Lennox Hearth Products FIRESTAR Merit Series User manual

KIT CONTENTS (See Figure 1):
1 ea. Robertshaw LP Regulator Kit (A)
1 ea. Robertshaw LP Pilot Orifice (B)
1 ea. #49 LP main burner orifice (39,000 BTU’s) (C)
1 ea. Instruction Sheet
TOOLS NEEDED (See Figure 2):
5/32” Long Allen Wrench Or T-Handle Wrench
#2 Phillips Screwdriver
7/16” Open End Wrench
3/4” Open End Wrench
FIRESTAR™ GAS CONVERSION INSTRUCTIONS NG TO LP
CAT. NO. 75173, MODEL FSTR-CK-NG TO LP
INSTALLATION INSTRUCTIONS FOR CONVERTING FROM NATURAL GAS (NG) TO
PROPANE GAS (LP). FOR USE WITH THE FIRESTAR™ GC3 B-VENT GAS FIREPLACE INSERT
775,251M
Rev. A, 09/2008
HEARTH PRODUCTS
KITS AND ACCESSORIES
WARNING
This conversion kit shall be installed by a qualified
service agency in accordance with the manufacturer's
instructionsandallapplicablecodesandrequirements
of the authority having jurisdiction. If the information
in these instructions is not followed exactly, a fire,
explosionorproductionofcarbonmonoxidemayresult
causing property damage, personal injury or loss of
life. The qualified service agency performing this
installation is responsible for the proper installation
of this kit and assumes responsibility for this conver-
sion. The installation is not proper and complete until
theoperation ofthe convertedapplianceischeckedas
specified in the manufacturers instructions supplied
with the kit.
IMPORTANT LE CANADA SEULEMENT
La conversion devra être effectuée conformément
aux recommandations des autorités provinciales
ayant juridiction et conformément aux exigences
du code d'installation CAN/CSA B149.1 .
IMPORTANT CANADA
Theconversionshallbecarriedoutinaccordancewith
the requirements of the provincial authorities having
jurisdiction and in accordance with the requirements
of the CAN/CSA B149.1 Installation code.
AVERTISSEMENT
Cet équipement de conversion sera installé par une
agencequalifiéedeserviceconformémentauxinstruc-
tionsdufabricantettoutesexigencesetcodesapplica-
blesdel'autorisésavoirlajuridiction. Sil'information
dans cette instruction n'est pas suivie exactement, un
feu, explosion ou production de protoxyde de carbone
peut résulter le dommages causer de propriété, perte
ou blessure personnelle de vie. L'agence qualifiée de
service est esponsable de l'installation propre de cet
équipment. L'installationn'estpaspropreetcompléte
jusqu'à l'opération de l'appareil converti est chéque
suivant les critères établis dans les instructions de
propriétaire provisionnées avec l'équipement.
IMPORTANT
The burner orifices provided in this kit are only for
use at elevations of 0 to 2,000 feet (610 M) in the
USA and 0 to 4,500 feet (0-1372 M) in Canada. At
higher elevations the BTU input must be de-rated
by 4% for every 1,000 feet (305 M) to maintain
the proper ratio of gas to air. If the installer must
convert the unit to adjust for varying altitudes, a
deration information stickermustbefilledoutbythe
installer and adhered to the appliance at the time
of the conversion. Contact your local gas supplier
for deration requirements for your area.
AB
Fig. 2 Figure 1 - Kit Contents
Figure 2 - Tools Needed
C
™
DRAFT
9/22/2008
1

READ ALL THE STEPS BEFORE STARTING THE CONVERSION.
INSTALLER NOTICE: THESE INSTRUCTIONS MUST BE LEFT WITH
THE APPLIANCE.
This kit contains components required to convert this appliance
from using Natural Gas to using Propane Gas as the only fuel.
All of these components must be replaced in order for the unit to
operate safely on Propane Gas.
When installing gas components use pipe joint compound or
Teflon tape on all pipe fittings before installing (ensure propane
resistant compounds are used, do not use pipe joint compounds
on flare fittings).
INSTALLATION INSTRUCTIONS
Step 1. TURN OFF THE GAS SUPPLY TO THE APPLIANCE. Unplug the
power cord for the blower.
Step 2.Locate the valve behind the right side access door. Using a phil-
lips screwdriver, remove and discard the two pressure regulator
mounting screws (see Figure 3). Remove the pressure regulator
and rubber gasket. Discard all removed components. Install
the new regulator. Ensure the rubber gasket on the back of the
pressure regulator is properly positioned when installing the new
pressure regulator using the new screws supplied with this kit.
Locate the label provided in the regulator kit. Write in the required
information, then affix it to the valve.
Figure 3 - Replace Regulator on Valve
Step 3. Remove the glass door by opening both latches on the right and
left side of the door (see Page 18 in the Installation and Operation
Manual). Carefully remove the logs. Exercise care so as not to
break the logs. Set aside in a safe place.
Step 4.Using a 5/32” allen wrench, remove the allen-head screw on the
left side of the air control panel as shown in Figure 4, then lift
out air control panel as shown in Figure 5.
Step 5.Using a 5/32” allen wrench, remove the screw which secures
burner tube assembly as shown in Figure 6. Then lift out burner
tube assembly as shown in Figure 7.
LO
HI
Remove These
Screws
Regulator
Gas Valve
(located in control com-
partment below firebox)
1. Replace Regulator.
2. Fill out & affix label
from regulator kit to
valve
Air Control Panel
Figure 4
Figure 5
Figure 6
Figure 7
Remove Allen-Head Screw
Firebox
Lift Out Air Control Panel
Remove Allen-Head Screw
Burner Tube Assembly
Lift Out Burner Tube Assembly
IMPORTANT NOTE: Do not overtighten the regulator screws.
Overtightened screws may result in little to no difference in
flame height when adjusted from high to low.
2NOTE: DIAGRAMS AND ILLUSTRATIONS ARE NOT TO SCALE.

