Monessen Hearth Direct Vent Gas Fireplace BDV400 User manual

MODELS:
BDV300, BDV400, BDV500, BDV600
BDV SERIES
DIRECT VENT GAS
FIREPLACE
INSTALLATION AND OPERATING
INSTRUCTIONS
WARNINGS
IF THEINFORMATION IN THESEINSTRUCTIONSARE
NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION
MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR LOSS OF LIFE.
– Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
– WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• 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.
• If you cannot reach your gas supplier, call the
fire department.
– Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
WARNING: Improper installation, adjustment,
alteration,servicesormaintenancecancauseinjuryor
propertydamage.Refertothismanual.Forassistance
or additional information consult a qualified installer,
service agency or the gas supplier.
This appliance may be installed in an aftermarket*,
permanently located, manufactured home (USA
only) or mobile home, where not prohibited by
local codes.
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.
* Aftermarket: Completion of sale, not for purpose of resale,
from the manufacturer.
DUE TO HIGH TEMPERATURES, THE
APPLIANCE SHOULD BE LOCATED
OUT OF TRAFFIC AND AWAY FROM
FURNITURE AND DRAPERIES.
CHILDREN AND ADULTS SHOULD
BE ALERTED TO THE HAZARDS OF
HIGH SURFACE TEMPERATURE AND
SHOULD STAY AWAY TO AVOID BURNS
OR CLOTHING IGNITION.
YOUNG CHILDREN SHOULD BE
SUPERVISED WHEN THEY ARE IN THE
SAME ROOM AS THE APPLIANCE.
CLOTHING OR OTHER FLAMMABLE
MATERIAL SHOULD NOT BE PLACED ON
OR NEAR THE APPLIANCE.
KEEP THE ROOM AREA CLEAR AND
FREE FROM COMBUSTIBLE MATERIALS,
GASOLINE, AND OTHER FLAMMABLE
VAPORS AND LIQUIDS.
READ BEFORE INSTALLING. SAVE THESE INSTRUCTIONS

2 54D0700
CONTENTS
Important Safety Information .......................... 3
Product Features.............................................. 5
Code Approval.................................................. 5
Pre-Installation Information
Installing Above 2000 Feet............................ 6
Orifice Sizes, Pressures and BTUs............... 6
Before You Install.......................................... 6
Fireplace Framing......................................... 7
Fireplace Dimensions.................................... 8
Fireplace Location......................................... 9
Clearances ...................................................... 10
Securing Fireplace to Floor or Framing........11
Installation Information.................................. 12
Vent Installation.............................................. 13
Installation Precautions............................... 13
Optional Top Vent Application ..................... 14
Installation Planning.................................... 15
Rear (Through the Wall) Applications ......... 18
Horizontal Termination Configuration.......... 20
Below Grade Installation............................. 22
Vertical Through-the-Roof Installation......... 23
Installation for Vertical Termination ............. 24
Fireplace Installation...................................... 26
Check Gas Type.......................................... 26
Installing Gas Piping to Fireplace/Burner
System Location.......................................... 26
Checking Gas Pressure................................. 28
Electrical Installation...................................... 29
Electrical Wiring .......................................... 29
Electronic Pilot Ignition Wiring..................... 30
Remote Wall Switch.................................... 31
Glass Removal................................................ 32
Final Installation............................................. 33
Rockwool Placement................................... 33
Log Placement............................................ 33
Lava Rock and Ember Placement............... 33
Operating Instructions (Milli-Volt)................. 34
What To Do If You Smell Gas...................... 34
Lighting Milli-Volt Pilot for the First Time..... 35
Lighting Milli-Volt Pilot................................. 35
Lighting Burner............................................ 36
To Turn Off Gas........................................... 36
Operating Instructions (Electronic Ignition) 37
What To Do If You Smell Gas...................... 37
Lighting Electronic Ignition ......................... 37
To Turn Off Gas........................................... 37
Cleaning and Maintenance............................ 38
Burner, Pilot and Control Compartment...... 38
Pilot Flame.................................................. 38
Burner Flame .............................................. 39
Vent System................................................ 39
Glass Door.................................................. 39
Logs ............................................................ 39
Rock Wool .................................................. 39
Troubleshooting ............................................. 40
Replacement Parts......................................... 42
Firebox Components................................... 42
Standing Pilot Engine ................................. 44
Electronic IGN Engine ................................ 44
Vent Components........................................ 47
Logs ............................................................ 49
Mass Residents Requirements ..................... 50
Warranty...........................................Back Cover

