KHLDV SERIES DIRECT VENT GAS FIREPLACE INSTALLATION AND OPERATING INSTRUCTIONS MODELS: KHLDV400 & KHLDV500 WARNING IF THE INFORMATION IN THESE INSTRUCTIONS IS 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.
CONTENTS Important Safety Information .......................... 3 Optional Fan/Blower Systems ....................... 26 Product Features .............................................. 5 Glass Removal ................................................ 29 Code Approval .................................................. 5 Final Installation ............................................. 30 Hearth Brick Placement .............................. 30 Rockwool Placement...................................
IMPORTANT SAFETY INFORMATION OWNER Please leave these instructions with the appliance. Please retain these instructions for future reference. WARNING INSTALLER • Read this owner’s manual carefully and completely before trying to assemble, operate, or service this fireplace. • Any change to this fireplace or its controls can be dangerous. • Improper installation or use of this fireplace can cause serious injury or death from fire, burns, explosions, electrical shock and carbon monoxide poisoning.
IMPORTANT SAFETY INFORMATION Continued from page 3 12. Do not use this fireplace to cook food or burn paper or other objects. 13. Never place anything on top of fireplace. 14. Do not use any solid fuels (wood, coal, paper, cardboard, etc.) in this fireplace. Use only the gas type indicated on rating plate. 15.
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.
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. Where the heating value of the gas has been reduced, these rules do not apply. • 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).
FIREPLACE FRAMING WARNING FIREBOX FRAMING WARNING Unit framing is to be rectangular front Firebox framing can be built before or after the appliance is set in place. Construct firebox framing following Figure to back. Failure to do so will cause fire 2 and the chart below for your specific installation requireand damage to property. ments. See Figure 3 on page 8 for firebox dimensions. The framing headers may rest on the top of the firebox standoffs. Do not bring headers below top of standoffs.
PRE-INSTALLATION INFORMATION FIREPLACE DIMENSIONS E J H I G D A K L F M N C B Figure 3 - Fireplace Dimensions DESCRIPTION 8 Key Letter KHLDV400 KHLDV500 Overall Front Width A 44 15/16" 48 15/16" Inside Width B 35 1/2" 39 1/2" Glass Width C 32" 36" CTR Pipe D 22 1/2" 24 1/2" Rear Width E 28 1/8" 32 1/8" Glass Height F 30" 30" Chassis Height G 38 7/16" 38 7/16" Depth H 23 7/8" 23 7/8" Height to Standoffs I 44 3/8" 44 3/8" CTR Height J 8 9/16" 8 9/16" Top
NOTE PRE-INSTALLATION INFORMATION COLD CLIMATE INSULATION If you live in a cold climate, seal all cracks around your appliance, and wherever cold air could enter the room, with noncombustible material. It is especially important to insulate the outside chase cavity between the studs and under the floor on which the appliance rests, if the floor is above ground level. FIREPLACE LOCATION Plan for the installation of your appliance.
CLEARANCES WARNING CLEARANCES TO COMBUSTIBLES Follow these instructions carefully to ensure safe installation. Failure to follow instructions exactly can create a fire hazard. The appliance cannot be installed on a carpet, tile or other combustible material other than wood flooring. If installed on carpet or vinyl flooring, the appliance shall be installed on a metal, wood or noncombustible material panel extending full width and depth of the appliance. COMBUSTIBLE MATERIAL AREA FIREPLACE WALL 1" 1.
SECURING FIREPLACE TO FLOOR OR FRAMING NOTE The fireplace must be secured to the floor and/or to framing studs as shown in Figure 6. Use two (2) wood screws or masonry/ concrete screws to secure fireplace to the floor. Use four (4) screws to attach fireplace to framing. The side nailing flanges are 1/2" or 5/8" to accommodate different wall thickness. Never install combustible materials over front face of fireplace.
INSTALLATION INFORMATION FINISHING MATERIAL NOTE: Any remote wiring (i.e. remote control, wall switch, and optional fan) must be done prior to final finishing to avoid costly reconstruction. Only noncombustible materials (i.e. brick, tile, slate, steel, or other materials with a UL fire rating of Zero) may be used to cover the black painted face of the appliance. It is permissible to bring combustible wall board to the top of the stand offs on the top and the sides of the unit.
WARNING VENT INSTALLATION Horizontal sections of this vent system require a minimum of 3" clearances to combustibles at the top of the flue and 1" clearance at the sides and bottom until the flue penetrates the outside wall. A minimum 1" clearance all around the flue is acceptable at this point of penetration. Vertical sections of this vent system require a minimum of 2" clearance to combustibles at the top of the unit directly above the stand-off.
