Archgard CHALET 1800 User manual

200-0241
Oct 2008
Users’ Installation
Operation and
Maintenance Manual
7116 Beatty Dr
Mission, BC V2V 6B4
Canada
CHALET 1800
CHALET 1800
WOOD
Fireplace
Insert
Installer: Please complete the details on the back cover
and leave this manual with the homeowner.
Homeowner: Please keep these instructions for future reference.
PRIOR TO FIRST FIRE: Remove all labels from glass. Clean fingerprints from plated
surfaces with a glass cleanser and soft cloth to prevent permanent staining.
CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE
TEMPERATURES, ESPECIALLY THE INSERT GLASS, AND SHOULD STAY AWAY TO AVOID
BURNS OR CLOTHING IGNITION. KEEP ALL SMALL PARTS AWAY FROM CHILDREN WHILE
ASSEMBLING SINCE THEY CAN CAUSE A CHOKING HAZARD.

Chalet 1800 Ins 2
Important Safety Notes 4
Rating Plate Label 5
Clearances 6
Dimensions 7
Specifications 8
COMPONENT INSTALLATION / MAINTENANCE AND OPERATION METHODS
Door Installation and Assembling 9
Face Plate Installation and Assembling 10
Blower / Fan Installation 11
Blower Operation & Diagram 12
Brick Removal And Installation 26
Air Tube And Ceramic Baffle Installation and Removal 26-27
Door And Glass Maintenance 28-29
Paint 29
INSERT INFORMATION FOR INSTALLATIONS
Venting Requirements 19
Precautions For Installation 13
Installation Methods 14-18
First Fire And Operation of Insert 19-20
TROUBLESHOOTING / SAFETY / CHIMNEY AND WOOD
Troubleshooting 20-21
Creosote & Chimney Fires 22-23
Safety Equipment 23
Chimney Maintenance 23
wood 23-24
Ash Disposal 25
ACCESSORY / PARTS REPLACEMENT
Accessory & Replacement Parts List 30-31
Archgard Warranty 32
Warranty Registration Card
Notes
Installation Information
TABLE OF CONTENTS

Chalet 1800 Ins 3
Congratulations on choosing a state-of-the-art Archgard Hearth Product!
The hand crafted Archgard CHALET 1800 WOOD Fireplace Insert has been designed to
provide you with comfort, security and economy for many years of trouble-free enjoyment.
It has been our experience that the overall enjoyment of your new appliance will be greatly
enhanced by becoming familiar with its installation, operation and maintenance. Prior to
installation, we ask that you take a few moments to read this manual.
We wish you and your family many years of enjoyment in the warmth and comfort of this
hearth appliance.
Thank you for choosing Archgard Industries!
ARCHGARD CHALET 1800 WOOD FIREPLACE INSERT
Surround Trim, Standard Black
(optional Brass or Nickel)
Standard Adjustable Faceplate
Firebox with Door and Spring
Handle
Blower

Chalet 1800 Ins 4
IMPORTANT SAFETY NOTES
1. When installing your insert, particular attention should be paid to fire protection. If this room heater is not
properly installed, a house fire may result. To reduce the risk of fire, follow the installation instructions. Con-
tact local building, fire officials or the authority having jurisdiction about restrictions, installation, inspection
and permit requirements in your area.
2. CAUTION: Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids
to start or “freshen up” a fire in this heater. Keep all such liquids well away from the heater while it is in use.
3. DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS SUCH AS GASOLINE, NAPHTHA OR ENGINE OIL.
Do not burn treated wood, or salt laden (driftwood, etc.) wood. Burning materials other than wood (including
charcoal) under adverse conditions may generate carbon monoxide in the home, resulting in illness or possi-
ble death.
4. Your insert should burn dry, standard firewood only. The use of cut lumber, plywood, “mill ends”, etc. is not
recommended as this fuel can easily overheat your wood insert. Chemically treated fire logs must not be
burned in your wood insert.
5. Do not store any fuel closer than 2 feet from your unit. Do not place wood, paper, furniture, drapes or other
combustibles near the appliance.
6. During operation, if any part of the insert starts to glow, the insert is in an over-fired condition. Close the air
control completely by pushing it in until the glowing has stopped. OVERFIRING VOIDS YOUR WARRANTY
and can be hazardous!
7. RISK OF FIRE! Do not operate with insert door open. It can overfire your appliance and could be hazardous
8. WARNING! Never draw outside combustion air from a wall, floor or ceiling cavity or from any
enclosed space such as an attic or garage or carport.
9. Check your chimney system thoroughly when installing into an existing masonry chimney. Seek professional
advice if in doubt about its condition.
10. Comply with all minimum clearances to combustibles as shown in this manual.
11. Build fire on brick firebox floor. Do not use grates, andirons or other methods to support fuel.
12. HOT WHILE IN OPERATION! Keep children, pets, clothing and furniture away. Contact can cause skin
burns.
13. Do not operate without fully assembling all components. Doing so will void your warranty, and could present
a serious safety hazard.
14. Solid fuel-burning appliances shall be installed in such a manner as to provide ventilation and combustion air
supply to allow for the proper combustion of fuel, chimney draft and the maintenance of safe temperatures.
15. The controls of your unit or the air supply passages should not be altered to increase firing for any reason.
16. If you burn the unit too slowly or at too low a setting your unit will not be operating as efficiently as it can. An
easy rule of thumb says that if your glass is clean, then your flue is clean and your exhaust is clean. Burn the
insert hot enough to keep your glass clean and you won't need to clean your flue as often.
17. Check you chimney twice a month for creosote accumulation and sweep as required.
18. Burning wet or green, unseasoned wood, could cause excessive creosote accumulation in the flue pipe and
chimney. This could result in a chimney fire. Store wood in a dry location.
19. Do not permit creosote or soot build-up in the chimney system. Check and clean chimney at regular inter-
vals. Failure to do so can result in a serious chimney fire.
20. Ashes should be disposed of carefully, using a metal container.
21. Do not connect to any air distribution duct or system.
22. Do not connect this unit to a chimney flue already serving another appliance.
23. This appliance must be connected to a chimney and terminate to the outside of the building envelope. Never
vent to another room or inside a building.
24. Do not operate if the gasket on the door is missing or damaged. Use only manufacturers approved parts
25. Do not operate with broken glass. Use only manufacturers approved replacement parts
26. Do not use “Black” or “Galvanized” pipe in your flue system
27. For further information refer to NFPA 211 (USA), CAN/CSA-B365 (Canada) or any other appropriate local
codes.