54D0700 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 surfaces to avoid burns or cloth-
ing 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 cir-
culating 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. See Cleaning and Maintenance, page 32.
11. Keep the area around your fireplace clear of combustible
materials, gasoline, and other flammable vapor and liq-
uids. Do not run fireplace where these are used or stored.
Do not place items such as clothing or decorations on or
around fireplace.
INSTALLER
Please leave these instructions with the appliance.
OWNER
Please retain these instructions for future reference .
IMPORTANT SAFETY INFORMATION
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.
CARBON MONOXIDE POISONING: Early signs of
carbon monoxide poisoning are similar to the flu with head-
aches, dizziness and/or nausea. If you have these signs, the
fireplace may not have been installed properly. Get fresh air
at once! Have the fireplace inspected and serviced by a quali-
fied 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 indi-
cated 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 problems, do
not use propane/LP fuel tank of less than 100 lbs. capac-
ity.
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
• Read this owner’s manual carefully and completely before trying to assemble, operate,
or service this fireplace.
• Any change to this fireplace or its controls can be dangerous.
• Improper installation or use of this fireplace can cause serious injury or death from
fire, burns, explosions, electrical shock and carbon monoxide poisoning.
WARNING

4 54D0700
IMPORTANT SAFETY INFORMATION
Continued from page 3
12. Do not use this fireplace to cook food or burn paper or
other objects.
13. Never place anything on top of fireplace.
14. Do not use any solid fuels (wood, coal, paper, cardboard,
etc.) in this fireplace. Use only the gas type indicated on
rating plate.
15. 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 flooring,
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
person to arrange for replacement of the unit.
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.
IMPORTANT:
PLEASE READ THE FOLLOWING CAREFULLY
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.
IMPORTANT:
PLEASE READ THE FOLLOWING CAREFULLY
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.
Please ensure that your room is well ventilated
during burn off — open all windows.
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.
Never connect unit to private
(non-utility) gas wells. This
gas is commonly known as
wellhead gas.
WARNING
www.nficertified.org
We suggest that our gas hearth
products be installed and
serviced by professionals who
are certified in the U.S. by the
National Fireplace Institute®
(NFI) as Gas Specialists.

54D0700 5
PRODUCT FEATURES AND CODE APPROVAL
Off/Pilot/On Knob
Optional Remote
Receiver
Figure 1 - BDV300, 400, 500, 600 Fireplace
• This appliance has been certi-
fied for use with either natural or
propane gas. See appropriate data
plates.
• This appliance is not for use with
solid fuels.
• The appliance is approved for
bedroom or bedsitting room
installations.
• The appliance must be installed
in accordance with local codes if
any. If none exist use the current
installation code. ANSI Z223.1/
NFPA 54 in the USA, CAN/CGA
B149 in Canada.
• 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.
Hi/Lo Knob
PRODUCT SPECIFICATIONS
The efficiency rating of this appli-
ance is a product thermal efficiency
rating determined under continuous
operating conditions and was deter-
mined independently of any installed
system.
Thermal Efficiency = up to 80%
CODE APPROVAL
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:
LISTED VENTED GAS FIREPLACE HEATER
TESTED TO: ANSI Z21.88-2002/CSA 2.33-2002 STANDARDS
A manufactured home (USA only) or mobile home OEM installation must conform with the Manufactured Home Con-
struction and Safety Standard, Title 24 CFR, Part 3280, or when such a standard is not applicable, the Standard for
Manufactured Home Installations, ANSI/NCSBCS A225.1, or Standard for Gas Equipped Recreational Vehicles and
Mobile Housing, CSA Z240.4.
Blower Control
On/Off/RS Switch
Ignitor

6 54D0700
PRE-INSTALLATION INFORMATION
INSTALLING ABOVE 2000 FEET
• In the USA, the appliance must be derated 4% for every 1,000 ft above 2,000 ft elevations.
• In Canada, these appliances are certified for altitudes of 0 – 2000 ft, and must be de-rated by 10 percent for installations
between 2000 and 4,500 ft. (derate an additional 4% for every 1,000 ft. above 4,500 ft. elevations).
ORIFICE SIZES, PRESSURES AND BTUs
NATURAL GAS PROPANE GAS
Manifold Press: (W.C.) 3.5" Manifold Press: (W.C.) 10"
Maximum Supply Pressure 10.5" Maximum Supply Pressure 13"
Minimum Supply Pressure 4.5" Minimum Supply Pressure 11"
Model Number BDV300 BDV400 BDV500 BDV600
Natural Propane Natural Propane Natural Propane Natural Propane
Max. Btu/hr Input 21,000 21,000 24,000 24,000 26,000 26,000 26,000 26,000
Min. Btu/hr Input 15,000 15,000 17,000 17,000 20,000 20,000 20,000 20,000
Orifice size #43 #54 #41 #53 #40 1.55mm #40 1.55mm
BEFORE YOU START
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)
• Rock Wool
• Log Set
ITEMS REQUIRED FOR INSTALLATION
Tools: Building Supplies:
• Phillips Screwdriver • Framing Materials
• Hammer • Wall Finishing Materials
• Saw and/or saber saw • Caulking Material (Noncombustible)
• Level • Fireplace Surround Material (Noncombustible)
• Measuring Tape • Piping Complying with Local Codes
• Electric Drill and Bits • Tee Joint
• Pliers • Pipe Sealant Approved for use with Propane/LPG
• Square (Resistant to Sulfur Compounds)
• Pipe Wrench

