T&C TC42 User manual

120209-12 TC42.NG06.C 5056.426.C1A
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.
These instructions are supplementary to the Installation and
Operating Instructions supplied with the replace and should be
kept together. Refer to the Installation and Operating Instructions
for proper gas supply, safety requirements and operating
instructions
TC42
CHALET II
BURNER KIT
INSTALLATION
INSTRUCTIONS
PART#
TC42.NG06.C
FOR TC42

Contents of Package
2
TC42.NG06.C 120209-12
• BURNER ASSEMBLY
• LOG GRATE
• TC42 LOGS
• EMBER MATERIAL
• HARDWARE PACKAGE

Fig. # 3
3
TC42.NG06.C 120209-12
1. Attach the burner assembly to the oor of
the rebox with two screws. (Fig. # 1)
2. Attach the manifold supply tube to the
bulk head tting and tighten. (Fig. # 2)
Ensure that there are no leaks.
3. Attach the pilot supply tube to the bulk
head tting and tighten. (Fig. # 3) Ensure
there are no leaks.
4. Attach spark electrode (ORANGE) and
sensor leads to the electrical bulk head.
(Fig.#4) (The spark electrode connection
has a red dot above it)
A panel set must now be installed. See
Installation and Operating Instructions
manual for details.
5. Position the grate over the burner tray
and attach to the oor with two screws
through holes located behind the front
legs of the grate. (Fig. # 5)
Fig. # 2
Fig. # 1
Fig. # 5
Fig. # 4
Burner/ Grate Installation
BURNER TRAY INSTALLATION
GRATE INSTALLATION

Ember Material Placement
LOG
GRATE
GLOWING EMBERS
4
TC42.NG06.C 120209-12
Fig. # 6
Ember Material
A large bag of ember material is shipped with the replace and needs to be installed on
the burner to ensure optimum performance and ame appearance.
1. Pull apart the material into ember size pieces (approximately 1” squares) and
gently place them into the burner pan. Do not compress, leave them loose for best
performance.
2. Fill the burner pan level with the top of the pan at rear, and gradually sloping forward
down to the rebox oor at the front, covering both burner tubes.
3. Place remaining ember material outside of the burner pan as desired to cover-up gas
lines and brackets.
Note:
Ember material placement and amount will affect ame appearance. More
ember material results in lower ame height. Add or remove as needed until
desired ame affect.

5
TC42.NG06.C 120209-12
Fig. #9
Fig. #11 Fig. #12
Fig. #10
Fig. # 7
Gas plumbing and vent connections should be completed before proceeding.
The logs are are fragile and should be handled with care. Unpack and inspect log set.There
should be a total of 7 logs. Position the logs as indicated by the following pictures. Place
the rear log back against the tabs located at the back of the grate. Place left log as pictured,
engaging the pins with corresponding holes on the underside of the log. Install the right log
into the grate and pull it forward into position as shown. Place the four remaining small logs
on the oor of the rebox in the positions and order as shown.
Log Set Assembly
Fig. # 8
Fig. #13
LOG #1 LOG #2
LOG #3 LOG #4
LOG #5 LOG #6
LOG #7
Note: Improper placement of logs will
cause sooting on internal parts and
glass.

Propane Conversion
If the unit is to be used on propane,
convert as follows using the compo-
nents supplied with this replace:
CAUTION
The gas supply and electrical power
must be shut off before proceeding
with the conversion.
Fig. # 15
Fig. # 16
Fig. # 14
WARNING
This conversion kit shall be
installed by a qualied
service agency in
accordance with the
manufacturer's instructions
and all applicable codes
and requirements of the
authority having
jurisdiction.
If the information in these
instructions is not followed
exactly, a re, explosion or
production of carbon
monoxide may result
causing property damage,
personal injury or loss of
life.
The qualied service
agency is responsible for
the proper installation of
this kit.
The installation is not
proper and complete un-
til the operation of the
converted appliance is
checked as specied in the
manufacturer's instructions
supplied with the kit.
Note: Factory supplied components must
be used to ensure correct input.
After conversion conrm proper manifold
pressure.
1. Ensure the burner, pilot and gas
supply are turned off, and the
appliance has cooled.
2. Remove the two screws securing the
manifold assembly to the burner.
(Fig. #14)
3. Remove the manifold assembly from the
burner. (Fig. #15)
4. With a ½”wrench remove the natural gas
orice (#25) and replace with propane
orice (3/32”) (our part # 5021.31)
(Fig. #16)
5. Fully open the primary air shutter.
6. Reinstall the manifold assembly
6
TC42.NG06.C 120209-12

Minimum
rate screw
7. With a 7/16”wrench loosen the pilot head
on the pilot assembly by a half-turn
(Fig. #17)
8. Slide the pilot adjustment band over and
ensure that the hole in the orice band is
showing. (Fig. #19 shows NG position,
Fig. # 20 shows LP position)
9. Remove the minimum rate screw located
in the valve.
(Fig. #21)
Fig. #20
Fig. # 21
Fig. # 17
Fig. # 19
7
TC42.NG06.C 120209-12
M
r
a

8
TC42.NG06.C 120209-12
Minimum
rate screw
NG LP
Fig #22
Fig #23
Fig #24
Fig #25
10. Replace the minimum rate screw with the
one provided in the propane conversion
kit supplied with this replace. Ensure
that the screw is fully installed.
(Fig. #22)
11. Pull off the rubber cap from the top of
the pressure regulator. (Fig. #23)
12. Press down on the center post and
rotate 90°. The center post should
stay down. (Fig. #24). Replace the
rubber cap.
13. Fill in the date and the name of the
person who performed the conversion
in the white area on the conversion
label. Peel off the protective backing
and apply the conversion label directly
over the gas specications on the rating
label.
14. Attach the access panel to the side of
the rebox with the previously removed
screws. (Fig. #25)
Note:
Gasket must be installed with access
panel.