Chalet 1800 Ins 5
SAFETY NOTE: If this insert is not properly installed, a
house fire may result. For your safety, follow the installation
instructions. Contact your local building or fire officials, or
any other authority having jurisdiction about restrictions and
permit/inspection requirements in your area.
WHEN LOCATING YOUR INSERT: Consider safety and
the fact that the insert will need a chimney. It is a good idea
to plan your installation on paper, using exact measure-
ments for clearances and floor protection before actually
beginning the installation.
These installation instructions describe the installation and
operation of the Archgard CHALET 1800 WOOD Fire-
place Insert. This insert meets the U.S. Environmental Pro-
tection Agency’s 1990 particulate emission standards. It is
also listed by Warnock Hersey Test Laboratories, Inc. to UL
Safety Standard 1482 and ULC S628. It also meets the re-
quirements of (UM) 84-HUD.
SAFETY LABEL
A copy of the label that accompanies each Archgard Chalet
1800 WOOD Fireplace Insert , is printed here for your con-
venience.
NOTE: Archgard units are constantly being improved. If
there is a conflict between the label on the unit and the one
printed here, the label on the unit is the correct one. The
safety label is attached to the side of the unit.
YOUNG CHILDREN SHOULD BE CAREFULLY
SUPERVISED WHEN THEY ARE IN
THE SAME ROOM AS THE APPLIANCE.
LISTED FACTORY BUILT FIREPLACE IN- SERT CERTIFIED FOR USE IN CANADA AND U.S.A
DO NOT REMOVE THIS JAN
FEB MAR
APR MAY JUN
DEC
NOV
OCT
SEPT AUG
JUL
2006 2007 2008
UNITED STATES ENVIRONMENTAL PROTECTION AGENCYCERTIFIED TO
COMPLY WITH JULY 1999, PARTICULATE EMMISSIONS STANDARDS.
SERIAL # XXXXX
HOT WHILE IN
OPERATION. DO
NOT TOUCH. KEEP
CHILDREN, CLOTH-
ING AND FURNI-
TURE AWAY.
CONTACT MAY
CAUTION
INSTALL AND USE IN ACCORDANCE WITH THE MANUFACTURER’S INSTALLATION AND OPERATING INSTRUCTIONS. INSTAL AND USE ONLY IN MASONARY FIREPLACE. CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION IN YOUR
MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS (MEASURED FROM
.COMPONENTS REQUIRED FOR INSTALLATION: FAN KIT(FK-1800INS) ELECTRICAL RATING: 1AMP, 60Hz, 120VOLTS 6 “/150MM STAINLESS STEEL LINER. DAN- GER, RISK OF ELECTRIC SHOCK, DISCONNECT POWER BEFORE SERVICING UNIT. DO NOT ROUTE POWER CORD UNDER OR INFRONT OF APPLIANCE. DO NOT REMOVE BRICKS OR MORTOR IN MASONARY FIREPLACE. FOR USE WITH SOLID FUEL ONLY. DO NOT USE GRATE OR ELEVATE FIRE. BUILD WOOD DIRECLT ON HEARTH. RISK OF SMOKE AND FLAME SPILLAGE, OPERATE ONLY WITH DOORS CLOSED, OPEN DOOR TO FEED FIRE ONLY. REPLACE GLASS WITH 5MM CERAMIC ONLY. INSPECT AND CLEAN CHIMNEY FREQUENTLY. UNDER CERTAIN CONDTIONS OF USE CREOSOTE BUILD UP MAY OCCUR RAPIDLY. DO NOT OVERFIRE, IF INSERT GLOWS, YOU ARE OVERFIRING. 303-0144
B
A C
E
D
Side Wall to Insert=
A Top of Insert to Bottom
of Mantle (Depth)=B Side of Insert to
Mantle Leg=C Hearth Extension
Front=D Hearth Extension Side
=E
16.25”/412.75 mm 6” = 26”/660mm
8” = 28”/711mm
12” = 32”/813mm
8.75”/222mm Canada=18”/450mm
USA= 16”/400,\mm Canada = 8”/200mm
USA = 8”/200mm
INSTALL ONLY ON A NON-COMBUSTIBLE HEARTH, COMBUSTIBLE FLOOR MUST BE PROTECTED BY NON-COMBUSTIBLE
This unit has been approved for use in
Washington State ,USA.

