Vermont Castings, Majestic Products: DVR33 INSTALLER/CONSUMER SAFETY INFORMATION PLEASE READ THIS MANUAL BEFORE INSTALLING AND USING APPLIANCE WARNING! 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. FOR YOUR SAFETY Installation and service must be performed by a qualified installer, service agency or the gas supplier. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance. • Do not touch any electric switch; do not use any phone in your building. • Immediately call your gas supplier from your neighbor's phone. Follow the gas suppliers instructions. • If you cannot reach your gas supplier call the fire department. DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. Rear Vented Direct Vent Gas Fireplace Model: DVR33 2823 Homeowner's Installation and Operating Manual Vermont Castings, Majestic Products 410 Admiral Blvd. • Mississauga, Ontario, Canada L5T 2N6 • 905-670-7777 www.majesticproducts.com • www.vermontcastings.com INSTALLER: DO NOT DISCARD THIS MANUAL - LEAVE FOR HOMEOWNER 10004920 01/03 Rev.0 10004920 1 Vermont Castings, Majestic Products: DVR33 Table of Contents PLEASE READ THE INSTALLATION & OPERATING INSTRUCTIONS BEFORE USING THE APPLIANCE. Thank You and Congratulations on Your Purchase of a Vermont Castings, Majestic Products Fireplace. IMPORTANT: Read all instructions and warnings carefully before starting installation. Failure to follow these instructions may result in a possible fire hazard and will void the warranty. Installation and Operating Instructions Important Curing/ Burning Instructions ........................................................................ 3 Proposition 65 Warning ............................................................................................... 3 Locating Your fireplace ................................................................................................ 3 Fireplace Dimensions .................................................................................................. 4 Clearance to Combustibles ......................................................................................... 5 Mantels ........................................................................................................................ 5 Hearth ........................................................................................................................ 5 Framing & Finishing .................................................................................................... 6 Final Finishing ............................................................................................................. 6 Gas Specifications ....................................................................................................... 6 Gas Inlet and Manifold Pressures ............................................................................... 6 Gas Line Installation .................................................................................................... 7 Remote ON/ OFF Switch Installation ........................................................................... 7 Alternate Switch Location ............................................................................................ 7 EB-1 Electrical Box ...................................................................................................... 8 Electronic Gas Control Valve ...................................................................................... 9 General Venting Information/ Termination Location/ Clearances ............................. 9 – 11 General Information for Connecting Vent Pipes ............................................................... 11 Crimped End Pipes/ Twist Lock Pipes ................................................................. 11, 12 Rear Wall Vent Application/ Installation .............................................................. 12, 13 How to Use the Vent Graph ...................................................................................... 14 Vertical Sidewall Application/ Installation .......................................................... 14 – 17 Below Grade Installation ..................................................................................... 17, 18 Vertical Through-the-Roof Applications & Installations ....................................... 18, 19 DVR33 Bracket Restricter Installation ....................................................................... 20 Twist Lock/ Crimped End Venting Components .................................................. 21, 22 Operating Instructions Glass Information ...................................................................................................... 23 Louvre Removal ........................................................................................................ 23 Window Frame Assembly Removal .......................................................................... 23 Glass Cleaning .......................................................................................................... 23 Installation of Logs and Lava Rock Material .............................................................. 24 Flame and Temperature Adjustment ......................................................................... 24 Flame Characteristics ................................................................................................ 25 Inspecting the Venting System .................................................................................. 25 Lighting and Operating Instructions ..................................................................... 26, 27 Troubleshooting Guides .................................................................................... 28 – 30 Fuel Conversion Instructions ..................................................................................... 31 General Maintenance ................................................................................................ 32 Cleaning the Standing Pilot Control System ............................................................. 32 Replacement Parts Parts Pictorial ...................................................................................................... 33, 34 Parts Number List ............................................................................................. 34 – 36 Optional Accessories Fan Kits ..................................................................................................................... 37 Hard Wire (Direct) Hook-up ....................................................................................... 37 Remote Controls ....................................................................................................... 38 Ceramic Refractory Panels ....................................................................................... 38 Decorative Bay Windows .......................................................................................... 