9
TC42.NG06.C 120209-12
1. Remove the plug from the manifold test
port. The plug is located between the
right side lintel and rebox side (bottom
port). (Fig. # 26)
2. Thread the extension test tting into the
open test port. (Fig. #27)
3. Attach a pressure gauge onto the
tting.
4. When testing is complete remove the
extension test tting and replace the
plug. Thread sealant will be required to
ensure a gas-tight connection.
Correct gas pressure requirement:
Supply Pressure Natural Gas Propane
(For purpose of input adjustment)
Minimum 5.0" WC 12.5" WC
Maximum 13.9" WC 13.9" WC
Manifold Pressure
Maximum 3.8" WC 11.0w" WC
Minimum 2.1" WC 5.5" WC
Note:To test the gas pressure, turn off the gas supply before removing the plug from
the supply pressure test port or manifold pressure test port.
Verify gas pressures with the replace lit and on the highest setting.
Fig #26
Fig #27
Gas Pressure Check

10
TC42.NG06.C 120209-12
Fig. # 28
The air shutter on the burner tube controls the primary combustion air to the gas burner
and is preset at the factory for natural gas fuel. Some adjustment may be necessary to
obtain desired ame and to eliminate carbon deposits. Evaluate ame appearance after
the replace has reached operating temperature. See Fig. #28 for proper ame pattern.
Open primary air shutter if the logs, glass, and rebox have carbon accumulation and /
or the ames are long, dark and stringy. The shutter may also be opened to enhance the
Ember Material glow and lessen the ame height.
Caution: Burner area may be hot!
Turn off the replace and allow the unit to cool before proceeding.
Caution: Proper air shutter setting is a
must.
The ame should be just orange and “lazy”.
It should NEVER be set to create sooting on
internal parts and glass.
Burner Flame Adjustment
To Adjust: (Fig. #29)
1. Open and remove window frame and set
aside.See "Window Frame Removal" sec-
tion found in the Installation and Operating
Instructions manual.
2. Remove the log set and set aside.
3. Loosen the screw in the Primary Air
Shutter.
4. Rotate the shutter to increase or decrease
the amount of primary air.
5. Reassemble in reverse order.
Fig. # 29
PRIMARY AIR SHUTTER

11
TC42.NG06.C 120209-12
Replacement Parts
ITEM.......DESCRIPTION............................................PART NO.
#1..........BURNER ASSEMBLY......................... TC42.NG06.C
#2..........7 PCS LOG SET ................................. 5094.42161
#3..........ORIFICE, NATURAL GAS (#25)......... 5022.12
ITEM.......DESCRIPTION............................................PART NO.
#4..........PILOT ASSEMBLY.............................. TCRP.5005025
#5..........MAIN SUPPLY TUBE (FLEX) ............. 5019.223
#6..........PILOT TUBE (FLEX).......................... 5019.225
#7..........PROPANE CONVERSION KIT........... TC42.LPCEO1
#1.... BURNER ASSEMBLY
1a GRATE
1b
BURNER INSULATION
1c BURNER TRAY SUPPORT SHIELD
1d PILOT SHIELD
1e TC42.NG01 BURNER WELD
1f MANIFOLD
1g 1/2 PIPE TO 1/2 TUBE CONNECTION
1h PILOT BRACKET
2a LOG #1
2b LOG #2
2c LOG #3
2d LOG #4
2e LOG #5
2f LOG #6
2g LOG #7
KIT CONTENTS:
3 ORIFICE, NATURAL GAS
4 PILOT ASSEMBLY
5 MAIN SUPPLY TUBE
6 PILOT TUBE
#2.... 7 PCS LOG SET
EMBER MATERIAL (Not shown)
2a
LOG #1
2b LOG #2
2c LOG #3
2d LOG #4
2e LOG #5
2f LOG #6
2g LOG #7
#3.... ORIFICE, NATURAL GAS (#25)
#4.... PILOT ASSEMBLY, CONVERTIBLE
#5.... MAIN SUPPLY TUBE (FLEX)
#6.... PILOT TUBE (FLEX)
#7.... PROPANE CONVERSION KIT (Not shown)
(WHEN ORDERING, INCLUDE PART NUMBER WITH DESCRIPTION)
*
NOT SHOWN
*
2a
2b 2c
2d 2g
2e
2f
#1
#2 #3
#4
#6 #5
1a
1b
1e
1d
1f
1h
1c 1g

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