TOA Electronics VF4000-CMP-2 User Manual

INSTALLATION AND OPERATING INSTRUCTIONS

STANDARD SERIES

Unvented Decorative Gas Fireplaces

P/N 903590 REV. N 12/2007

MODELS

VF4000-CHN-2 VF4000-CHP-2 VF4000-CMN-2 VF4000-CMP-2

INSTALLER: Leave this manual with the appliance. CONSUMER: Retain this manual for future reference.

US

FOR USE ONLY WITH DECORATIVE TYPE UNVENTED ROOM HEATERS.

DO NOT BUILD A WOOD FIRE.

WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE. REFER TO THIS MANUAL. FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

					WARNING: DO NOT BURN WOOD OR OTHER MATERIAL IN
	WARNING: IF THE INFORMATION IN THIS MANUAL
					THESE APPLIANCES.
	IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLO-
	SIONMAYRESULTCAUSINGPROPERTYDAMAGE,				CAREFULLY REVIEW THE INSTRUCTIONS SUPPLIED WITH
	PERSONAL INJURY OR LOSS OF LIFE.				THE DECORATIVE TYPE UNVENTED ROOM HEATER FOR
					THE MINIMUM FIREPLACE SIZE REQUIREMENT.
	FOR YOUR SAFETY: Do not store or use gasoline
					DO NOT INSTALL THE APPLIANCE IN THIS FIREBOX, UN-
	or other flammable vapors or liquids in the vicinity
					LESS THIS FIREBOX MEETS THE MINIMUM DIMENSIONS
	of this or any other appliance.				REQUIRED FOR THE INSTALLATIONS.
	FOR YOUR SAFETY: What to do if you smell gas:
					This is an unvented gas-fired heater. It uses air
	•	DO NOT light any appliance.			(oxygen) from the room in which it is installed.
					Provisions for adequate combustion and ventila-
	•	DO NOT touch any electrical switches.
					tion air must be provided. Refer to Combustion
	•	DO NOT use any phone in your building.
					and Ventilation Air Section, Page 3.
	• Immediately call your gas supplier from a
		neighbor’s phone.			Due to high temperatures, the appliance should be located out
	Follow your gas suppliers instructions.
					of traffic and away from furniture or draperies.
	• If your gas supplier cannot be reached, call the
		fire department.			Do not place clothing or other materials on or near this appli-
					ance.
	Installation and service must be performed by a				IMPORTANT: READ AND UNDERSTAND THESE INSTRUCTIONS
	qualified installer, service agency or the gas sup-
					COMPLETELY BEFORE INSTALLING YOUR UNVENTED ROOM
	plier.
					HEATERS.	1
		NOTE: DIAGRAMS &		ILLUSTRATION NOT TO SCALE.

TABLE OF CONTENTS
General Information .........................	page	2
Inventory .........................................	page	2
Tools and Building Supplies ............	page	2
Installation Applications ..................	page	2
Important Safety Information ..........	page	2
Codes ..............................................	page	3
Combustion and Ventilation Air .......	page	3
Location of Fireplace .......................	page	4
Clearances .......................................	page	5
Preinstallation ..................................	page	5
Installation – Built-In .......................	page	5
Connecting Gas Line ........................	page	6
Gas Pressure Check .........................	page	6
Electrical Wiring – Optional Blower . page		7
Finished Wall Details .......................	page	8
Installation – Surround ....................	page	8
Log Assembly ..................................	page	8
Flame Appearance ...........................	page	9
Optional Equipment .........................	page 10
Forced Air Kit ...................................	page 10
Operation and Care ..........................	page	11
Cleaning and Servicing ....................	page 11
Replacement Parts ..........................	page 11
Accessories/Components ................	page 12
Appliance Specifications ..................	page 13
CH Operating Instructions ...............	page 14
CM Operating Instructions ...............	page 16
Troubleshooting Guide ....................	page 17
Replacement Parts List ....................	page 18
Replacement Parts ..........................	page 19

GENERAL INFORMATION

The VF4000 Series Unvented Room Heaters covered in this manual feature ceramic fiber split logs which glow realistically when the heater is operating.

