Monessen Hearth IDV490NV User manual

DIRECT VENT GAS INSERT
READ BEFORE INSTALLING. SAVE THESE INSTRUCTIONS
INSTALLATION AND
OPERATING
INSTRUCTIONS
MODELS:
IDV490NV, IDV490PV,
IDV380NV, AND IDV380PV
WARNINGS
IF THE INFORMATION IN THESE INSTRUCTIONS
ARE 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 fl ammable 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
any
appliance.
• Do not touch
any
any
electrical switch; do not use
any
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 fi re department.
– Installation and service must be performed by a qualifi ed installer, service agency or the
gas supplier.
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 certifi ed kit is used.

2
57D0016
CONTENTS
Important Safety Information
..........................
3
Product Features
..............................................
5
Code Approval
..................................................
5
Pre-Installation Information
Installing Above 2000 Feet
............................
6
Orifi ce Sizes, Pressures and BTUs
...............
6
Insert Dimensions
.........................................
6
Fireplace and Insert Dimensions
....................
7
General Installation Information
.....................
8
Clearances
....................................................
8
Installation
.........................................................
9
Insert Clearances
..........................................
9
Mantel Clearances
........................................
9
Hearth Requirements
....................................
9
Insert Placement
.........................................
10
Zero-Clearance (Metal) Fireplace
Requirements
...............................................
11
Vent Installation
..............................................
12
Installation Precautions
...............................
12
Vent Requirements
.....................................
13
Altitude Considerations
...............................
14
Vent Confi gurations
.....................................
15
Manifold Removal and Installation
..............
16
Insert Installation
Check Gas Type
..........................................
17
Installing Gas Piping to Insert/Burner System
Location
......................................................
17
Checking Gas Pressure
.................................
19
Electrical Installation
.....................................
20
Electrical Wiring
..........................................
20
Remote Wall Switch
....................................
20
Log Placement
................................................
21
Surround and Trim Installation
.....................
24
Installing Facing
..........................................
24
Installing On/Off Switch
...............................
24
Filigree Panels and Cabinet
Door Frame Installation
............................
25
Door Installation
.............................................
26
Operating Instructions
...................................
27
What To Do If You Smell Gas
......................
27
Lighting Pilot for the First Time
...................
27
Lighting Pilot
...............................................
28
Lighting Burner
............................................
Lighting Burner ............................................Lighting Burner
29
To Turn Off Gas
...........................................
29
Adjusting Blower Speed
..............................
29
Air Shutter Adjustment (Natural Gas Only)
..
30
Glass Replacement
........................................
31
Cleaning Maintenance
....................................
32
Venting System
...........................................
32
Cleaning Glass
............................................
32
Pilot and Burner Flames
.............................
32
Firebox Cleaning
.........................................
33
Maintaining Your Heater’s Appearance
.......
33
Yearly Service Procedure
............................
34
Blower
..............................................................
35
Replacement Parts
.........................................
36
Troubleshooting
.............................................
38
Warranty
...........................................
Back Cover
Thank you and congratulations on your purchase of a Monessen Fireplace.

57D0016
3
Make certain you read and understand all warnings. Keep this
manual for reference. It is your guide to the safe and proper
operation of this insert.
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 certifi ed kit is used.
2. For propane/LP insert, 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. 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 neighborʼs
phone. Follow the gas supplierʼs instructions.
INSTALLER
Please leave these instructions with the owner.
OWNER
Please retain these instructions for future reference
.
IMPORTANT SAFETY INFORMATION
This insert is a vented product. This insert must be properly
installed by a qualifi ed service person. The glass door must be
properly seated and sealed. If this unit is not properly installed
by a qualifi ed 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 fl u with head-
aches, dizziness and/or nausea. If you have these signs, the
insert may not have been installed properly. Get fresh air at
once! Have the insert inspected and serviced by a qualifi ed
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 infl uence
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.
Continued on page 4
• Read this owner’s manual carefully and completely before trying to assemble, operate,
or service this insert.
• Any change to this insert or its controls can be dangerous.
• Improper installation or use of this insert can cause serious injury or death from fi re,
burns, explosions, electrical shock and carbon monoxide poisoning.
• Improper installation, adjustment, alteration, services or maintenance can cause injury
or property damage. Refer to this manual. For assistance or additional information
consult a qualifi ed installer, service agency or the gas supplier.
• 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.
WARNINGS