38 Decorative Frame Trims ............................................................................................ 39 2 10004920 Vermont Castings, Majestic Products: DVR33 Installation and Operating Instructions This gas appliance should be installed by a qualified installer in accordance with local building codes and with current CSAB149.1 Installation codes for Gas Burning Appliances and Equipment. If the unit is being installed in a mobile home, the installation should comply with the current CAN/CSA Z 240.4 code. For U.S.A. Installations follow local codes and/or the current National Fuel Gas Code. ANSI Z223.1. PROPOSITION 65 WARNING Fuels used in gas, wood-burning or oil fired appliances, and the products of combustion of such fuels, contain chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. California Health & Safety Code Sec. 25249.6 FOR SAFE INSTALLATION AND OPERATION PLEASE NOTE THE FOLLOWING: This appliance may be installed in an aftermarket, 1. This fireplace gives off high temperatures and permanently located, manufactured home, or should be located out of high traffic areas and away mobile home where not prohibited by local codes. from furniture and draperies. This appliance is only for use with type of gas 2. Children and adults should be alerted to the hazards indicated on the rating plate. This appliance is not convertible for use with other gases, of the high surface temperatures of this fireplace, unless a certified kit is used. and should stay away to avoid burns or ignition of clothing. 3. Children should be carefully supervised when in the IMPORTANT: PLEASE READ THE FOLLOWING CAREFULLY same room as your fireplace. Remove any plastic from trim parts before turning the 4. Under no circumstances should this fireplace be fireplace On. modified. Parts removed for servicing should be It is normal for fireplaces fabricated of steel to give off some replaced prior to operating this fireplace again. expansion and/ or contraction noises during the start up or 5. Installation and any repairs to this fireplace must be cool down cycle. Similar noises are found with your furnace performed by a qualified installer, service agency or heat exchanger or car engine. gas supplier. A professional service person should It is not unusual for a Vermont Castings, Majestic Products be contacted to inspect this fireplace annually. Make gas fireplace to give off some odor the first time it is burned. This is due to the manufacturing process. it a practice to have all of your gas fireplaces Please open all windows to ensure your room checked annually. More frequent cleaning may be is well ventilated. required due to excess lint and dust from carpeting, It is recommended that you burn your fireplace for at least bedding material, etc. ten (10) hours the first time you use it. If the optional fan kit 6. Control compartments, burners and air passages in has been installed, place the fan switch in the “Off” position this fireplace should be kept clean and free of dust during this time. and lint. Make sure the gas valve and pilot light are turned off before you attempt to clean this fireplace. Locating Your Fireplace 7. The venting system (chimney) of this fireplace should be checked at least once a year and if needed your venting system should be cleaned. 8. Keep the area around your fireplace clear of comA E B Y bustible materials, gasoline and other flammable vapor and liquids. This fireplace should not be used X C as a drying rack for clothing, nor should Christmas stocking or decorations be hung in the area of it. D 9. Under no circumstances should any solid fuels Y B X (wood, coal, paper or cardboard etc.) be used in this F fireplace. 10. The flow of combustion and ventilation air must not LU584-R be obstructed in any way. 11. When fireplace is installed directly on carpeting, vinyl Fig. 1 Locating Your Gas Fireplace A) Flat on wall B) Cross corner C) Island ** tile or any combustible material other than wood, this D) Room divider */ ** E) Flat on wall corner* F) Chase installation fireplace must be installed on a metal or wood panel Y) 6 in. minimum extending the full width and depth of the fireplace. Notes (Fig. 1): 12. This fireplace requires adequate ventilation and * When you install your Vermont Castings, Majestic Products fireplace in (D) Room divider or (E) Flat on wall corner positions, a minimum of (Y), combustion air to operate properly. 6 in. (153 mm) clearance must be maintained from the perpendicular 13. This fireplace must not be connected to a chimney wall and the front side edge of the fireplace. flue serving a separate solid fuel burning fireplace. ** Island (C) and Room Divider (D) installation is possible if the horizontal 14. When the fireplace is not in use it is recommended portion of the vent system (X) does not exceed 20 ft. (610 cm). See that the gas valve be left in the OFF position. details in Venting Section. 10004920 3 Vermont Castings, Majestic Products: DVR33 Fireplace Dimensions CL S Rough Opening Depth L 4" Dia. (102mm) 7" Dia. (178mm) E G O F Recessed Nailing Flange N ⁵⁄₈" (16mm) Rough Opening Width 33¹⁄₂" ¹⁄₂" (13mm) L Rough Opening Height M 1" (25mm) P B C R Electrical Access B H T Gas Line Access (102mm) 4" - U 2" (52mm) D 1" A (25mm) I J Q 2" (52mm) K Fig. 2 Fireplace specifications and framing dimensions. Appliance Dimensions A B C D E F G H I J K R S T U 33” 287/8” 16 3/8” 31” 22 1/16” 111/2” 14 3/4” 24 1/2” 5” 7 1/2” 8 1/2” 31” 16 1/2” 191/2” 8” 838 mm 733 mm 416 mm 787 mm 560 mm 292 mm 375 mm 622 mm 127 mm 127 mm 216 mm 787 mm 419 mm 495 mm 208 mm Framing Dimensions 4 L M N O P 36” 51” 251/2” 12” 29” 914 mm 1295 mm 648 mm 305 mm 737 mm Q 331/2” 851 mm 10004920 Vermont Castings, Majestic Products: DVR33 Clearance to Combustibles Appliance Top Bottom Side Back Venting Concentric sections of DV Vent Non-concentric sections of DV Vent Sides and bottom Top 0” (0 mm) 0” (0 mm) 0” (0 mm) 0” (0 mm) Mantel Leg J Black Surround Face 1” (25 mm) I H G F 1” (25 mm) 2” (50 mm) K L M N Mantels O The height that a combustible mantel is fitted above the fireplace is dependent on the depth of the mantel. This also applies to the distance between the mantel leg (if so fitted) and the fireplace. Refer to Fig. 4a and Fig. 4b, and the Mantel Charts below for the correct mounting height and widths. The distances and reference points are not affected by the fitting of a bay window front trim kit. Noncombustible mantels and legs may be installed at any height and width around the appliance. To prevent discoloration, use only heat-resistant paint or lacquer to finish the mantel. Side of Combustion Chamber Mantel Leg CFM164b V Mantel Leg Dimensions (Minimum Width) W Ref. Mantel Leg Depth Ref. Mantel Leg from Side of Combustion Opening F G H I J 10" (254 mm) 8" (203 mm) 6" (152 mm) 4" (101 mm) 2" ( 50 mm ) K L M N O 11 1/2" (292 mm) 9 1/2" (241 mm) 7 1/2" (191 mm) 5 1/2" (140 mm) 3 1/2" ( 89 mm ) X Y Z A B C D E Fireplace Fig. 4b Mantel leg dimensions Hearth Top Louvre Assembly Top of Combustion Chamber Bottom of Door Trim CFM146 Mantel Shelf Dimensions (Minimum Height) Ref. Mantel Shelf Depth Ref. Height above Firebox V W X Y Z 10" (254 mm) 8" (203 mm) 6" (152 mm) 4" (101 mm) 2" ( 50 mm ) A B C D E 17" (432 mm) 15" (381 mm) 13" (330 mm) 11" (279 mm) 9" (229 mm) Fig. 4a Combustible mantel leg minimum installation 10004920 CFM166a A hearth is not mandatory, but is recommended for aesthetic purposes. We recommend using a noncombustible hearth which projects out 12” (305 mm) or more from the front of the fireplace. Cold climate installation recommendation: When installing this unit against a noninsulated exterior wall or chase, it is mandatory that the outer walls be insulated to conform to applicable insulation codes. CFM174 5 Vermont Castings, Majestic Products: DVR33 Framing and Finishing Final Finishing Check fireplace to make sure it is levelled and properly positioned. 