These heaters are manually controlled. Models VF4000-CMN-2 and VF4000-CMP-2 feature a gas valve incorporating a millivolt operating system.

A spark ignition system (piezo) allows the heater pilot gas to be lit without the use of matches or batteries and permits operation of the heater during a power outage.

These heaters are fitted with a specially designed pilot (ODS) which responds to the amount of oxygen available in the room and shuts the heater off before the oxygen level drops below 18%. The pilot can be relit only when fresh air is available. Refer to the Combustion and Ventilation Air section.

The VF4000 Series Unvented Room Heaters may be built into a framed wall, or installed in an optional oak surround.

This heater has been tested to the standards of ANSI Z21.11.2 unvented heaters.

Do not install these unvented room heaters in a bedroom or bathroom as all units exceed maximum allowable BTU/Hr input of 10,000.

Inventory

Unvented Gas Fireplace Gas connection fittings

Installation and Operating Instructions

Tools and Building Supplies

Normally Required

Tools Should Include:

Phillips screwdriver

Hammer

Saw and/or Sabersaw

Measuring tape

Electric drill and bits

Pliers

Square

Piping complying with local codes

Pipe wrench

Tee joint

Pipe compound

Building Supplies Should Include:

Framing materials Wall finishing materials

Caulking materials (noncombustible) Fireplace surround materials

Installation Applications

1.Fireplace built into a framed wall.

2.Fireplace installed with oak surround and/ or platform (Refer to the SUR-5/6 unfinished oak veneer surround installation instructions, P/N 903593).

Check the inventory list to be sure that you have all the necessary parts in usable condition. Also check for concealed damage.

IMPORTANT SAFETY INFORMATION

INSTALLER: PLEASE LEAVE THESE INSTRUCTIONS WITH THE OWNER.

OWNER: PLEASE RETAIN THESE INSTRUCTION FOR FUTURE REFERENCE.

IMPORTANT: BEFORE STARTING YOUR HEATERINSTALLATION,READTHESEINSTALLATION INSTRUCTIONS CAREFULLY TO BE SURE YOU UNDERSTAND THEM COMPLETELY AND IN ENTIRETY. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD CAUSE A HEATER MALFUNCTION RESULTING IN SERIOUS INJURY AND/OR PROPERTY DAMAGE.

WARNING: THESE APPLIANCES ARE DESIGNED TO OPERATE ON NATURAL OR PROPANE GAS ONLY. THE USE OF OTHER FUELS OR COMBINATION OF FUELS WILL DEGRADE THE PERFORMANCE OF THIS SYSTEM AND MAY BE DANGEROUS.

		UNVENTED GAS			ROOM HEATER SPECIFICATIONS AND			TECHNICAL DETAILS
						Valve		Regulator Pressure	Gas Inlet
	Model No.		Gas Type		Maximum BTU/HR	Operation	Ignition	Setting	Pressure
	VF4000-CHN-2		Natural		25,000	Manual	Piezo	5" w.c.	Max 10 ¹⁄" w.c.
	VF4000-CMN-2								Min. 6" w.c.
	VF4000-CHP-2		Propane/		25,000	Manual	Piezo	10" w.c.	Max 13" w.c.
	VF4000-CMP-2		LPG						Min. 11" w.c.
2
					NOTE: DIAGRAMS & ILLUSTRATION NOT TO SCALE.

WARNING: FAILURE TO COMPLY WITH THE INSTALLATION AND OPERATING INSTRUCTIONS PROVIDED IN THIS DOCUMENT WILL RESULT IN AN IMPROPERLY INSTALLED AND OPERATING UNVENTED ROOM HEATER, VOIDING ITS WARRANTY. ANY CHANGE TO THIS HEATER AND/OR ITS OPERATING CONTROLS IS DANGEROUS. IMPROPER INSTALLATION OR USE OF THIS HEATER CAN CAUSE SERIOUS INJURY OR DEATH FORM FIRE, BURNS, EXPLOSION OR CARBON MONOXIDE POISONING.