Chalet 1800 Ins 6
Minimum Fireplace Size
Insert Clearances to Combustibles
Your fireplace opening requires the following minimum sizes:
Height Width Depth From back of adjust-
able faceplate to front
of flue collar
22” (559mm) 25” (635mm) 16” (406mm) 6” to 9”(152mm to
229mm)
Side Wall to Insert
=
A
Top of Insert to
Bottom of Mantle
(Depth)F = B
Side of Insert to
Mantle Leg = C
Hearth Extension
- Front = D
Hearth Extension
- Side = E
16.25""/412.75mm
6” = 26"/660mm
8” = 28”/711mm
12” = 32”/813mm
8.75""/222mm
Canada =
18"/450mm
USA =
16”/400mm
Canada =
8"/200mm
USA = 8”/200mm
A
B
C
D E
Hearth Protection
In the USA, the floor pad (ember protection) must be of non-combustible material and must extend 16" in
front of the door opening and 8" to the sides and rear of the unit. Consult with your local inspector/authority
having jurisdiction or check the NFPA 211 or local codes.
In Canada, the floor pad (ember protection) must be of non-combustible material and must extend
18" (450mm) in front of the door opening and 8" (200mm) to the sides of the unit. A 0.38 mm (0.015 in)
thick metal sheet or a grouted ceramic floor-tile surface installed in accordance with recognized Building
Codes shall be considered a durable pad. A floor pad shall not be placed on top of a carpet unless the pad
is structurally supported to prevent displacement and distortion. Consult with your local inspector or check
the CSA B365.
All floor protection must be non-combustible (i.e., metals, brick, stone, mineral fiber boards, etc.). Any or-
ganic materials (i.e., plastics, wood paper products, etc.) are combustible and must not be used.
F = (mantle depth)

Chalet 1800 Ins 7
DIMENSIONS 40” (1016 mm)
46” (1168 mm) Optional
24” (609 mm)
21.75” (553 mm)
21.75” (553 mm)
25.25”(641 mm)
6.125” (154 mm)
28” (711 mm)
27.875 “(708 mm)
40” (1016 mm)
20” (508 mm )
24” (610 mm)
Adjustable
9” - 12” (229 - 305 mm)
27.875 “(708 mm)
6” ID (152.4 mm)
Adjustable
9”- 12”(229– 305 mm)
28” (711mm)
32” (813 mm) Optional
6” ID

Chalet 1800 Ins 8
SPECIFICATIONS
MODEL CHALET 1800 WOOD FIREPLACE INSERT
HEIGHT OF BODY 21.75” (553 mm)
WIDTH of BODY 24” (609.6 mm)
DEPTH of BODY 25.250” (641 mm)
E.P.A. EMISSIONS 3.6 grams / hour
E.P.A. OUTPUT RATING 10,700 - 35,500 BTU / HR (3,134 - 10,397 watt)
APPROXIMATE HEATING AREA 800 - 1,500 FEET2 (74.3 - 139.4 METRE2)
DURATION ON LOW FIRE 6 - 10 HOURS
INSERT BODY WEIGHT
WITH PACKAGING 310 lb (140.61 kg)
Surround Panels
Standard (width x height) 40"W x 28"H (1016mm x 711mm)
Optional (width x height) 46"W x 32"H (1168mm x 813mm)

Chalet 1800 Ins 9
The door comes assembled with the glass and gasket.
1. Run the threaded end of the handle
through the hole in the cast door.
2. Insert the clevis pin into the roller and
washer.
3. Insert the end of the clevis pin assembly
into the hole in the end of the handle
4. Close the door and see how the door
closes. If it is too tight, turn the handle
clockwise to loosen it. If it is too loose,
turn the handle counter clockwise to
bring the door closer to the stove body.
5. To verify that the doors are well sealed,
insert a piece of paper between the
door and the stove body. You shouldn’t
be able to pull the paper out. Tighten it
to the point where the paper is starting
to tear when you are pulling it out.
6. Insert the cotter pin into the end of the
clevis pin to keep the assembly from
coming apart.
7. Attach spring handle by rotating the
spring counter clockwise onto the rod.
Ensure that the spring screws onto the
rod at least ½”.
9. Cover the holes with the two decorative
plug buttons
Clevis Pin Cotter Pin
Roller
Washer
Cotter pin goes
through clevis pin
as shown here:
CAUTION: THIS UNIT CONTAINS SMALL PARTS DURING ASSEMBLY THAT SHOULD BE KEPT AWAY
FROM CHILDREN DUE TO CHOKING HAZARD WHICH COULD RESULT IN PERSONAL INJURY OR DEATH.