1. Choose the unit location. 2. Place the unit into position and secure it to the floor with 1.5” (38 mm) screws, or nails. The holes to secure the unit to floor are located just behind the access door grille on the left and right side of the unit. Noncombustible materials such as brick or tile may be extended over the edges of the face of the appliance. DO NOT cover the window frame assembly, any vent, louvre assembly top or louvre assembly bottom. If a Trim Kit is going to be installed on the fireplace, the brick or tile will have to be installed flush with the edges of the appliance. 3. Frame in the fireplace with a header across the top. It is important to allow for the finished wall face when setting the depth of the frame. 4. Attach the fireplace to the frame using the adjustable frame drywall strips (located behind the access door for shipping). Preset the depth to suit the facing material of the wall. The strips are adjustable to 1/2” (13 mm), 5/8” (16 mm), or 3/4” (19 mm). (Fig. 5) 5. Screw through the slotted holes in the drywall strip and into predrilled holes in fireplace side. Measure from face of fireplace to the face of the drywall strip to confirm the final depth. Gas Specifications Fuel Gas Control Max. Input BTU/h DVR33RN Nat Millivolt 20,000 14,000 DVR33RP Prop Millivolt 20,000 15,000 DVR33EN Nat 24 V Hi/ Lo 20,000 14,000 DVR33EP Prop 24 V Hi/ Lo 20,000 15,000 Model Min. Input BTU/h Gas Inlet and Manifold Pressures C A Adjustable Drywall Strip (Nailing Flange) B Screw Position A B C Drywall Depths 1/2” (13 mm) 5/8” (16 mm) 3/4” (19 mm) Natural LP (Propane) Inlet Minimum 5.5” w.c. 11” w.c. Inlet Maximum 14” w.c. 14” w.c. Manifold Pressure 3.5” w.c. 10” w.c. DVR33 CERTIFIED TO ANSI Z21.88-2002 / CSA 2.33-2002 Vented Gas Fireplace Heaters High Elevations Adjustable 1/2”, 5/8” & 3/4” Spacing FP1023 Fig. 5 Adjustable drywall strip (nailing flanges). Input ratings are shown in BTU per hour and are certified without deration for elevations up to 4,500 feet (1,370 m) above sea level. For elevations above 4,500 feet (1,370 m) in USA, installations must be in accordance with the current ANSI Z223.1 and/or local codes having jurisdiction. In Canada, please consult provincial and/or local authorities having jurisdiction for installations at elevations above 4,500 feet (1,370 m). 6 10004920 Vermont Castings, Majestic Products: DVR33 Gas Line Installation When purging the gas lines, the front glass must be removed. The gas pipeline can be brought in through the side of the fireplace as well as the bottom. Knockouts are provided on the bottom behind the valve to allow for the gas pipe installation and testing of any gas connection. It is most convenient to bring the gas line in from the rear right side of the valve as this allows fan installation or removal without disconnecting the gas line. The gas line connection can be made with properly tinned 3/8” copper tubing, 3/8” rigid pipe or an approved flex connector. Since some municipalities have additional local codes, it is always best to consult your local authority and the CSA-B149.1 installation codes. For USA installations consult the current National Fuel Gas Code, ANSI Z223.1. Remote ON/OFF Switch Installation Do not wire the remote ON/OFF wall switch for this gas appliance into a 120 V power supply. 1. Thread the wiring through the electrical knockout located on either side of the unit. Take care not to cut the wire or insulation on metal edges. Ensure the wire is secured and protected from possible damage. Run one end of the gas control valve and the other end to the conveniently located wall switch. 2. Attach the wire to the ON/OFF switch and install the switch into the receptacle box. Attach the cover plate to the switch. 3. Connect the wire to the gas control valve (Fig. 7). Remote ON/OFF Switch TPTH 1/2" GAS SUPPLY TP 1/2" NPTx 1/2" FLARE SHUT-OFF VALVE 3/8" FLEX LINE (FROM VALVE) TH W584-9 Fig. 7 Remote switch wiring diagram for RN or RP models. FP297a Fig. 6 Typical gas supply installation. Always check for gas leaks with a mild soap and water solution applied with a brush no larger than 1” (25 mm). Never apply soap and water solution with a spray bottle. Do not use an open flame for leak testing. Alternate Switch Location The remote switch can be installed on either side of the access door. Mount the switch to the bracket provided and screw the bracket to either side of the frame, using the prepunched holes (Fig. 8). Do not subject the fireplace valve to test pressures exceeding 1/2 p.s.i. Isolate, or disconnect this and any other gas appliance control from the gas line when pressure testing. The gas control is equipped with a captured screw type pressure test point; therefore, it is not necessary to provide a 1/8" test point up stream of the control. When using copper or flex connector use only approved fittings. Always provide a union when using black iron pipe so that the gas line can be easily disconnected for burner or fan servicing (Fig. 6). See the gas specification for pressure details and ratings. CFM104 Fig. 8 Alternate switch location. 10004920 7 Vermont Castings, Majestic Products: DVR33 EB-1 Electrical Box The fireplace, when installed, must be electrically connected and grounded in accordance with local codes or, in the absence of local codes, with the current CSA C22.1 Canadian Electrical Code Inside Electrical Box Retaining Screw Front o f Unit For USA installations, follow the local codes and the national electrical code ANSI/NFPA No. 70. It is strongly suggested that EB-1 Electrical Junction Box wiring be carried out by a licensed electrician. Outside Ensure that the power to the supply line has been disconnected before commencing this procedure. To connect the EB-1 box to the house electrical supply follow the steps below. 1. Unscrew the retaining screw from the EB-1 base plate (Fig. 9), and remove the EB-1 assembly from the fireplace. 2. Remove the front cover of the EB-1 box. 3 Remove the plug socket assembly from the EB-1 box. 4. Feed the supply line in from the outside through the cable clamp (Fig. 9). 