User's Manual

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MODEL: ASHTON AI42DV

LEXINGTON FORGE

DIRECT VENT GAS INSERT

INSTALLATION AND OPERATING INSTRUCTIONS

WARNINGS

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 qualied installer, service agency or the

gas supplier.

WARNING: Improper installation, adjustment,

alteration, services or maintenance can cause injury or

property damage. Refer to this manual. For assistance

or additional information consult a qualied 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

certied 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.

DUE TO HIGH TEMPERATURES, THE

APPLIANCE SHOULD 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 BURNS OR

CLOTHING IGNITION.

YOUNG CHILDREN SHOULD 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

Summary of content (40 pages)

PAGE 1
LEXINGTON FORGE DIRECT VENT GAS INSERT INSTALLATION AND OPERATING INSTRUCTIONS MODEL: ASHTON AI42DV WARNINGS 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 flammable 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.
PAGE 2
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.
PAGE 3
IMPORTANT SAFETY INFORMATION WARNING INSTALLER Please leave these instructions with the owner. OWNER Please retain these instructions for future reference. • 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, burns, explosions, electrical shock and carbon monoxide poisoning.
PAGE 4
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.
PAGE 5
PRODUCT FEATURES AND CODE APPROVAL PRODUCT SPECIFICATIONS • This appliance has been certified 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 code. ANSI Z223.1/NFPA 54 in the USA, CAN/CGA B149 in Canada.
PAGE 6
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 certified 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 Manifold Press: (W.C.) Maximum Supply Pressure Minimum Supply Pressure 3.5" 10.5" 4.
PAGE 7
FIREPLACE AND INSERT DIMENSIONS � �� Side Front � � Fireplace Opening Top Figure 2 - External Insert Dimensions L M N - Fireplace opening height Fireplace opening width Depth of insert O P Q - Firebox width at insert depth (N) Firebox depth at insert back height (Q) Insert back height AI42 A B C 48D0139 FIREPLACE 251/4" 641mm 36" 914mm 34" 863mm D E F G H I J K FIREPLACE 237/8" 606mm 12" 304mm 323/4" 831mm 17" 432mm 191/4" 489mm 221/2" 572mm 241/4" 616mm 173/4" 451mm L M N O P Q MINIMUM OPE
PAGE 8
GENERAL INSTALLATION INFORMATION The following factors should be taken into consideration: • This insert should have sufficient access for its safe operation and maintenance. • The flow 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 flammable liquids may be stored.
PAGE 9
INSTALLATION INSERT CLEARANCES No combustibles (ie: drapes, doors) may be within, or swing within, 36" of the front of the inset. 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.
PAGE 10
INSTALLATION INSERT PLACEMENT • Insert must be placed within a code-conforming masonry fireplace or a tested and listed zero-clearance (metal) fireplace. Repair any fireplace damage prior to installation. • Because the insert uses a circulation blower, clean the fireplace, smoke shelf, and chimney before installing. Paint interior surface of the fireplace with latex paint to further eliminate dust. • This heater may be placed in a bedroom.
PAGE 11
INSTALLATION ZERO-CLEARANCE (METAL) FIREPLACE REQUIREMENTS The damper and grate must be removed. • The smoke shelf internal baffles, screen, refractory, and metal or glass doors may be removed (if applicable). WARNING • • Do not cut any sheet metal parts of the fireplace in which this gas fireplace insert is installed. THIS IS STRICTLY PROHIBITED! Do not remove or alter the insulation or any structured rigid frame members (metal sides, floor, door frame, face of the fireplace, etc.).
PAGE 12
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. NOTICE WARNING VENT INSTALLATION Failure to follow these instructions will void the warranty. INSTALLATION PRECAUTIONS Consult local building codes before beginning the installation.
