Monessen Hearth KHLDV SERIES manual

MODELS: KHLDV400 & KHLDV500 KHLDV SERIES DIRECT VENT GAS FIREPLACE INST ALLA TION AND OPERA TING INSTRUCTIONS READ BEFORE INST ALLING. SA VE THESE INSTRUCTIONS DUE TO HIGH TEMPERA TURES, THE APPLIANCE SHOULD BE LOCA TED OUT OF TRAFFIC AND A W A Y FROM FURNITURE AND DRAPERIES. CHILDREN AND ADUL TS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURF AC[...]

2 73D0024 CONTENTS Important Safety Information .......................... 3 Product Features .............................................. 5 Code Approval .................................................. 5 Pre-Installation Information Installing Above 2000 Feet ............................ 6 Ori fi ce Sizes, Pressures and BTUs ............... [...]

73D0024 3 4. Never install the fireplace • in a recreational vehicle • where curtains, furniture, clothing, or other flammable objects are less than 42" from the front, top, or sides of the fireplace • in high traffic areas • in windy or drafty areas 5. This fireplace reaches high temperatures. Keep children and adults away from hot su[...]

4 73D0024 IMPORT ANT SAFETY INFORMA TION 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. This appliance, when insta[...]

73D0024 5 PRODUCT FEA TURES AND CODE APPROV AL Off/Pilot/On Knob Figure 1 - KHLDV Series Fireplace • 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 appl[...]

6 73D0024 PRE-INST ALLA TION INFORMA TION INST ALLING 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 p[...]

73D0024 7 H G D F E A C B A 1 / 2 "o r 5 / 8 " C A G C G A 1 / 2 " or 5 / 8 " FIREBOX FRAMING Firebox framing can be built before or after the appliance is set in place. Construct firebox framing following Figure 2 and the chart below for your specific installation require- ments. See Figure 3 on page 8 for firebox dimensions. T[...]

8 73D0024 E H J A D L K C F M B I G N PRE-INST ALLA TION INFORMA TION Figure 3 - Fireplace Dimensions FIREPLACE DIMENSIONS DESCRIPTION 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"[...]

73D0024 9 Y E A B C D F Y X PRE-INST ALLA TION INFORMA TION FIREPLACE LOCA TION Plan for the installation of your appliance. This includes determining where the unit is to be installed, the vent configuratio n to be used, framing and finishing details, and whether any optional accessories (i.e. blower, wall switch, or remote control) are desired. C[...]

10 73D0024 FIREPLACE WA L L COMBUSTIBLE MA TERIAL AREA 6" 5" 3" 2.5" 4.5" 45° 3.5" 3.5" 1" 1.5" 1.5" Follow these instructions carefully to ensure safe installation. Failure to follow in struc tions exactly can create a fi re hazard. The appliance cannot be installed on a carpet, tile or other com[...]

73D0024 11 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. SECURING FIREPLACE [...]

12 73D0024 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 system could result in serious injury , property damage or loss of life. W ARNING Failure to follow these instructions [...]

73D0024 13 VENT INST ALLA TION Figure 7 - Combustible Clearances for V ent Pipe A minimum of 3" clearance to the top is required along horizontal length until fl ue pipe penetrates outside wall. A minimum 1" clearance to combustibles permitted all around fl ue at outside wall Horizontal sections of this vent system require a minimum of [...]

14 73D0024 VENT INST ALLA TION INST ALLA TION 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. FOR HORIZONT AL TERMINA TION Select the am[...]

73D0024 15 V V V V V V V V D L E B C F B B BB B M I A A J H G A Operable Fixed Closed Fixed Closed Opera- ble K A A A G VENT INST ALLA TION Always maintain minimum clearances around vent systems. The minimum clearances to combustibles for horizontal vent pipe are 3" at the top and 1" at the sides and bottom of the vent system until the pi[...]

16 73D0024 V G G=6" (152mm) F F=6" (152mm) V V G G = Combustible 24"(610mm) Noncombustible 18"(457mm) Combustible & Noncombustible H = 24" (610mm) J = 20" (508mm) V H J C = Maximum depth of 48" (1219mm) for alcove location D = Minimum width for back wall of alcove location Combustible - 38" (965mm) Noncom[...]