5. Connect black wire of the power supply line to the brass screw (polarized) of the socket assembly. 6. Connect the white wire of the power line to the chrome screw of the socket assembly. 7. Connect the ground wire of the supply line to the green screw of the socket assembly. 8. Refit the socket assembly back into the electrical box and replace the cover plate. Secure the cable with the clamp on the outside of the unit to prevent strain on the connections. 9. The EB-1 electrical junction box is now ready to supply power to the FK-12 or FK-24 fan kits, if so fitted. 8 nit t of U Fron The EB-1 electrical junction box has been supplied standard with this model to allow for easy installation of an optional fan kit. FP580 Fig. 9 EB-1 receptacle. 10004920 Vermont Castings, Majestic Products: DVR33 Electronic Gas Control Valve This appliance may be fitted with a Honeywell Ignition Module. To install the remote On/ Off starter switch on electronic ignition units (Fig. 10): PILOT 1. Thread the wiring through the holes on the side panels of the appliance. Take care not to cut the wire or insulation on metal edges. Route the wire to a conveniently located receptacle box. 2. Attach the wire to the On/ Off switch and install the switch into the receptacle box. 3. Connect the White wire from the wall switch to the Black wire from the transformer, using an approved wire nut. Connect the Black wire from the wall switch to the Black wire running from the #6 position of the ignition module, also using an approved wire nut. HONEYWELL IGNITION MODULE 2 3 4 ORANGE 1 RED 24V GRD MV/VP PV 5 24V 6 SENSE SPARK 8 9 GREEN MV ORANGE LO HI NOVA SIT 822 VALVE BLUE WHITE POWER CORD W/FEMALE SPADE 24 VAC HOT 120 VAC RTN WHITE BLACK BLACK YELLOW BLACK OFF WHITE GREEN 24 VAC RET 120 VAC HOT WALL SWITCH 40VA TRANSFORMER BLACK WHITE 10004083-Fig1 Fig. 10 Honeywell Ignition Module. General Venting Information Your fireplace is approved to be vented either through the side wall, or vertically through the roof. • Only venting components specifically approved and labeled for this fireplace may be used. • Venting terminals shall not be recessed into a wall or siding. • Horizontal venting must be installed on a level plane without any incline or decline. There must not be any obstruction such as bushes, garden sheds, fences, decks or utility buildings within 24" from the front of the termination hood. 10004920 Do not locate termination hood where excessive snow or ice build up may occur. Be sure to check vent termination area after snow falls, and clear to prevent accidental blockage of venting system. When using snow blowers, make sure snow is not directed towards vent termination area. Location of Vent Termination It is imperative to observe minimum clearances (shown on the following page) when locating vent terminations. 9 Vermont Castings, Majestic Products: DVR33 General Venting Information–Termination Location INSIDE CORNER DETAIL G V H A D V N N E V B C V L B Fixed Closed Ope F B V Operable rab V le V Fixed Closed G V B B B V J M X I A V VENT TERMINATION X AIR SUPPLY INLET G V K X V A AREA WHERE TERMINAL IS NOT PERMITTED Canadian Installations 1 A = Clearance above grade, veranda, porch, 12 in. (30 cm) deck or balcony B = Clearance to window/door that may be opened 6 in. (15 cm) for appliances <10,000 Btuh (3 kW); 12 in (30 cm) for appliances >10,000 Btuh (3 kW) and <100,000 Btuh (30 kW); 36 in. (91 cm) for appliances >100,000 Btuh (30 kW) C = Clearance to permanently closed window 12 in. (305 mm) recommended to prevent window condensation D = Vertical clearance to ventilated soffit located above the terminal within a horizontal distance 18 in. (458 mm) of 2 ft. (610 mm) from the center line of the terminal E = Clearance to unventilated soffit 12 in. (305 mm) F = Clearance to outside corner (See next page.) G = Clearance to inside corner (See next page.) H = Clearance to each inside of center line 3 ft. (91 cm) within a height of 15 ft. (4.57 m) extended above meter/regulator assembly above the meter/regulator assembly I = Clearance to service regulator vent outlet 3 ft. (91 cm) J = Clearance to non-mechanical air supply 6 in. (15 cm) for appliances <10,000 Btuh inlet to building or the combustion air inlet (3 kW); 12 in. (30 cm) for appliances to any other appliance >10,000 Btuh (3 kW) and <100,000 Btuh (30 kW); 36 in (91 cm) for appliances >100,000 Btuh (30 kW) K = Clearance to a mechanical air supply inlet 6 ft. (1.83 m) US Installations CFM145a 2 12 in. (30 cm) 6 in. (15 cm) for appliances <10,000 Btuh (3 kW); 9 in. (23 cm) for appliances >10,000 Btuh (3 kW) and <50,000 Btuh (15 kW); 12 in. (30 cm) for appliances >50,000 Btuh (15 kW) 12 in. (305 mm) recommended to prevent window condensation 18 in. (458 mm) 12 in. (305 mm) (See next page.) (See next page.) 3 ft. (91 cm) within a height of 15 ft. (4.57 m) above the meter/regulator assembly 3 ft. (91 cm) 6 in. (15 cm) for appliances <10,000 Btuh (3 kW); 9 in. (23 cm) for appliances >10,000 Btuh (3 kW) and <50,000 Btuh (15 kW); 12 in. (30 cm) for appliances >50,000 Btuh (15 kW) 3 ft. (91 cm) above if within 10 ft. (3.05 m) horizontally 7 ft. (2.13 m)† L = Clearance above paved sidewalk or a 7 ft. (2.13 m)† paved driveway located on public property M = Clearance under veranda, porch, deck or 12 in. (30 cm)‡ 12 in. (30 cm)‡ balcony N = Clearance above a roof shall extend a minimum of 24” (610 mm) above the highest point when it passes through the roof surface, and any other obstruction within a horizontal distance of 18” (450 mm). 1 In accordance with current CSA-B149 Installation Codes. 2 In accordance with current ANSI Z223.1/ NFPA 54 National Fuel Gas Codes. † A vent shall not terminate directly above a sidewalk or paved driveway which is located between two single-family dwellings, and which serves both dwellings. ‡ Only permitted if veranda/porch/deck is fully open on a of minimum two sides beneath the floor. NOTES: • Local codes or regulations may require different clearances. • The special venting system used on Vermont Castings, Majestic Products Direct Vent Fireplaces are certified as part of the appliance, with clearances tested and approved by the listing agency. Fig. 11 Vent termination clearances 10 10004920 Vermont Castings, Majestic Products: DVR33 Termination Clearances Termination clearances for buildings with combustible and noncombustible exteriors. Inside Corner Recessed Location Outside Corner A= Combustible 6"(152mm) Noncombustible 2"(50mm) A V B= Combustible 6"(152mm) Noncombustible 2"(50mm) V D C C E V B Balcony with perpendicular side wall Balcony with no side wall G V V G= Combustible NonCombustible 12"(305mm) C = Maximum depth of 48" (1219mm) for recessed location. H Combustible & NonCombustible D = Minimum width for back wall of a recessed location. Combustible 38"(965mm) Noncombustible 24"(610mm) J E = Clearance from corner in recessed location. Combustible 6"(152mm) Noncombustible 2"(50mm) H = 24"(610mm) J = 20"(508mm) CFM115 Fig. 12 Termination clearances. General Information for Connecting Vent Pipes Crimped End Pipes 1" (25 mm) from crimped end of pipe Before joining elbows and pipes, apply a bead of high temperature sealant to the crimped end of the elbow or pipe. Join the pipes using a 2” (50 mm) overlap and secure the joints with three sheet metal screws (Fig. 13). Wipe off excess sealant. Canadian Installations: The venting system must be installed in accordance with the current CSA-B149.1 installation code. USA Installations: The venting system must conform to local codes and/ or the current National Fuel Code ANSI Z223.1. Only venting components manufactured by Vermont Castings, Majestic Products may be used in Direct Vent systems. 