PAGE 13
VENT INSTALLATION WARNING VENT REQUIREMENTS • Make sure the exhaust pipe on heater connects to exhaust portion of cap. Attach flex liners. See Figure 7. • Do not crimp or rupture liner when bending it into chimney offsets. • The exhaust vent must reline the entire length of chimney and terminate above chimney top. • Vent must meet all vent manufacturer’s requirements when installed.
PAGE 14
VENT INSTALLATION VENT CONFIGURATIONS Termination Kit (part # AI42TK43) Exhaust Exhaust Inlet 4" (100mm) Exhaust UL 1777 Gas Liner 3" (75mm) Inlet Recommended block-off plate (non-combustible metal). Prevents odors from chimney entering room. Suggestion: Paint fireplace cavity with latex paint to eliminate possibility of odors from fireplace circulating into the room. Any cracks or damage inside chimney must be repaired.
PAGE 15
VENT INSTALLATION MANIFOLD REMOVAL AND INSTALLATION The manifold is shipped attached to insert. It may be removed to allow tight installation. Manifold may be loosened and rotated for desired pipe location. Flex Vent Chimney Extra 3" (914mm) 1. Remove brick liner and baffle. Chimney 2. Remove manifold. Place manifold in fireplace. 3. Route flex vent through chimney from above. See Figure 10. Leave an extra 3" (914mm) at the top. Flex Vent 4. Attach flex vent to manifold. See Figure 11.
PAGE 16
INSERT INSTALLATION CHECK GAS TYPE Use proper gas type for the insert you are installing. If you have conflicting gas type, do not install insert. See dealer where you purchased the insert for proper insert according to your gas type. CAUTION WARNING INSTALLING GAS PIPING TO INSERT LOCATION A qualified installer or service person must connect appliance to gas supply. Follow all local codes. For propane/LP units, never connect insert directly to the propane/LP supply.
PAGE 17
Only persons licensed to work with gas piping may make the necessary gas connections to this appliance. CAUTION WARNING INSERT INSTALLATION A manual shutoff valve is factory installed upstream of the appliance. Union tee and plugged 1 / 8 " NPT pressure tapping point should be installed upstream of the appliance. See Figure 15. NOTE : The gas line connection may be made using 1/2" rigid tubing or an approved flex connector.
PAGE 18
CHECKING GAS PRESSURE Check gas type. The gas supply must be the same as stated on the appliance’s rating decal. If the gas supply is different from the fireplace, STOP! Do not install the appliance. Contact your dealer immediately. 2. Install and attach 30" (762mm) flex line provided with on this appliance to 1/2" gas line. 3. After completing gas line connection, purge air from gas line and test all gas joints from the gas meter to the fireplace for leaks.
PAGE 19
ELECTRICAL INSTALLATION ELECTRICAL WIRING CAUTION WARNING This insert will work without any electrical supply. Electricity is only needed if you install a remote wall mounted switch. Electrical connections should only be performed by a qualified, licensed electrician. Main power must be off when connecting to main electrical power supply or performing service. All wiring shall be in compliance with all local, city, and state codes.
PAGE 20
LOG PLACEMENT WARNING Before you begin — This unit is supplied with seven (7) ceramic fiber logs. Do not handle these logs with your bare hands. Always wear gloves to prevent skin irritation from ceramic fibers. After handling the logs, wash your hands gently with soap and water to remove any traces of fibers. The positioning of the logs is critical to the safe and clean operation of this heater. Sooting and other problems may result if the logs are not properly and firmly positioned in the appliance.
PAGE 21
LOG PLACEMENT 5. Place right base log (#3) to the right of rear log (#1). See Figure 20. 6. Place left center log (#4) on top two pins next to left base log (#2). Line up hole in bottom left center log (#4) with pin on burner. See Figure 21. Right Base Log (#3) �� Figure 20 - Installing Right Log #3 Left Center Log (#4) �� Pins Right Center Log (#5) Figure 21 - Installing Left Center Log #4 7. Set right center log (#5) on two pins to the left of right base log. See Figure 22.
