Monessen Hearth Covington Direct Vent KHLDV400 User manual






73D0024 8/09 Rev. 10


      
    

         


 
  
  

  

  

      
       


       



       


          
        


 


730024
KHLDV cover




      


     
    

    



       


   


273D0024
KHLDV Series Gas Fireplace 
 
 
 
High Elevations ...................................................... 5
Gas Pressures ....................................................... 5
Gas Specifications & Orifice Size .......................... 5
 
 
Before You Start ..................................................... 7
Fireplace Framing .................................................. 7
Fireplace Location .................................................. 8
 
 
 

Installation Precautions .........................................11
Installation Clearances ..........................................11
Installation Planning ............................................. 12
Vertical Termination .............................................. 12
Horizontal Termination ......................................... 12
How to Use a Vent Graph .................................... 14
Vertical/Horizontal Termination Configurations .... 15
Below Grade Installation ...................................... 17
Vertical Through-the-Roof Applications ................ 18
Installation for Vertical Termination ...................... 19
 
Check Gas Type................................................... 21
Install Gas Piping ................................................ 21
 
 
Electrical Wiring ................................................... 23
 
 
 
Lighting Pilot for the First Time ............................ 27
Lighting Pilot ........................................................ 28
Lighting Burner ..................................................... 29
To Turn Off Gas .................................................... 29
 
 

  

  

  
Operating Instructions .......................................... 36
To Turn Off Gas .................................................... 36

  
Remote Control Operation ................................... 40
 
 
Hearth Brick Placement ....................................... 44
Rockwool Placement ........................................... 44
Log Placement ..................................................... 45
 
Burner, Pilot and Control Compartment ............... 48
Pilot Flame ........................................................... 48
Burner Flame ....................................................... 48
Venting System .................................................... 49
Glass Door ........................................................... 49
Logs ..................................................................... 49
Rock Wool ........................................................... 49
 
 
Firebox Components ............................................ 53
Standing Pilot Millivolt Control ............................ 54
Signature Command System ............................... 56
Venting Components ............................................ 58
Logs ..................................................................... 60
 
 
 






73D0024 3
KHLDV Series Gas Fireplace
4. Never install the fireplace
• in a recreational vehicle
• where curtains, furniture, clothing, or other flam-
mable 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 surfaces to avoid burns or
clothing ignition. Fireplace will remain hot for a time after
shutdown. Allow surfaces to cool before touching.
6. Carefully supervise young children when they are in
the room with fireplace.
7. Do not modify fireplace under any circumstances. Any
parts removed for servicing must be replaced prior to
operating fireplace.
8. Turn fireplace off and let cool before servicing, install-
ing, or repairing. Only a qualified service person should
install, service, or repair the fireplace. Have burner
system inspected annually by a qualified service
person.
9. You must keep control compartments, burners, and
circulating air passages clean. More frequent cleaning
may be needed due to excessive lint and dust. Turn off
the gas valve and pilot light before cleaning fireplace.
10. Have venting system inspected annually by a qualified
service person. If needed, have venting system cleaned
or repaired. Refer to Cleaning and Maintenance, Page
48.
11. Keep the area around your fireplace clear of combus-
tible materials, gasoline, and other flammable vapor and
liquids. Do not run fireplace where these are used or
stored. Do not place items such as clothing or decora-
tions on or around fireplace.
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, card-
board, etc.) in this fireplace. Use only the gas type
indicated on rating plate.

Please leave these instructions with the appliance.

Please retain these instructions for future reference .

This fireplace is a vented product. This fireplace must be
properly installed by a qualified service person. The glass
door must be properly seated and sealed. If this unit is not
properly installed by a qualified service person with glass
door properly seated and sealed, combustion leakage can
occur.
 Early signs of carbon
monoxide poisoning are similar to the flu with headaches,
dizziness and/or nausea. If you have these signs, the fire-
place may not have been installed properly. Get fresh air
at once! Have the fireplace inspected and serviced by a
qualified service person. Some people are more affected
by carbon monoxide than others. These include pregnant
women, people with heart or lung disease or anemia,
those under the influence of alcohol, and those at high
altitudes.
Propane/LP gas and natural gas are both odorless. An
odor-making agent is added to each of these gases. The
odor helps you detect a gas leak. However, the odor added
to these gases can fade. Gas may be present even though
no odor exists.
Make certain you read and understand all warnings. Keep
this manual for reference. It is your guide to safe and proper
operation of this fireplace.
1. 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 certified
kit is used.
2. For propane/LP fireplace, do not place propane/LP
supply tank(s) inside any structure. Locate propane/LP
supply tank(s) outdoors. To prevent performance prob-
lems, do not use propane/LP fuel tank of less than 100
lbs. capacity.
3. If you smell gas
• shut off gas supply.
• 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.
Continued on page 4
 

 
 



473D0024
KHLDV Series Gas Fireplace 
Continued from page 3
15. This appliance, when installed, 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.
16. Do not obstruct the flow of combustion and ventilation
air in any way. Provide adequate clearances around
air openings into the combustion chamber along with
adequate accessibility clearance for servicing and
proper operation.
17. When the appliance is installed directly on carpeting,
tile or other combustible material other than wood floor-
ing, you must set appliance on a metal or wood panel
or hearth pad extending the full width and depth of the
appliance.
18. Do not use fireplace if any part has been exposed to
or has been under water. Immediately call a qualified
service technician to inspect the appliance and replace
any part of the control system and any gas control which
as been submerged in water.
19. Do not operate fireplace if any log is broken.
20. Do not use a blower insert, heat exchanger insert, or
any other accessory not approved for use with this
fireplace.
21. Do not operate the fireplace with glass door removed,
cracked, or broken.