VENT INSTALLATION INSTALLATION PLANNING There are two basic types of direct-vent installation: • Horizontal Termination • Vertical Termination It is important to select the proper length of vent pipe for the type of termination you choose. It is also important to note the wall thickness. Select the amount of vertical rise desired. All horizontal run of venting must have 1/4" rise for every 12" of run towards the termination. You may use up to three 90° elbows in this vent configuration.
VENT INSTALLATION FOR HORIZONTAL TERMINATION Inside Corner Detail G V H A D E C B B G B V L F Fixed Closed Operable B I Opera- Fixed ble Closed V V V B A V Vent Terminal A V A M B V J Air Supply Inlet A K A Area Where Terminals Not Permitted Figure 8 - Horizontal Vent Termination Location MINIMUM DISTANCES A = Clearance above the grade, a veranda, porch, deck, or balcony [*12" (305mm) minimum]. B = Clearance to window or door that may be opened [*12" (305mm) minimum].
VENT INSTALLATION TERMINATION CLEARANCES FOR BUILDINGS WITH COMBUSTIBLE AND NONCOMBUSTIBLE EXTERIORS D C C G G=6" (152mm) V V V E F=6" (152mm) F Combustible – 6" (152 mm) Noncombustible – 2" (51mm) Inside Corner Outside Corner C = Maximum depth of 48" (1219mm) for alcove location D = Minimum width for back wall of alcove location Combustible - 38" (965mm) Noncombustible - 24" (610mm) E = Clearance from corner in alcove location Combustible - 6" (152mm) Noncombustible - 2" (51mm) H G V V J Com
VENT INSTALLATION VERTICAL/HORIZONTAL TERMINATION CONFIGURATIONS Since it is very important that the venting system maintain its balance between the combustion air intake and the flue gas exhaust, certain limitations as to vent configurations apply and must be strictly adhered to. The Vent Graph, showing the relationship between vertical and horizontal side wall venting, will help to determine the various dimensions allowable. See Figure 10.
VENT INSTALLATION VERTICAL/HORIZONTAL TERMINATION CONFIGURATIONS (continued) • 90° A If a 90° elbow is used in the horizontal vent run (level height maintained) the horizontal vent length is reduced by 36". See Figures 11 and 12, page 17. This does not apply if the 90° elbows are used to increase or redirect a vertical rise. See Figure 14.
VENT INSTALLATION BELOW GRADE INSTALLATIONS When it is not possible to meet the required vent terminal clearances of 12" above grade level, a snorkel kit is recommended. It allows installation depth down to 7" (178mm) below grade level. The 7" (178mm) is measured from the center of the horizontal vent pipe as it penetrates through the wall. Ensure that sidewall venting clearances are observed.
VENT INSTALLATION VERTICAL (THROUGH-THE-ROOF) APPLICATIONS This gas fireplace has been approved for, • Vertical installations up to 40' (12m) in height. Up to a 10' (3m) horizontal vent run can be installed within the vent system using a maximum of two 90° elbows. See Figure 18. 40' Maximum Height 12' Minimum Height 10' Maximum 24" Min.
VENT INSTALLATION INSTALLATION FOR VERTICAL TERMINATION 1. Determine the route your vertical venting will take. If ceiling joist, roof rafters or other framing will obstruct the venting system, consider an offset. See Figure 20 to avoid cutting load bearing members. For optimal flame appearance, a restrictor disk is necessary on straight vertical runs of 10' of more. • Runs may not incorporate elbows. • The disk is part number 56D3027 and is included in installation manual packet.
VENT INSTALLATION 3. Cut a hole in the roof using the locating hole as a center point. (Cover any exposed open vent pipes before cutting hole in roof). The 101/2"x101/2" (241mm x 241mm) hole must be measured on the horizontal. Actual length may be larger depending on the pitch of the roof. There must be a 1" minimum clearance from the vent pipe to combustible materials. (Insulation should be considered a combustible material). 4. Connect a section of pipe and extend up through the hole.
FIREPLACE INSTALLATION CHECK GAS TYPE Use proper gas type for the fireplace you are installing. If you have conflicting gas type, do not install fireplace. See dealer where you purchased the fireplace for proper fireplace for your gas type or conversion kit. CAUTION WARNING INSTALLING GAS PIPING TO FIREPLACE / BURNER SYSTEM LOCATION A qualified installer or service person must connect appliance to gas supply. Follow all local codes.
Only persons licensed to work with gas piping may make the necessary gas connections to this appliance. CAUTION WARNING FIREPLACE INSTALLATION A manual shutoff valve must be installed upstream of the appliance. Union tee and plugged 1/8" NPT pressure tapping point should be installed upstream of the appliance. See Figure 24. NOTE : The gas line connection may be made using 1/2" rigid tubing or an approved flex connector.
