Royal R-3500TR Assembly instructions

Installers Guide
536-981-C 11/98
- Do not store or use gasoline or other flam-
mable vapors and liquids in the vicinity of
this or any other appliance.
-What to do if you smell gas
• Do not try to light any appliance.
• Do not touch any electrical switch.
• Do not use any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
- Installation and service must be performed by a
qualified installer, service agency, or the gas
supplier.
WARNING: IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION,
SERVICE OR MAINTENANCE CAN
CAUSE INJURY OR PROPERTY
DAMAGE. REFER TO THIS MANUAL.
FOR ASSISTANCE OR ADDITIONAL
INFORMATION CONSULT A QUALI-
FIED INSTALLER, SERVICE AGENCY,
OR THE GAS SUPPLIER.
Underwriters
Laboratories Listed
READ THIS MANUAL BEFORE INSTALLING
OR OPERATING THIS APPLIANCE. THIS
INSTALLERS GUIDE MUST BE LEFT WITH
THE APPLIANCE FOR FUTURE REFERENCE.
1.This appliance may be installed in an
aftermarket,permanentlylocated,
manufactured (mobile) home, where
not prohibited by local codes.
2.This appliance is only for use with the
type of gas indicated on the rating
plate. This appliance is not convertible
for use with other gases, unless a
certified kit is used.
WARNING: IF THE INFORMATION
IN THESE INSTRUCTIONS IS NOT
FOLLOWED EXACTLY, A FIRE OR
EXPLOSION MAY RESULT
CAUSING PROPERTY DAMAGE,
PERSONAL INJURY, OR DEATH.
This product is covered by one or more of the following patents: (United States) 4,112,913; 4,408,594; 4,422,426; 4,424,792; 4,520,791; 4,793,322;
4,852,548; 4,875,464; 5,000,162; 5,016,609; 5,076,254 5,191,877; 5,218,953; 5,328,356; 5,429,495; 5,452,708; 5,542,407; 5,613,487; (Australia) 543790;
586383; (Canada) 1,123,296; 1,297,746; 2,195,264; (Mexico) 97-0457; (New Zealand) 200265; or other U.S. and foreign patents pending.
Models:
R-3500TR
R-4500TR
R-6500TR
Please contact your Royal Fireplaces dealer for any
questions or concerns. For the number of your nearest
Royal Fireplaces dealer, please call 1-800-393-9484.
Printed in U.S.A. Copyright 1998,
Hearth Technologies Inc.
6665 West Highway13, Savage, MN 55378

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SAFETY AND WARNING INFORMATION
READ and UNDERSTAND all instructions carefully before starting the installation.
FAILURE TO FOLLOW these installation instructions may result in a possible fire hazard
and will void the warranty.
Prior to the first firing of the fireplace,
READ the Using Your Fireplace section of the
Owners Guide .
DO NOT USE this appliance if any part has been under water. Immediately CALL a
qualified service technician to inspect the unit and to replace any part of the control
system and any gas control which has been underwater.
THIS UNIT IS NOT FOR USE WITH SOLID FUEL.
Installation and repair should be PERFORMED by a qualified service person. The
appliance and venting system should be
INSPECTED before initial use and at least
annually by a professional service person. More frequent cleaning may be required due
to excessive lint from carpeting, bedding material, etc. It is
IMPERATIVE that the unit’s
control compartment, burners, and circulating air passageways
BE KEPT CLEAN to
provide for adequate combustion and ventilation air.
Always
KEEP the appliance clear and free from combustible materials, gasoline, and
other flammable vapors and liquids.
NEVER OBSTRUCT the flow of combustion and ventilation air. Keep the front of the
appliance
CLEAR of all obstacles and materials for sevicing and proper operations.
Due to the high temperature, the appliance should be
LOCATED out of traffic areas and
away from furniture and draperies. Clothing or flammable material
SHOULD NOT BE
PLACED on or near the appliance.
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
CAREFULLY SUPERVISED when they are in the same room as the appliance.
These units
MUST use one of the vent systems described in the Installing the
Fireplace section of the
Installers Guide . NO OTHER vent systems or components
MAY BE USED .
This gas fireplace and vent assembly
MUST be vented directly to the outside and MUST
NEVER
be attached to a chimney serving a separate solid fuel burning appliance. Each
gas appliance
MUST USE a separate vent system. Common vent systems are
PROHIBITED .
INSPECT the external vent cap on a regular basis to make sure that no debris is
interfering with the air flow.
The glass door assembly
MUST be in place and sealed, and the trim door assembly
MUST be in place on the fireplace before the unit can be placed into safe operation.
DO NOT OPERATE this appliance with the glass door removed, cracked, or broken.
Replacement of the glass door should be performed by a licensed or qualified service
person.
DO NOT strike or slam the glass door.
The glass door assembly
SHALL ONLY be replaced as a complete unit, as supplied by
the gas fireplace manufacturer. NO SUBSTITUTE material may be used.
DO NOT USE abrasive cleaners on the glass door assembly. DO NOT ATTEMPT to
clean the glass door when it is hot.
Turn off the gas before servicing this appliance. It is recommended that a qualified
service technician perform an appliance check-up at the beginning of each heating
season.
Any safety screen or guard removed for servicing must be replaced before operating
this appliance.
i