Chalet 1800 Ins 10
Faceplate Installation
NOTE: There is from 6” to 9” of adjustability between the back of the faceplate and the front of
1) Start the installation by screwing the 4
angle clips into the predrilled holes in the
top and bottom of each side of the insert.
2) From the back, screw the lou-
vered section to the top section of
the faceplate.
3) Depending on how much of the insert is protruding out
of the firebox, you may be able to assemble the faceplate
by inserting the 2 supplied screws into each faceplate leg
and sliding them into the adjustable keyhole slots in the
top faceplate but don’t tighten them down yet. Then being
careful to start the left leg over the air shutter control on
the left side of the unit, slide the faceplate assembly over
the insert and install the supplied black hex screws. Put-
ting some masking tape over the top of the insert may
keep you from scratching the paint . If the unit is further
back in the fireplace, it would be better to just install the
right side leg and top and put them in position and then
install the left side leg and the two black hex screws.
4) (In the photo, the hex screws
are plated so that you can see
them, the ones that come with
the appliance are black)
Tighten all screws. Install the
finish surround

Chalet 1800 Ins 11
1. Remove the fan assembly from the box and inspect for any damage to the assembly. If
damage is noticed call your dealer, distributor or courier company and have components
replaced before installing kit.
2. Remove the bottom louver and install the two angles on each side of the insert.
3. Install the Snap Disc assembly and screw it into the two holes located in the insert body as
shown.
4. If the wires are disconnected during installation, hook up the
two black wires with spade connectors, from the fan, to the
matching male connectors on the snap disc.
5. Align the holes in the sides of the fan housing with the holes in the two brackets that were
just installed and attach with the black hex screws.
CAUTION: The connection cord should not be in contact with any hot surfaces. Do not route cord un-
der or in front of unit.
BLOWER / FAN INSTALLATION
The CHALET 1800 WOOD Fireplace Insert is certified for operation with or without the optional fan and may
be installed at any time by attachment at the front of the insert and plugging in the 3-prong power cord.
CAUTION: Do not plug in Fan Assembly until full assembly has been completed.
Electrical Rating = 120V AC / 1.0 amps
Fan Output Rating = 150 c.f.m.

Chalet 1800 Ins 12
FAN WIRING
Automatic
To operate the fan automatically, push the top switch on the side of the fan housing
to "AUTO" and the bottom switch to either "HIGH" or "LOW" for fan speed. This will
allow the fan to turn on as the stove comes up to operating temperature. It will also
shut the fan system off after the fire has gone out and the unit cools to below a use-
ful heat output range.
Manual
To manually operate the fan system, push the top switch to "MAN" and the bottom
switch to either "HIGH" or "LOW". This will bypass the sensing device and allow full
control of the fan. Switching from "AUTO" to "MAN" or "HIGH" to "LOW" may be
done anytime.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring
errors can cause improper and dangerous operation.
FAN OPERATION
WARNING: Electrical Grounding Instructions
This appliance is equipped with a three-pronged (grounding) plug for your protection against shock
hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut
or remove the grounding prong from this plug.
The CHALET 1800 WOOD Fireplace Insert 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.
120

Chalet 1800 Ins 13
BEFORE INSTALLING AND USING THIS APPLIANCE.
The installation of Smoke and Carbon Monoxide detectors along with a minimum of a five pound
fire extinguisher is highly recommended in any home .
When you first fire up your CHALET 1800 WOOD Fireplace Insert, you may notice the smoke de-
tectors operating more frequently. This may be due to the curing of stove paint or oils from manu-
facturing or fumes caused by accidentally leaving the door open. Do not disconnect the detectors.
Consult local building or fire officials about restrictions and installation inspection and permit re-
quirements in your area.
Let your home insurance company know that you plan to install this CHALET 1800 WOOD Fire-
place Insert in your home.
Please read this entire manual before you install and use this CHALET 1800 WOOD Fireplace In-
sert in your home. Failure to follow instructions may result in property damage, bodily injury or
even death.
Install and use only in accordance with manufacturer’s installation and operating instructions.
Have the chimney & fireplace inspected and swept prior to installing the CHALET 1800 WOOD
Fireplace Insert to be sure that the chimney/fireplace meets local requirements for construction
and clearances for Chimneys and Fireplaces and/or N.F.P.A. 211Standards in the USA and Pro-
vincial Building codes and CSA B365 - Installation Code for Solid Fuel Appliances in Canada or
any other applicable local code requirements and is OK to have an insert installed into it and also
ensure that the flue is free of creosote.
Do not connect the insert to a chimney system servicing another appliance
The chimney damper may be removed to install the chimney liner. Check local codes first
If using a Direct Connect, a means must be provided for removal of the insert to clean the chimney
flue.
If using a Direct Connect, a clean-out door may be required, by your Authority having Jurisdiction
A permanent metal warning label must be attached to the back of the fireplace stating that the fire-
place may have be altered and may be unsafe to use without the insert.
Do not use unlabelled parts, or substitute parts made for another chimney system .
Install only to liner/chimney manufacturer's installation instructions.
The chimney must be suitable for wood burning use.
Check for creosote build up or other obstructions.
Inspect your chimney for cracks, loose mortar or
other physical defects, if any are found, use the full
liner method of installation, do not use the blocker
plate or Direct Connect method.
RECOMMENDED MINIMUM CHIMNEY HEIGHTS
The chimney must be at least 3 ft. (.9m) higher
than the highest point where it passes through the
roof and at least 2 ft. (.6m) higher than the highest
part of the roof or structure within 10 ft. (3m) of the
chimney, measured horizontally. These are code
requirements and cannot guarantee a suitable
draft. We recommend using a minimum total sys-
tem height of 12 ft. (3.6m), measured from the flue
collar to the bottom of the chimney cap)