CHECKING GAS PRESSURE AND ELECTRICAL INSTALLATION 1. 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. 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. Use a solution of 50/50 water and soap solution or a gas sniffer. 4.
REMOTE WALL SWITCH INSTALLATION REMOTE WALL MOUNTED SWITCH ON OFF PILOT HI LO TH TP TH/TP ON OFF RS OFF OPTIONAL REMOTE WALL SWITCH ON OFF Figure 26 - Wiring Diagram for Wall Switch Do not connect wall switch of heater to a 110V circuit. CAUTION WARNING NOTE: Extended lengths of wire may cause the fireplace not to function properly. Longer length of wire is permitted if the wire is made out of larger gauge (diameter) wire. Always check with local code.
OPTIONAL FAN/BLOWER SYSTEM 120 VAC 60Hz Factory Supplied Not Supplied JUNCTION BOX Figure 27 - Junction Box Wiring Diagram Figure 27a - Blower Wiring Diagram WARNING Failure to replace the access cover with the one provided with the blower kit, and then running the blower, will cause excessive temperatures and could cause a fire, property damage and/or loss of life. WARNING 7. Remove the access covers on the right and left side walls of the firebox toward the front by unfastening the screws.
OPTIONAL FAN/BLOWER SYSTEM Figure 28 - Blower Access Plates Figure 29 - Blower Access Plates Figure 30 - Assembling Blowers to Access Plates.
GLASS REMOVAL GLASS FRAME REMOVAL 1. Remove the plate located in front of the glass at the bottom. 2. Remove rod provided for screen assembly located beneath the cover plate. 3. Rotate the access doors on the right and left side of the glass toward the glass. 4. Remove glass frame by releasing the three latches located at the top of the firebox. Tilt glass away from the unit, lift glass frame up and away from the unit. Figure 32.
FINAL INSTALLATION BRICK, LIGHT BULB, AND LENS PLACEMENT 1. Remove the trapezoidal light shroud located at the back of the firebox by unfastening the three screws. 2. Disassemble the trapezoidal light shroud by unfastening the four screws which secure the front to the back. Set lens with the orange painted surface toward the bottom. Center the lens right to left. Reassemble the front to the back and set the side. 3. Place the right side panel by sliding it at an angle to clear the grate.
FINAL INSTALLATION LOG PLACEMENT 1. Place the rear log over the grate toward the back by positioning the holes over the large pins located at the right and left. When the log is in place, the back surface of the log will come in contact with the light trapezoid deflector. 2. Place the log over the pilot by holding the log with the wide end toward the back and the branch toward the front and left.
FINAL INSTALLATION 5. Place the upper left log at angle over the rear and the middle logs by matching the indentation on the bottom of the log with protrusion on the rear log. Set the pointed end of the log over the flat surface of the middle log. When this log is in place the pointed end will come in contact with the back of the pilot log placed in step #2. 6.
OPERATING INSTRUCTIONS (MILLI-VOLT) 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 which must be lit with built-in piezo ignitor while following these instructions exactly. B. BEFORE OPERATING smell all around the appliance area for gas.
OPERATING INSTRUCTIONS (MILLI-VOLT) APPROVED LEAK TESTING METHOD 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. DANGER • Electronic sniffer Never check for gas leak with open flame! NOTE: Remove any excessive pipe compound from the connections.
OPERATING INSTRUCTIONS (MILLI-VOLT) LIGHTING BURNER T LIGHTING THE BURNER Depress and turn the knob counterclockwise to the “ON” position. See Figure 37. It will take less than four (4) seconds for the burner to ignite. OFF RS The “ON/OFF/RS” switch for the main burner can be found behind door of the fireplace. 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 36.
WARNING CLEANING AND MAINTENANCE Turn off gas before servicing fireplace. It is recommended that a qualified service technician perform these check-ups at the beginning of each heating season BURNER, PILOT AND CONTROL COMPARTMENT Keep the control compartment, logs, and burner areas surrounding the logs clean by vacuuming or brushing at least twice a year. Make sure the burner porting, pilot air opening and burner air opening are free of obstructions at all times.
CLEANING AND MAINTENANCE VENT SYSTEM The fireplace and venting system should be inspected before initial use and at least annually by a qualified field service person. Inspect the external vent cap on a regular basis to make sure that no debris is interfering with the airflow. Inspect entire venting system to ensure proper function. GLASS DOOR Thoroughly clean the inside of the glass door after using the fireplace for ten hours. Periodically clean the glass door as necessary.