PAGE 22
LOG PLACEMENT 8. Place one end of right top log (#6) on cutout of right base log (#3). Line up hole in bottom or right top log (#6) with pin on right center log (#5). See Figure 23. 9. Lay top “Y” log (#7) across rear log (#1) and left center logs #4. Place “Y” log (#7) on two (2) pins provided. See Figure 24.
PAGE 23
LOG PLACEMENT 10. Break up rock wool (ember material) into dime-sized pieces. Place evenly across burner surface and mesh of grate. See Figures 25 and 26. Do not exceed 1" depth of coverage. Lightly cover the airspace between logs and burner with small pieces rock wool for a better burner flame and glow. See Figure 26. Also, use additional small pieces of rock wool to lightly cover the airspace in front of burner. See Figure 27.
PAGE 24
SURROUND AND TRIM INSTALLATION INSTALLING FACING 1. Line up surround with unit opening. 2. Attach surround to unit with four (4) screws provided. See Figure 28. Surround Top of Trim Trim Screws 3. Install magnetic “ L” bracket to bottom of surround with two (2) screws and (2) nuts provided. See Figure 28. Back of Trim ASSEMBLING OPTIONAL TRIM 1. Lay out trim and “L” brackets on floor. See Figure 29 “L” Bracket 2. Put trim together at 45° angles to form a corner.
PAGE 25
FILIGREE INSTALLATION 1. Line up four (4) screw holes on filigree facing with four (4) screw holes on surround. See Figure 31. 2. Attach filigree facing with four (4) screws provided. See Figure 31. NOTICE INSTALLING FILIGREE FACING Remove all fingerprints from facing with a 50/50 vinegar and water solution before lighting the heater. Any fingerprints left on the facing will be permanent when heater is lit.
PAGE 26
DOOR INSTALLATION Slide one door onto hinges. Repeat for other door. See Figure 32. NOTICE INSTALLING DOORS Remove all fingerprints from facing with a 50/50 vinegar and water solution before lighting the heater. Any fingerprints left on the facing will be permanent when heater is lit.
PAGE 27
OPERATING INSTRUCTIONS WARNING FOR YOUR SAFETY READ BEFORE LIGHTING If you do not follow these instruction exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with a pilot piezo ignition system. Follow these instructions exactly to light pilot. B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
PAGE 28
OPERATING INSTRUCTIONS T LEAK TESTING (continued) You may check for gas leaks with the following methods only: • Soap and water solution • An approved leak testing spray WARNING LIGHTING PILOT FOR THE FIRST TIME If using a soap and water solution to test for leaks, DO NOT spray solution onto control body.
PAGE 29
OPERATING INSTRUCTIONS LIGHTING BURNER T MAIN BURNER SWITCH The “ON/OFF/REMOTE” switch for the main burner can be found on the right side of insert surround. This switch allows you to turn on and to turn off the main burner without using the gas valve knob. Make sure the button is in the “ON” position to light the main burner. See Figure 34. LIGHTING THE BURNER Depress and turn the knob counterclockwise than four (4) seconds for the burner to ignite. to the “ON” position. See Figure 35.
PAGE 30
CLEANING AND MAINTENANCE Make sure the gas valve knob is in the “OFF” position. Wait at least five (5) minutes before starting maintenance. VENTING SYSTEM A qualified agency should examine the venting system annually. CAUTION CLEANING GLASS Clean the ceramic glass periodically. Condensation will sometimes form on the glass during a cold startup. This is normal for all gas fireplaces and inserts. This condensation often attracts dust and lint to the surface of the glass.
PAGE 31