Table of
Contents
Safety and Warning Information ..........................i
Section 1: Approvals and Codes .....................1
Approval Listings and Codes ....................................1
Appliance Certification ..............................................1
Installation Codes .....................................................1
High Altitude Installations ..........................................2
Section 2: Getting Started.................................3
Introducing the Royal Fireplaces ..............................3
Pre-installation Preparation .......................................3
Section 3: Installing the Fireplace....................8
Step 1 Locating the Fireplace .................................8
Step 2 Framing theFireplace..................................9
Step 3 Installing the Vent System .........................10
A. Vent System Approvals.........................10
B. Installing System Components .............23
C.VentTermination ....................................29
Step 4 Positioning, Leveling,and
Securing the Fireplace ..............................34
Step 5 The Gas Control Systems ........................34
Step 6 The Gas Supply Line.................................35
Step 7 Gas Pressure Requirements ....................36
Step 8 Wiring the Fireplace ..................................37
Step 9 Finishing ....................................................39
Step 10 I
nstalling Trim, Logs, and Ember Materia l ...40
InstallingtheTrim .......................................40
Positioning the Logs ..................................41
Placing the Ember Material .......................41
Step 11 Before Lighting the Fireplace.....................43
Step 12 Lighting the Fireplace ................................43
After the Installation...................................43
Section 4: Maintenance and Servicing ............44
Section 5: Replacement Parts
and Accessories..............................46
Replacement Parts .................................................46
Accessories ............................................................50
i i

1
1
Approvals
and Codes
Approval Listings
and Codes
Appliance Certification
The Royal Fireplaces models discussed in this
Installers Guide have been tested to certification
standards and listed by the applicable laboratories.
CERTIFICATION
MODEL LABORATORY TYPE STANDARD
R-6500TR Under riters Direct Vent ANSI Z21.50CGA2.22
Laboratories Decorative
R-4500TR Under riters Direct Vent ANSI Z21.50 CGA2.22
Laboratories Decorative
R-3500TR Under riters Direct Vent ANSI Z21.50CGA2.22
Laboratories Decorative
NOTE: ALL MODELS ARE UL LISTED TO UL307B THE STANDARD
FOR GAS-BURNING HEATING APPLIANCES FOR MANUFACTURED
HOMES AND RECREATIONAL VEHICLES.
Installation Codes
The fireplace installation must conform to local codes. Before installing the
fireplace, consult the local building code agency to ensure that you are in
compliance ith all applicable codes, including permits and inspections.
In the absence of local codes, the fireplace installation must conform to the
National Fuel Gas Code ANSI Z223.1 (in the United States) or the CAN/CGA-
B149 Installation Codes (in Canada). The appliance must be electrically
grounded in accordance ith local codes or, in the absence of local codes ith
the National Electric Code ANSI/NFPA No. 70 (in the United States), or to the
CSA C22.1 Canadian Electric Code (in Canada).
These models may be installed in a bedroom or bed-sitting room in the U.S.A.
and Canada.