Chalet 1800 Ins 14
INSTALLATION INTO A MASONRY CHIMNEY
In the USA, there are two ways that this insert can be installed into a masonry fireplace. One is
with a full Stainless Steel Liner or Positive Flue Connection or the second method, which is called
the Direct Connection or the connection from the flue collar of the insert to the first flue tile in the
chimney.
We at Archgard recommend the Full Liner installation for numerous reasons.
The CHALET 1800 WOOD Fireplace Insert is designed with a 6" flue collar and by installing a full
liner from the top of the flue collar of the insert all the way to the top of the chimney optimizes draft
conditions and performance and it eliminates the need to pull the insert out of the fireplace every
time you need to have the chimney swept.
You will find that if you are doing the full reline, you may also have to insulate the liner to manu-
facturers installation instructions. The benefit to insulating the liner is that it stays hotter, therefore
you will get a better draft and less condensation which means less creosote which means a safer
better performing system.
The other installation option is the Direct Connection. In this method, a blocker plate is installed in
the throat area of the fireplace with a hole, the diameter of the flue pipe, cut out in the area above
the flue of the insert. This blocker plate is installed and a stainless pipe (stainless steel because it
is in a concealed space - do not use black or galvanized pipe) installed through the hole and up to
the first flue tile. The insert is installed into the firebox and the flue pipe is hooked up to it and the
assembly is sealed.
If it’s an inside chimney and the flue cross-sectional area is more than three times the cross-
sectional area of the flue collar on the insert or if it’s an outside chimney, meaning if it has at least
one side exposed to the weather, and it’s cross-sectional area is more than two times that of the
flue collar of the insert, then, according to NFPA 211, you cannot install the insert with the Direct
Connect method. You must install a full liner.
The cross sectional area of the 6” flue collar is 26 square inches. Once you start venting this ap-
pliance into an oversize flue, the exhaust gases start slowing down and so does the draft. Once
the draft slows down, the by-products of combustion have more time to give off their heat to the
chimney walls and reduce the draft even more, this is called “residence time” and at the same
time depositing tar droplets on the chimney walls as creosote. The optimum rule of venting is to
have flue gas temperature in the vent system above dew point (in a vapor) so that the exhaust ex-
its the top of your chimney before it turns from a vapor state to a moisture state and condenses on
the chimney walls forming acids and creosote. If the flue is oversized, install a full liner

Chalet 1800 Ins 15
FULL LINER INSTALLATION
There are different ways of installing a full liner, you can drop it in from the top or bring it up from
the bottom.
In the USA, in order to meet the requirements of UL 1777, you may have to insulate your liner and
if you do, it will have to be done as a system to manufacturers certified installation instructions.
In Canada, you can run ULC S635 or ULC S640 liner systems. If you would like to obtain a sys-
tem with certified reduced clearances, there are manufacturers who have tested their ULC S640
liners for close clearance and even zero clearance to combustibles using their own insulation/
installation requirements which must be adhered to. As Archgard has no control over what liner
system is being used with the CHALET 1800 WOOD Fireplace Insert, here we can only give a
general overview of the installation procedure of dropping a generic uninsulated liner from the top
of the chimney and connecting it to the flue collar of the appliance. It is of the utmost impor-
tance that the installation instructions of the liner system that you will be using be con-
sulted when doing your installation.
1. If you will be doing any modifications to the damper assembly or to the back wall or smoke
shelf (first check if you are allowed to do so), to accommodate the liner, now would be a good
time to so and to fasten the permanent warning label, that comes with the insert, to the back
wall of the fireplace warning future owners that the fire-
place may have been altered to do this installation, in
the event that the insert is ever removed.
2. Drop the liner down from the top of the chimney. If it is
a tight fit or if offsets are present, you may have to at-
tach a cone to the end of the liner with some rope com-
ing out the end of it or just squeezing the ends of the
liner together and duct taping some rope to the end it.
Drop the rope down and with someone at the bottom
pulling on the rope and someone at the top pushing on
the liner, it should get to the bottom.
3. When it gets past the smoke shelf (you may have prob-
lems getting the liner past this point, you may have to
order an ovalized liner or you may wish to ovalize a
section of liner yourself. If you ovalize it yourself, check
with the liner manufacturer to see if they will honor any
warrantees if you ovalize the liner. If you aren’t careful
or don’t have the equipment, you could damage the
liner when you ovalize it), if you squeezed the ends of
the liner, cut the damaged ends off with a knife and tin
snips. If an adapter is being used, rivet it onto the flex
liner now. Rivets work better on thin liner because
screws tend to work their way out (loosen out) but if
you use rivets, make sure you use rivets that are
marked SSSS for Stainless Steel Shank and Stainless
Steel Rivet. If you use rivets that just say SS then all
you are getting is a Steel Shank and Steel Rivet and they will corrode in a short time.
NOTE: a) masonry or steel shall not be removed from the fireplace to accommodate the appli-
ance; (b) masonry or steel, including the damper plate, may be removed from the smoke shelf
and adjacent damper frame if necessary to accommodate a flue liner, provided that their removal
will not weaken the structure of the fireplace and chimney and will not reduce protection to com-
bustible materials.