10004920 Screw CFM175 Fig. 13 Apply a bead of high temperature sealant. 11 Vermont Castings, Majestic Products: DVR33 Twist Lock Pipes Max. 20" (508 mm) When using Vermont Castings, Majestic Products twist-lock pipe it is not necessary to use sealant on the joints. The only areas of the venting system that need to be sealed with high temperature silicone sealant are the collars on the fireplace and termination, and the sliding joint of any telescopic vent section used in the system. Top view flat installation To join twist lock pipes together, simply align the beads of the male end with the grooves of the female end, twisting the pipe until the flange on the female end contacts external flange on the male end. It is recommended that you secure the joints with three (3) sheet metal screws, however this is not mandatory with twist lock pipe (Fig. 14). Max. 20" (508 mm) To make it easier to assemble the joints we suggest putting a lubricant (Vaseline or similar) on the male end of the twist lock pipe prior to assembly. Top view corner installation Female End Male End FP1188 Fig. 15 Rear vent application, maximum horizontal distance. Rear Wall Vent Installation Step 1 Locate and cut the vent opening in the wall. Screw Holes TWL100 Fig. 14 Twist-Lock pipe joints. Rear Wall Vent Application When installed as a rear vent unit this appliance may be vented directly to a termination located on the rear wall behind the appliance • Only Vermont Castings, Majestic Products venting components are approved to be used in these applications (See Venting Components listed for different installation requirements). • The maximum horizontal distance between the rear of the appliance (or end of the transition elbow in a corner application) and the outside face of the rear wall is 20” (508 mm) (Fig. 15). • Only one 45˚ elbow is allowed in these installations. • The minimum clearances between any combustible material and the vent pipe sections are: Top 2” (50 mm) Sides 1” (25 mm) Bottom 1” (25 mm) 12 For combustible walls first frame in opening (Fig. 16). Combustible Walls: Cut a 10³⁄₈”H x 9³⁄₈” W (265 mm x 240 mm) hole through the exterior wall and frame as shown. Noncombustible Walls: Hole opening should be 7¹⁄₂” (190 mm) in diameter. Zero clearance sleeve is only required for combustible walls. Step 2 Measure wall thickness, and cut zero clearance sleeve to proper length; i.e., max. 12” (304.8 mm). Assemble sleeve to its maximum opening (103⁄8” x 93⁄8”) and attach to firestop with #8 sheet metal screws (supplied). Install firestop assembly (Fig. 17). Step 3 Measure the horizontal length requirement for the venting including a 2” (50 mm) overlap, i.e. from the elbow to the outside wall face plus 2” (50 mm) (Fig. 15). 10004920 Vermont Castings, Majestic Products: DVR33 Vent Opening — Combustible Wall Finished Wall (240mm) 9³⁄₈" These ends screwed to appliance These ends should be even Vent Termination 10³⁄₈" (254mm) (framing detail) Vent Opening — Noncombustible Wall 7¹⁄₂" (190mm) CFM116 FP1005 Fig. 16 Vent opening, side wall. Fig. 18 Flat to the wall installation. 12" (304.8 mm) max. #8 Screws (2) #8 Screws (2) Firestop (Side View) CFM135a Fig. 17 Zero clearance sleeve. Step 4 Install the 4” (100 mm) vent to the appliance collar and secure with 3 sheetmetal screws. Install the 7” (175 mm) vent pipe to the appliance collar and secure with 3 sheetmetal screws. It is not necessary to seal this connection. If a 45˚ elbow is being used attach the elbow to the appliance in the same manner then attach the venting to the elbow. It is critical that there is no downward slope away from the appliance when connecting the vent or elbow. Step 5 Guide the venting through the vent hole as you place the appliance in its installed position. Guide the 4” (100 mm) and 7” (175 mm) collars of the vent termination into the outer ends of the venting. Do not force the termination. If the vent pipes do not align with the termination remove and realign the venting at the appliance flue collars (Fig. 18). Attach the termination to the wall as outlined in the instruction sheet supplied with the termination. 10004920 13 Vermont Castings, Majestic Products: DVR33 How To Use the Vent Graph Vertical Sidewall Application The Vent Graph should be read in conjunction with the following vent installation instructions to determine the relationship between the vertical and horizontal dimensions of the vent system. Since it is very important that the venting system maintain its balance between the combustion air intake and the flue gas exhaust, certain limitations as to vent configurations apply and must be strictly adhered to. 1. Determine the height of the center of the horizontal vent pipe exiting through the outer wall. Using this dimension on the Sidewall Vent Graph (Fig. 19), locate the point intersecting with the slanted graph line. 2. From the point of this intersection, draw a vertical line to the bottom of the graph. 3. Select the indicated dimension, and position the fireplace in accordance with same. Example A: If the vertical dimension from the floor of the fireplace is 11’ (3.4 m) the horizontal run to the face of the outer wall must not exceed 14’ (4.3 m) Example B: If the vertical dimension from the floor of the unit is 7’ (2.14 m) the horizontal run to the face of the outer wall must not exceed 8¹⁄₂’ (2.6 m) The Vent Graph, showing the relationship between vertical and horizontal side wall venting, will help to determine the various dimensions allowable. Minimum clearance between vent pipes and combustible materials is one 1” (25 mm) on top, bottom and sides unless otherwise noted. When vent termination exits through foundations less than 20” (508 mm) below siding outcrop, the vent pipe must flush up with the siding. It is best to locate the fireplace a way that minimizes the number of offsets and horizontal vent length. The horizontal vent run refers to the total length of vent pipe from the flue collar of the fireplace (or the top of the Transition Elbow) to the face of the outer wall. Horizontal plane means no vertical rise exists on this portion of the vent assembly. 