2
High Altitude Installations
U.L. Listed gas fireplaces are tested and approved for elevations from 0 to
2,000 feet in the U. S. A. and from 0 to 4,500 feet in Canada.
When installing this fireplace at an elevation above 2,000 feet (in the United
States), it may be necessary to decrease the input rating by changing the
existing burner orifice to a smaller size. Input should be reduced four percent
(4%) for each 1,000 feet above sea level, unless the heating value of the gas
has been reduced, in hich case this general rule ill not apply. To identify the
proper orifice size, check ith the local gas utility.
When installing this fireplace at an elevation bet een 2,000 and 4,500 feet (in
Canada), the input rating must be reduced by ten percent (10%).
When installing this fireplace at an elevation above 4,500 feet (in Canada),
check ith local authorities.
Consult your local gas utility for assistance in determining the proper orifice for
your location.

3
2
Getting
Started
Introducing the
Royal Fireplaces
Gas Fireplaces
Royal Fireplaces direct vent gas fireplaces are
designed to operate ith all combustion air siphoned
from outside of the building and all exhaust gases
expelled to the outside.
The information contained in this Installers Guide,
unless noted other ise, applies to all models and gas
control systems.
Gas fireplace diagrams, including the dimensions, are
sho n in this section.
Pre-installation
Preparation This gas fireplace and its components are tested and
safe hen installed in accordance ith this Installers
Guide. Report to your dealer any parts damaged in
shipment, particularly the condition of the glass. Do
not install any unit with dama ed, incomplete, or
substitute parts.
The vent system components and trim doors are
shipped in separate packages. The gas logs are
packaged separately and must be field installed.
Read all of the instructions before startin the
installation. Follow these instructions carefully
durin the installation to ensure maximum safety
and benefit. Failure to follow these instructions
will void the owners warranty and may present a
fire hazard.
The Royal Fireplaces arranty ill be voided by, and
Hearth Technologies Inc. disclaims any responsibility
for, the follo ing actions:
 Installation of any damaged fireplace or vent system
component.
 Modification of the fireplace or direct vent system.
 Installation other than as instructed by Hearth
Technologies Inc.
 Improper positioning of the gas logs or the glass
door.
 Installation and/or use of any component part not
manufactured and approved by Hearth Technolo-
gies Inc. not ithstanding any independent testing
laboratory or other party approval of such compo-
nent part or accessory.
ANY SUCH ACTION MAY POSSIBLY CAUSE A
FIRE HAZARD.

4
When planning a fireplace installation, its necessary to determine:
Where the unit is to be installed.
The vent system configuration to be used.
Gas supply piping.
Electrical iring.
Framing and finishing details.
Whether optional accessoriesdevices such as a fan, all s itch, or remote
controlare desired.
If the fireplace is to be installed on carpeting or tile, or on any combustible
material other than ood flooring, the fireplace should be installed on a metal or
ood panel that extends the full idth and depth of the fireplace.

5
Fi ure 1. Dia ram of the R-6500TR

6
Fi ure 2. Dia ram of the R-4500TR

7
Fi ure 3. Dia ram of the R-3500TR

8
3
Installing the
Fireplace
Step 1
Locating the
Fireplace
The diagram belo sho s space and clearance
requirements for locating a fireplace ithin a room.
ABCD E
R-6500TR 49 16 1/4 35 3/8 50 70 3/4
R-4500TR 42 16 1/4 31 7/8 45 63 3/4
R-3500TR 37 16 1/4 29 3/8 41 1/2 58 3/4
NOTE: DIMENSIONS SHOWN IN INCHES.
Fi ure 4. Fireplace Dimensions, Locations,
and Space Requirements
Clearance Requirements
The top and back of the fireplace are defined by stand-offs.
MODEL RECESSED DEPTH
R-6500TR 16 1/4
R-4500TR 16 1/4
R-3500TR 16 1/4
The minimum clearance to a perpendicular all extending past the face of the
fireplace is 3 inches (76.2mm).
The back of the fireplaces may be recessed into combustible construction, as
sho n belo .
Minimum Clearances from the Fireplace to
Combustible Materials
Glass Back of Sides of Top of
Front Floor Fireplace Fireplace Fireplace Ceilin
36 inches 0 1/2 inch 1/2 inch
(914 mm) (13mm)
31 inches
(787mm)
(13mm) R-3500TR:11/2”(38mm)
R-4500TR:31/4”(83mm)
R-6500TR:31/4”(83mm)

