Superior DR-400 Installation Instructions Manual

INSTALLATION INSTRUCTIONS VENTED GAS FIREPLACE HEATERS - DIRECT VENT MODELS P/N 700,020M REV. M 11/2004 RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors or liquids in the vicin- ity of this or any other appliance. FOR YOUR SAFETY: What to do if you smell gas: • DO NOT light any appliance. • DO NOT touch any electrical switches. • DO NOT use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow your gas suppliers instructions. • If your gas supplier cannot be reached, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. MODELS POUR VOTRE SÉCURITÉ: Ne pas entreposer ni utiliser d'essence ni d'autre vapeurs ou liquides inflammables dans le voisinage de cet appareil ou de tout autre appareil. POUR VOTRE SÉCURITÉ: Que faire si vous sentez une odeur de gaz: • Ne pas tenter d'allumer d'appareil. • Ne touchez à aucun interrupteur. Ne pas vous servir des téléphones se trouvant dans le batiment où vous vous trouvez. • Evacuez la piéce, le bâtiment ou la zone. • Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur. • Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le service dos incendies. L'installation et service doit être exécuté par un qualifié installeur, agence de service ou le fournisseur de gaz. AVERTISSEMENT: ASSUREZ-VOUS DE BIEN SUIVRE LES INSTRUCTIONS DONNÉ DANS CETTE NOTICE POUR RÉDUIRE AU MINIMUM LE RISQUE D'INCENDIE OU POUR ÉVITER TOUT DOMMAGE MATÉRIEL, TOUTE BLESSURE OU LA MORT. DIRECT VENT DT-400 & DR-400 WARNING: IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLO- SION MAY RESULT CAUSING PROPERTY DAM- AGE, PERSONAL INJURY OR LOSS OF LIFE. This appliance may be installed in an aftermar- ket permanently located, manufactured home (USA only) or mobile home, where not prohib- ited by local codes. 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. tlo villi M sle d o M cin o rtc elE sle d o M N M C 0 0 4 - T D N E C 0 0 4 - T D P M C 0 0 4 - T D P E C 0 0 4 - T D N M C 0 0 4 - R D N E C 0 0 4 - R D P M C 0 0 4 - R D P E C 0 0 4 - R D OTL Report No. 116-F-17-4

Figure 1 Installation must conform to local codes. In the absence of local codes, installation must com- ply with the current National Fuel Gas Code, ANSI Z223.1. (In Canada, the current CAN-1 B149 installation code.) Electrical wiring must comply with the National Electrical Code ANSI/ NFPA 70 - (latest edition). (In Canada, the current CSA C22-1 Canadian Electrical Code.) TABLE OF CONTENTS Packaging ........................................ page 2 Introduction ..................................... page 2 General Information......................... page 2 Location .......................................... page 4 Appliance and Vent Clearances ....... page 4 Vent Termination Clearances ........... page 5 Typical Installation Sequence .......... page 5 Detailed Installation Steps ............... page 5 Step 1. Framing ............................. page 5 Step 2. Routing Gas Line ............... page 5 Fireplace Specifications ................... page 8 Step 3. Install the Venting System . page 8 Vertical Termination Systems .......... page 9 Vent Section Length Chart ............... page 9 Vertical Vent Tables and Figures...... page 12 Horizontal Termination System ........ page 14 Horizontal Vent Tables and Figures . page 16 Venting Using Flexible Vent Pipe ..... page 19 Step 4. Field Wiring ....................... page 20 Step 5. Optional Blower Kit Wiring page 20 Step 6. Connecting Gas Line.......... page 21 Step 7. Installing Logs ................... page 22 Step 8. Checking Unit Operation ..... page 22 Step 9. Installing Glass Door ......... page 22 Step 10. Burner Adjustments........... page 23 Step 11. Hood Installation ............... page 23 Finishing Requirements ................... page 23 Cold Climate Insulation.................... page 24 Installation Accessories ................... page 24 Gas Conversion Kits.................. page 26 TYPICAL INSTALLATION DO NOT ATTEMPT TO ALTER OR MODIFY THE CONSTRUCTION OF THE APPLIANCE OR ITS COMPONENTS. ANY MODIFICATION OR ALTERATION MAY VOID THE WARRANTY, CERTIFICATION AND LISTINGS OF THIS UNIT. PACKAGING The assembled vented gas fireplace heater is packaged with: 1 -one log set shrink-wrapped to the in- side surface of the front glass enclo- sure panel. 