30 29 28 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 eg: A 11 10 9 8 7 eg: B 6 Vertical Dimension From The Floor Of the unit To The Centre Of The Horizontal Vent Pipe 27 When installing the appliance as a rear vent unit, the 90° or 45° transition elbow attached directly to the rear of the unit is NOT INCLUDED in the following criteria and calculations. Unless this transition elbow is specifically mentioned, it should be ignored when calculating venting layouts. (3) x 90 degree elbows Min. 7.5' (2.3 m) 5 4 Max. 20' (6.1 m) 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Horizontal Dimension From the Outside Face of the Wall to the Center of the Fireplace Vent Flange Sidewall Vent Graph showing the relationship between vertical and horizontal dimensions for a Direct Vent flue system. CFM102 Fig. 19 Sidewall venting graph. (Dimensions in feet.) 14 Fig. 20 Maximum three (3) 90° elbows per installation. • The maximum number of 90˚ elbows per side wall installation is three (3) (Fig. 20). 10004920 Vermont Castings, Majestic Products: DVR33 As shown in Fig. 22, the total of dimension A and B is not to be greater than 17’ (5.2 m). Max. 3' (914 mm) Fig. 21 Maximum horizontal run with no rise. • If a 90˚ elbow is used in the horizontal vent run (level height maintained), the maximum horizontal vent length is reduced by 36” (914 mm) (Fig. 22). This does not apply if the 90˚ elbows are used to increase or redirect a vertical rise (Fig. 20). Example: According to the vent graph (page 14), the maximum horizontal vent length in a system with a 7.5’ (2.3 mm) vertical rise is 20’ (6 m), and if a 90˚ elbow is required in the horizontal vent, it must be reduced to 17’ (5.2 m). • The maximum number of 45˚ elbows permitted per side wall installation is two (2). These elbows can be installed in either the vertical or horizontal run. • For each 45˚ elbow installed in the horizontal run, the length of the horizontal run MUST be reduced by 18” (45 cm). This does not apply if the 45˚ elbows are installed on the vertical part of the vent system. • The maximum number of elbow degrees in a system is 270˚ (Fig. 23). Example: Elbow 1 = 90˚ Elbow 2 = 45˚ Elbow 3 = 45˚ Elbow 4 = 90˚ Total angular variation = 270˚ 1 + 2 + 3 + 4 = 270º Elbow 4 Elbow 3 Elbow 2 Elbow 1 “B” 7’ (2134 mm) “A” 10’ (3048 mm) Ignore Transition Elbow 90° Elbow = 3’ 7’6” (2286 mm) A + B = 17’ (5.2 m) max. Fig. 23 Maximum elbow usage. Redirected vertical rise V584-201 Fig. 22 Maximum vent run with elbows. 10004920 15 Vermont Castings, Majestic Products: DVR33 Vertical Sidewall Installation Step 1 Locate vent opening on the wall. It may be necessary to first position the fireplace and measure to obtain hole location. Depending on whether the wall is combustible or noncombustible, cut opening to size. (For combustible walls, frame in opening first (Fig. 24). X Combustible Walls: Cut a 9³⁄₈”H x 9³⁄₈” W (240 mm x 240 mm) hole through the exterior wall and frame. Noncombustible Walls: Hole opening must be 7¹⁄₂” (190 mm) in diameter. Vent Opening: Combustible Wall 9 3/8” (240 mm) VSW height X 9 3/8” (240 mm) Fig. 26 Vertical height requirements. Step 3 Framing Detail Fireplace Hearth Vent Opening: Noncombustible Wall Place fireplace into position. Measure the vertical height (X) required from the base of the flue collars to the center of the wall opening (Fig. 26). Step 4 71/2” Dia. (190 mm) VO584-100 Fig. 24 Locate vent opening on wall. 12" (304.8 mm) max. Apply a bead of high temperature silicone sealant to the inner and outer flue collars of the fireplace and using appropriate length of pipe section(s) attach to fireplace with three (3) screws. Follow with the installation of the inner and outer elbow, again secure joints as described in the ‘Connecting Vent Pipe’ section. Step 5 #8 Screws (2) #8 Screws (2) Firestop (Side View) Always install horizontal venting on a level plane. CFM135a Fig. 25 Adjustable zero clearance sleeve. Zero clearance sleeve is required only for combustible walls. Step 2 Measure wall thickness and cut zero clearance sleeve parts to proper length (12” [305 mm] max.). Assemble sleeve and attach to firestop with #8 sheetmetal screws (supplied). Install firestop assembly (Fig. 25). 16 Measure the horizontal length requirement including a 2” (50 mm) overlap, i.e. from the elbow to the outside wall face plus 2” (50 mm)—or the distance required if installing a second 90˚ elbow (Fig. 27). Step 6 Use the appropriate length of pipe sections—telescopic or fixed—and install. The sections which go through the wall are packaged with the starter kit, and can be cut to suit if necessary. NOTE: Sealing vent pipe and firestop gaps with high temperature sealant will restrict cold air being drawn in around fireplace. 10004920 Vermont Castings, Majestic Products: DVR33 High Temperature Sealant If installing a snorkel, a minimum 24” (610 mm) vertical rise is necessary. The maximum horizontal run with the 24” (610 mm) vertical pipe is 36” (915 mm). This measurement is taken from the collar of the fireplace (or transition elbow) to the face of the exterior wall. See the Sidewall Venting Graph for extended horizontal run if the vertical exceeds 24” (610 mm). X 1. Establish vent hole through the wall (Fig. 24, page 16). 2. Remove soil to a depth of approximately 16” (406 mm) below base of snorkel. Install drain pipe. Install window well (not supplied). Refill hole with 12” (305 mm) of coarse gravel leaving a clearance of approximately 4” (100 mm) below snorkel (Fig. 28). 3. Install vent system. CFM137 Fig. 27 Horizontal length requirement. Step 7 Apply high temperature sealant to 4” (100 mm) and 7” (175 mm) collars or the termination one inch away from crimped end. Guide the vent terminations 4” and 7” collars into their respective vent pipes. Double check that the vent pipes overlap the collars by 2” (50 mm). Secure the termination to the wall with screws provided and caulk around the wall plate to weatherproof. As an alternative to screwing the termination directly to the wall, you may also use expanding plugs or an approved exterior construction adhesive. Or, you may attach the termination with screws through the inner body into the 4” vent pipe—however, for this method, you must extend the 4” pipe approximately 6” (150 mm) beyond the outer face of the wall. 4. Ensure a watertight seal is made around the vent pipe coming through the wall. 5. Apply high temperature sealant caulking (supplied) around the 4” and 7” snorkel collars. 6. Slide the snorkel into the vent pipes and secure to the wall. 7. Level the soil so as to maintain a 4” clearance (100 mm) below snorkel (Fig. 28). Zero Clearance Sleeve, if required 7DVSKS (Snorkel) Firestop 7" pipe Screws Min. clearance 4" (102 mm) Ground Window well Gravel 24" (608 mm) min.