Lexington Forge ASHTON AI42DV Installation And Operating Instructions Manual
LEXINGTON FORGE
DIRECT VENT GAS INSERT
INSTALLATION AND OPERATING INSTRUCTIONS
MODEL: ASHTON AI42DV
IF THE INFORMATION IN THESE INSTRUCTIONS ARE
NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION
MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR LOSS OF LIFE.
– Do not store or use gasoline or other ammable
vapors and liquids in the vicinity of this or any
other appliance.
– WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the
re department.
– Installation and service must be performed
by a qualied installer, service agency or the
gas supplier.
WARNING: Impro p er installation, adjustment,
alteration, services or maintenance can cause injury or
property damage. Refer to this manual. For assistance
or additional information consult a qualied installer,
service agency or the gas supplier.
This appliance is only for use with the type of gas
indicated on the rating plate. This appliance is
not convertible for use with other gases, unless a
certied kit is used.
This appliance may be installed in an aftermarket*,
permanently located, manufactured home, where not
prohibited by local codes.
*Aftermarket: Completion of sale, not for purpose of resale, from
the manufacturer.
WARNINGS
DUE TO HIGH TEMPERATURES, THE
APPLIANC E SH O ULD BE LOCATED
OUT OF TRAFFIC AND AWAY FROM
FURNITURE AND DRAPERIES.
CHILDREN AND ADULTS SHOULD BE
ALERTED TO THE HAZARDS OF HIGH
SURFACE TEMPERATURE AND SHOULD
STAY AWAY TO AVOID BURN S OR
CLOTHING IGNITION.
YOUNG CHILDREN SHOUL D BE
SUPERVISED WHEN THEY ARE IN THE
SAME ROOM AS THE APPLIANCE.
CLOTHING OR OTHER FLAMMABLE
MATERIAL SHOULD NOT BE PLACED
ON OR NEAR THE APPLIANCE.
KEEP THE ROOM AREA CLEAR AND
FREE FROM COMBUSTIBLE MATERIALS,
GASOLINE, AND OTHER FLAMMABLE
VAPORS AND LIQUIDS.
READ BEFORE INSTALLING. SAVE THESE INSTRUCTIONS
48D0139 3
CONTENTS
CONGRATULATIONS!
You have purchased a state-of-the-art gas appliance featuring the Lex-Fire Burn System
available exclusively on Lexington Forge gas appliances.
The Lex-Fire Burn System sets a new standard for flame appearance through innovative log
design, burner technology and ember placement. Each element effecting combustion and
flame appearance was carefully scrutinized and strategically balanced during the design
process to provide a product that was truly
“BORN TO BURN.”
Important Safety Information .......................... 3
Product Features.............................................. 5
Code Approval.................................................. 5
Pre-Installation Information
Installing Above 2000 Feet............................ 6
Orifice Sizes, Pressures and BTUs............... 6
Insert Dimensions ......................................... 6
Fireplace and Insert Dimensions .................... 7
General Installation Information ..................... 8
Clearances.................................................... 8
Installation......................................................... 9
Insert Clearances.......................................... 9
Mantel Clearances ........................................ 9
Hearth Requirements.................................... 9
Insert Placement ......................................... 10
Zero-Clearance (Metal) Fireplace
Requirements...............................................11
Vent Installation.............................................. 12
Installation Precautions............................... 12
Vent Requirements ..................................... 13
Altitude Considerations ............................... 13
Vent Configurations..................................... 14
Manifold Removal and Installation .............. 15
Insert Installation
Check Gas Type.......................................... 16
Installing Gas Piping to Insert/Burner System
Location ...................................................... 16
Checking Gas Pressure ................................. 18
Electrical Installation ..................................... 19
Electrical Wiring .......................................... 19
Remote Wall Switch.................................... 19
Log Placement................................................ 20
Surround and Trim Installation ..................... 24
Installing Facing .......................................... 24
Assembling Optional Trim........................... 24
Installing Trim.............................................. 24
Installing On/Off Switch............................... 24
Filigree Installation......................................... 25
Door Installation ............................................. 26
Operating Instructions................................... 27
What To Do If You Smell Gas...................... 27
Lighting Pilot for the First Time ................... 27
Lighting Pilot ............................................... 28
Lighting Burner............................................ 29
To Turn Off Gas........................................... 29
Adjusting Blower Speed.............................. 29
Cleaning Maintenance.................................... 30
Venting System........................................... 30
Cleaning Glass............................................ 30
Pilot and Burner Flames ............................. 30
Firebox Cleaning......................................... 30
Air Shutter Adjustment (Natural Gas Only).. 31
Glass Replacement ........................................ 32
Maintenance.................................................... 33
Maintaining Your Heater’s Appearance....... 33
Yearly Service Procedure............................ 33
Blower.............................................................. 35
Replacement Parts ......................................... 36
Troubleshooting ............................................. 38
Warranty...........................................Back Cover
2 48D0139
IMPORTANT SAFETY INFORMATION
INSTALLER
Please leave these instructions with the owner.
• Read this owner’s manual carefully and completely before trying to assemble, operate,
or service this insert.
• Any change to this insert or its controls can be dangerous.
• Improper installation or use of this insert can cause serious injury or death from fire,
WARNING
burns, explosions, electrical shock and carbon monoxide poisoning.
This insert is a vented product. This insert must be properly
installed by a qualied service person. The glass door must be
properly seated and sealed. If this unit is not properly installed
by a qualied service person with glass door properly seated
and sealed, combustion leakage can occur.
CARBON MONOXIDE POISONING: Early signs of
carbon monoxide poisoning are similar to the u with headaches, dizziness and/or nausea. If you have these signs, the
insert may not have been installed properly. Get fresh air at
once! Have the insert inspected and serviced by a qualied
service person. Some people are more affected by carbon
monoxide than others. These include pregnant women, people
with heart or lung disease or anemia, those under the inuence
of alcohol, and those at high altitudes.
Propane/LP gas and natural gas are both odorless. An odormaking agent is added to each of these gases. The odor helps
you detect a gas leak. However, the odor added to these gases
can fade. Gas may be present even though no odor exists.
Make certain you read and understand all warnings. Keep this
manual for reference. It is your guide to the safe and proper
operation of this insert.
1. This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible
for use with other gases unless a certied kit is used.
2. For propane/LP insert, do not place propane/LP supply
tank(s) inside any structure. Locate propane/LP supply
tank(s) outdoors. To prevent performance problems, do not
use propane/LP fuel tank of less than 100 lbs. capacity.
3. If you smell gas
• shut off gas supply.
• do not try to light any appliance.
• do not touch any electrical switch; do not use any
phone in your building .
• immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
OWNER
Please retain these instructions for future reference
4. Never install the insert
• in a recreational vehicle
• where curtains, furniture, clothing, or other ammable
objects are less than 36" from the front, top, or sides
of the insert
• in high trafc areas
• in windy or drafty areas
5. This insert reaches high temperatures. Keep children and
adults away from hot surfaces to avoid burns or clothing
ignition. Insert will remain hot for a time after shutdown.
Allow surfaces to cool before touching.
6. Carefully supervise young children when they are in the
room with insert.
7. Do not modify this insert under any circumstances. Any
parts removed for servicing must be replaced prior to
operating insert.
8. Turn insert off and let cool before servicing, installing, or
repairing. Only a qualied service person should install,
service, or repair the insert. Have burner system inspected
annually by a qualied service person.
9. You must keep control compartments, burners, and cir-
culating air passages clean. More frequent cleaning may
be needed due to excessive lint and dust from carpeting,
bedding material, pet hair, etc. Turn off the gas valve and
pilot light before cleaning insert.
10. Have venting system inspected annually by a qualied
service person. If needed, have venting system cleaned
or repaired. See Cleaning and Maintenance, page 30.
11. Keep the area around your insert clear of combustible
materials, gasoline, and other ammable vapor and liquids. Do not run insert where these are used or stored.
Do not place items such as clothing or decorations on or
around insert.
Continued on page 4
.
48D0139 3
48D0139 5
IMPORTANT SAFETY INFORMATION
Continued from page 3
12. Do not use this insert to cook food or burn paper or other
objects.
13. Never place anything on top of insert.
14. Do not use any solid fuels (wood, coal, paper, cardboard,
etc.) in this insert. Use only the gas type indicated on
rating plate.
15. This appliance, when installed, must be electrically
grounded in accordance with local codes or in the
absence of local codes, with the National Electrical
Code, ANSI/NFPA 70, or the Canadian Electrical Code,
CSA C22.1.
16. Do not obstruct the ow of combustion and ventilation
air in any way. Provide adequate clearances around
air openings into the combustion chamber along with
adequate accessibility clearance for servicing and proper
operation.
17. Do not use insert if any part has been exposed to or
under water. Immediately call a qualied service person
to arrange for replacement of the unit.
18. Do not operate insert if any log is broken.
19. Do not operate the insert with glass door removed,
cracked, or broken.
4 48D0139
PRODUCT SPECIFICATIONS
• This appliance has been
certied for use with either
natural or propane gas. See
appropriate data plates.
• This appliance is not for use
with solid fuels.
• The appliance is approved
for bedroom or bedsitting
room installations.
• The appliance must be
installed in accordance
with local codes if any. If
none exist use the current
installation co d e . ANSI
Z223.1/NFPA 54 in the
USA, CAN/CGA B149 in
Canada.
PRODUCT FEATURES AND CODE APPROVAL
• This appliance is mobile
home approved.
• The appliance must be prop-
erly connected to a venting
system.
Off/Pilot/On
Knob
Hi/Lo
Knob
Optional
Remote
Receiver
Blower
Gas
Shutoff
Figure 1 - AI42DV Insert
Valve
On/Off/
Remote Switch
The efciency rating of this appliance is a product thermal efciency rating determined under continuous operating conditions and was determined independently of any installed system.
Thermal Efciency = up to 80%
CODE APPROVAL
These appliances have been tested by CSA and found to comply with the established standards for VENTED GAS FIREPLACE HEATERS in the USA and Canada as follows:
LISTED VENTED GAS FIREPLACE HEATER
TESTED TO: ANSI Z21.88-2002/CSA 2.33-2002 STANDARDS
ATTENTION MASSACHUSETTS RESIDENTS:
This Lexington Forge product must be installed by a licensed gas tter.
48D0139 5
48D0139 7
PRE-INSTALLATION INFORMATION
INSTALLING ABOVE 2000 FEET
• In the USA, the appliance must be derated 4% for every 1,000 ft above 2,000 ft elevations.
• In Canada, these appliances are certied for altitudes of 0 – 2000 ft, and must be de-rated by 10 percent for installations
between 2000 and 4,500 ft. (derate an additional 4% for every 1,000 ft. above 4,500 ft. elevations).
ORIFICE SIZES, PRESSURES AND BTUs
NATURAL GAS PROPANE GAS
Manifold Press: (W.C.) 3.5" Manifold Press: (W.C.) 10"
Maximum Supply Pressure 10.5" Maximum Supply Pressure 13"
Minimum Supply Pressure 4.5" Minimum Supply Pressure 11"
Model Number AI42
NATURAL PROPANE
Max. Btu/hr Input 42,000 40,000
Min. Btu/hr Input 29,000 28,000
Orifice sizes (as shipped) Front: #44 Front: #55
Rear: #43 Rear: #55
The ASHTON AI42 is equipped with a variable output gas control.
NOTE: Ashton AI42 model insert works without any electrical supply.
Optional blower must have electricity.
INSTALLATION PLANNING
Plan for the installation of your insert. This includes determining the size of replace in which unit is to be installed, length of
venting to be used, and nishing details, and whether any optional accessories (i.e. wall switch, or remote control) are desired.
Consult your local building code agency to ensure compliance with local codes, including permits and inspections.
6 48D0139
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FIREPLACE AND INSERT DIMENSIONS
Side
Fireplace Opening
Figure 2 - External Insert Dimensions
Front
Top
L - Fireplace opening height O - Firebox width at insert depth (N)
M - Fireplace opening width P - Firebox depth at insert back height (Q)
N - Depth of insert Q - Insert back height
AI42
FIREPLACE FIREPLACE MINIMUM OPENING
A 251/4" 641mm D 237/8" 606mm L 231/2" 596mm
B 36" 914mm E 12" 304mm M 35" 889mm
C 34" 863mm F 323/4" 831mm N 17" 432mm
G 17" 432mm O 241/2" 616mm
H 191/4" 489mm P 17" 831mm
I 221/2" 572mm Q 191/4" 489mm
J 241/4" 616mm
K 173/4" 451mm
48D0139 7
48D0139 9
GENERAL INSTALLATION INFORMATION
The following factors should be taken into consideration:
• This insert should have sufcient access for its safe operation and maintenance.
• The ow of combustion and ventilation air must not be obstructed.
• Minimum clearances to combustibles, such as mantels, must be maintained. See Figures 3 and 4, pages 10 and 11.
• Never obstruct the front opening of the insert.
• Do not install in the vicinity where gasoline or other ammable liquids may be stored.
• These units can be installed in a bedroom. See National Fuel Gas Code ANSI Z233.1/NFPA 54 (current edition), the
Uniform Mechanical Code (current edition), and Local Building Codes for specic installation requirements.
IMPORTANT: Your direct vent insert was designed to be installed in an existing wood burning fireplace.
The location and clearances are subject to local building codes.
INSERT APPLICATIONS
Before installing the gas replace insert, consider the functioning needs of the replace. Conrm the size of the replace
cavity, the design of the chimney, and the availablility of the gas supply and electricity for the insert fan.
IMPORTANT: Your direct vent insert is designed to be only vented vertically with a minimum height of
10 feet.
When the unit is installed into a woodburning replace, the minimum distance the mantel can be placed above the replace is
governed by local building codes applicable to woodburning replaces. Consult local authorities having jurisdiction for these
clearances. The underside of the mantel will become warm. Use only nishes which are heat resistant and do not discolor.
CLEARANCES
MINIMUM FIREPLACE SIZE/CLEARANCES TO COMBUSTIBLES
The dimensions shown in Figures 4 and 5, pages 10 and 11, are minimum clearances to
maintain when installing this heater. Follow these instructions carefully to ensure safe
installation. Failure to follow instructions exactly can create a fire hazard.
WARNING
Maintain the following minimum clearances for service and maintenance. See pages 9 and 10.
8 48D0139
INSERT CLEARANCES
No combustibles (ie: drapes, doors) may be within, or swing within, 36" of the front of the inset.
INSTALLATION
Figure 3 - Mantel Clearances
MANTEL CLEARANCES
NOTE: The combustible area above the facing must not protrude more than 3/4" from the facing. If it
does, it is considered a mantel and must meet the mantel requirements shown above.
HEARTH REQUIREMENTS
The insert must be installed on a non-combustible hearth extending a minimum of 12" from the replace opening (local
codes may require a larger hearth). The hearth must also extend to both sides of the face (see the table above for the exact
width of the face).
48D0139 9
48D0139 11
INSTALLATION
INSERT PLACEMENT
• Insert must be placed within a code-conforming masonry replace or a tested and listed zero-clearance (metal) replace.
Repair any replace damage prior to installation.
• Because the insert uses a circulation blower, clean the replace, smoke shelf, and chimney before installing. Paint interior
surface of the replace with latex paint to further eliminate dust.
• This heater may be placed in a bedroom. Please be aware of the large amount of heat this appliance produces when
determining a location.
For tight fits you may remove the manifold.
See “Removing the Mainfold,” page 15
Minimum 35" (889mm)
Minimum 231/2"
(597mm)
The insert protrudes
17" (432mm) into
the fireplace.
Run the on/off switch wires
to the right — behind the
surround panels
Figure 4 - Insert Placement
The gas line
should be installed
prior to insert
placement.
Use the leveling
bolts for fireplaces
with recessed floors
Run the power
cord either side of
the insert along
the face.
10 48D0139
INSTALLATION
ZERO-CLEARANCE (METAL) FIREPLACE REQUIREMENTS
• The damper and grate must be removed.
• The smoke shelf internal baf es, screen, refractory, and metal or glass doors may be removed (if applicable).
Do not cut any sheet metal parts of the
fireplace in which this gas fireplace
insert is installed. THIS IS STRICTLY
PROHIBITED!
WARNING
• Do not remove or alter the insulation or any structured rigid frame members (metal sides, oor, door frame, face of the
replace, etc.).
Figure 5 - Metal Fireplace Zero-Clearance Requirements
IMPORTANT:Please review the following carefully.
It is normal for inserts fabricated of steel to give off some expansion and/or contraction noises during the start up or cool
down cycle. Similar noises are found with your furnace heat exchanger or car engine.
It is not unusual for your Lexington Forge insert to give off some odor the rst time it is burned. This is due to the curing of
the paint and any undetected oil from the manufacturing process.
Please ensure that your room is well-ventilated. OPEN ALL WINDOWS DURING INITIAL BURN OFF/
CURING PHASE.
Burn your insert for a least six (6) hours on “HIGH” the rst time you use it. Place fan in the “OFF” position during
this time.
48D0139 11
48D0139 13
VENT INSTALLATION
Read all instructions completely and thoroughly before attempting installation. Failure
to do so could result in serious injury, property damage or loss of life. Operation of
improperly installed and maintained venting systems could result in serious injury,
property damage or loss of life.
WARNING
Failure to follow these instructions will
void the warranty.
NOTICE
INSTALLATION PRECAUTIONS
Consult local building codes before beginning the installation. The installer must make sure to select the proper vent system
for installation. Before installing vent kit, the installer must read this insert manual and vent kit instructions.
Only a qualied installer/service person should install venting system. The installer must follow these safety rules:
• Wear gloves and safety glasses for protection.
• Use extreme caution when using ladders or when on rooftops.
• Be aware of electrical wiring locations in walls and ceilings.
The following actions will void the warranty on your venting system:
• Installation of any damaged venting component.
• Unauthorized modication of the venting system.
• Installation of any component part not manufactured or approved by Lexington Forge.
• Installation other than permitted by these instructions.
This insert must be vented to the outside. The venting system must NEVER be attached
to a chimney serving a separate solid fuel burning appliance. Each gas appliance must
use a separate vent system. Do not use common vent systems.
WARNING
12 48D0139
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