2 - one plastic bag containing the literature package which consists of the homeowner's care and operation instructions, installation instructions and warranty; plastic bag lo- cated in the control area. 3 - one vent restrictor for use in top vent appli- cations; restrictor is taped to the inside of the cabinet bottom. 4 - one hood wrapped in plastic taped to the front of the top unit standoffs. 5 - one bag of glowing embers located in the control area. INTRODUCTION These vented gas fireplace heaters are sealed combustion, air circulating gas fireplaces de- signed for residential applications. These appli- ances must be installed with the Secure Vent™ and /or Secure Flex™ vent systems routed to the outside atmosphere. Millivolt appliances are designed to operate on natural or propane gas. A millivolt gas control valve with piezo ignition system provides safe, efficient operation. External electrical power is required to operate the optional blower if in- stalled in these units. GENERAL INFORMATION Note: Installation and repair should be per- formed by a qualified service person. The appli- ance should be inspected annually by a quali- fied professional service technician. More fre- quent inspections and cleanings may be re- quired due to excessive lint from carpeting, bedding material, etc. It is imperative that the control compartment, burners and circulating air passage ways of the appliance be kept clean. S'assurer que le brùleur et le compartiment des commandes sont propres. Voir les instruc- tions d'installation et d'utilisation qui accompagnent l'appareil. Provide adequate clearances around air open- ings and adequate accessibility clearance for service and proper operation. Never obstruct the front openings of the appliance. These appliances are designed to operate on natural or propane gas only. These millivolt and electronic versions of these appliances are listed by Omni Test Laboratories for installation in bedrooms and mobile homes. Electronic appliances are designed to operate on natural or propane gas. An electronic inter- mittent pilot ignition system provides safe, efficient operation. External electrical power is required to operate these units. This installation manual will help you obtain a safe, efficient, dependable installation for your appliance and vent system. Please read and understand these instructions before beginning your installation.

hti w sle d o M tlo villi M e vla V s a G d etalu d o M -ylla u n a M s a G e n a p o r P d n a la r uta N sr e b m u N le d o M ) H / U T B ( eta r tu p nI 0 0 4 - T D 0 0 4 - R D 0 0 5,7 1 ot 0 0 5,3 1 . o N le d o M e zis e cifir O la r uta N e n a p o r P 0 0 4 - T D 5 4 # 8 4 0.0 h c ni 0 0 4 - R D Table 1 Test gage connections are provided on the front of the millivolt gas control valve (iden- tified IN for the inlet and OUT for the mani- fold side). A ¹⁄₈" NPT test gage connection is provided at the inlet and outlet side of the electronic gas control valve. Minimum inlet gas pressure to these appli- ances is 5.0 inches water column (1.24 kPa) for natural gas and 11 inches water column (2.74 kPa) for propane for the purpose of input adjustment. Maximum inlet gas supply pressure to these appli- ances is 10.5 inches water column (2.61 kPa) for natural gas and 13.0 inches water column (3.23 kPa) for propane. The millivolt appliances are manually controlled and feature a spark ignitor (piezo) that allows the appliance's pilot gas to be lit without the use of matches or batteries. This system provides continued service in the event of a power outage. Do not use these appliances if any part has been under water. Immediately call a qualified, pro- fessional service technician to inspect the ap- pliance and to replace any parts of the control system and any gas control which have been under water. Ne pas se servir de cet appareil s'il a été plongé dans l'eau, complètement ou en partie. Appeler un technicien qualifié pour inspecter l'appareil et remplacer toute partie du système de contrôle et toute commande qui ont été plongés dans l'eau. Installations at Altitudes of 0 to 4500 ft.