Chalet 1800 Ins 16
4. If you are using a 6” outside dimension Stainless Steel liner (since this is a concealed area do
not use “black” or “galvanized” pipe), the liner will slip right into the flue collar and can be at-
tached into the three pre-punched flue collar holes or the two supplied angle brackets and the
front flue collar hole may be used. NOTE: In some cases you may need to use some rigid
components like elbows or a transition box to make the connection from the liner to the insert
(contact venting component supplier for availability and information). Or you may have to use
an ovalized section of liner or remove some brick from the back wall of the smoke shelf.
Please check with the Authority having Jurisdiction before using some of these components
or doing this type of work to make sure this is compliant in your area.
5. If the firebox floor is “dropped”, screw in the supplied leveling bolts before installing the insert.
Put a level from the top of the hearth to the back of the firebox and measure how high the
drop is, in the area at the back of the firebox where the insert leveling bolts are. Push the in-
sert into position in the fireplace opening. When you start sliding the insert back over the drop
floor, reach under the insert and start to unscrew the leveling legs to the
height that is needed to make the insert sit level when it is in it’s final
resting place.
6. If the fireplace opening is high enough for you to get into the top of the insert, then you can
reach in and get the liner and fit it into the flue collar and mechanically attach it. If the room is
not there, then install the optional flex to rigid adaptor on the end of the liner, slip in the cross
bar and screw on the two nuts according to manufacturers instructions, and finish the liner to
the same height as the finished insert height and push it up out of the way before installing
the insert
7. Remove the Secondary Air Tubes and Baffle Plates from the insert. After installing the insert
into the firebox reach in through the flue collar and grab the cross bar on the liner adapter and
pull down.
8. Take the “hook” piece out of the kit and hook it over the cross bar and then take the longer
crossbar with the nut in the middle and put the hook through the nut and tighten that assem-
bly to the bottom of the insert.
10.Go back to the top of the chimney and seal off the top of the chimney and liner with the
manufacturers terminations. NOTE: More reasons for insulating the liner and sealing it at the
top is that it will stop down drafts when the appliance is not operating and keeps room air
from entering the chimney cavity. When it is raining on the metal flashing or raincap, the insu-
lation deadens the sound. The insulation stops condensation from forming on the bottom of
the metal flashing and dripping down the chimney and sometimes right on top of the insert.
12.Back inside, if necessary, reinstall the bricks, secondary air tubes and ceramic baffle plates.
13.Finish by installing the faceplate/trim and door and the optional blower if ordered.
Leveling Bolts
FLEX TO RIGID ADAPTOR