* Drain Support horizontal pipes every 3’ (91 cm) with metal pipe straps. Foundation wall * Minimum 24" (608 mm) vertical pipe must be installed when using 7DVSKS Kit. Below Grade Installation When it is not possible to meet the required vent terminal clearances of 12” (305 mm) above grade level, a Snorkel Vent Kit #7DVSKS is recommended. It allows installation depth down to 7” (178 mm) below grade level. The 7” (178 mm) is measured from the center of the horizontal vent pipe as it penetrates through the wall. NOTE: Ensure that sidewall venting clearances are observed. If the venting system is installed below ground, we recommend a window well with adequate and proper drainage to be installed around the termination area. 10004920 CFM193 Fig. 28 Below grade installation. Do not backfill around snorkel. A clearance of at least 4” (102 mm) must be maintained between the snorkel and the soil. 17 Vermont Castings, Majestic Products: DVR33 If the foundation is recessed, use recess brackets (not supplied) for securing lower portion of the snorkel. • Up to two 45° elbows may be used within the Fasten brackets to wall first, then secure to snorkel with self drilling #8 x 1/2 sheet metal screws. It will be necessary to extend vent pipes out as far as the protruding wall face (Fig. 29). • Snorkel • Two sets of 45° elbows offsets may be used within the vertical sections. From 0 to a maximum of 8’ (2.5 m) of vent pipe can be used between elbows (Fig. 30). • 7DVCS supports offsets (Fig. 32). This application will require that you first determine the roof pitch and use the appropriate starter kit. (See Venting Components List). • The maximum angular variation allowed in the system is 270° (Fig. 31). • The minimum height of the vent above the highest point of penetration through the roof is 2’ (610 mm) (Fig. 33). Foundation Recess Wall screws Sheetmetal screws Watertight Seal Around Pipe CFM139 Fig. 29 Snorkel installation, recessed foundation. horizontal run. For each 45° elbow used on the horizontal plane, the maximum horizontal length must be reduced by 18” (450 mm). Example: Maximum horizontal length No elbows = 10’ (3 m) 1 x 45° elbows = 8.5’ (2.6 m) 2 x 45° elbows = 7’ (2.1 m) A minimum of an 8’ (2.5 m) vertical rise is required. Vertical Through-the-Roof Applications This Gas Fireplace has been approved for, • Vertical installations up to 40’ (12 m) in height. Up to a 10’ (3 m) horizontal vent run can be installed within the vent system using a maximum of two 90° elbows (Fig. 30). * 45 degree elbows * Maximum 8' (2.5m) * Max. 40' (12 m) Min. 7.5' (2.3 m) TTR_max45 Fig. 31 Maximum elbow usage. Max. 10' (3.1 m) TTR max dim Fig. 30 Support straps for horizontal runs. 18 10004920 Vermont Castings, Majestic Products: DVR33 Vertical Through-the-Roof Installation 1. Locate your fireplace. 2. Plumb to center of the (4”) flue collar from ceiling above and mark position. 3. Cut opening equal to 9 3/8” x 9 3/8” (240 mm x 240 mm). 4. Proceed to plumb for additional openings through the roof. In all cases, the opening must provide a minimum of 1 inch clearance to the vent pipe, i.e., the hole must be at least 9 3/8” x 9 3/81 (240 mm x 240 mm). 5. Place fireplace into position. 6. Place firestop(s) #7DVFS or Attic Insulation Shield #7DVAIS into position and secure (Fig. 32). 7. Install roof support (Fig. 33) and roof flashing, making sure upper flange is below the shingles (Fig. 34). 8. Install appropriate pipe sections until the venting is above the flashing (Fig. 34). 9. Install storm collar and seal around the pipe. 10. Add additional vent lengths for proper height (Fig. 33). 11. Apply high temperature sealant to 4” and 7” collars of vertical vent termination and install. If a room is above ceiling level, a firestop spacer must be installed on each level (top and bottom) of the ceiling joists. If an attic is above ceiling level, a 7DVAIS (Attic Insulation Shield) must be installed. Always face the enlarged ends of the vent section downward. Typical Ceiling Support Application Typical Roof Support Application FP1184 Fig. 32 Venting supports. Min. 2’ (610 mm) FP1189 Fig. 33 Minimum termination to roof clearance. (3) #5 Sheet Metal Screws per Joint Sealant Storm Collar Attic Insulation Shield (3) #5 Sheet Metal Screws per Joint Sealant Storm Collar TWL101a Upper Floor Fig. 34 Roof flashing. 11" 11" Ceiling Installation Joist Firestop Spacer Nails (4) FP1029 Fig. 32 Attic insulation shield and firestop spacer. 10004920 19 Vermont Castings, Majestic Products: DVR33 DVR33 Bracket Restricter Installation NOTES: When installing DVR33 with a vertical through-the-roof configured flue system, the bracket restricter supplied with the appliance (part# 10002910) should be fitted to the appliance at installation. For DVR33 numbers A12H00, A12I00, A14A00 and A14B00 only, the restricter plate for the vertical termination (part# 10003246) must be installed for vertical runs over 20’ (6.1 m). Fitting the Bracket Restricter 1. Remove the window glass/frame assembly. Locate the baffle firebox assembly in the top rear of the firebox (Fig. 35). 2. Remove the four (4) nuts along the front edge, and the three (3) screws along the rear edge of the baffle assembly. Remove the baffle assembly from the firebox. 3. Remove the two (2) screws from the top face of the baffle assembly (Fig. 36). Place the bracket restricter as it is shown in Fig. 37, and secure it by refitting the screws. 4. Refit the baffle assembly to the firebox, replacing the three (3) screws and four (4) nuts. 5. Refit window glass/frame per the appropriate sections. Fig. 36 Top face of baffle assembly Fig. 37 Assembling bracket restricter to baffle assembly Baffle firebox assembly Fig. 35 Baffle firebox assembly 20 10004920 Vermont Castings, Majestic Products: DVR33 Twist Lock Venting Components 7DVRVT - Through-the-Wall Rear Vent Termination Starter Kit-Model 7TDVSK - Sidewall Venting Starter Kit-Model 7TDVSKV - Vertical Venting for 7TDVSKV-A order 1/12 to 6/12 roof pitch for 7TDVSKV-B order 7/12 to 12/12 roof pitch for 7TDSKV-F order flat roof Starter Kit-Model 7TDVSKS - Snorkel Kit for Below Grade Installation 45˚ elbow kit 7TDVT45 for Vertical Installation Offsets 7TDR45 for Rear Vent Application 90˚ Transition elbow kit 7TDVRT90 for Vertical Sidewall Applications or through-the-roof. Telescopic vent sections 7TDVP1218 -12” to 18” adjustable length 7TDVP3564 -35” to 64” adjustable length Pipe sections for vertical or horizontal venting Model 7TDVP8” 4 per box Model 7TDVP12” 4 per box Model 7TDVP24” 4 per box Model 7TDVP36” Model 7TDVP48” Firestop Spacer Model 7DVFS Attic Insulation Shield Model 7DVAIS Vertical/Horizontal Combination Offset Support Model 7DVC 10004920 21 Vermont Castings, Majestic Products: DVR33 Crimped End Venting Components 7DVRVT - Through the wall Rear Vent Termination Starter Kit-Model 7DVSK - Sidewall Venting Starter Kit-Model 7TDVSKV - Vertical Venting for 7DVSKV-A order 1/12 to 6/12 roof pitch for 7DVSKV-B order 7/12 to 12/12 roof pitch for 7DSKV-F order flat roof Starter Kit-Model 7TDVSKS-Snorkel Kit for Below Grade Installation 45˚ elbow kit 7DVT45 for Vertical Installation Offsets 7DV45 for Rear Vent Application 90˚ Transition elbow kit 7DVRT90 for Vertical Sidewall Applications or through-the-roof. Telescopic vent sections 7DVP6106” to 10” adjustable length 7DVP101810” to 18” adjustable length 7DVP183418” to 34” adjustable length 7DVP346634” to 66” adjustable length Pipe sections for vertical or horizontal venting Model 7DVP8” 4 per box Model 7DVP12” 4 per box Model 7DVP24” 4 per box Model 7DVP36” Model 7DVP48” Firestop Spacer Model 7DVFS Attic Insulation Shield Model 7DVAIS Vertical/Horizontal Combination Offset Support Model 7DVCS 22 10004920 Vermont Castings, Majestic Products: DVR33 Operating Instructions Glass Information Use only glass approved by Vermont Castings, Majestic Products on this fireplace. • The use of any non-approved replacement glass will void all product warranties. • Care must be taken to avoid breakage of the glass. • Under no circumstances should this appliance be operated without the front glass in place, or with the glass in a damaged condition. • Replacement glass (complete with gasket) is available through your Vermont Castings, Majestic Products dealer, and should only be installed by a licensed qualified service person. 