54D0700 7
H
G
D
F
E
A
C
B
A
1/ " 5/ "
C
A
G
C
G
A1/2" or 5/8
"
FIREPLACE FRAMING
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 requirements. See Figure 3 on Page 8 for firebox dimensions. The framing
headers may rest on the top of the firebox standoffs. Do not bring headers below top of standoffs.
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.
300 400 500 600
A 331/2" 371/2" 411/2" 471/2"
B 371/4" 407/8" 407/8" 407/8"
C 281/4" 291/4" 331/4" 391/4"
D 141/8" 145/8" 165/8" 195/8"
E 5511/16" 607/8" 647/8" 707/8"
F 2713/16" 307/16" 327/16" 357/16"
G 133/4" 153/4" 153/4" 153/4"
H 393/8" 431/16" 457/8" 501/8"
Corner Installation
Stud Location
Inside Chase Installation
Recessed Installation
Do not fill spaces around firebox with
insulation or other materials. This
could cause a fire.
WARNING
Figure 2 - Framing Dimensions

8 54D0700
A
E
D
B
C
N
M
K
L
FGJ
31/2"
1/2"
81/4"
5/8"
H
I
1/2"
5/8"
5/8"
1/2"5/8"1/2"
Drywall
Support
Tabs
PRE-INSTALLATION INFORMATION
Figure 3 - Fireplace Dimensions
DESCRIPTION Key Letter BDV300 BDV400 BDV500 BDV600
Overall Front Width A 331/16" 371/16" 411/16" 471/16"
Inside Width B 297/8" 32" 36" 42"
Glass Width C 27" 29" 33" 39"
CTR Pipe D 161/2" 181/2" 201/2" 231/2"
Rear Width E 28" 29" 33" 39"
Glass Height F 18" 203/8" 203/8" 203/8"
Chassis Height G 337/8" 371/2" 371/2" 371/2"
Depth H 14" 16" 16" 16"
Height to Standoffs I 37" 401/2" 401/2" 401/2"
CTR Height J 295/8" 331/8" 331/8" 331/8"
Top Face K 21/8" 11/4" 11/4" 11/4"
Side Face L 11/2" 21/2" 21/2" 21/2"
Bottom Face M 15/16" 15/16" 15/16" 15/16"
Overall Front Height N 315/8" 343/4" 343/4" 343/4"
FIREPLACE DIMENSIONS

54D0700 9
Y
EAB
C
D
F
Y
X
PRE-INSTALLATION INFORMATION
FIREPLACE LOCATION
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 inspec-
tions.
The following factors should be taken into consideration:
• Clearance to side-wall, ceiling, woodwork, and windows. Minimum clearances to combustibles must be maintained.
• This fireplace may be installed along a wall, across a corner, or use an exterior chase. See Figure 4 for suggested loca-
tions.
• 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 not install in the vicinity where gasoline or other flammable liquids may be stored.
• Vent pipe routing. See Venting section found in this manual for allowable venting configurations.
• 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.
Figure 4 - Locating Gas Fireplace
A Flat on Wall
B Cross Corner
C Island**
D Room Divider*
E Flat on Wall Corner*
F Chase Installation
Y 4" Minimum
** Island (C) and room divider (D) installation is possible as long as the horizontal portion of vent system (X)
does not exceed 20'. See Installing Horizontal Termination Configuration on pages 18 and 19.
* 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.

10 54D0700
12"
Maximum
Depth
11"Minimum
71"Minimum
Minimum 4"
From Both
Side Walls
Follow these instructions carefully to ensure safe installation. Failure to follow
instructions exactly can create a fire hazard.
The appliance cannot be installed on a carpet, tile or other combustible material other
than wood flooring. If installed on carpet or vinyl flooring, the appliance shall be installed
on a metal, wood or noncombustible material panel extending full width and depth of
the appliance.
WARNING
CLEARANCES
CLEARANCES TO COMBUSTIBLES
MANTEL CLEARANCES
NOTE: The combustible area above the facing must not protrude more than 3/4" from the facing. If it does,
it is considered a mantel and must meet the mantel requirements listed in this manual.
Figure 6 - Clearances