- Units are tested and approved for elevations of 0 to 4500 feet (0 to 1372 meters). Installations at Altitudes above 4500 ft.- For elevations above 4500 feet (1372 meters), install the unit according to the regulations of the local authorities having jurisdiction and, in the USA, the latest edition of the National Fuel Gas Code (ANSI Z223.1) or, in Canada, the latest edition of the CAN1-B149.1 and .2 codes. WARNING: FAILURE TO COMPLY WITH THE INSTALLATION AND OPERATING IN- STRUCTIONS PROVIDED IN THIS DOCU- MENT WILL RESULT IN AN IMPROP- ERLY INSTALLED AND OPERATING AP- PLIANCE, VOIDING ITS WARRANTY. ANY CHANGE TO THIS APPLIANCE AND/OR ITS OPERATING CONTROLS IS DANGER- OUS. IMPROPER INSTALLATION OR USE OF THIS APPLIANCE CAN CAUSE SERI- OUS INJURY OR DEATH FROM FIRE, BURNS, EXPLOSION OR CARBON MON- OXIDE POISONING. These appliances must be isolated from the gas supply piping system (by closing their individual manual shut-off valve) during any pressure test- ing of the gas supply piping system at test pressures equal to or less than ¹⁄₂ psig (3.5 kPa). These appliances and their individual shut-off valves must be disconnected from the gas supply piping system during any pressure test- ing of that system at pressures in excess of ¹⁄₂ psig (3.5 kPa). These appliances must not be connected to a chimney or flue serving a separate solid fuel burning appliance. 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. Turn off the gas supply to the appliance and have it serviced by a qualified professional, as it may not be op- erating correctly. WARNING: CHILDREN AND ADULTS SHOULD BE ALERTED TO THE HAZARDS OF HIGH SURFACE TEMPERATURES. USE CAUTION AROUND THE APPLIANCE TO AVOID BURNS OR CLOTHING IGNITION. YOUNG CHILDREN SHOULD BE CARE- FULLY SUPERVISED WHEN THEY ARE IN THE SAME ROOM AS THE APPLIANCE. WARNING: DO NOT PLACE CLOTHING OR OTHER FLAMMABLE MATERIALS ON OR NEAR THIS APPLIANCE. AVERTISSEMENT: SURVEILLER LES ENFANTS. GARDER LES VÊTEMENTS, LES MEUBLES, L'ESSENCE OU AUTRES LIQUIDES À VAPEUR INFLAMMABLES À COTE DE L'APPAREIL. Millivolt Models - Millivolt models come standard with the manually-modulated gas valve; flame ap- pearance and heat output can be con- trolled at the gas valve. Input of millivolt models is shown in the following table: All Models - Maximum manifold pressure is 3.5 in. w.c. (0.87 kPa) for natural gas and 10 in. w.c. (2.49 kPa) for LP/Propane gas. Table 1 shows the units' gas orifice size for the elevations indicated. Electronic Models - Electronic models have a fixed rate gas valve. Input of electronic models is shown in the following table: This appliance may be installed in an af- termarket permanently located, manufac- tured home (USA only) or mobile home, where not prohibited by local codes. This appliance is only for use with the type of gas indicated on the rating plate. This ap- pliance is not convertible for use with other gases, unless a certified kit is used. Cet appareil peut être installé dans un maison préfabriquée (É.-U. seulement) ou mobile déjà installée à demeure si les réglements locaux le permettent. Cet appareil doit être utilisé uniquement avec les types de gaz indiqués sur la plaque signalétique. Ne pas l'utiliser avec d'autres gaz sauf si un kit de con- version certifié est installé. eta R - d e xiF hti w sle d o M cin o rtc elE e vla V s a G s a G e n a p o r P d n a la r uta N sr e b m u N le d o M ) H / U T B ( eta r tu p nI 0 0 4 - T D 0 0 4 - R D 0 0 5,7 1