73D0024 17 24" Min. • The maximum number of 90° elbows per side wall installation is three (3). See Figure 11. • A minimum of 24" is required before a 90 ° elbow. If a 90° elbow is fitted directly after 24" vertical section mounted to the top of the fireplace, the maximum horizontal vent run before the termination or a vertica[...]

18 73D0024 VERTICAL/HORIZONT AL TERMINA TION CONFIGURA TIONS (continued) • 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. Example:[...]

73D0024 19 VENT INST ALLA TION BELOW GRADE INST ALLA TIONS 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 penetr[...]

20 73D0024 40' Maximum Height 12' Minimum Height 10' Maximum Support Straps Every 3' 24" Min. 24" Min. VERTICAL (THROUGH-THE-ROOF) APPLICA TIONS 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[...]

73D0024 21 10 1 / 2 " 10 1 / 2 " VENT INST ALLA TION INST ALLA TION FOR VERTICAL TERMINA TION 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 res[...]

22 73D0024 ROOF PITCH H (feet) Flat to 6/12 1.0 Over 6/12 to 7/12 1.25 Over 7/12 to 8/12 1.5 Over 8/12 to 9/12 2.0 Over 9/12 to 10/12 2.5 Over 10/12 to 1 1/12 3.25 Over 1 1/12 to 12/12 4.0 *H = Minimum height from roof to lowest discharge oopening of vent. VENT INST ALLA TION 3. Cut a hole in the roof using the locating hole as a center point. (Cov[...]

73D0024 23 Figure 23 - External Regulator with V ent Pointing Down (Propane/LP Only) Use only new black iron or steel pipe. Internally tinned copper or copper tubing can be used per National Fuel Code, section 2.6.3, providing gas meets hydrogen sulfide limits, and where permitted by local codes. Gas piping system must be sized to provide minimum i[...]

24 73D0024 3" Minimum FIREPLACE INST ALLA TION A listed 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. IMPORT ANT : Install main gas valve (equipment shutoff valve) in an accessible location. The main g[...]

73D0024 25 CHECKING GAS PRES SURE AND ELECTRICAL INST ALLA TION 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. 2. To ease installation, a 24" (mm) flex line with manual shut-of[...]

26 73D0024 ON OFF OPTIONAL REMOTE WALL SWITCH ON OFF OPTIONAL REMOTE WALL SWITCH PILOT HI L O ON OFF TH TP TH/TP ON OFF RS REMOTE W ALL MOUNTED SWITCH A remote wall switch and up to fifteen (15) feet of 18 Ga. wire may be used with this appliance. Attach the wall switch in a junction box at the desired location on the wall. See Figure 26 . Do not e[...]

73D0024 27 120 V AC 60Hz JUNCTION BOX F actor y Supplied Not Supplied 7. Remove the access covers on the right and left side walls of the firebox toward the front by unfastening the screws. NOTE: The access covers are not identical. See Figure 28 8. Two screws are already mounted to each cover which would be utilized to mount the blower to the plat[...]

28 73D0024 OPTIONAL F AN/BLOWER SYSTEM Figure 28 - Blower Access Plates Figure 29 - Blower Access Plates Figure 30 - Assembling Blowers to Access Plates. Figure 31 - Replacing Side Panels[...]

73D0024 29 GLASS REMOV AL Figure 32 - Removing Glass Frame Glass Frame Each clamp has a quick spring force. When reinstalling clamps, keep fi ngers clear . CAUTION GLASS FRAME REMOV AL 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 do[...]

30 73D0024 WHITE BLUE BLACK BLA CK BLACK WHITE W HITE LIGHT LIGHT TERMINAL BLOCK JUNCTION BOX RHEOST A T LIGHT FINAL INST ALLA TION ROCK WOOL PLACEMENT 1. Place rock wool on the front burner to provide glowing embers. For best results, pull the rock wool apart into dime size pieces and place on top of burner. Also place the same size ember over the[...]

73D0024 31 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[...]

32 73D0024 Step 4 Step 5 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 pl[...]

73D0024 33 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. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHA T TO DO IF YOU SMELL GAS: • Turn [...]

34 73D0024 PILO T O F F P I L O T O N Continued on next page APPROVED LEAK TESTING METHOD You may check for gas leaks with the following methods only: • Soap and water solution • An approved leak testing spray • Electronic sniffer If using a soap and water solution to test for leaks, DO NOT spray solution onto control body . W ARNING NOTE: Re[...]

