Monessen Hearth Unvented Vent-Free Fireboxes BUF400 User manual

For use with a listed gas-fired
unvented decorative room heater
not to exceed 40,000 BTU/hr. Do
Not Build a Wood Fire.
READ AND SAVE THESE INSTRUCTIONS
WARNINGS
If the information in this manual 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.
– Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
MODELS:
BUF400
BUF500
UNVENTED VENT-
FREE FIREBOXES
INSTALLATION AND OPERATING
INSTRUCTIONS
Carefully review the instructions
supplied with the decorative type
unventedroomheaterforthemini-
mum fireplace size requirement.
DO NOT INSTALLANAPPLIANCE
IN THIS FIREBOX UNLESS THIS
FIREBOX MEETS THE MINIMUM
DIMENSIONS REQUIRED FOR
THE INSTALLATION.
WARNINGS
If the information in this manual 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.
– Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
WARNINGS

2 61D1013
CONTENTS
Important Safety Information ................................. 3
Product Features......................................................5
Before You Start.....................................................5
General Installation Information .............................6
Firebox External Dimensions.................................6
Minimum Hearth Dimensions.................................7
Location of Fireplace ...............................................7
Clearances and Height Requirements....................8
Fireplace Framing...................................................10
Gas Line Installation ..............................................12
Canopy and Radiant Face Plates Installation......13
Other Optional Equipment.....................................14
Forced Air Kit .......................................................14
Brass or Chrome Louvers....................................14
Brass or Chrome Trim..........................................14
Firebrick...............................................................14
Optional Wide Canopy.........................................14
Illustrated Parts Breakdown..................................15
Warranty..................................................Back Cover

61D1013 3
9. The installation must conform with local codes or, in
the absence of local codes, with the National Fuel Gas
Code, ANSI Z223.l/NFPA54.
10. This unit complies with ANSI Z21.91.2001 ventless fire-
box enclosures for gas-fired unvented decorative room
heaters.
11. Do not install heater in a bathroom or bedroom.
12. Correct installation of the ceramic fiber logs, proper
location of the heater, and annual cleaning are necessary
to avoid potential problems with sooting. Sooting,
resulting from improper installation or operation,
can settle on surfaces outside the fireplace. See log
placement instructions for proper installation.
13. Avoid any drafts that alter burner flame patterns. Do not
allow fans to blow directly into fireplace. Do not place
a blower inside burn area of firebox. Ceiling fans may
create drafts that alter burner flame patterns. Sooting
and improper burning will occur.
14. Caution: Candles, incense, oil lamps, etc. produce
combustion byproducts including soot. Vent-free
appliances will not filter or clean soot produced by
these types of products. In addition, the smoke and/or
aromatics (scents) may be reburnt in the vent-free
appliance which can produce odors. It is recommended
to minimize the use of candles, incense, etc. while the
vent-free appliance is in operation.
15. An unvented gas-fired heater uses air (oxygen) from the
room in which it is installed. Provisions for adequate
combustion and ventilation air must be provided. See
installation guidelines.
INSTALLER
Please leave these instructions with the appliance.
OWNER
Please retain these instructions for future reference .
IMPORTANT
Read these instructions carefully before installing or trying to operate a vent-free gas heater in this firebox.
IMPORTANT SAFETY INFORMATION
1. Due to high temperatures, the appliance should
be located out of traffic and away from furniture
and draperies.
2. Children and adults should be alerted to the hazard
of high surface temperature and should stay away
to avoid burns or clothing ignition.
3. Young children should be carefully supervised
when they are in the same room with the apli-
ance.
4. Do not place clothing or other flammable material
on or near the appliance.
5. Any safety screen or guard removed for servicing
an appliance, must be replaced prior to operating
the heater.
6. Installation and repair should be done by a qualified
service person.
7. To prevent malfunction and/or sooting, an unvented
gas heater should be cleaned before use at least
annually by a professional service person. More
frequent cleaning may be required due to exces-
sive lint from carpeting, bedding material, etc. It is
imperative that control compartments, burners and
circulating air passageways be kept clean.
8. CARBON MONOXIDE POISONING: Early signs of
carbon monoxide poisoning are similar to the flu with
headaches, dizziness and/or nausea. If you have these
signs, obtain fresh air immediately. Have the heater
serviced as it may not be operating properly. Continued on page 4
• Any change to this heater or its controls can be dangerous.
• Improper installation or use of the heater can cause serious injury or death from fire,
burns, explosion or carbon monoxide poisoning.
• Do not allow fans to blow directly into the fireplace. Avoid any drafts that alter
burner flame patterns.
• Do not use a blower insert, heat exchanger insert or other accessory, not approved
for use with this heater where applicable.
WARNING

4 61D1013
IMPORTANT SAFETY INFORMATION
Continued from page 3
16. Keep room area clear and free from combustible materi-
als, gasoline and other flammable vapors and liquids.
17. Unvented gas heaters are a supplemental zone heater.
They are not intended to be a primary heating appli-
ance.
18. Unvented gas heaters emit moisture into the living area.
In most homes of average construction, this does not pose
a problem. In houses of extremely tight construction,
additional mechanical ventilation is recommended.
19. During manufacturing, fabricating and shipping, various
components of this appliance are treated with certain
oils, films or bonding agents. These chemicals are not
harmful but may produce annoying smoke and smells
as they are burned off during the initial operation of the
appliance; possibly causing headaches, or eye or lung
irritation. This is a normal and temporary occurrence.
The initial break-in operation should last two to three
hours with the burner at the highest setting. Provide
maximum ventilation by opening windows or doors to
allow odors to dissipate. Any odors remaining after this
initial break-in period will be slight and will disappear
with continued use.
20. Input ratings are shown in BTU per hour and are for
elevations up to 2,000 feet. For elevations above 2,000
feet, input ratings should be reduced 4 percent for each
1,000 feet above sea level. Refer to the National Fuel
Gas Code.
21. The appliance and its appliance main gas valve must be
disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
excess of 1/2 psig (3.5 kPa).
22. The appliance must be isolated from the gas supply
piping system by closing its equipment shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 psig
(3.5 kPa).
23. Do not use this room heater if any part has been under
water. Immediately call a qualified service technician
to inspect the room heater and to replace any part of the
control system and any gas control which has been under
water.
24. Never burn solid fuels in a fireplace where a unvented
room heater is installed.
25. Always have a fireplace screen in place when the appli-
ance is in operation, and unless other provisions for
combustion air are provided, the screen shall have an
opening(s) for induction of combustion air.
26. Do not fill spaces around the firebox with insulation or
other materials. These spaces must be maintained to pre-
vent the firebox from coming in contact with combustible
materials.
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.
Never connect unit to private
(non-utility) gas wells. This
gas is commonly known as
wellhead gas.
WARNING

61D1013 5
The BUF400 and BUF500 are vent-free fireboxes and feature a self contained heat-circulating system. This unit also features
a 2-in1, flexible-face system that converts the circulating system into a radiant system in seconds.
This installation manual will enable you to obtain a safe, efficient and dependable installation of your vent-free
fireplace system.
Do not alter or modify the firebox or its components under any circumstances. Any modification or alteration of the firebox
system, including but not limited to the firebox and accessories, may void the warranty, listings and approvals of this system
and could result in an unsafe and potentially dangerous installation.
BEFORE YOU START
Carefully inspect the contents for shipping damage. If any parts are missing or damaged, immediately inform the
dealer from whom you purchased the appliance. Do not attempt to install any part of the appliance unless you have
all the parts in good condition.
MAKE SURE YOU HAVE RECEIVED ALL PARTS
Check your packing list to verify that all listed parts have been received. You should have the following:
1. Vent-Free Gas Firebox 3. Five (5) sheet metal screws for canopy
2. Canopy 4. Installation and Operating Instructions
WHAT YOU WILL NEED FOR INSTALLATION
TOOLS BUILDING SUPPLIES
• Phillips screwdriver • Square • Framing materials
• Hammer •
Piping complying with local codes • Wall finishing materials
• Saw and/or sabersaw • Tee joint • Caulking material (noncombustible)
• Level • Pipe wrench • Fireplace surround materials (noncombustible)
• Measuring tape • Pliers
• Electric drill and bits • Pipe sealant approved for use with propane/L.P.G. (resistant to sulfur compounds)
Refer to the installation instructions provided with the log sets for items required for log set installation.
PRODUCT FEATURES
Do not attempt to burn solid wood fuels, vented gas log sets, or any other combustible
in this unvented firebox. Also, do not install a vent-free gas log set in this firebox
if the minimum clearance and height requirements of the log set are too large
for the firebox.
WARNING
Illustrations shown in this manual reflect “typical” installations with nominal dimensions
and are for design and framing reference only. Actual installations may vary due to
individual design preferences. However, always maintain minimum clearances to
combustible materials and do not violate any specific installation requirements.
NOTICE

6 61D1013
BUF400: 2413/16"
23/16"
69/16"
103/8"
147/16"
BUF400: 40"
BUF400: 36"
241/4"
61/2"
219/16"
21"
34"
6"
2"
BUF500: 3013/16"
BUF500: 46"
BUF500: 42"
In planning the installation for the appliance it is necessary to determine where the unit is to be installed and whether optional
accessories are desired. Gas supply piping should also be planned. The following steps represent the normal sequence of
installation. Each installation is unique, however, and might require a different sequence.
1. Position firebox prior to framing or into prepared framing.
2. Field wire main power supply to models with fan kit. (Electrical connections should only be performed by an experi-
enced, licensed /certified tradesman). Electrical outlet is needed with fan kit.
3. Plumb gas line. (Gas connections should only be performed by an experienced, licensed/certified tradesman).
4. Install vent-free gas log heater per the instructions provided with the vent-free gas log heater.
5. Complete finish wall material, surround and optional hearth extension to your individual taste.
FIREBOX EXTERNAL DIMENSIONS
GENERAL INSTALLATION INFORMATION
Figure 1 - Firebox Dimensions

61D1013 7
17"
21
1
/
2
"
BUF400: 35
1
/
2
"
BUF400: 203/8
"
BUF500: 263/8"
BUF500: 41
1
/
2
"
Figure 3 - Location of Firebox
MINIMUM HEARTH DIMENSIONS
GENERAL INSTALLATION INFORMATION
Figure 2 - Minimum Hearth Dimensions
Carefully select the best location for installation of your vent-free
firebox. The following factors should be taken into consider-
ation:
• Clearance to side wall, ceiling, woodwork and windows.
See “Clearances/Height Requirements on page 8. Minimum
clearances to combustibles must be maintained.
• Location must not be affected by drafts caused by kitchen
exhaust fans, ceiling fans, return air registers for forced air
furnaces / air conditioners, windows or doors.
• Installation must provide adequate ventilation and combus-
tion air.
• DO NOT INSTALL THIS FIREBOX IN A BEDROOM
OR BATHROOM.
• Location should be out of high traffic or windy or drafty
areas.
• DO NOT INSTALL WHERE CURTAINS, FURNITURE,
CLOTHING OR OTHER FLAMMABLE OBJECTS ARE LESS THAN 42" FROM FRONT OF HEATER.
• Never obstruct the front opening of the vent-free firebox or restrict the flow of combustion and ventilation air.
• Minimize modifications to existing construction. Refer to Figure 3 below for location suggestions.
• Do not install in the vicinity where gasoline or other flammable liquids may be stored. The vent-free firebox must be
kept clear and free from these combustible materials.
LOCATION OF FIREBOX

8 61D1013
9"
Minimum
42"
Minimum
9"
Minimum
Ensure that minimum clearances shown in Figures 4 through 7 are maintained. Left and right clearances are determined
when facing the front of the firebox.
Follow these instructions carefully to ensure safe installation. Failure to follow these requirements may create a
fire hazard.
1. Sidewall clearances: The clearance from the inside of the appliance to any combustible wall should not be
less than 9". See Figure 4.
2. Ceiling clearance: The ceiling must be at least 42” from the top of the firebox opening. See Figure 4.
3. Back wall clearnace: The appliance may be placed against a combustible back wall.
Figure 4 - Clearance and Height Requirements
Continued on page 10
CLEARANCES AND HEIGHT REQUIREMENTS

61D1013 9
12"
10"
8"
6"
21/2"
12"16" 19"21"23"
CLEARANCES AND HEIGHT REQUIREMENTS
4. Mantel clearances: The canopy supplied with the unit must
be installed. If a combustible mantel is installed, it must meet
the clearance requirements as shown in Figure 5. However,
if lower mantel height is desired, refer to page 14 for canopy
options.
5. Floor clearance: This inner chamber firebox floor must be installed at least 5" above any combustible flooring mate-
rial, such as carpeting or asphalt tile, which is closer than 14" to the base of the firebox. See Figure 6.
Or
The inner chamber firebox floor may be installed nearer to the floor if a minimum of 14" of noncombustible material
such as slate or marble is installed between the base of the firebox and the combustible flooring. See Figure 7.
Figure 5 - Mantel Clearances
Figure 6 - Minimum Clearance above
Combustible Flooring
Figure 7 - Minimum Clearance above Combustible
Flooring with Non-Combustible Material Installed at
Base of Fireplace
Non-Combustible
Material
5" Minimum 14" Minimum
Can Be
Less than 5" Non-Combustible
Material

10 61D1013
201/2"
331/16"
400: 401/4"
129/16"
400: 66"
400: 2413/16"
41
3
/
4
"
500: 3013/16"
500: 461/4"
500: 72"
400: 2413/16"
400: 401/4"1/2" or 5/8"
203/4"
500: 3013/16"
500: 461/4"
341/4"
400: 401/4"
500: 461/4"
400: 2413/16"
203/4"
400: 403/4"1/2" or 5/8"
500: 3013/16"
500: 463/4"
FIREPLACE FRAMING
Firebox framing can be built before or after the appliance is set in place. Construct firebox framing following Figures 8
through 11 and the chart below for your specific installation requirements. See Figure 1 on Page 6 for firebox dimensions.
The framing headers may rest on the top of the firebox 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.
Figure 8 - Corner Installation
Figure 10 - Stud Location
Figure 9 - Inside Chase Installation
Figure 11 - Recessed Installation
Do not fill spaces around firebox with insulation or other materials. This could cause
a fire.
WARNING

61D1013 11
FIREPLACE FRAMING
1. Bend out the nailing flanges located on each side of the firebox.
2. Slide the firebox into prepared framing or position firebox in its final position and frame later.
3. Level the firebox by checking the top edge of the firebox. Shim if necessary.
4. Anchor firebox to the side framing members using 8d nails or other suitable fasteners. See Figure 12.
5. The canopy must be installed for safe operation of the heater. See page 13 for canopy installation details.
Figure 12 - Location of Nailing Flanges
Nail Sides
Through Nailing
Flanges
The fireplace must be installed giving
full consideration to the clearance
and height requirements identified in
this manual.
WARNING

12 61D1013
GAS LINE INSTALLATION
Consult all local codes. All gas piping must be installed to comply with local codes, or in the absence of local codes, with
the latest edition of the National Fuel Gas Code ANSI Z223.1/NFPA54.
Remove the baseplate for ease of gas line installation. Remove three (3) screws along the front edge of the baseplate.
Remove four (4) screws which secure the baseplate to the combustion casing (two at rear and one along each side).
Replace baseplate prior to connecting gas line to heater. Consult heater installation and operating instructions for correct
installation of the heater into the firebox.
The 1/2" gas line may enter either from the left side or right side of the firebox. Gas access holes are provided on
both sides of the firebox.
Install a 1/2" gas line through the hole provided in the firebox. Outside the firebox, the gas line connects to a gas shut-off valve
recessed flush into the wall or floor. The valve should be controlled by a removable valve key for safety.
An ANSI approved manual shut-off valve, union and plugged 1/8" NPT pressure tapping point must be installed
upstream of the heater.
A sediment trap may be upstream of the heater to prevent moisture and contaminants from passing through trap to the heater
controls and burners. Failure to do so could prevent the heater from operating reliably. Consult applicable codes.
An external regulator must be used on all propane / L.P.G. heaters, in addition to the regulator fitted to the heater,
to reduce the supply tank pressure to 13" w.c. (maximum). Any copper tubing used to supply propane / L.P.G. from
the tank must be internally tinned.
Note: When connecting propane / L.P.G. vent-free room heaters, you must use pipe sealant resistant
to propane / L.P.G.
Important: Hold heater regulator with a wrench to prevent movement when connecting to inlet piping.
Check gas type: The gas supply must be the same as stated on the heater’s rating plate. If the gas supply
is different, DO NOT INSTALL THE HEATER. Contact your dealer for the correct model.
After completing connection, test all gas joints from the gas meter to the gas heater regulator for leaks. Using soap and
water solution or a gas sniffer. DO NOT USE AN OPEN FLAME.
Plumbing connections should only be performed by a qualified, licensed plumber.
Main gas supply must be off when plumbing gas line to fireplace or performing
service.
WARNING
Connecting directly to an unregulated
propane / L.P.G. tank can cause an
explosion.
WARNING
Do not connect directly to natural gas 1/2 PSI or 2 PSI systems. Always make sure
natural gas pressure is regulated 10.5 w.c. (maximum before operating the unit).
WARNING

61D1013 13
CANOPY INSTALLATION
INSTALLING CANOPY
A canopy is furnished with each firebox and MUST be installed for safe operation. See Figure 14.
1. Locate three (3) holes at the top of the front frame. See Figure 13.
2. Align the canopy with the holes in the top of the frame.
3. Secure canopy to front of frame with screws provided. See Figure 13.
The firebox canopy must not be
modified or replaced with a canopy
that maybe providedwith theunvented
decorative room heater.
WARNING
Close fireplace screen panel before
operating a decorative type unvented
room heater.
WARNING
Figure 13 - Installing Canopy
Canopy
Screws
Front
Frame

14 61D1013
OPTIONAL EQUIPMENT
FORCED AIR KIT (FA2A)
If you are installing the forced air kit, Model FA2A, see the installation instructions provided with the kit for electrical
wiring requirements, or the blower installation section. The firebox must be connected to main power supply at time of
firebox installation. The blower must be installed prior to the installation of the vent-free heater. The electrical connec-
tions must be made before the firebox is framed and enclosed in the finished walls.
Electrical connections should only be performed by a qualified, licensed electrician,
main power must be off when connecting to main electrical power supply or
performing service.
The blower 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.
WARNING

61D1013 15
1
2
3
3
ILLUSTRATED PARTS LIST
ITEM DESCRIPTION QTY BUF400 BUF500
1 Canopy 1 26D4568 26D4706
2 Screen Panel 2 26D0131 26D0187
3 Screen Rod 2 26D0132 26D0133
4 Rear Refractory 1 61D0102 61D0107
5 Side Refractory 2 61D0101 61D0101
6 Bottom Refractory 1 61D0100 61D0106

April 2006 P/N 61D1013 • Rev. 3
MONESSEN HEARTH SYSTEMS
LIMITED LIFETIME WARRANTY POLICY
The following components are warranted for life to the original owner, subject of proof of purchase: Firebox,
Combustion Chamber, Heat Exchanger, Grate, and Stainless Steel Burners.
FIVE YEAR WARRANTY
The following components are warranted for 5 years to the original owner, subject of proof of purchase: Vent
Free Ceramic Fiber Logs, Catalytic Filter and Aluminized Burners.
BASIC WARRANTY
Monessen Hearth Systems (MHS) warrants the components and materials in your gas appliance to be free from
manufacturing and material defects for a period of two years from date of installation. After installation, if any of
the components manufactured by MHS in the appliance are found to be defective in materials or workmanship,
MHS will, at its option, replace or repair the defective components at no charge to the original owner. MHS
will also pay for reasonable labor costs incurred in replacing or repairing such components for a period of
two years from the date of installation. Any products presented for warranty repair must be accompanied
by a dated proof of purchase.
This Limited Lifetime Warranty will be void if the appliance is not installed by a qualified installer in accordance
with the installation instructions. The Limited Lifetime Warranty will also be void if the appliance is not operated
and maintained according to the operating instructions supplied with the appliance, and does not extend to (1)
firebox/burner assembly damage by accident, neglect, misuse, abuse, alteration, negligence of others, including
the installation thereof by unqualified installers, (2) the costs of removal, reinstallation or transportation of
defective parts on the appliance, or (3) incidental or consequential damage. All service work must be performed
by an authorized service representative.
This warranty is expressly in lieu of other warranties, express or implied, including the warranty of merchantability
of fitness for purpose and of all other obligations or liabilities. Monessen Hearth Systems, Inc. does not
assume for it any other obligations or liability in connection with the sale or use of the appliance. In states
that do not allow limitations on how long an implied warranty lasts, or do not allow exclusion of indirect
damage, those limitations of exclusions may not apply to you. You may also have additional rights not covered
in this Limited Lifetime Warranty.
MHS reserves the right to investigate any and all claims against the Limited Lifetime Warranty and decide
upon method of settlement.
For information about this warranty, contact:
Technical Services
Monessen Hearth Systems
149 Cleveland Drive
Paris, Kentucky 40361