Figure 2 Figure 3 APPLIANCE AND VENT CLEARANCES The appliance is approved with zero clearance to combustible materials on all sides (as de- tailed in Table 2 ), with the following excep- tion: When the unit is installed with one side flush with a wall, the wall on the other side of the unit must not extend beyond the front edge of the unit. In addition, when the unit is re- cessed, the side walls surrounding the unit must not extend beyond the front edge of the unit. See Figure 2. LOCATION In selecting the location, the aesthetic and functional use of the appliance are primary concerns. However, vent system routing to the exterior and access to the fuel supply are also important. Consideration should be given to traffic ways, furniture, draperies, etc., due to elevated surface temperatures (Figure 2 ). The location should also be free of electrical, plumbing or other heating/air conditioning ducting. These direct vent appliances are uniquely suited for installations requiring a utility shelf posi- tioned directly above the fireplace. Utility shelves like these are commonly used for locating television sets and decorative plants. To provide for the lowest possible shelf surface use the alternate rear vent outlet with attached venting routed in a way to minimize obstruc- tions to the use of the space above the appli- ance. Do not insulate the space between the appliance and the area above it. See Figure 3. The minimum height from the base of the appliance to the underside of combustible ma- terials used to construct a utility shelf in this fashion is shown in the table in Figure 3. The appliance should be mounted on a fully supported base extending the full width and depth of the unit. The appliance may be located on or near conventional construction materi- als. However, if installed on combustible ma- terials, such as carpeting, vinyl tile, etc., a metal or wood barrier covering the entire bot- tom surface must be used. Shelf Above Fireplace With Rear Venting Do not insulate the space between the appliance and the area above it. Shelf Height (see table) Shelf Height (see table) Do not insulate the space between the appliance and the area above it. Shelf Above Fireplace With Top Venting . o N le d o M ) m m ( s e h c ni th gie H fle h S w o blE e e r g e D 0 9 e n O hti w - tn e V p o T k c a B e ht tu O th gia rt S - tn e V r a e R tn e V e r u c e S x elF e r u c e S tn e V e r u c e S x elF e r u c e S 0 0 4 - T D 8/1 4 4 ) 1 2 1 1 ( 8/7 5 4 ) 5 6 1 1 ( A / N A / N 0 0 4 - R D A / N A / N 4/1 3 3 ) 5 4 8 ( 4/1 3 3 ) 5 4 8 ( K C A B ) m m 3 1 ( .ni 2/1 sre c a p s ) m m 0 ( .ni 0 S E D I S ) m m 3 1 ( .ni 2/1 sre c a p s ) m m 0 ( .ni 0 S R E C A P S P O T ) m m 0 ( .ni 0 R O O L F ) m m 0 ( .ni 0 m otto B m o rF ot tin U fo g nilie C ) m m 6 2 6 1 ( .ni 4 6 T N E V * ) m m 4.5 2 ( .ni 1 S E C N A R A E L C E C I V R E S T N O R F )srete m 9.0 ( .te e F 3 (Rear Vent Application HORIZONTAL VENT without a chase) HORIZONTAL VENT (Rear Vent Application With a chase) HORIZONTAL VENT (Top Vent Application) VERTICAL VENT (Top Vent Application) (Rear Vent VERTICAL VENT Application) APPLICATION REAR VENT APPLICATION TOP VENT APPLICATION TOP VENT REAR VENT APPLICATION TOP VENT APPLICATION RECESSED INSTALLATION TOP VENT APPLICATION APPLICATION TOP VENT APPLICATION TOP VENT Typical Locations

h cti P fo o R H )te ef( 2 1/6 ot talF 0.1 2 1/7 ot 2 1/6 re v O 5 2.1 2 1/8 ot 2 1/7 re v O 5.1 2 1/9 ot 2 1/8 re v O 0.2 2 1/0 1 ot 2 1/9 re v O 5.2 2 1/1 1 ot 2 1/0 1 re v O 5 2.3 2 1/2 1 ot 2 1/1 1 re v O 0.4 Right Side Front Corner of Fireplace Framing 6 ¹⁄₂" (152 mm) 3" (76 mm) 12 X Roof Pitch is X/12 2 FT MIN. 2 FT MIN. Lowest Discharge Opening H* *H = MINIMUM HEIGHT FROM ROOF TO LOWEST DISCHARGE OPENING OF VENT TERMINATION HEIGHTS FOR VENTS ABOVE FLAT OR SLOPED ROOFS Horizontal Overhang Vertical Wall Vent Termination Storm Collar Concentric Vent Pipe Flashing 1 inch (25.4 mm) Minimum Clearance to Combustibles Figure 4 Figure 5 - Side Elevation View Figure 7 Horizontal Vent Termination Clearances The horizontal vent termination must have a minimum of 3" (76 mm) clearance to any overhead combustible projection of 2 ¹⁄₂" (64 mm) or less. See Figure 5. For projections exceeding 2 ¹⁄₂" (64 mm), see Figure 5. For additional vent location restrictions refer to Figure 7 on page 6. Terminate multiple vent terminations accord- ing to the installation codes listed at the top of this page. Vertical Vent Termination Clearances VENT TERMINATION CLEARANCES These instructions should be used as a guide- line and do not supersede local codes in any way. Install vent according to local codes, these instructions, the current National Fuel Gas Code (ANSI-Z223.1) in the USA or the current standards of CAN/CGA-B149.1 and - B149.2 in Canada. Terminate single vent caps relative to building components according to Figure 4. See Figure 31 or 32 for the recess allowances, into exterior walls, of the round and square horizontal terminations. Step 2. (page 5) Route gas supply line to appliance location. Step 3. (page 8) Install the vent system and exterior termination. Step 4. (page 20) Field Wiring Millivolt Appliances – The operating control switch is factory installed. Step 5. (page 20) Install blower kit (optional equipment). Step 6. (page 21) Make connection to gas supply. Step 7. (page 22) Install the logs, vermicu- lite and glowing embers. Step 8. (page 22) Checkout appliance opera- tion. Step 9. (page 22) Install glass door frame assembly. Step 10. (page 23) Adjust burner to ensure proper flame appearance. Step 11. (page 23) Install the hoods. Step 1. FRAMING Frame these appliances as illustrated in Fig- ures 8 on page 7, unless the appliance is to be installed in a corner. See Figure 9 on page 7 for corner framing installations. All framing details must allow for a minimum clearance to combustible framing members as shown in Table 2 on page 4. If the appliance is to be elevated above floor level, a solid continuous platform must be constructed. Headers may be in direct contact with the appli- ance top spacers but must not be supported by them or notched to fit around them. All construc- tion above the appliance must be self supporting, DO NOT use the appliance for structural support. Step 2. ROUTING GAS LINE Route a ¹⁄₂" (13 mm) gas line along the inside of the right side framing as shown in Figure 7. Gas lines must be routed, constructed and made of materials that are in strict accordance with local codes and regulations. All appliances are factory-equipped with a flex- ible gas line connector and ¹⁄₂ inch shutoff valve. (See step 6 on page 20). TYPICAL INSTALLATION SEQUENCE The typical sequence of installation follows, however, each installation is unique resulting in variations to those described. See the page numbers references in the follow- ing steps for detailed procedures. Step 1. (page 5) Construct the appliance framing. Position the appliance within the framing and secure with nailing brackets. DETAILED INSTALLATION STEPS The appliance is shipped with all gas controls and components installed and pre-wired. Re- move the shipping carton, exposing the front glass door. Remove the top panel. Remove the cardboard from underneath the pressure relief plates. Gently depress the outer top corners of the access panel until the catches "pop" the panel free, allowing it to swing out and down to open. Open the two latches (located under the firebox floor) securing the glass door. Remove the door by tilting it outward at the bottom and lifting it up. Set the door aside protecting it from inadvertent damage. See Figure 50 on page 21. Remove the two card- board pad strips from between the firebox subfloor and the firebox sides. The fireplace should be secured to the side framing members using the unit's nailing flanges - one top and bottom on each side of the fireplace front. See Figure 6. Use 8d nails or their equivalent. Figure 6 Note: The nailing flanges, combustible members and screw heads located in areas directly adjacent to the nailing flanges, are EXEMPT from the 1/2” clearance to combustible requirements for the firebox outer wrapper. Combustible framing may be in direct contact with the nailing flanges and may be located closer than 1/2” from screw heads and the firebox wrapper in areas adjacent to the nailing flanges. Frame the opening to the exact dimensions specified in the framing details of this manual. Side Framing Unit Nailing Flange (No clearance to combustible framing is required) Left Side Front Corner of Fireplace Shown (Right Side Requirements the Same) Unit Being Secured By Its Nailing Flanges To The Framing 3" (76 mm) 12" (305 mm) Termination Kit Combustible Projection greater than 2¹⁄₂ inches in length Horizontal Vent Termination Clearances Combustible Projection 2¹⁄₂ inches or less in length 18" (457 mm) Ventilated Soffit Unventilated Soffit