AIR SHUTTER ADJUSTMENT (NATURAL GAS ONLY) ADJUSTING THE AIR SHUTTER The venturi of the burner is equipped with an air shutter. The opening of the venturi has been set at 1/4" for Natural Gas and fully open for Propane installation at sea level. The rear burner on Natural Gas Models may be adjusted for high altitude as follows: • To increase air mixture, push up the adjustment rod located beneath the insert. This opens the shutter more and will stop sooting. See Figure 41.
PAGE 32
1. Always use gloves when handling broken glass. WARNING CAUTION GLASS REPLACEMENT Make sure the glass panel edges do not touch any metal parts during thermal expansion. Put on gloves. Remove frame from insert by releasing two clamps on bottom of insert and lifting the door up and off the unit. See Figure 43. Frame 2. Remove the 7 / 8 " rope from around glass frame. See Figure 43. 3. Using a 5/16" socket, remove hex nuts from glass retaining brackets. Remove retaining brackets. See Figure 44. 4.
PAGE 33
MAINTENANCE MAINTAINING YOUR HEATER’S APPEARANCE Fingerprints or other marks left on optional gold or nickel surface may become etched in place if they are not wiped clean prior to turning stove on. Clean gold or nickel with a 50/50 vinegar and water solution and soft cloth soft cloth. NOTE: Make sure heater is cool before cleaning. Using cleaners other than a 50/50 vinegar and water solution may leave a film that becomes permanently etched into the gold or nickel.
PAGE 34
MAINTENANCE 5. Replace log set and rock wool per instructions on pages 20-23. Replace glass. Make sure gasket along perimeter of glass contacts face of firebox and forms an airtight seal. Realign if airtight seal is not formed. Replace glass and glass frame if damaged. 6. Inspect area behind access door. Clean if necessary. Check gas control valve and all gas lines. If damaged, do not use heater. Contact your dealer. 7. Start pilot and turn on main burner.
PAGE 35
BLOWER BLO24 ACCESSORY PARTS LIST: DESCRIPTION Right Blower Left Blower QTY PART NUMBER 1 1 33D0700 45D0240 1 1 1 1 45D0258K 23D6100 26D0746 41D0203 PARTS NOT SHOWN Thermostat Bracket Thermostat Speed Control Wire Harness NOTE: Unplug power cord before servicing. The blowers are attached to insert bottom and back with Velcro. To remove blower for servicing, pull away from Velcro and disconnect wires. Right Blower CAUTION Left Blower Label all wires prior to disconnection when servicing controls.
PAGE 36
REPLACEMENT PARTS �� 36 �� 48D0139
PAGE 37
REPLACEMENT PARTS REPLACEMENT PARTS ARE AVAILABLE THROUGH YOUR RETAILER AI42 Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Burner Assembly Left Log Support Bracket Right Log Support Bracket SIT 820 Nova Valve Front Injector Rear Injector Tube Valve/Burner Pilot Assembly Rocker Switch Shutoff Valve Venturi Burner Gasket Hi/Lo Knob Extension Knob Extension ON/OFF Ignitor Battery Module Ignitor Wire Harness ON/OFF Wire Harness 3/8" Union Nipple, 10.
PAGE 38
WARNING WARNING TROUBLESHOOTING Turn appliance OFF and allow to cool before servicing. Only a qualified service person should service and repair the heater. Note: All troubleshooting items are listed in order of operation. OBSERVED PROBLEM POSSIBLE CAUSE REMEDY Spark ignitor will not light the pilot after repeated pressing of spark ignitor. 1. Battery needs replacing 2. Defective ignitor 1. Replace battery 2. Check connections to ignitor.
PAGE 39
INSTALLATION RECORDS THE FOLLOWING INFORMATION MUST BE RECORDED BY THE INSTALLER FOR WARRANTY PURPOSES AND FUTURE REFERENCE. LEXINGTON FORGE Model: _____________________________ Name of Owner: Name of Installer: Address: Address: Phone: Phone: Name of Dealer: Address: Phone: Manufactured by LEXINGTON FORGE 149 Cleveland Drive Paris, Kentucky 40361, U.S.A.
PAGE 40
WARRANTY COVERAGE Lexington Forge warrants its products to be free of defects in material and workmanship and backs each product with a Limited Lifetime Warranty. This warranty is to the original purchaser of a Lexington Forge product and is not transferable. LIFETIME WARRANTY Covered under this warranty are the insert body, combustion chamber, door frame, gold plating (manufacturing defects only), glass (thermal breakage only), heat exchange system, and burner.