Carbon Monoxide Poisoning: Early signs of carbon monoxide poisoning are similar to the flu with headaches, dizziness and/or nausea. If you have these signs, obtain fresh air immediately. Turn off the gas supply to the heater and have it serviced by a qualified professional, as it may not be operating correctly.

•Due to high temperatures, the heater should be located out of traffic and away from furniture and draperies.

•Children and adults should be alerted to the hazard of high surface temperatures and should stay away to avoid burns or clothing ignition.

•Young children should be carefully supervised when they are in the same room with the heater.

•Do not place clothing or other flammable material on or near the heater for the purpose of drying.

•Installation and repair should be done by a qualified service person. The heater should be inspected before use and at least annually by a professionalserviceperson.Morefrequentcleaning may be required due to excessive lint from carpeting, bedding material, etc. It is important that control compartments, burners and circulating air passageways of the heater be kept clean.

•Allow the heater to cool before servicing. Always shut off any electricity or gas to the heater while performing service work.

•Do not install the VF4000 series heaters in a bedroom or bathroom.

•The installation must conform with local codes or, in the absence of local codes with the National Fuel Gas Code, ANSI Z223.1.

•The heater and its individual shut-off valve must be disconnected from the gas supply piping system while performing any tests of the gas supply piping system at pressures in excess of 1/2 psig.

•The heater must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig.

•Any safety screen or guard removed for servicing the heater must be replaced prior to operating the heater.

•Keep heater area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

•Do not use these appliances if any part has been under water. Immediately call a qualified professional service technician to inspect the appliance and to replace any parts of the control system and any gas control which have been under water.

•Input ratings are shown in BTU per hour and are for elevations up to 7,000 feet. Operating heater above elevations of 7,000 feet may cause ODS pilot outage.

•Ensure that the heater is clean when operating. Excessive dust accumulation on the burner and logs will increase the amount of carbon monoxide formation and could lead to carbon monoxide poisoning and death.

CODES

Adhere to all local codes or in their absence the latest edition of The National Fuel Gas Code ANSI Z223.1 or NFPA54 which can be obtained from The American National Standards Institute, Inc. (1430 Broadway, New York, NY, 10018) or National Fire Protection Association, Inc. (Batterymarch Park, Quincy, MA, 02269).

Massachusetts And New York Requirements

These appliances are approved for installation in the following USA locations listed in the following:

Massachusetts:

These fireplaces are approved for installation in the US state of Massachusetts if the following additional requirements are met-

•Installation and repair must be done by a plumber or gas fitter licensed in the Commonwealth of Massachusetts.

•The flexible gas line connector used shall not exceed 36 inches (92 centimeters) in length.

•The individual manual shut-off must be a T- handle type valve.

NOTE: DIAGRAMS & ILLUSTRATION NOT TO SCALE.

•Vent-Free appliances may NOT be installed in bedrooms or bathrooms.

•A working smoke detector must be installed in the area where vent-free appliances are installed.

Seller of unvented propane or natural gasfired supplemental room heaters shall provide to each purchaser a copy of 527 CMR 30 upon sale of the unit.

New York:

These fireplaces are approved for installation in the US state of New York, but not in New York City.

COMBUSTION AND VENTILATION AIR

These heaters shall not be installed in a confined space. The heater may be located in unusually tight construction provided the space is unconfined, or if confined, is provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all connected spaces meets the criteria for an unconfined space, (National Fuel Gas Code ANSI Z223.1 (latest edition), Section 5.3). Generally 50 ft 3 per 1,000 BTU input of all operating appliances in the space.

The National Fuel Gas Code defines a confined space as a space whose volume is less than 50 ft 3 per 1,000 BTU/Hr (4.8 m3 per kw) of the aggregate input rating of all appliances installed in that space and an unconfined space as a space whose volume is not less than 50 ft 3 per 1,000 BTU/Hr (4.8 m3 per kw) of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconfined space.

Unusually tight construction is defined as construction where:

a.wall and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with a rating or one perm or less with openings gasketed or sealed, and

b.weather stripping has been added on operable windows and doors, and

c.caulking or sealants are applied to areas such as joints around window and door frames, between sole plates and floors, between wallceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other openings.