Step 6. Usinga7/16”open-endwrench,removethepilotorificebyloosening
the nut (see Figure 5)on the end of the pilot supply tube. Once the
nut is removed, slide the nut down the tube, then pull the supply
tube down no more than 1/2” out of the fitting and orifice will fall
out. Once the orifice is out, discard it and put the new one in, then
reinstall the nut.
Pilot Assembly
Figure 8
Step 7. Using a 3/4” open-end wrench, remove burner orifice. Replace
with #49 LP orifice that is supplied in this kit. Make sure to use
pipe sealing compound on threads of new orifice (see Figure 9).
Pilot Tube Nut
LO
HI
Burner Orifice
Gas Valve
Figure 9 - Replace Burner Orifice
Figure 10
Figure 11
Air Shutter
Step 8. Adjust the air shutter as follows (see Page 12 in the Installation
and Operation Manual); The main burner has an adjustable air
shutter located at the end of the burner (see Figures 10 and 11).
Using a phillips screwdriver, loosen the air shutter setscrew just
enough so the air shutter can be rotated by hand (See Figures 10
and 11).
The setscrew for the air shutter is secured tightly from the factory
so that it does not rotate from the factory setting during shipping.
Once you loosen the setscrew just enough so that it can be rotated
by hand, then reinstall the burner tube, you will be able to access
and adjust the air shutter from behind the right side panel to a
100% open gap for propane gas (below valve).
After step 12, with the appliance lit and fully warmed up, evaluate
the burner flame appearance and re-adjust air shutter for proper
flame appearance, if necessary.
Setscrew
Air Shutter
3
NOTE: DIAGRAMS AND ILLUSTRATIONS ARE NOT TO SCALE.

Step 9. Turn on gas supply and test for gas leaks using a gas leak test
solution (see Test Procedure on Page 11 in the Installation and
Operation Manual).
Step 10.Using a manometer, test the inlet and manifold gas pressure per
instructions in the Installation and Operation Manual (Page 11)
and as shown in the following 2 tables.
Step 11.Reinstall the the log set and glass door assembly. See Pages
9 and 10 (Log Set Installation) and Page 18 (Door Assembly
Installation) in the Installation and Operation Manual.
Step 12.Light the appliance per the lighting instructions label on appliance
(when viewing the insert from the front, it is located behind the
right side door, on the right) or lighting instructions on Page 13
in the Installation and Operation Manual. Inspect for proper pilot
and burner flame appearances. See Flame Color and Behavior
on Page 14 and Inspect The Pilot System For Proper Flame on
Page 16 in the Installation and Operation Manual. Also see
Figures 12 and 13.
Figure 13 - Burner Flame Appearance
No Blue Flame
Center
Soot at
Flame Tip
Dark Orange
Flame
IMPROPERLY
BURNING FLAME
Soot above
Flame Tip No Soot at
Flame Tip
PROPERLY
BURNING FLAME
Semi-Transparent
Yellow Flame
Blue Flame
Center
Ports on Pan
Burner Assembly
Figure 12 - Proper Pilot Flame Appearance
Millivolt Pilot
Thermopile
Igniter
Gas Pilot Hood
3/8” to
1/2”
Inlet Gas Supply Pressure
Fuel # Minimum Maximum Desired
LP 10.5" WC/po. C.E
(2.62 kPa)
13.0" WC/po. C.E
(3.23 kPa)
11" WC/po. C.E
(2.74 kPa)
Manifold Gas Supply Pressure
Fuel # Low High
LP (Lo) 5.4" WC/po. C.E
(1.35 kPa)
(Hi) 10.0" WC/po. C.E
(2.49 kPa)
Printed in U.S.A. © 2008 Lennox Hearth Products
P/N 775,251M REV. A 09/2008
Lennox Hearth Products reserves the right to make changes at any time, without notice, in
design, materials, specifications, prices and also to discontinue colors, styles and products.
Consult your local distributor for fireplace code information.
1110 West Taft Avenue • Orange, CA 92865
4