9
Minimum Clearances from the Vent Pipe to
Combustible Materials
For Vertical
For Horizontal Sections Sections At Wall Firestops
Top Bottom Sides Top Bottom Sides
3 inches 1 inch 1 inch 1 inch 2-1/2 inches 1/2 inch 1 inch
(75 mm) (25 mm) (25 mm) (25 mm) (63.7 mm) (13 mm) (25 mm)
For minimum clearances, see the direct vent
termination clearance diagrams on pages 36 and 38 in
this section.
Step 2
Fra ing the
Fireplace
Fireplace framing can be built before or after the
fireplace is set in place. Framing should be positioned
to accommodate all coverings and fireplace facing
material. The diagram belo sho s framing reference
dimensions.
CAUTION MEASURE FIREPLACE DIMENSIONS, AND
VERIFY FRAMING METHODS AND WALL
COVERING DETAILS, BEFORE FRAMING
CONSTRUCTION BEGINS.
The framing headers may
rest on the fireplace stand-offs.
Model A B C D E
R-6500TR 49 42 1/4 16 1/4 44 29 1/2
R-4500TR 42 38 1/4 16 1/4 41 25 1/2
R-3500TR 37 33 16 1/4 36 1/2 22
NOTE: DIMENSIONS SHOWN IN INCHES
Fi ure 5. Framin Dimensions
Framing should be
constructed of 2 X 4 lumber or heavier.
WARNING:
To ensure proper
clearances, the front
framing header must be
installed on its narrow
edge and to the front of
the frame.

10
Vent System
Termination Kits Vent System Components
SL D-SERIES
D-SERIES
SLK-01D
SLK-TVCD
SLK-01TRD
Fi ure 6. Vent Components and Terminations
A. Vent System Approvals
These models have vent starting collars on both the top and
the back of the unit. Depending upon the installation,
decide hich ONE set of starting collars ill be used to
attached the vent system. The starting collar sealing cap
must remain on the starting collar NOT used.
These models use SL-D-series, direct vent components
hen using the TOP vent collars and D-series direct vent
components hen using the REAR vent collars.
The flame and ember appearance may vary based on
the type of fuel burned and the venting configuration used.
WARNING YOU MUST NOT MIX D-SERIES
AND SL D-SERIES COMPONENTS IN ANY
VENT SYSTEM CONFIGURATION.
Identifying Vent Components
Approved vent system components are labeled for
identification. NO OTHER VENTING SYSTEMS OR
COMPONENTS MAY BE USED. Detailed installation
instructions are included ith each vent termination kit
and should be used in conjunction ith this Installers
Guide. Figure 6 sho s vent system components and
terminations.
The vent systems installed on this gas fireplace may
include one, t o, or three 90° elbo assemblies. The
relationships of vertical rise to horizontal run in vent
configurations using 90° elbo s MUST BE strictly
adhered to. The rise to run relationships are sho n in the
venting dra ings and tables on the next several pages.
NOTE: T o 45° elbo s may be used in place of one
90° elbo . You MUST al ays maintain the MAXIMUM
and MINIMUM rise-to-run ratios in the vent system
hen using 45° elbo s.
Step 3
Installing the
Vent System
DVK-TVCD
DVK-01TRD
DVK-01D

11
Fi ure 7. D-Series Direct Vent Component Specifications
(5-inch inner pipe / 8 5/8-inch outer pipe)
NOTE: PIPES OVERLAP 1 3/8 INCHES (34.93 mm) AT EACH JOINT.
DV-90D
6 5/32
5 7/87 3/8
DV-45D
6 7/16
11 1/16 6 1/2
8 5/8
8 1/2
5 1/16
8 /12 11 5/8
8 5/8
11 15/16
DV-36D
35 3/4
47 3/4
DV-48D
5 3/4
8 3/4
11 3/4
DV-12D DV-09D DV-06D
6-5/32"
7-3/8" 5-7/8"
8-1/2"
8-5/8"
(220 mm)
11-15/16"
11-5/8" 11-1/16"
6-1/2"
8-5/8"
5-1/16"
8-1/2"
6-7/16"
35-3/4"
47-3/4"
11-3/4" 8-3/4" 5-3/4"
NOTE: PIPES OVERLAP 1-3/8 INCHES (34.93 mm) AT EACH JOINT.