73D0024 35 T PILO T O F F P I L O T O N O F F P I L O T O N PILO T Figure 37- On Position PILO T O F F P I L O T O N Figure 36 - On/Off/RS Switch OFF ON RS OPERA TING INSTRUCTIONS (MILLI-VOL T) LIGHTING BURNER MAIN BURNER SWITCH The “ON/OFF/RS” switch for the main burner can be found behind door of the fireplace. This switch allows you to turn [...]

36 73D0024 Figure 40 - Pilot Flame Thermopile Thermocouple T urn off gas before servicing fi replace. It is recommended that a quali fi ed service technician perform these check-ups at the beginning of each heating season W ARNING BURNER FLAME The flames from the burner should be visually checked as soon as the heater is installed and periodicall[...]

73D0024 37 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. GLAS[...]

38 73D0024 TROUBLESHOOTING ST ANDING PILOT IGNITION SYMPTOM POSSIBLE CAUSE ACTION 1. Spark ignitor will not light pilot after repeated triggering of piezo. 2. Pilot will not stay lit after carefully follow- ing lighting instruc- tions. . Pilot burning, valve knob turned to “ON,” switch is turned to “ON” or “RS,” but burner will not igni[...]

73D0024 39 TROUBLESHOOTING ST ANDING PILOT IGNITION SYMPTOM POSSIBLE CAUSE ACTION 4. Frequent pilot outage problem. 5. The pilot and main burner extinguish while in operation 6. Glass Soots 7. Flame burn blue and lifts off burner (ghost- ing) A. Pilot flame may be too high or too low, causing pilot safety to drop out A. Inner vent pipe leaking exha[...]

40 73D0024 2 9 10 7 3 4 6 1 11 ILLUSTRA TED P ARTS LISTS FIREBOX COMPONENTS AND ACCESSORIES[...]

73D0024 41 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 Firebr[...]

42 73D0024 ILLUSTRA TED P ARTS LISTS 1 2 3 4 5 6 7 8 10 1 1,12,13, 14 ST ANDING PILOT — MILLIVOL T CONTROL 2T 2 I 2C 8[...]

73D0024 43 ST ANDING PILOT – MILLIVOL T CONTROL ILLUSTRA TED P ARTS LISTS Item Description Qty KHLDV400NV KHLDV400PV KHLDV500NV KHLDV500PV 1 Gas V alve Assembly 1 37D01 17 37D01 18 37D01 17 37D01 18 2 Pilot Assembly 1 20H2048 20H2049 20H2048 20H2049 2C Replacement Thermocouple 1 37D1067 37D1067 37D1067 37D1067 2 I Replacement Igniter and Wire 1 3[...]

44 73D0024 10 9 8 5 6 4 3 2 HOT 1 7 VENT COMPONENTS FOR 5" X 8" ILLUSTRATED PARTS LIST Item Qty/ Box Description Simpson Duravent Selkirk Monessen P/N 11 Horizontal High Wind Termination Cap 1285 5DT-HC 11 Horizontal Termination Cap with Built-In Vinyl Siding Standoff, Heat Deflector, Firestop and Adjustable Pipe 7" to 11" BHR8T[...]

73D0024 45 LOGS ILLUSTRA TED P ARTS LISTS Item Description 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[...]

46 73D0024 NOTES NOTE REGARDING VENTED PRODUCTS This product must be installed by a licensed plumber or gas fi tter when installed within the Commonwealth of Massachu- setts. Any residence with a direct vent product must have a CO detector installed in the residence. Installation of the fi replace or vented gas log in the State of Massachusetts r[...]

73D0024 47 SPECIAL REQUIREMENTS CONTINUED 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFP A 720 and be ANSI/UL 2034 listed and IAS certi fi ed. 3. SIGNAGE. A metal or plastic identi fi cation plate shall be permanently mounted to the exterior of the bui[...]

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73D0024 51 NOTES[...]

52 73D0024 AUGUST 2008 P/N 73D0024 • Rev . 5 LIMITED LIFETIME WARRANTY POLICY LIFETIME W ARRANTY 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 W ARRANTY The following components are warranted five (5) ye[...]