4
57D0016
IMPORTANT SAFETY INFORMATION
Continued from page 3
4. Never install the insert
• in a recreational vehicle
• where curtains, furniture, clothing, or other fl ammable
objects are less than 36" from the front, top, or sides
of the insert
• in high traffi c areas
• in windy or drafty areas
5. This insert reaches high temperatures. Keep children and
adults away from hot surfaces to avoid burns or clothing
ignition. Insert 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 insert.
7. Do not modify this insert under any circumstances. Any
parts removed for servicing must be replaced prior to
operating insert.
8. Turn insert off and let cool before servicing, installing, or
repairing. Only a qualifi ed service person should install,
service, or repair the insert. Have burner system inspected
annually by a qualifi ed 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 from carpeting,
bedding material, pet hair, etc. Turn off the gas valve and
pilot light before cleaning insert.
10. Have venting system inspected annually by a qualifi ed
service person. If needed, have venting system cleaned
or repaired. See
Cleaning and Maintenance
, page 32.
11. Keep the area around your insert clear of combustible
materials, gasoline, and other fl ammable vapor and liq-
uids. Do not run insert where these are used or stored.
Do not place items such as clothing or decorations on or
around insert.
12. Do not use this insert to cook food or burn paper or other
objects.
13. Never place anything on top of insert.
14. Do not use any solid fuels (wood, coal, paper, cardboard,
etc.) in this insert. 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 fl ow 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. Do not use insert if any part has been exposed to or
under water. Immediately call a qualifi ed service person
to arrange for replacement of the unit.
18. Do not operate insert if any log is broken.
19. Do not operate the insert with glass door removed,
cracked, or broken.
Never connect unit to private
(non-utility) gas wells. This
gas is commonly known as
wellhead gas.
WARNING
www.nfi certifi ed.org
We suggest that our gas hearth
products be installed and
serviced by professionals who
are certifi ed in the U.S. by the
National Fireplace Institute
®
(NFI) as Gas Specialists.

57D0016
5
PRODUCT FEATURES
AND
CODE APPROVAL
Off/Pilot/On Knob
Optional
Remote
Receiver
Figure 1 - IDV490NV, IDV490PV, IDV380NV, and IDV380PV Inserts
• This appliance has been
certifi ed 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 instal-
lation code. ANSI Z223.1/
NFPA 54 in the USA, CAN/
CGA B149 in Canada.
• The appliance must be prop-
erly connected to a venting
system.
Hi/Lo Knob
PRODUCT SPECIFICATIONS
The effi ciency rating of this appliance is a product thermal effi ciency rating determined under continuous operating condi-
tions and was determined independently of any installed system.
Thermal Effi ciency = up to 80%
CODE APPROVAL
These appliances have been tested by CSA and found to comply with the established standards for VENTED GAS FIRE-
PLACE HEATERS in the USA and Canada as follows:
LISTED VENTED GAS FIREPLACE HEATER
TESTED TO: ANSI Z21.88-2002/CSA 2.33-2002 STANDARDS
On/Off/
Remote Switch
Blower Knob
Gas
Shutoff
Valve
ATTENTION MASSACHUSETTS RESIDENTS:
This product must be installed by a licensed gas fi tter.
Gas
Piezo Ignitor
On/Off Switch
This appliance may be installed
in an aftermarket*, permanently
in an aftermarket*, permanently
located, manufactured
located, manufactured
home, where not prohibited
by local codes.
WARNING
* Aftermarket: Completion of sale, not for
purpose of resale, from the manufacturer.