6. Tilt window frame assembly out slightly at the bottom, lift the frame up and away from the fireplace. 7. To replace window frame assembly, reverse this procedure. Lower Clamps Window Frame Assembly Louvre Removal To remove the louvre assembly top, lift the panel up and out from the fireplace (Fig. 38). NOTE: The louvre assembly bottom is hinged at the bottom edge and swings down. Window Frame Assembly Pull Clamp Hook Push Clamp Handle FP1191 Fig. 39 Window frame assembly removal. Glass Cleaning 2. It is necessary to periodically clean the glass panel. Louvre Assembly Top 1. Window Frame Assembly FP444 Fig. 38 Remove louvre assembly top. Window Frame Assembly Removal 1. Turn the fireplace OFF (including the pilot). 2. If the unit has been operating, allow time for the components to cool. 3. Remove the louvre assembly top. 4. Open the louvre assembly bottom. 5. Release the two clamps along lower edge of the frame by pulling down on clamp handles (Fig. 39). 10004920 During start-up, it is normal for condensation to form on the inside of the panel. This condensation causes lint, dust and other airborne particles to cling to the surface of the glass. Also, initial paint curing may deposit a slight film on the glass. It is therefore recommended the glass panel be cleaned two or three times with a non-ammonia-based household cleaner and warm water within the first few weeks of operation. We recommend using gas fireplace glass cleaner. After the initial cleaning process, clean the glass two or three times during each operating season, depending on the environment in the house. Clean the glass after the first two weeks of operation. Do not clean glass when it is hot. Do not use abrasive cleaners. Do not strike or slam the glass. 23 Vermont Castings, Majestic Products: DVR33 Installation of Logs and Lava Rock Material The logs are fragile and should be handled with care. Keep the packaging material out of the reach of children, and dispose of the material in a safe manner. During this procedure, refer to Fig. 40 for log identification. 1. Remove the top louvre assembly. 2. Remove the window frame assembly. See “Window Frame Assembly Removal” on page 23. 3. Fit the rear right log (A34) in place on the rear log support. The hole in the underside of the log fits over the pin on the right end of the support shelf. 4. Fit the front/rear left log (A33) in place on the rear log support. The hole in the underside of the log fits over the pin on the left end of the support shelf. 5. Fit the front right log (A35) in place, the top end of the log with the hole in the underside aligning with the knob on the rear right log (A34), and the other end with the cut slot resting on the right side edge of the front grate. 6. Fit the front center log (A36) on the center slot of the front grate. The flat end of this log sets against the back wall of the front grate plate. A34 A33 A35 Lava Rock: (Part Number 10001454) Remove from packaging and spread over the sides of the burner housing. Do not place this material on the burner tiles. Fig. 41 DVR33 Log Set Assembly. NOTE: Glowing lava rock for DVR33 is only allowed to be positioned at the front area (radiant portion) of the burner housing assembly. Flame and Temperature Adjustment RN/RP and EN/EP Models For units equipped with ‘HI/LO’ valves the flame adjustment is accomplished by rotating the ‘HI/LO’ adjustments knob located near the center of the gas control valve (Fig. 41 and Fig. 42). Turn counterclockwise to decrease flame height Turn clockwise to increase flame height Honeywell Valve Honeywell Fig. 41 Flame adjustment knob for Honeywell Valve. A36 Fig. 40 DVR33 Log Set (top view) The log set contains two types of lava rocks. Placing these materials is best done after the logs have been installed. Glowing Lava Rock: (Part Number 57897) Remove from the packaging and spread them over the burner tiles in a random fashion to fill the space highlighted in Fig 41. 24 Turn counterclockwise to increase flame height Turn clockwise to decrease flame height SIT Valve Nova820 Fig. 42 Flame adjustment knob for SIT Valve. 10004920 Vermont Castings, Majestic Products: DVR33 Flame Characteristics Inspecting the Venting System It is important to periodically perform a visual check of the pilot and burner flames. Compare them to the pictorials illustrated below (Fig. 43 and Fig. 44). If the flame patterns appear abnormal, contact a qualified service provider for service and adjustment. 3/8” – 1/2” This appliance venting system is designed and constructed to develop a positive flow adequate to remove flow gases to the outside atmosphere. Any foreign objects in the venting system, except those designed specifically for the venting system, may cause spillage of flue gases. To inspect the venting system, make sure the main gas valve is off. Remove the window frame assembly (Refer to Window Frame Assembly Removal section). Using a flashlight, check the area above the baffle in the combustion dome. Clean if necessary. SIT Pilot RN/RP Pilot_SIT SIT Pilot EN/EP SIT_pilot PSE Pilot RN/RP CFM181 Fig. 43 Correct pilot flame appearance. Fig. 44 Correct burner flame appearance. 10004920 25 Vermont Castings, Majestic Products: DVR33 Lighting and Operating Instructions FOR YOUR SAFETY, READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This heater has a pilot which must be lit manually. When lighting the pilot follow these instructions exactly. B. BEFORE LIGHTING smell all around the heater area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS • Do not try to light any fireplace. • Do not touch any electric 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. C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it, call a qualified service technician. Applying force or any attempted repair may result in a fire or explosion. D. Do not use this fireplace if any part has been under water. Immediately call a qualified service technician to inspect the heater and to replace any part of the control system and any gas control which has been under water. Lighting Instructions 1. STOP! Read the safety information above. 2. