Rasmussen RPK3-N Owner's manual

12028 E. Philadelphia St. Whittier , CA 90601 U.S.A.
[phone] FAX [phone]
[e-mail] www.rasmussen.biz
RPK3-
N
/
P
REV: RPK3 0608
Assembly, Installation, and Operation Instructions for RPK3-N/P for use with 15" to 30" F, FX, CS
(Natural Gas) or FA, FA-X, CA (Propane Gas) Burners
ATTENTION! READ INSTRUCTIONS CAREFULLY BEFORE ASSEMBLY.
Required Tools and Materials: Adjustable Wrench, Pipe Wrench, Screw Driver, Phillips Screw Driver, Pipe sealing
compound (only required if fittings not already prepared with pre-wrapped Teflon thread tape).
RPK3 Parts List: (Note: Assembly of this accessory also requires fittings included with the Burner Pan)
All Models:
• Valve
• Pilot Thermogenerator with
pilot tubing and thermopile
leads.
• Pilot Support bracket
• Heat Shield
• 10" Aluminum Connector
• 20' length wire (20 AWG
Type CL2)
• Fittings:
1 3/8 Flared x 3/8 MIP
1 3/8 Flared x 3/8 FIP
elbow
1 3/8 MIP x 3/8 FIP elbow
• Fasteners:
1 10-32 x 3/8 nut
3 10-32 x 3/8 bolts
LP Gas Models ("-P")
• 3 Burner orifices (#45, #49
and #53)
• 1 1/2 x 3/8 Air Mixer
Suggested Firebox Layout and Required Parts: Pilot Control Valves are adversely effected by heat. The best
protection is afforded by placing safety control valve assembly outside the firebox (Figure 1). If the valve is placed
inside firebox, it must be placed as far forward and to the side of the burner pan as possible (Figure 2).
NOTE: If it is not possible to enclose the control valve inside a separate vault the valve must be shielded from heat
and fire. Use the provided Heat Shield and position the valve to prevent direct heat radiation to the control valve.
Heat shields can also be constructed of brick and/or metal with fiberglass insulation material. The design of the
shield should prevent direct heat radiation to the control valve.
FIREBOX
Valve Vault
(Min: 12x8x8)
Conduit for Pilot
Tubing and Wire
1/2" Threaded Black Pipe
(Gas Supply) Gas Supply
Shut-Off Valve
Wire from
Valve to
Controller
RPK3 Valve Placement
Options
(as viewed from above)
Valve Assembly
outside firebox.
Forward and to the Side
of the burner pan.
RPK3 Gas
Valve
Gas Supply
Shut-Off Valve
Burner Pan
Figure 1 Figure 2
ASSEMBLY: (Note: If fittings do
not come pre-wrapped with
Teflon threaded tape, pipe
compound must be applied to
the non-flared input threads).
STEP ONE: Burner Pan Fittings
(Figure 3).
1. Ensure that Burner Plug
(provided with Burner Pan) is
inserted into opposite end of
burner pipe (see Burner Pan
Instructions) and wrench tighten.
2. Thread the NAT Gas or LP Gas
Burner Pan Inlet Assembly
into burner pan.
Burner orifice
Air Mixer Internally Tapped 3/8
flared x 3/8 MIP elbow
Burner Pan Tube
Figure 3
Burner Plug
Internally Tapped 3/8
flared x 3/8 MIP elbow
Burner orifice
NAT LP
Burner Orifice Orifice
18" #36 #53
24" #29 #49
30" #29 #45
LP GAS BURNER INLET
ASSEMBLY (MA-2)
NAT GAS BURNER
INLET ASSEMBLY
• Natural Gas Burners (F, FX, CS) Insert the appropriate Burner Orifice (see chart at Figure 3) into the Internally
Tapped 3/8 Flared x 3/8 MIP Elbow and wrench tighten. (Orifice and Fitting are provided with Burner Pan).
• Propane Gas Burners (FA, FA-X, CA) requires MA-2 Air Mixer Assembly (see Figure 3). Insert the appropriate
Burner Orifice (see chart at Figure 3) into the Internally Tapped 3/8 Flared x 3/8 MIP Elbow and wrench tighten.
Thread the Air Mixer onto the 3/8 Flared x 3/8 MIP Elbow and wrench tighten with air intake holes positioned
horizontally (parallel to the floor).
1

STEP TWO: Attach Pilot (Figure 4).
1. With the Pilot Thermo-generator beneath the Pilot Support Bracket, insert the 10-32 Bolts through the pre
drilled-holes in Pilot Support Bracket into the threaded holes of the Pilot Thermogenerator Assembly. Tighten
with Screw driver.
2. Insert 10-32 Bolt through the Pilot Support Bracket and pre-drilled hole in back of Burner Pan (side of CS/CA
pan-see "CS/CA Burner Pan Side View" at Figure 4). Thread 10-32 Nut onto the 10-32 Bolt and tighten. Ensure
that Pilot Burner is centered over Burner Tube.
3. Route Pilot Tubing and Thermopile Leads to Control Valve location.
Burner Tube
Center Line
Thermogenerator
Pilot Burner
Pilot Support
Bracket
Pilot
Thermogenerator
Assembly
10-32 Bolts
10-32 Nut
CS/CA Burner
Pan (Side View)
Pilot Support
Bracket (CS)
Fi
g
ure 4
Pilot Tubing and
Thermopile Leads
F/FA/FX/FAX Burner Pan
(Top View)
STEP THREE: Valve Fittings (Figure 5).
IN
3/8 flared x
3/8 MIP
elbow
3/8 MIP x
3/8 FIP elbow
3/8 flared x
3/8 MIP
Pilot Input
Valve Inlet
Valve Outlet
Figure 5
1. Thread 3/8 Flared x 3/8 MIP fitting into inlet side of valve and wrench tighten.
2. Thread 3/8 MIP x 3/8 FIP Elbow into outlet side of valve and wrench tighten.
3. Thread non- tapped 3/8 Flared x 3/8 MIP Elbow into valve outlet 3/8 MIP x 3/8 FIP elbow. Wrench tighten.
IN
Pilot Tubing
10" Aluminum
Connector
VALVE
Pilot Input
Fitting
Thermopile Leads
Valve Outlet 3/8
Flared x 3/8 MIP
Elbow
Burner Inlet 3/8
Flared x 3/8 MIP
Elbow
Figure 6
STEP FOUR: Connect Burner and Pilot Gas Supply
(Figure 6).
1. Connect 10" Aluminum Connector between the
flared ends of the valve output 3/8 flared x 3/8 MIP Elbow
and the burner input 3/8 flared x 3/8 MIP Elbow. Bend
the 10" Aluminum Connector to obtain the optimum
Valve position (forward and to the side of the burner pan).
2. Thread (using no pipe compound) the JPG-9 Pilot
Input Fitting into valve Pilot Input and wrench tighten.
From Thermopile Valve
Terminal Block
Figure 7
"Outside"Terminals"
Accessory Remote
Connection
To Accesory
Controller
STEP FIVE: Connect Thermopile and Controller
Wiring:
1. Attach the JPG-9 Thermogenerator Leads to the
"TH-TP" and Center terminal of valve. See Figures 6 and 7.
2. Connect the Accessory Wiring (tab ends) to the two
outside terminals of the Valve Terminal Block as
shown in Figure 7.
CAUTION: This is a millivolt system. DO NOT connect to 115 V line. Safety controls damaged by heat or
115 volt electricity are not covered by warranty.
NOTE: Thermostat wiring is 20 AWG Type CL2. Electrical resistance for wire lengths greater than 20 feet
may exceed the Thermogenerator’s ability to operate correctly.
2

STEP SIX: Install Heat Shield.
Heat Shield
Figure 6
CAUTION! Heat Shield Must Be Installed To Prevent
Premature Valve Failure And/Or Voiding Of Valve
Manufacturer's Warranty
1. Insert the notched portion of the Heat Shield between
the Valve outlet 3/8 MIP x 3/8 FIP Elbow and the 3/8 Flared x
3/8 MIP Elbow (Figures 6 and 7). Ensure that the Heat
Shield is over the VALVE ASSEMBLY. Pilot tubing and wire
leads should be behind the shield exiting towards the rear.
VALVE
Heat
Shield
(Top
View)
Fi
g
ure 7
CAUTION: The safety control valve must be protected to a max ambient temperature of 175° F.
Excessive heat to the valve is indicated by melted plastic on the valve body.
STEP SEVEN: Connecting Accessory Controller:
Using the 20' accessory control wiring attached to the two outside terminals of the Valve Terminal Block (see Figures
6 and 7), connect the Switch Control Accessory Option (Remote, Thermostat, Switch, etc.) to valve.
Switch Control Accessory Options:
ULTRA-SONIC WIRELESS REMOTE (Model "F10-AB)
INFRARED WIRELESS REMOTE WITH THERMOSTAT (Model "IRRC")
WALLSWITCH (Model"WS-1")
WALL THERMOSTAT (Model "TS-1")
WALL TIMER (60 MINUTE TIMER) (Model "WT-1")
CRACKLER Sound Generator option for F10 AB or IRRC (Model "CF5")
• Accessory REMOTE LOG HOUSE (Model "RH") is available for use as a heat resistant "log" in which the receiver portion of
Wireless remote option F10 AB or IRRC may be located.
• Accessory CRACKLER LOG HOUSE (Model "CH") is available for use as a heat resistant "log" in which the CRACKLER
Sound Generator option for both the F10 AB and IRRC wireless remotes may be located.
LIGHTING
CAUTION! DAMPER AND GLASS DOORS MUST BE FULLY OPEN BEFORE LIGHTING OR BURNING FOR
PROPER VENTILATION AND TO PREVENT HEAT DAMAGE TO VALVE.
THE FLUE MUST VENT ALL PRODUCTS OF COMBUSTION.
F, FX & CS burners use Natural Gas. Fill Burner Pan with the white sand provided with burner.
FA, FA-X & CA burners use LP Gas. Fill Burner Pan with black volcanic ash provided with burner.
STEP ONE: Pilot Lighting:
NOTE: The Gas Dial has complete control of gas to pilot and burner. The Gas Dial cannot be turned to "OFF" without first
depressing dial in "PILOT" position and then rotating clockwise to "OFF". (see Figure 8)
1. Depress and turn Gas Dial to "OFF" position. (Figure 8)
2. Set Accessory Control to "OFF" (Remote Control) or to lowest temperature setting (Thermostat)
3. Wait at least 5 minutes to allow gas which may have accumulated around burner to escape.
4. Turn Gas Dial to "PILOT" position.
5. Depress and hold Gas Dial until air is
bled and gas flows to pilot.
6. Light pilot. Continue to hold in the Gas
Dial until the Pilot flame remains lit
when knob is released (approximately 60
to 90 seconds). If Pilot does not remain lit,
repeat steps1through 5and "PILOT" "ON"
PILOT
+
v
+
+
+
+
v
+
PILOT ADJUST COVER CAP
Figure 8
"OFF"
+
+
v
+
allow more time after Pilot Lighting before releasing knob.
7. Turn Gas Dial to "ON".
1/2" Figure 10
Pilot
Flame
Thermogenerator
STEP TWO: Pilot Adjustment
1. The PILOT FLAME should be steady and soft blue surrounding
approximately 1/2 inch of the thermocouple tip (see Figure 10).
2. If pilot flame adjustment is necessary, use a narrow long stem screw driver
to turn PILOT ADJUST SCREW. The PILOT ADJUST SCREW is l
ocated on the Gas Valve (see Figure 9). Turn clockwise for less flame,
counter clockwise for more flame.
3

OPERATION
IMPORTANT! CHIMNEY DAMPER MUST BE WIDE OPEN
CAUTION! DAMPER AND GLASS DOORS MUST BE FULLY OPEN BEFORE LIGHTING OR BURNING FOR
PROPER VENTILATION AND TO PREVENT HEAT DAMAGE TO VALVE.
THE FLUE MUST VENT ALL PRODUCTS OF COMBUSTION.
Burner ON or OFF (Switch and Remote Valve):
With the Gas Dial (Figure 9) in the "ON" position, place the Wall or Remote Switch to "ON" or raise the
Thermostat Setting (Thermostat). To turn burner off (pilot remains lit) place Wall or Remote Switch to the "OFF"
position or to the lowest Thermostat Setting (Thermostat).
Adjusting Burner Flame Height:
Flame size at the burner is adjustable at the Gas Dial (Figure 9). Turn Gas Dial counter clockwise for more flame,
clockwise for less flame.
Switch Operation: Place manual switch in the "ON" position (Figure 9).
Remote Operation :
Place Remote Receiver switch in the "REMOTE" position. (Figure 10) Burner on or off is now "Remotely Controlled"
by the Remote Transmitter. Individual operating instructions for each Accessory Option are included with the
individual accessory.
Complete Shutdown (Including Pilot):
Place Accessory Control Switch position to "OFF" or Thermostat Control to the lowest setting. Slightly push
and turn Gas Cock Dial to "OFF". (Figure 9)
IMPORTANT!: To shutdown overnight or for any prolonged period, slide receiver switch to "OFF".