Chalet 1800 Ins 17
INSTALLATION INTO A MASONRY CHIMNEY WITH A DIRECT CONNECT
Check with you local Authority having Jurisdiction before you begin you begin an installation of a Direct
Connect System to ensure compliance with local codes, including the need for permits and follow-up in-
spections. If required, always obtain a building permit so that insurance protection benefits cannot be un-
expectedly cancelled. Contact your local dealer if any assistance is required during installation.
NOTE: In some areas, you may be required to install a clean out/inspection door on the backside of your
chimney, just above the smoke shelf area. A means must be provided for removal of the insert to clean
the chimney flue. Check with your local Authority Having Jurisdiction for more information about require-
ments in your area.
1. If you are going to remove the damper and frame, install a clean out door and fasten the permanent
warning label, that comes with the insert, to the back wall of the fireplace warning future owners that
the fireplace may have been altered to do this installation, in the event that the insert is ever removed,
now would be a good time to do it. If you will be securing the damper in the open position, do it now.
2. Once these are done, carry on with the preparation of the Blocker plate
2. You will need some sheet metal, at least 24 guage in thickness, two inches larger all around
than the throat area of the fireplace. Depending on the fit, you will need some flat gasketing,
some masonry anchors and some stainless steel liner to go from the top of the flue collar of
the insert to the first flue tile in the chimney.
3. With a piece of soapstone or chalk, mark a line, using a level, just below the damper on the
backside, sides and front in the throat area of the fireplace. Installing the blocker plate hori-
zontally will make it much easier to cut the hole for the liner to go through. It’s easier to cut a
tight round hole than a tight oval hole.
NOTE: a) masonry or steel shall not be removed from the fireplace to accommodate the appli-
ance; (b) masonry or steel, including the damper plate, may be removed from the smoke shelf
and adjacent damper frame if necessary to accommodate a flue liner, provided that their removal
will not weaken the structure of the fireplace and chimney and will not reduce protection to com-
bustible materials.
4. Layout the measurements onto the sheet metal leaving an two inches all the way around for a
flange (do not measure exactly mark your measurements short, the gasket will take up the
gap)
5. Cut out your marks and notch the four corners so that you can bend the flanges down and
then you can insert your fasteners into them. Because you measured short, do not bend the
flanges over at a 90o angle but closer to 60o Drill the holes for your anchors
7. Test the fit by pushing the blocker plate into the throat of the fireplace. Now determine where
the hole for the liner will go in the plate either by measuring or by pushing the insert into posi-
tion and marking the hole location. Mark your anchor hole locations at the same time
Blocker Plate
Front of fireplace
Bend flanges
at dotted lines
Back wall of fireplace

Chalet 1800 Ins 18
8. Drill the anchor holes in the firebox
9. Cut the hole in the sheet metal. An easy way is to put the sheet metal over a block of wood and
hammering into the centre of where the hole will be with the claw of your hammer and then cutting
the resulting gash out with tin snips.
10.Using some adhesive gasketing material, tape the gasket around the flanges of the blocker plate
and then push it into position in the fireplace and anchor it.
11.Slide the Stainless Steel liner (since this is a concealed area do not use “black” or “galvanized” pipe)
in through the hole and slide the insert into position and attach the liner into the flue collar and seal
the hole in the blocker plate with some rope gasket. You could cut the hole for the liner a little large
and then using some rope gasket, a little larger in circumference than the hole, cut through it and
slip it all around the edge of the cut hole and screw it into the blocker plate in a few places so that
when you slip the liner through, it will make a good seal or you could just take the gasket and screw
it around the hole in the blocker plate so that when the liner goes through the hole, it will make for a
good tight fit and will be the seal between the liner and blocker plate.
12.If you are using a 6” outside dimension liner, the liner will slip right into the flue collar and will be at-
tached by the three pre-punched flue collar holes or the two supplied angle brackets and the front
flue collar hole may be used. If the optional flex to rigid adaptor is being used(using something like
this makes installation much easier if you have to install through the appliance), slip in the cross bar
and screw on the two nuts (following the manufacturers instructions).
13.Push the liner up so that will be ready to pull down into the insert flue collar.
14.If the firebox floor is “dropped”, put a level from
the top of the hearth to the back of the firebox
and measure how high the drop is towards the
back of the firebox in the area where the insert
leveling legs will be. Push the insert into posi-
tion in the fireplace opening. When you start sliding the insert back over the drop floor, reach under
the insert and start to unscrew the leveling legs to the height that
is needed to make the insert sit level when it is in it’s final resting
place.
15.If the fireplace opening is high enough for you to get into the top
of the insert, then you can reach in and get the liner and fit it into
the flue collar and mechanically attach it. If the room is not there,
then reach in through the inside of the in-
sert by removing the air tubes and baffle
plates and then reaching up through the
flue collar and grabbing the cross bar on
the liner and pulling it down. Take the
“hook” piece out of the kit and hook it
over the cross bar and then take the
longer crossbar with the nut in the mid-
dle and put the hook through the nut and
tighten that assembly to the bottom of
the insert (contact venting component
supplier for availability and information).
16.If necessary, reinstall the bricks, secondary air tubes and ce-
ramic baffle plates.
17.Finish by installing the faceplate/trim and door and the blower if
it was removed for installation of the insert. BLOCKER PLATE INSTALLATION
SS Liner
Blocker
Plate
First Flue Tile
Optional
Cleanout
FLEX TO RIGID ADAPTOR