6
57D0016
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 certifi ed 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).
The IDV490NV, IDV490PV, IDV380NV, and 380IDVPV are equipped with a variable output gas control.
ORIFICE SIZES, PRESSURES AND BTU
s
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"
NOTE: IDV490NV, IDV490PV, IDV380NV, and IDV380PV inserts work without any electrical supply.
Blower must be attached to 110/120 VAC.
INSTALLATION PLANNING
Plan for the installation of your insert. This includes determining the size of fi replace in which unit is to be installed, length of
venting to be used, and fi nishing details, and whether any optional accessories (i.e. wall switch, or remote control) are desired.
Consult your local building code agency to ensure compliance with local codes, including permits and inspections.
Model Number IDV490NV IDV490PV IDV380NV IDV380PV
Model Number IDV490NV IDV490PV IDV380NV IDV380PV
Model Number IDV490NV IDV490PV IDV380NV IDV380PV
NATURAL PROPANE NATURAL PROPANE
NATURAL PROPANE NATURAL PROPANE
NATURAL PROPANE NATURAL PROPANE
NATURAL PROPANE NATURAL PROPANE
Max. Btu/hr Input 40,000 37,500 30,500 28,000
Max. Btu/hr Input 40,000 37,500 30,500 28,000
Max. Btu/hr Input 40,000 37,500 30,500 28,000
Max. Btu/hr Input 40,000 37,500 30,500 28,000
Min. Btu/hr Input 26,500 29,000 20,500 22,000
Min. Btu/hr Input 26,500 29,000 20,500 22,000
Min. Btu/hr Input 26,500 29,000 20,500 22,000
Min. Btu/hr Input 26,500 29,000 20,500 22,000
Orifi ce sizes (as shipped) #30 #50 #32 #51
Orifi ce sizes (as shipped) #30 #50 #32 1.55mm
Orifi ce sizes (as shipped) #30 #50 #32 1.55mm
Orifi ce sizes (as shipped) #30 #50 #32 1.55mm
Model Number IDV490NV IDV490PV IDV380NV IDV380PV
NATURAL PROPANE NATURAL PROPANE
Max. Btu/hr Input 40,000 37,500 30,500 28,000
Min. Btu/hr Input 26,500 29,000 20,500 22,000
Orifi ce sizes (as shipped) #30 #50 #32 1.55mm

57D0016
7
A
16˝
18˝
21˝
28˝
21˝
Top
Side
A
Front
M
L
A
18˝
20˝
23˝
31˝
23˝
IDV380 Opening
IDV490 Opening
Figure 2 - External Insert Dimensions
FIREPLACE AND INSERT DIMENSIONS
INSERTS
IDV490NV/PV
IDV380NV/PV
IDV490NV/PV
IDV380NV/PV
A
24
3
/
4
" - 629mm
22
3
/
4
" - 578mm
H
22
3
/
4
" - 578mm
20
3
/
4
" - 527mm
B
33
11
/
16
" - 856mm
30
3
/
16
" - 767mm
I
23
13
/
16
" - 605mm
21
5
/
8
" - 549mm
C
31
1
/
8
" - 791mm
27
5
/
8
" - 702mm
J
24
15
/
16
" - 633mm
22
3
/
4
" - 578mm
D
19
11
/
16
" - 500mm
17
7
/
16
" - 443mm
K
18
5
/
16
" - 465mm
16
5
/
16
" - 414mm
E
11
1
/
2
" - 292mm
10
3
/
8
" - 264mm
L
9
27
/
32
" - 250mm
8
23
/
32
" - 221mm
F
33" - 838mm
29
1
/
2
" - 749mm
M
5
5
/
8
" - 143mm
4
1
/
2
" - 114mm
G
17
1
/
2
" - 445mm
15
9
/
16
" - 395mm

8
57D0016
GENERAL INSTALLATION INFORMATION
The following factors should be taken into consideration:
• This insert should have suffi cient access for its safe operation and maintenance.
• The fl ow of combustion and ventilation air must not be obstructed.
• Minimum clearances to combustibles, such as mantels,
must be maintained.
See Figures 3 and 4, pages 9 and 10.
• Never obstruct the front opening of the insert.
• Do
not
install in the vicinity where gasoline or other fl ammable liquids may be stored.
• 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 specifi c installation requirements.
IMPORTANT: Your direct vent insert was designed to be installed in an existing wood burning fi replace.
The location and clearances are subject to local building codes.
INSERT APPLICATIONS
Before installing the gas fi replace insert, consider the functioning needs of the fi replace. Confi rm the size of the fi replace
cavity, the design of the chimney, and the availablility of the gas supply and electricity for the insert fan.
IMPORTANT: Your direct vent insert is designed to be only vented vertically with a minimum height of
10 feet.
When the unit is installed into a woodburning fi replace, the minimum distance the mantel can be placed above the fi replace is
governed by local building codes applicable to woodburning fi replaces. Consult local authorities having jurisdiction for these
clearances. The underside of the mantel will become warm. Use only fi nishes which are heat resistant and do not discolor.
The dimensions shown in
Figures 4 and 5, pages 9 and 10,
are minimum clearances to
maintain when installing this heater. Follow these instructions carefully to ensure safe
installation. Failure to follow in struc tions exactly can create a fi re hazard.
WARNING
CLEARANCES
MINIMUM FIREPLACE SIZE/CLEARANCES TO COMBUSTIBLES
Maintain the following minimum clearances for service and maintenance.
See pages 9 and 10.

57D0016
9
8" (203mm)
INSTALLATION
INSERT CLEARANCES
No combustibles (ie: drapes, doors) may be within, or swing within, 36" of the front of the inset.
MANTEL CLEARANCES
NOTE: The combustible area above the facing must not protrude more than
3
/
3/ 3
4
/4/
" from the facing. If it
does, it is considered a mantel and must meet the mantel requirements shown above.
HEARTH REQUIREMENTS
The insert must be installed on a non-combustible hearth extending a minimum of 12" from the fi replace opening (local
codes may require a larger hearth). The hearth must also extend to both sides of the face (see the table on
page 7
).
page 7). page 7
Figure 3 - Mantel Clearances

10
57D0016
INSTALLATION
INSERT PLACEMENT
• Insert must be placed within a code-conforming masonry fi replace or a tested and listed zero-clearance (UL-127, solid
fuel) fi replace. Repair any fi replace damage prior to installation.
• Because the insert uses a circulation blower, clean the fi replace, smoke shelf, and chimney before installing.
• This heater may be placed in a bedroom. Please be aware of the large amount of heat this appliance produces when
determining a location.
The gas line
should be installed
prior to insert
placement.
Run the on/off switch wires
to the right — behind the
surround panels
(See Page 24)
Run the power
cord either side of
the insert along
the face.
Use the leveling
bolts for fi replaces
with recessed fl oors
The insert
protrudes into the fi replace.
See Page 7 for Dimension.
For Minimum Dimension,
For Minimum Dimension,
See Page 7
For tight fi ts you may remove the manifold.
See
“Removing the Mainfold,” page 16.
Figure 4 - Insert Placement
For Minimum Dimension,
See Page 7

57D0016
11
Grate
ZERO-CLEARANCE (METAL) FIREPLACE REQUIREMENTS
• The damper and grate must be removed.
• The smoke shelf, internal baffl es, screen, refractory, and metal or glass doors may be removed (if applicable).
• Installer must attach red warning plate to the inside of the fi rebox of fi replace with
screws supplied.
• Do not cut any sheet metal parts of the fi replace in which this gas fi replace insert is
installed.
THIS IS STRICTLY PROHIBITED!
•
If factory-built fi replace has no gas access hole(s) provided, drill a 1.5" (37.5mm) or
less through lower sides or bottom of fi rebox. You must plug the access hole with
noncombustible insulation after gas supply line has been installed.
• If your factory-built fi replace has air passages on the face for zero capabilities, DO
NOT BLOCK THESE PASSAGES!
WARNING
• Do not remove or alter the insulation or any structured rigid frame members (metal sides, fl oor, door frame, face of the
fi replace, etc.).
INSTALLATION
Figure 5 - Metal Fireplace Zero-Clearance Requirements
IMPORTANT:Please review the following carefully.
It is normal for inserts 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 your insert to give off some odor the fi rst time it is burned. This is due to the curing of the paint and any
undetected oil from the manufacturing process.
Please ensure that your room is well-ventilated. OPEN ALL WINDOWS DURING INITIAL BURN OFF/
CURING PHASE.
Burn your insert for a least six (6) hours on “HIGH” the fi rst time you use it. Place fan in the “OFF” position during
this time.

12
57D0016
VENT INSTALLATION
Read all instructions completely and thoroughly before attempting installation. Failure
to do so could result in serious injury, property damage or loss of life. Operation of
improperly installed and maintained venting systems could result in serious injury,
property damage or loss of life.
WARNING
Failure to follow these instructions will
void the warranty.
NOTICE
INSTALLATION PRECAUTIONS
Consult local building codes before beginning the installation. The installer must make sure to select the proper vent system
for installation. Before installing vent kit, the installer must read this insert manual and vent kit instructions.
Only a qualifi ed installer/service person should install venting system. The installer must follow these safety rules:
• Wear gloves and safety glasses for protection.
• Use extreme caution when using ladders or when on rooftops.
• Be aware of electrical wiring locations in walls and ceilings.
The following actions will void the warranty on your venting system:
• Installation of any damaged venting component.
• Unauthorized modifi cation of the venting system.
• Installation of any component part not manufactured or approved by Monessen.
• Installation other than permitted by these instructions.
This insert must be vented to the outside. The venting system must NEVER be attached
to a chimney serving a separate solid fuel burning appliance. Each gas appliance must
use a separate vent system. Do not use common vent systems.
WARNING

57D0016
13
VENT INSTALLATION
VENT REQUIREMENTS
• Make sure the exhaust pipe on heater connects
to exhaust portion of cap. Attach flex liners.
See
Figure 6.
• Do not crimp or rupture liner when bending it into
chimney offsets.
WARNING
Figure 6 - Venting Unit
Exhaust
Inlet
Maximum Height
40' (12.9 M)
Minimum Height
10' (3 M)
Maximum
1' (305mm)
Offset at
Base of
Insert
• Make sure you have the following before installing
490 unit:
• 4" and 3" UL 1777 Listed gas liner for air
inlet and exhaust
• Vertical termination kit (AI42TK43A)
• Make sure you have the following before installing
380 unit:
• 3" and 3" UL 1777 Listed gas liner for air inlet and
exhaust
• Vertical termination kit (AI31TK33A)
• The exhaust vent must reline the entire length of chimney and terminate above chimney top.
• Vent must meet all vent manufacturerʼs requirements when installed.

14
57D0016
High-Temp
Silicone
High-Temp
Silicone
VENT INSTALLATION
ALTITUDE CONSIDERATIONS
This heater has been tested at altitudes ranging from sea level to 4,500 feet (USA), 0-2000 feet (Canada). In this testing,
heater with standard orifi ce burns correctly with just an air shutter adjustment. If you need to resize orifi ce for use at high
altitude, contact your dealer.
Failure to adjust air shutter properly may lead to
improper combustion which can create a safety
hazard. Consult your dealer or installer if you
suspect an improperly adjusted air shutter
WARNING
Figure 7 - Connecting Exhaust Pipe to Heater
Exhaust
(centered on unit)
Inlet
490 Unit
- 4" and 3" UL
1777 Gas Liner
380 Unit
- 3" and 3" UL
1777 Gas Liner
Termination Kit
490 Unit
- AI42TK43A
380 Unit
- AI31TK33A
Apply high-temperature silicone
to lines on both ends and
secure with two (2) screws.
(centered on unit)

57D0016
15
VENT INSTALLATION
VENT CONFIGURATIONS
Recommended block-off
plate (non-combustible
metal). Prevents
odors from chimney
entering room.
Exhaust
Any cracks or
damage inside
chimney must
be repaired.
The block-off plate
(AI42AK43 or
AI31AK33) must
seal intake to the
chimney space so
that air is drawn
down chimney for
combustion air.
Block-off Plate
- (AI42AK43 or
AI31AK331)
non-combustible
materials
Inlet
Masonry
Fireplace
NOTE: You may use either reline confi guration with a masonry or zero-clearance fi replace.
Exhaust
Inlet
Termination Kit
490 unit
- part # AI42TK43A
380 unit
- part #AI31TK33A
4" (100mm) or 3" (75mm)
Exhaust UL 1777 Gas Liner
3" (75mm) Inlet
Figure 8 - Inlet and Exhaust Reline
Figure 9 - Exhaust Only Reline
UL-127,
Solid Fuel
Z.C. fi rebox

16
57D0016
VENT INSTALLATION
MANIFOLD REMOVAL AND INSTALLATION
The manifold is shipped attached to insert. It may be removed to allow tight installation. Mani-
fold may be loosened and rotated for desired pipe location.
1. Remove brick liner and baffl e.
2. Remove manifold. Place manifold
in fi replace.
3. Route fl ex vent through chimney
from above.
See Figure 10.
Leave
an extra 3" (914mm) at the top.
4. Attach fl ex vent to manifold.
See
Figure 11.
Seal with silicone and
attach with screws.
5. Place manifold in an upright
position. Have someone pull
on the excess fl ex vent.
Figure
12.
Temporarily attach fl ex vent
to top of chimney. Leave some
extra slack in fl ex vent.
6. Slide insert into place. Guide
the manifold over the insert
until it is fully in place.
Figure 13.
7. Remove any slack from fl ex
vent. Attach manifold to insert.
Figure 13.
8. Remove any excess slack in
fl ex line. Attach vent termina-
tion.
Figure 13.
Figure 12 - Pulling On
Excess Flex Vent
Figure 13 - Sliding Insert
Into Place
Manifold
Chimney
Figure 10 - Placing
Manifold Into Fireplace
Figure 11 - Attaching
Flex Vent to Manifold
Flex Vent
Extra 3"
(914mm)
Manifold
Flex Vent
Chimney
Manifold
Chimney
Excess
Flex Vent
Slack in
Flex Vent
Manifold
Bracket
Nut
Insert
Excess Slack Taken
Out of Flex Vent
Vent
Termination
Chimney
Chimney
Chimney
9. Replace
baffl e and
brick liner.
Bracket
Nut

57D0016
17
Figure 14 - External Regulator with Vent Pointing
Down (Propane/LP Only)
Use only new black iron or steel pipe.
Internally tinned copper or copper
tubing can be used per National
Fuel Code, section 2.6.3, providing
gas meets hydrogen sulfide limits,
and where permitted by local codes.
Gas piping system must be sized to
provide minimum inlet pressure (listed
on data plate) at the maximum fl ow rate
(BTU/hr). Undue pressure loss will
occur if the pipe is too small.
CAUTION
INSERT INSTALLATION
CHECK GAS TYPE
Use proper gas type for the insert you are installing. If you have confl icting gas type, do not install insert. See dealer where
you purchased the insert for proper insert according to your gas type.
INSTALLING GAS PIPING TO INSERT LOCATION
For propane/LP units, never connect insert directly to the propane/LP supply. This
burner system requires an external regulator (not supplied). Install the external regulator
between the burner system and propane/LP supply.
CAUTION
A qualifi ed installer or service person
must connect appliance to gas supply.
Follow all local codes.
WARNING
INSTALLATION ITEMS NEEDED
Make sure you have the items listed below before installing appliance.
• External regulator (supplied by installer) • Piping (check local codes) • Sealant (resistant to propane/LP gas)
• Test gauge connection* • Sediment trap (optional but recomended)
• Tee joint • Pipe wrench
• approved fl exible gas line with gas connector (if allowed by local codes — not provided)
* A CSA design-certifi ed equipment shutoff valve with
1
/
8
" NPT tap is an acceptable alternative to test gauge connection.
Purchase the CSA design-certifi ed equipment shutoff valve from your dealer.
For propane/LP connections only, the installer must supply an external regulator. The external regulator will reduce incoming
gas pressure. You must reduce incoming gas pressure to between 11 and 13 inches of water. If you do not reduce incoming
gas pressure, burner system regulator damage could occur. Install external regulator with the vent pointing down as shown
in
Figure 27.
Pointing the vent down protects it from freezing rain or sleet.
External
Regulator
100 gal. (min)
Propane/LP
Supply Tank
Vent
Pointing
Down
100 gal. (min)
Regulator
When using copper or flex connectors use only fittings
approved for gas connections. The gas control inlet is
3
/
8
" NPT.

18
57D0016
3" Minimum
INSERT INSTALLATION
A listed manual shutoff is factory installed upstream of appliance. Union tee and plugged
1
/
8
" NPT pressure tapping point
should be installed upstream of the appliance.
See Figure 15.
IMPORTANT: The main gas valve is for turning on or shutting off the gas to the insert.
Check your building codes for any special requirements for
locating equipment shutoff valve to inserts.
Apply pipe joint sealant lightly to threads. This will prevent
excess sealant from going into pipe. Excess sealant in pipe
could result in clogged burner system valves.
A manual shutoff valve is factory
installed upstream of the appliance.
Union tee and plugged
1
/
8
" NPT
pressure tapping point should be
installed upstream of the appliance.
See Figure 15.
CAUTION
Use pipe joint sealant that is resistant
to liquid petroleum (LP) gas.
CAUTION
We recommend that you install a sediment trap/drip leg in supply line as shown in
Figure 15
. Locate sediment trap/drip
leg where it is within reach for cleaning. Install in piping system between fuel supply and burner system. Locate sediment
trap/drip leg where trapped matter is not likely to freeze. A sediment trap traps moisture and contaminants. This keeps them
from going into the burner system gas controls. If sediment trap/drip leg is not installed or is installed wrong, burner system
may not run properly.
Figure 15 - Gas Connection
Tee Joint
Pipe Nipple
Cap
Approved Flexible
Gas Line Supplied
with Appliance
Sediment Trap/Drip Leg
Natural Gas
From Gas Meter
(4.5" W.C. to 10.5" W.C. Pressure)
Propane/LP
From External Regulator
(11" W.C. to 13" W.C. Pressure)
NOTE : The gas line connection may be made using
1
/
1/ 1
2
/2/
" rigid tubing or an approved fl ex connector. Since
some municipalities have additional local codes it is always best to consult your local authorities
and the current edition of the National Fuel Gas Code ANSI.Z223.1, NFPA54. In Canada CAN/CGA-
B149 (1 or 2) Installation Code.
Only persons licensed to work with
gas piping may make the necessary
gas connections to this appliance.
WARNING

57D0016
19
CHECKING GAS PRES SURE
1. Check gas type. The gas supply must be the same as
stated on the applianceʼs rating decal. If the gas supply
is different from the fi replace, STOP! Do not install
the appliance. Contact your dealer immediately.
2. Install and attach 30" (762mm) fl ex line provided with
on this appliance to
1
/
2
" gas line.
3. After completing gas line connection, purge air from
gas line and test all gas joints from the gas meter to
the fi replace for leaks. Use a soap and water solution
or a gas sniffer.
4. To adjust fl ame height, turn HI/LO knob to HI to get
maximum pressure to burner. Turn HI/LO knob to LO
to get minimum pressure.
5. To check gas pressures at valve, turn captured screw
counter clockwise 2 or 3 turns and then place tubing to
pressure gauge over test point. Turn unit to high.
See
Figure 16.
After taking pressure reading, be sure and
turn captured screw clockwise fi rmly to reseal. Do not
over torque. Check test points for gas leaks with a soap
and water solution or an electronic gas leak detector.
Do not use open fl ame to check for
gas leaks.
WARNING
Figure 16 - Gas Pressure Check at Gas Valve
Pressure
Test “IN”
Pressure
Test “OUT”
HI/LO
Knob
Test “IN”
Pilot Adjustment
Screw

20
57D0016
ON OFF
PILOT HI
LO
ON
OFF
TH
TP
TH/TP
ON
OFF
Optional
15’ Wall Switch
ON
OFF
Optional
Remote Control
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




REMOTE WALL MOUNTED SWITCH
A remote wall switch and up to fi fteen (15) feet of 18 Ga. wire may be used with this appliance. Attach the wall switch in a
junction box at the desired location on the wall.
See Figure 17
.
NOTE:
Extended lengths of wire may cause the fi replace not to function properly. Longer length of wire
is permitted if the wire is made out of larger gauge (diameter) wire. Always check with local
code.
Figure 17 - Wiring Diagram for Wall Switch
ELECTRICAL INSTALLATION
ELECTRICAL WIRING
Electrical connections should only be performed by a qualifi ed, licensed electrician.
Main power must be off when connecting to main electrical power supply or performing
service. All wiring shall be in compliance with all local, city, and state codes. The
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 (latest edition)
and
Canadian Electrical Code, CSA C22.1.
WARNING
Label all wires before disconnecting when servicing controls. Wiring errors can cause
improper and dangerous operation.
CAUTION
Verify proper operation after servicing.
This insert will work without any electrical supply. Electricity is only needed to operate blower.