12
Fi ure 8. SL D-Series Direct Vent Component Specifications
(4-inch inner pipe / 6 5/8-inch outer pipe)

13
STRAIGHT UP
VERTICAL VENTING
V (FT.)
40' AX.
Fi ure 9. Strai ht up Vertical Ventin
NOTE: For vertical ventin over 20 feet a restrictor plate is recommended
for improved flame appearance. See accessories pa e for kit number.
Instructions are provided in the kit.
Use SL D-Series
components only.

14
STRAIGHT OUT HORI ONTAL
VENTING
H
Max. Run
24" (610 mm)
Use D-Series components only.
Fi ure 10. Strai ht Out Horizontal Ventin

15
VENTING WITH ONE (1) 90o ELBOW
V (FT.) H (FT.)
1' IN. (305mm) 2' AX. (610mm)
2' IN. (610mm) 4' AX. (1.22m)
3' IN. (914mm) 6' AX. (1.86m)
4' IN. (1.22m) 8' AX. (2.48m)
V+H =40' AX. (12.2m) H= 8' AX. (2.48m)
Use D-Series
components only.
Fi ure 11. Ventin with One 90° Elbow

16
Fi ure 12. Ventin with One 90° Elbow - TR MODELS
Use SL D-Series components only.
MODEL R-3500TR
V (MIN.) H (MAX.)
90oElbow on Top 3 FT (914mm)
1 FT (305mm) 3 FT (914mm)
2 FT (610mm) 4 FT (1.22m)
3 FT (914mm) 6 FT (1.86m)
4 FT (1.22m) 8 FT (2.48m)
5 FT (1.52m) 16 FT (4.8m)
VENTING WITH ONE (1) 90o ELBOW NATURAL GAS
H MAX. = 16 FT (4.8m) V + H MAX. = 40 FT (12.2m)
MODEL R-4500TR MODEL R-6500TR
H (MAX.) H (MAX.)
2.5 FT (863mm) 2 FT (610mm)
3 FT (914mm) 3 FT (914mm)
4 FT (1.22m) 4 FT (1.22m)
6 FT (1.86m) 6 FT (1.86m)
8 FT (2.48m) 8 FT (2.48m)
16 FT (4.8m) 16 FT (4.8m)
MODEL R-3500TR
V (MIN.) H (MAX.)
90oElbow on Top 3 FT (914mm)
1 FT (305mm) 3 FT (914mm)
2 FT (610mm) 4 FT (1.22m)
3 FT (914mm) 6 FT (1.86m)
4 FT (1.22m) 8 FT (2.48m)
5 FT (1.52m) 16 FT (4.8m)
VENTING WITH ONE (1) 90o ELBOW PROPANE
H MAX. = 16 FT (4.8m) V + H MAX. = 40 FT (12.2m)
MODEL R-4500TR MODEL R-6500TR
H (MAX.) H (MAX.)
2.5 FT (863mm) NOT ALLOWED
3 FT (914mm) 2 FT (610mm)
4 FT (1.22m) 4 FT (1.22m)
6 FT (1.86m) 6 FT (1.86m)
8 FT (2.48m) 8 FT (2.48m)
16 FT (4.8m) 16 FT (4.8m)

17
Fi ure 13. Ventin with Two 90° Elbows
VENTING WITH TWO (2) 90° ELBOWS
VHH + H
1
1´ IN. (305 mm) 2´ AX. (610 mm) 4´ AX. (1.22 m)
2´ IN. (610 mm) 4´ AX. (1.22 m) 8´ AX. (2.4 m)
3´ IN. (914 mm) 6´ AX. (1.86 m) 12´ AX. (3.6 m)
4´ IN. (1.22 m) 8´ AX. (2.48 m) 16´ AX. (4.8 m)
H = 8´ AX.(2.48 m) H + H1= 16´ AX.(4.8m)
V + H + H1 = 40 (12.2m) AX.
VENTING WITH TW0 (2) 90° ELBOWS
V (FT) H + H1 (FT)
1´ IN. (305 mm) 2´ AX. (610 mm)
2´ IN. (610 mm) 4´ AX. (1.22 m)
3´ IN. (914 mm) 6´ AX. (1.86 m)
4´ IN. (1.22 m) 8´ AX. (2.48 m)
H + H1= 8´ AX. (2.48 m)
V + H + H1= 40 (12.2m) AX.
Use D-Series
components only.