3

Use the following equations to determine if you have a confined or unconfined space.

1.Determine the volume of space — ft 3.

Length x Width x Height = _____ ft 3 (Include adjoining rooms with doorless passageways or ventilation grills between rooms.)

Example: 20' (L) x 16' (W) x 8' (H) = 2560 ft 3

2.Divide the volume of space by 50 ft 3 to determine the maximum BTU/Hr the space can support.

______ (volume of space – ft 3)/ 50 ft 3 = (Maximum BTU/Hr the space can support)

Example: 2560 ft 3 / 50 ft 3 = 51.2

or 51,200 BTU/Hr the space can support.

3.Add the BTU/Hr of all the fuel burning appliances in the space.

Vent-Free heater	_______	BTU/Hr
Gas appliance #1*	_______	BTU/Hr
Gas appliance #2	+ _______	BTU/Hr
Total = _______		BTU/Hr
Example:
VF4000 Vent-free heater 25,000		BTU/Hr
Gas appliance #1	34,000	BTU/Hr
(water heater)
Total = 59,000		BTU/Hr

* Do not include direct-vent gas appliances. Direct-vent is sealed combustion and draws combustion air from the outdoors.

4. Compare the maximum BTU/Hr the space can support with the actual amount of BTU/ Hr used.

_________	BTU/Hr
	(max. the space can support)
_________	BTU/Hr
	(actual amount of BTU/Hr used)
Example:
51,200	BTU/Hr
	(max. the space can support)
59,000	BTU/Hr
	(actual amount of BTU/Hr used)

The space in the above example is a confined space because the actual BTU/Hr used is more than the maximum BTU/Hr the space can support. You must provide additional fresh air.

4

WARNING: IF THE AREA IN WHICH THE HEATER MAY BE OPERATED IS SMALLER THAN THAT DEFINED AS AN UNCONFINED SPACE, PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR BY ONE OF THE METHODS DESCRIBED IN THE NATIONAL FUEL GAS CODE, ANSI Z223.1 1992, SECTION 5.3 OR APPLICABLE LOCAL CODES.

Your options are:

a.Rework equations adding the space of adjoining room(s). If the extra volume provides an unconfined space, then remove door or add ventilation grills between rooms. Refer to National Fuel Gas Code, ANSI Z223.1 1992, Section 5.3.

b.Vent room directly to the outdoors. Refer to National Fuel Gas Code, ANSI Z223.1 1992, Section 5.3.

c.Install a lower BTU/Hr heater, to make the area an unconfined space.

If the actual BTU/Hr used is less than the maximum BTU/Hr the space can support, then the space is an unconfined space. You will need no additional fresh air ventilation for an unconfined space.

LOCATION OF FIREPLACE

Carefully select the best location for installation of your VF4000 series Unvented Room Heater. The following factors should be taken into consideration:

•Clearance to side wall, ceiling, woodwork and windows.

•Location must not be affected by drafts caused by kitchen exhaust fans, return air registers for forced air furnaces/air conditioners, windows or doors.

•Installation must provide adequate ventilation and combustion air.

•Do not install the VF4000 series heaters in a sleeping room or bathroom.

•Never obstruct the front opening of the heater or restrict the flow of combustion and ventilation air.

NOTE: DIAGRAMS & ILLUSTRATION NOT TO SCALE.

•This appliance may be installed in an aftermarket* manufactured (Mobile) Home, where not prohibited by state or local codes.

*Aftermarket: Completion of sale, not for purpose of resale, from the manufacturer.

•Minimize modifications to existing construction. Refer to Figure 1 for location suggestions.

Figure 1

To ensure even heat distribution, it is best to position the heater centrally against the longest wall of the room. Make sure there is adequate ventilation where the heater is installed. The gas appliance will shut off if the oxygen level falls below 18%.

These appliances are uniquely suited for installations requiring a utility shelf positioned directly above the fireplace. Utility shelves like these are commonly used for locating television sets and decorative plants.

