Monessen Hearth Direct Vent Gas Fireplace KHLDV SERIES User manual

MODELS: KHLDV400 & KHLDV500
KHLDV SERIES
DIRECT VENT GAS FIREPLACE
INSTALLATION AND
OPERATING INSTRUCTIONS
READ BEFORE INSTALLING. SAVE THESE INSTRUCTIONS
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
STAYAWAY TO AVOID BURNS OR CLOTHING
IGNITION.
YOUNG CHILDRENSHOULD BE SUPERVISED
WHEN THEYARE INTHE SAME ROOMAS 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.
IF THE INFORMATION IN THESE INSTRUCTIONS IS 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.
– Installationandservicemustbeperformedbyaqualified
installer, service agency or the gas supplier.
WARNING: Improper installation, adjustment, alteration,
services or maintenance can cause injury or property
damage. Refer to this manual. For assistance 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 isonly for usewith the typeof 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.
WARNING

2 73D0024
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 Start............................................ 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 Planning.................................... 14
Vertical/Horizontal Termination
Configuration............................................... 17
Below Grade Installation............................. 19
Vertical Through-the-Roof Applications....... 20
Installation for Vertical Termination ............. 21
Fireplace Installation...................................... 23
Check Gas Type.......................................... 23
Installing Gas Piping to Fireplace/Burner
System Location.......................................... 23
Checking Gas Pressure................................. 25
Electrical Installation...................................... 25
Electrical Wiring .......................................... 25
Remote Wall Switch Installation ................... 26
Optional Fan/Blower Systems....................... 26
Glass Removal................................................ 29
Final Installation............................................. 30
Hearth Brick Placement .............................. 30
Rockwool Placement................................... 30
Log Placement............................................ 31
Operating Instructions (Milli-Volt)................. 33
Lighting Pilot for the First Time.................... 33
Lighting Pilot................................................ 34
Lighting Burner............................................ 35
To Turn Off Gas........................................... 35
Cleaning and Maintenance............................ 36
Burner, Pilot and Control Compartment...... 36
Pilot Flame.................................................. 36
Burner Flame .............................................. 36
Vent System................................................ 37
Glass Door.................................................. 37
Logs ............................................................ 37
Rock Wool .................................................. 37
Troubleshooting ............................................. 38
Illustrated Parts Lists..................................... 40
Firebox Components................................... 40
Standing Pilot Millivolt Control .................... 42
Vent Components........................................ 44
Logs ............................................................ 45
Mass Residents Only ..................................... 46
Warranty...........................................Back Cover

73D0024 3
4. Never install the fireplace
• in a recreational vehicle
• where curtains, furniture, clothing, or other flammable
objects are less than 42" from the front, top, or sides
of the fireplace
• in high traffic areas
• in windy or drafty areas
5. This fireplace reaches high temperatures. Keep children
and adults away from hot 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 35.
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
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 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 73D0024
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
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 fire-
place.
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.

73D0024 5
PRODUCT FEATURES AND CODE APPROVAL
Off/Pilot/On Knob
Figure 1 - KHLDV Series Fireplace
• This appliance has been certified for use with
either natural or propane gas. See appropriate data
plates.
• This appliance is not for use with solid fuels.
• The appliance is approved for bedroom or bedsitting
room installations.
• The 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.
Hi/Lo Knob
PRODUCT SPECIFICATIONS
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 Z21.88-2005/CSA 2.33-2005 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.
On/Off/RS Switch
Ignitor
Light Control
Blower Control (optional)
Access Panel
• 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.
The efficiency rating of this appliance is a product thermal efficiency rating determined under continuous operating condi-
tions and was determined independently of any installed system.
Thermal Efficiency = up to 72%

6 73D0024
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. Where the heating value of
the gas has been reduced, these rules do not apply.
• In Canada, these appliances are certified for altitudes of 0 – 2000 ft, and must be de-rated by 10 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"
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 • Non-combustible finishing material or dura-rock*
• Pipe Wrench • Caulking material (non-combustible)
• Level • Fireplace surround material (non-combustible)
• 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)
* 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.
Model Number KHLDV400 KHLDV500
Gas Type Natural Propane Natural Propane
Max. Btu/hr Input 40,000 40,000 50,000 50,000
Min. Btu/hr Input 28,500 30,500 35,500 38,500
Rear Orifice Size #35 (.110") #52 (.0635") #30 (.1285") #50 (.070")
Front Orifice Size #49 (.073") #56 (.0465") 2.3 mm #55 (.052")

73D0024 7
H
G
D
F
E
A
C
B
A
1/2"or5/8"
C
A
G
C
G
A1/2" or 5/8"
FIREBOX FRAMING
Firebox framing can be built before or after the appliance
is set in place. Construct firebox framing following Figure
2and the chart below for your specific installation require-
ments. 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. Please note:
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 com-
bustible 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.
FIREPLACE FRAMING
Do not fill spaces around firebox with
insulation or other materials. This
could cause a fire.
WARNING
Figure 2 - Framing Dimensions
KHLDV400 KHLDV500
A 45 5/16" 49 5/16"
B 44 3/4" 44 3/4"
C 28 1/8" 32 1/8"
D 14 1/16" 16 1/16"
E 75 7/8" 79 7/8"
F 37 15/16" 39 15/16"
G 23 7/8" 23 7/8"
H 53 5/8" 56 7/16"
Unit framing is to be rectangular front
to back. Failure to do so will cause fire
and damage to property.
WARNING

8 73D0024
E
H
J
A
D
L
K
C
F
M
B
IG
N
PRE-INSTALLATION INFORMATION
Figure 3 - Fireplace Dimensions
FIREPLACE DIMENSIONS
DESCRIPTION Key Letter KHLDV400 KHLDV500
Overall Front Width A 44 15/16" 48 15/16"
Inside Width B 35 1/2" 39 1/2"
Glass Width C 32" 36"
CTR Pipe D 22 1/2" 24 1/2"
Rear Width E 28 1/8" 32 1/8"
Glass Height F 30" 30"
Chassis Height G 38 7/16" 38 7/16"
Depth H 23 7/8" 23 7/8"
Height to Standoffs I 44 3/8" 44 3/8"
CTR Height J 8 9/16" 8 9/16"
Top Face K 4 1/4" 4 1/4"
Side Face L 4" 4"
Bottom Face M 38 1/16" 38 1/16"
Finish Hearth Rise N 1" 1"

73D0024 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.
• These units can be installed in a bathroom.
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 6" 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.
NOTE
COLD CLIMATE INSULATION
If you live in a cold climate, seal all cracks around your appliance, and wherever cold air could enter the room,
with noncombustible material. It is especially important to insulate the outside chase cavity between the studs
and under the floor on which the appliance rests, if the floor is above ground level.

10 73D0024
FIREPLACE
WALL
COMBUSTIBLE
MATERIAL
AREA
6"
5"
3"
2.5" 4.5"
45°
3.5"
3.5"
1" 1.5"
1.5"
Follow these instructions carefully to ensure safe installation. Failure to follow
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 5 - Clearances from the mantel,
ceiling, and side wall. Figure 5a - Mantel clearances.