Direct Vent type appliances draw all combustion air from outside of the dwelling through the vent pipe.
These appliances have been tested by CSA and found to comply with the established standards for
DIRECT VENT GAS FIREPLACE HEATERS in the USA and Canada as follows:

TESTED TO: ANSI Z21.88b-2008/CSA 2.33b-2008 STANDARDS
A manufactured home (USA only) or mobile home OEM installation must conform with the Manufactured
Home Construction and Safety Standard, or when such a standard is not
applicable, the , or 
.
WARNING
!
HOT GLASS WILL
CAUSE BURNS.
DO NOT TOUCH GLASS
UNTIL COOLED.
NEVER ALLOW CHILDREN
TO TOUCH GLASS.

     





It is normal for fireplaces fabricated of steel to give off
some expansion and/or contraction noises during the
start up or cool down cycle. Similar noises are found with
your furnace heat exchanger or car engine.



It is not unusual for gas fireplaces to give off some odor
the first time it is burned. This is due to the manufacturing
process.


It is recommended that you burn your fireplace for at
least ten (10) hours the first time you use it. Place the
fan switch in the “OFF” position during this time.

73D0024 5
KHLDV Series Gas 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 appliance must be installed in accor-
dance with local codes if any. If none exist
use the current installation code. ANSI
Z223.1/NFPA 54 in the USA, CSA B149 in
Canada.
• This appliance is mobile home approved.
• The appliance must be properly connected
to a venting system.
• The appliance is not approved for closet or
recessed installations.
FP2124
KHLDV controls
Off/Pilot/On Knob
Figure 1 -
KHLDV Series Fireplace
(shown with Millivolt)
Hi/Lo Knob
On/Off/RS Switch
Ignitor
Light Control
Blower Control
(optional)
Access Panel
FP2124


Input ratings are shown in BTU per hour and are certified
without deration for elevations up to 4,500 feet (1,370
m) above sea level.
For elevations above 4,500 feet (1,370 m) in USA,
installations must be in accordance with the current
ANSI Z223.1/NFPA 54 and/or local codes having juris-
diction.
In Canada, please consult provincial and/or local authori-
ties having jurisdiction for installations at elevations
above 4,500 feet (1,370 m).
Natural Propane (LP)
Inlet Minimum 4.5” w.c. 11.0” w.c.
Inlet Maximum 10.5” w.c. 13.0” w.c.
Manifold Pressure 3.5” w.c. 10.0” w.c.

 
    
KHLDV500NV Nat. 50,000 35,500
KHLDV500PV LP 50,000 38,500
KHLDV500NSC Nat. 50,000 35,500
KHLDV500PSC LP 50,000 38,500

    
KHLDV500 Nat. 2.3 mm #30 (.1285)
KHLDV500 LP #50 (.070") #55 (.052")

673D0024
KHLDV Series Gas Fireplace 
D
E
J
H
O
P - Min. Rough Opening Width
Q
S
R
R
T
Min. Rough
Opening
Depth
1/2” or 5/8”
Min. Rough
Opening
Height
730129
DVKHL/KHLDV dims
A
B
C
L
K
F
M
N
IG
Figure 2 -
Fireplace and Framing Dimensions
  
A 44ZB\zn" (1141 mm) 48ZB\zn" (1243 mm)
B 35Z\x" (902 mm) 39Z\x" (1003 mm)
C 32" (813 mm) 36" (914 mm)
D 22Z\x" (572 mm) 24Z\x" (622 mm)
E 28Z\," (714 mm) 32Z\," (816 mm)
F 30" (762 mm) 30" (762 mm)
G 38M\zn" (976 mm) 38M\zn" (976 mm)
H 23M\," (606 mm) 23M\," (606 mm)
I 44C\," (1127 mm) 44C\," (1127 mm)
J 8>\zn" (218 mm) 8>\zn" (218 mm)
K 4Z\v" (108 mm) 4Z\v" (108 mm)
L 4" (102 mm) 4" (102 mm)
M 38Z\zn" (967 mm) 38Z\zn" (967 mm)
N 1" (25 mm) 1" (25 mm)
Framing Dimensions
O 44C\v" (1137 mm) 44C\v" (1137 mm)
P 45B\zn" (1153 mm) 49B\zn" (1253 mm)
Q 23M\," (606 mm) 23M\," (606 mm)
R 53B\," (1362 mm) 56M\zn" (1434 mm)
S 75M\," (1927 mm) 49M\," (2029 mm)
T 37ZB\zn" (964 mm) 39ZB\zn" (1014 mm)