Chalet 1800 Ins 19
VENT SPECIFICATIONS
Your CHALET 1800 WOOD Fireplace Insert was de-
signed for and tested on a 6” (152mm) chimney,
15’ (4.57m) high, (includes insert height) measured
from the base of the insert. The further your stack
height or diameter varies from this configuration, the
greater the possibility of performance problems. In
addition, exterior conditions such as roof line, sur-
rounding trees, prevailing winds and nearby hills can
influence insert performance. Your local dealer is the
expert in your geographic area and can usually make
suggestions or discover solutions that will correct any
flue problem you may have, allowing your wood insert
and its flue system to operate correctly and provide
safe and economical heat for your home.
OPERATION
Air quality is important to all of us, and if we choose to
use wood to heat our homes, we should do so respon-
sibly. To do this, we need to learn to burn our inserts
in the cleanest way possible. Doing this will allow us to
continue using our wood inserts for many years to
come.
AIR CONTROL - PRIMARY AIR SYSTEM
(DRAFT CONTROL)
The primary air enters at the base of the firebox and
travels through passages toward the upper front of the
firebox, near the top of the glass door. This preheated
air supplies the necessary fresh oxygen to mix with the
unburned gases, helping to create secondary combus-
tions. This air is regulated by the Primary Control at
the bottom left side of the appliance. For more primary
air, pull the control out. For less air, push the control
in.
Pull this control all the way out when first starting the
insert. Once the fire has been established you may ad-
just this control to set the burn rate of the fire. If this
damper is closed at first start-up, the fire will burn very
slowly and could soot the appliance.
When shutting down the insert, fully open the air con-
trol. This allows the chimney temperatures to remain as
high as possible for as long as possible. Cold chimney
temperatures create creosote.
FIRST FIRE
1. The first step in building a fire is to open the air con-
trol.
2. Crumple four or five sheets of newspaper and put
them on the firebox in the centre of the heater
(never use a grate or build the fire off the floor of the
insert)– be generous and you will have more suc-
cess. Hold the paper down with 10 to 15 pieces of
dry kindling. Softwoods, such as cedar and pine,
make good kindling (use the species available in
your region).
Place the kindling on and behind the newspaper, so
that the combustion air reaches the newspaper first
where you light it. It is also a good idea to add one
or two small pieces of dry firewood to the kindling
load before lighting.
3. Light the newspaper and close (but don’t latch) the
door. When the paper is flaming brightly and the
kindling catches and the chimney is producing
strong draft, latch the door. CAUTION: Never leave
the unit unattended if door is left open. This pro-
cedure is for start-up only, as the unit may over
-heat if the door is left open for too long.
4. When the flames from the kindling load begin to
subside, gradually add several small pieces of
wood. Avoid smothering the fire with the new wood.
Place the pieces on and behind the burning kin-
dling. Wood should be flaming until it is reduced to
charcoal. Never let a fire smoulder because smoul-
dering wastes wood. For the first few hours, the in-
sert will give off an odor from the paint. You may
want to leave some windows and/or doors open to
provide adequate ventilation while this temporary
condition exists. In some instances, your smoke de-
tector may alarm. Do not build hot fires in your in-
sert for the first few days until the paint has had a
chance to cure with some moderate fires.

Chalet 1800 Ins 20
5. Before opening your door to reload, open the draft fully for approximately 10 to 15 seconds until the fire
has been reestablished. This will minimize any smoking.
All fuel burning appliances consume oxygen during operation. It is important that you supply a source of
fresh air to your unit while burning.
Ignore the fire until you notice the room, space or house cooling off. A new load cools the firebox, so it
needs to be heated up again. Then add the right amount of wood to suit the conditions. Wood burns best in
cycles. A cycle starts when wood is placed on and behind a raked coal bed. A cycle ends when the load is
reduced to the same sized coal bed. Do not force wood into the firebox to try and fill it.
We recommend that when you first fire up your CHALET 1800 WOOD Fireplace Insert, you leave a door
and/or window open in order to vent the smoke that may be created from the unit’s paint curing. The paint
will smell a little for the first burn or two as it cures.
TROUBLESHOOTING
The most common factors for poor draft are:
a) Air supply/House depressurization
b) Environmental conditions
c) Cold chimneys
d) Poor chimney/connector installation/ design and maintenance
a) Air supply / House depressurization – Inside the home, household appliances such as clothes dryers,
bathroom fan, central vacuums, forced-air furnaces, etc, compete for air, resulting in air starvation to
the fire. This creates a condition known as negative pressure. When a negative pressure situation is
experienced, the combustion gases can be drawn from the chimney and into the house. This condition
is commonly referred to as down-drafting. Increased amounts of insulation, vinyl windows and extra
caulking in various places can all keep heat in but may also make a home more airtight. Seal the leaks
that are high in the house because the house acts as a chimney and as hot air leaves the house at the
ceiling level, more air comes in at lower levels to make up for the air that leaves. Make sure there is
adequate air for the appliance in the house.
b) Environmental Conditions - High trees, low-lying house location such as in a valley, tall buildings or
structures surrounding your house and windy conditions can cause poor draft.
c) Cold Chimney Temperature - Avoid cold chimney temperatures by burning a hot fire for the first fifteen
to forty minutes, being careful not to over-fire the insert. Where possible, install a thermometer on or in
the flue pipe so temperatures can be monitored.
d) Chimney Installation and Maintenance - Avoid using too many elbows or long horizontal runs. Too
short a chimney can cause difficult start-up, dirty glass, smoking when door is open, and even re-
duced heat output. Too tall a chimney may prompt excessive draft, which can result in very short burn
times and excessive heat output. If in doubt, contact a chimney expert and/or chimney manufacturer
for help. Clean chimney, rain caps and especially the spark arrestor regularly, to prevent creosote
build-up, which will significantly reduce chimney draw.