(Remote Model) Operation Of Ultrasonic Remote Control
Before you start: Both the transmitter and receiver require 9 volt batteries to
operate in remote control. The blue and black receiver wire leads are for
the optional sound producing device (CRACKLER). The receiver must be
protected from overheating. Locate receiver well away from heat.
Accessory REMOTE LOG HOUSE (Model "RH") is available for use as a
heat resistant "log" in which the receiver may be located.
Operation Tips: This is a sound operated remote (unlike TV remotes which are
Infrared and operate instantly) and requires you to aim and hold the
transmitter for 1 to 3 seconds to operate.
Manual: Switch
from OFF to ON;
ON to OFF
REMOTE OFF ON
Remote: Switch to
REMOTE. Aim,
press button and
hold transmitter at
receiver.
When switching from
REMOTE to OFF,
first turn set off using
the transmitter.
Figure 10
Manual Operation: (Receiver switch position ON or OFF) does not require batteries.
Remote Operation: Requires good batteries. If you turn the gas log on using the remote control and then turn the set
off by sliding the receiver switch from REMOTE to OFF, when you replace the switch to REMOTE it will remain in
the last selected remote position (in this case ON) and turn the gas log on.
ATTENTION:
Your Gas Log set should be operated for the first 2-3 hours at a low flame setting to
allow tempering of the refractory logs.
WARNING: NEVER OPERATE YOUR GAS LOG WITH GLASS DOORS CLOSED. ALLOW AN ADEQUATE
PERIOD OF COOLING AFTER USE BEFORE CLOSING GLASS DOORS.
CAUTION: This is a millivolt system. DO NOT connect to 115 V line. Safety controls damaged by heat or
115 volt electricity are not covered by warranty.
CAUTION! DAMPER AND GLASS DOORS MUST BE FULLY OPEN BEFORE LIGHTING OR BURNING FOR
PROPER VENTILATION AND TO PREVENT HEAT DAMAGE TO VALVE
WARNING! Heat Shield Must Be Installed To Prevent Premature Valve Failure And/Or Voiding Of Valve
Manufacturer's Warranty
CAUTION: The safety control valve must be protected to a max ambient temperature of 175° F.
Excessive heat to the valve is indicated by melted plastic on the valve body.
IMPORTANT!: To shutdown overnight or for any prolonged period, slide receiver switch to "OFF".
4

STEP FIVE: LIGHTING and Operation.
1. Refer to burner instructions regarding burner pan medium
installation.
2. Slightly push Control Valve knob and turn to “OFF”. Wait five
minutes before lighting.
3. Slightly push knob and turn to “PILOT". Depress knob and
light pilot. Continue to depress until pilot remains lit when
knob is released. Turn knob to “on”. Pilot should remain lit.
4a.(SWITCH) Close switch ("ON"). Adjust to desired flame
height with blue valve knob.
4b.(REMOTE) Slide receiver switch to “remote”. Aim remote
transmitter toward the log set and press white button on
transmitter for two to five seconds (red light on transmitter
should be lit).
5. Repeat steps 2. Through 5 above if the appliance fails to light
or if pilot goes out.
6. For complete shutdown, slightly push knob and turn to “off”.
CAUTION! DAMPER AND GLASS DOORS MUST BE FULLY OPEN BEFORE LIGHTING OR BURNING FOR
PROPER VENTILATION AND TO PREVENT HEAT DAMAGE TO VALVE
IN
PARTS LIST:
1 Pilot Support Bracket
1 JPG-9 Pilot-Thermo Generator
Assembly with Pilot Tubing
and Thermopile Leads
3 10-32 bolts/ 1 10-32 nut
1 3/8 flared x 1/2 FIP (NAT) or
MA2-air mixer (LP)
1 10" Aluminum Connector
1 3/8 flared x 3/8 MIP elbow
1 3/8 MIP x 3/8 FIP elbow
1 Valve
1 3/8 flared x 3/8 MIP
LP GAS MA-2
AIR MIXER ASSEMBLY
Burner orifice
Pilot Suport
Bracket
Pilot-Thermogenerator Assembly
Pilot Tubing
Thermopile
Leads
10" Aluminum
Connector
3/8 flared x 1/2 FIP
3/8 flared x 3/8 MIP elbow 3/8 MIP x 3/8 FIP elbow
VALVE
3/8 flared x 3/8 MIP
air mixer
3/8 flared x 3/8 MIP elbow
Burner Tube
Pilot Input
Fitting
Pilot Input
Figure 1
Burner Orifice
18" #53
24" #49
30" #45
5