73D0024 7
KHLDV Series Gas Fireplace


Read this homeowner manual thoroughly and follow all
instructions carefully. Inspect all contents for shipping
damage and immediately inform your dealer if any damage
is found. Do not install any unit with damaged, incomplete,
or substitute parts. Check your packing list to verify that
all listed parts have been received. You should have the
following:
• Fireplace (Firebox and Burner System)
• Log Set
• Rock Wool
• Noncombustible Panel

• Phillips Screwdriver • Framing Materials
• Hammer • Wall Finishing Materials
• Saw and/or saber saw • Level
• Measuring Tape • Pliers
• Electric Drill and Bits • Square
• Pipe Wrench • Tee Joint
• Noncombustible finishing material or dura-rock*
• Caulking Material (noncombustible)
• Fireplace Surround Material (noncombustible)
• Piping Complying with Local Codes
• Pipe Sealant Approved for use with Propane/LPG
(Resistant to sulfur compounds)
* Only used if desired to cover painted face other than using tiles
or marble. If tiles or marble are used around the face then the
non-combustible material is not needed.

      
     









Firebox framing can be built before or after the appliance
is set in place. Refer to Figure 2 for firebox dimensions
and framing. Construct firebox framing following Figure
2 for your specific installation requirements. The framing
headers may rest on the top of the firebox standoffs. Do
not bring headers below top of standoffs.  When
planning your framing and installation, keep in mind that
your gas line will come in on the right side of the box (as
you are facing it) and your electricity will come in on the
left side.
The firebox may be installed directly on a combustible floor
or raised on a platform of an appropriate height. When
the firebox is installed directly on carpeting, tile, or other
combustible material, other than wood flooring, the firebox
shall be installed on a metal or wood panel extending the
full width and depth of the enclosure.

       
        


873D0024
KHLDV Series Gas Fireplace 

Plan for the installation of your appliance. This includes determining where the unit is to be installed,
the vent configuration to be used, framing and finishing details, and whether any optional accessories
(i.e. blower, wall switch, or remote control) are desired. Consult your local building code agency to
ensure compliance with local codes, including permits and inspections.
The following factors should be taken into consideration:
• Clearance to side-wall, ceiling, woodwork, and windows. Minimum clearances to combustibles

• This fireplace may be installed along a wall, across a corner, or use an exterior chase. Refer to
Figure 3 for suggested locations.
• Location should be out of high traffic areas and away from furniture and draperies due to heat
from appliance.
• Never obstruct the front opening of the fireplace.
• Do install in the vicinity where gasoline or other flammable liquids may be stored.
• Vent pipe routing. Refer to the Venting section found in this manual for allowable venting con-
figurations.
• These units can be installed in a bedroom. See National Fuel Gas Code ANSI Z233.1/NFPA 54
— (current edition), the Uniform Mechanical Code — (current edition), and Local Building Codes
for specific installation requirements.
• These units can be installed in a bathroom.
Figure 3 -
Locating Gas Fireplace
** Island (C) and room divider (D) installation is possible as long
as the horizontal portion of vent system (X) does not exceed
20'. Refer to Installing Horizontal Termination Configuration
on Page 15.
* When you install your fireplace in (D) room divider or (E)
flat on wall corner positions (Y), a minimum of 6" clearance
must be maintained from perpendicular wall and front of
fireplace.
Y
EAB
C
D
F
Y
X
FP1948
A Flat on Wall
B Cross Corner
C Island**
D Room Divider*
E Flat on Wall Corner*
F Chase Installation
Y 6" Minimum

73D0024 9
KHLDV Series Gas Fireplace
72” Minimum
Ceiling
12” Max.
Depth
21/2” Max Depth
10” min.
From Opening
16” Min.
From Opening
6” Min.
FP2128
mantel clearances










        

FP2128
12"
16"
10"
12"
6"
21/2"
FP2204
mantel clearances
Wall
Stud
Insulation
Board
Standoff
Top of Fireplace
Opening
FP2235

Figure 4 -
Clearances from the mantel, ceiling, and side wall.
6"
5"
3"
21/2"41/2"
45°
1"
31/2"
FP2129
mantel leg
11/2"
FP2129
Fireplace Opening
Figure 5 -
Mantel clearances


10 73D0024
KHLDV Series Gas Fireplace
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.


   

FP2130
secure fireplace to floor
6”
Framing Members
Noncombustible Material
Noncombustible
Material Must Rise
at Least to Top of
Stand off
Secure to Floor Behind
Access Panels
All Combustible Materials
Must Keep 3/4" Spacing
Nailing Flange
FP2130
Figure 6 -
Secure Fireplace to Floor and Framing Studs

 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 com-
bustible wall board to the top of the stand-offs on the top and the sides of the unit. A 300°F minimum
adhesive may be used to attach facing materials to the black surface. If joints between the finished
wall and the fireplace surround are sealed, a 300°F minimum sealant material (General Electric
RTV103 or equivalent) must be used.