To provide for the lowest possible shelf surface, combustible materials used to support a utility shelf directly above these appliances should be positioned just above the appliance top spacers. The minimum height from the base of the VF4000 to the underside of combustible materials used to construct a utility shelf is 37-1/4” (946 mm).

The appliance should be mounted on a fully supported base extending the full width and depth of the unit. The appliance may be located on or near conventional construction materials. However, if installed on combustible materials, such as carpeting, vinyl tile, etc., a metal or wood barrier covering the entire bottom surface must be used.

If the appliance is to be elevated above floor level, a solid continuous platform must be constructed.

WARNING: MAINTAIN MINIMUM CLEARANCES.

Do not install in the vicinity of gasoline or other flammable liquids. The heater must be kept clear and free from these combustible materials and may not be located near where they are stored.

Clearances

WARNING: DO NOT INSTALL VF SERIES UNVENTED ROOM HEATERS IN SLEEPING QUARTERS, OR IN RECREATIONAL VEHICLES.

WARNING: DO NOT INSTALL THE VF UNVENTED ROOM HEATER:

•WHERE CURTAINS, FURNITURE, CLOTHING OR OTHER FLAMMABLE OBJECTS ARE LESS THAN 42" FROM THE FRONT OF THE UNVENTED ROOM HEATER.

•IN HIGH TRAFFIC AREAS.

•IN WINDY OR DRAFTY AREAS.

Ensure the minimum clearances shown in Figures 2 and 3 are maintained.

Minimum clearance to combustibles are:

	Appliance:	side and back - 0"
		floor - 0"
		adjacent wall - 6"
		ceiling - 37-1/2” (953 mm)
		Combustible
		Finished Wall
		Materials
			12"
			( mm)
			10''	Header
	26"		8''
	( mm)			Spacer
			6''
	22-1/2"
	( mm)
	18-5/8"			1/4" Gap
	( mm)
			2-1/2"	Required
		14-1/2"	( mm)
		( mm)
			8"	Top of Appliance
		( mm)		Top of Door Frame

VF Series

Figure 2

A hearth extension is not required with this appliance. If a hearth extension is used, do not block the lower control compartment door. Any hearth extensions used is for appearance only and does not have to conform to standard hearth extension installation requirements.

Note: Combustible wall finish materials and/or surround materials must not be allowed to encroach the area defined by the appliance front face (black sheet metal). Never allow combustible materials to be positioned in front of or overlapping the appliance front face.

6" Clearance to Combustible Side Wall

Max. Projection (See Fig. 2)

37-1/2" Min. to Ceiling

Combustible (953 mm) Mantel

(See Fig. 2)

Figure 3

PREINSTALLATION

Check that all listed parts have been received.

Carefully inspect the heater case and contents for shipping damage and immediately inform the dealer from whom you purchased the gas fireplace if any damage is found.

The appliance is shipped with all gas controls and components installed and pre-wired. Remove the shipping carton. The nailing flanges are installed at each side of the appliance backwards when shipped from the factory to protect the unit from shipping damage. Remove the nailing flanges and retain for use when installing the appliance in framing. Remove three screws and remove the screen panel. Remove the logs and set aside.

Check Gas Type

This appliance can only be connected to the gas type specified on the appliance data plate. This appliance can not be modified in the field for a different gas type. If the gas type to be used is not the one specified contact the dealer to obtain the correct gas appliance.

Note: Illustrations shown in this manual reflect “typical” installations with nominal dimensions and are for design and framing reference only. Actual installations may vary due to individual design preferences. However, always maintain minimum clearances to combustible materials and do not violate any specific installation requirements.

NOTE: DIAGRAMS & ILLUSTRATION NOT TO SCALE.

Note: The following steps represent the normal sequence of installation. Each installation is unique, however, and might require a different sequence.

CAUTION: HEATERS CREATE WARM AIR CURRENTS. THESE CURRENTS MOVE HEAT TO WALL SURFACES NEXT TO HEATER. INSTALLING HEATER NEXT TO VINYL OR CLOTH WALL COVERINGS OR OPERATING HEATER WHERE IMPURITIES IN THE AIR (SUCH AS TOBACCO SMOKE) EXISTS, MAY DISCOLOR WALLS.

Step 1. Position heater in desired location (freestanding, onto surround base or into prepared framing) and secure.

Step 2. Plumb gas line. (Gas connections should only be performed by an experienced, licensed/ certified tradesman.)

Step 3. Assemble logs and test flame appearance.

Step 4. Complete finish wall material, surround and optional hearth extension to your individual taste.

INSTALLATION STEPS

Built-In Systems

WARNING: DO NOT ALLOW FANS TO BLOW DIRECTLY INTO THE FIREPLACE. AVOID ANY DRAFTS THAT ALTER BURNER FLAME PATTERNS.

WARNING: DO NOT USE A BLOWER INSERT, HEAT EXCHANGER INSERT OR OTHER ACCESSORY NOT APPROVED FOR USE WITH THIS HEATER.

Do not burn solid fuels in this listed unvented gas room heater.

Step 1. Frame VF4000 appliance enclosures as illustrated in Figures 4, 5 and 6.

Note: The framed depth (15-1/2" for a flat wall, 29" for a corner VF4000) must always be measured from a finished surface. If a wall covering such as drywall is to be attached to the rear wall, then the dimension must be measured from the drywall surface.

Note: Framing dimensions in Figures 4 - 6 are calculated for a nailing flange depth of 1/2" (13 mm).

5

		Back Wall of
		Chase/Enclosure
	Outside Wall	Including Finishing
		Materials If Any.
		15-1/2"
		(394mm)
		37" (940mm)
	Figure 4
		Back Wall of
		Chase/Enclosure
		Including Finishing
		Materials If Any.
	41"
	(1041mm)	13-1/2"
		(343mm)
		29"
		(737mm)

37" (940mm)

58-1/2" (1486mm)

Figure 5

37-1/4" (946 mm)

15-1/2" (394 mm)

37" (940 mm)

Figure 6

Step 2. Route a 1/2" (13 mm) gas line along the left or right side framing (Figure 7 ).

All appliances have a 3" long 3/8" NPT nipple installed at the regulator. To quickly and easily complete the gas line routing, use the gas flex line kit, Model GFLV.

Step 3. Position appliance into prepared framing, secure with 6d nails at the nailing flange along each side.

Step 4. Connecting Gas Line – Make gas line connections. All codes require a shut-off valve mounted in the supply line. Figure 8 illustrates two methods for connecting the gas supply. Installation methods and materials must be in compliance with local codes.

6

3"	7"
(76 mm)	(178 mm)

Figure 7

The gas control valve is located in the lower control compartment. To access the valve open the lower control compartment door (Figure 9 ).

The regulator has a 3/8" NPT thread inlet port and is fitted with a 3" (76 mm) long nipple, ³⁄" NPT on both ends. Plan the connections accordingly.

We recommend that the gas line be routed for the right side of the appliance to ensure adequate access to the rear lower compartment for installation and servicing of the optional FAB-1100 blower.

Control Valve (Standard)

Lower Control

Compartment Door

Figure 9

Secure all joints tightly using appropriate tools and sealing compounds (ensure propane resistant compounds are used in propane applications).

Turn on gas supply and test for gas leaks, using a gas leak test solution (also referred to as bubble leak solution).

Note: Using a soapy water solution (50% dish soap, 50% water) is an effective leak test solution but it is not recommended, because the soap residue that is left on the pipes/ fittings can result in corrosion over time. Never use an open flame to check for leaks.

		Gas Flex Line Kit, Model GFLV
	1/2" x 3/8" Flare	3/8" NPT x 3/8"
		Flare Fitting
	Shut-Off Valve	Gas Valve
		3/8" Flex Tubing
		3/8" Nipple, Standard
		with all Units
	Gas Stub	3/8" Union
		3/8" Close Nipple
		3/8" Shut-Off Valve
		1/2" x 3/8" Reducer
	Figure 8

NOTE: DIAGRAMS & ILLUSTRATION NOT TO SCALE.