TROUBLESHOOTING STANDING PILOT IGNITION SYMPTOM POSSIBLE CAUSE ACTION 1. Spark ignitor will not light pilot after repeated triggering of piezo. A. Wire disconnected. A. Open door and check to make sure wire is connected to ignitor. B. Check for spark at electrode and pilot. If no spark and electrode wire is properly connected, replace pilot assembly. C. Check remote/manual shut off valve from fireplace. Low pressure can be caused by bent lines, restricted lines, low pressure line pressure.
TROUBLESHOOTING STANDING PILOT IGNITION SYMPTOM POSSIBLE CAUSE 4. Frequent pilot outage problem. A. Pilot flame may be too high or A. Clean and adjust the pilot flame for maximum flame impingetoo low, causing pilot safety ment on thermocouple. to drop out 5. The pilot and main burner extinguish while in operation A. Inner vent pipe leaking A. Check for flue product leak. Replace defective pipe section. exhaust gases back into system B. Horizontal vent improperly B.
ILLUSTRATED PARTS LISTS FIREBOX COMPONENTS AND ACCESSORIES 11 4 6 1 10 7 3 2 9 40 73D0024
ILLUSTRATED PARTS LISTS FIREBOX COMPONENTS AND ACCESSORIES Description Qty KHLDV400 KHLDV500 Standard Features 1 Bulb 2 73D0020 73D0020 2 Bulb Socket 2 73D0019 73D0019 3 Glass Frame Assembly 1 73D1015K 73D0159K 4 Junction Block 1 73D0018 73D0018 5 Junction Box Assembly (not shown) 1 26D2128K 26D2128K 6 Light Lens 1 73D0022 73D0022 7 Panel, Access, Clean 2 73D0029K 73D0029K 10 Cottage Clay Firebrick Set 1 FBKHLDV400CC FBKHLDV500CC 10 Cottage Red Firebrick Set 1 FB
ILLUSTRATED PARTS LISTS STANDING PILOT — MILLIVOLT CONTROL 2C 1 2I 2T 2 5 6 3 4 7 8 8 11,12,13, 14 10 42 73D0024
ILLUSTRATED PARTS LISTS STANDING PILOT – MILLIVOLT CONTROL Item Description 1 2 2C Gas Valve Assembly Pilot Assembly Replacement Thermocouple 2I Replacement Igniter and Wire 2T Replacement Thermopile 3 Tube, Rear, Venturi 3 Tube, Front, Venturi 3 Tube, Rear, Through-Wall 3 Tube, Front, Through-Wall 4 Flexhose w/ Shutoff Valve 5 Rocker Switch 6 Piezo Igniter 7 Rear Injector 7 Front Injector 8 Rear Burner Assembly 8 Front Burner Assembly 9 Venturi 10 Wire Assembly 10 Wire Assembly Qty KHLDV400NV KHLDV400P
ILLUSTRATED PARTS LIST 8 VENT COMPONENTS FOR 5"X 8" 7 4 1 9 3 5 2 10 6 HO T Simpson Duravent Selkirk Item Qty/ Box 1 1 Horizontal High Wind Termination Cap 1 1 Horizontal Termination Cap with Built-In Vinyl Siding Standoff, Heat Deflector, Firestop and Adjustable Pipe 7" to 11" BHR8TK 1 1 Horizontal Termination Cap Built-In Vinyl Siding Standoff, Heat Deflector, Firestop, 90° Elbow, Adjustable Pipe 7" to 11", and 12" Section of Pipe.
ILLUSTRATED PARTS LISTS LOGS Item Description 73D0024 Qty KHLDV400 KHLDV500 1 Log #1 1 73D0532 73D0134 2 Log #2 1 73D0533 73D0135 3 Log #3 1 73D0534 73D0136 4 Log #4 1 73D0535 73D0137 5 Log #5 1 73D0536 73D0138 6 Log #6 1 73D0537 73D0139 7 Log #7 1 73D0538 73D0140 45
NOTES MASSACHUSETTS RESIDENTS ONLY: PLEASE READ AND FOLLOW THESE SPECIAL REQUIREMENTS NOTE REGARDING VENTED PRODUCTS This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts. Any residence with a direct vent product must have a CO detector installed in the residence. Installation of the fireplace or vented gas log in the State of Massachusetts requires the damper to be permanently removed or welded in the fully open position.
SPECIAL REQUIREMENTS CONTINUED 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
NOTES 48 73D0024
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LIMITED LIFETIME WARRANTY POLICY LIFETIME WARRANTY The following components are warranted for life to the original owner, subject to proof of purchase: Firebox, Combustion Chamber, Heat Exchanger, Grate and Stainless Steel Burners. FIVE YEAR WARRANTY The following components are warranted five (5) years to the original owner, subject of proof of purchase: Ceramic Fiber Logs.