit before considering the installation.

.

PAGE 7

Lennox BV4000C User Manual

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 Temperature Probe locate the plug on the top, right-hand side of the bypass control 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.

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) close 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.

PAGE 8

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 surround 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 chimney connection system as specified for 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 extending 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 ordering information). Do not push insert in completely 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.

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

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.

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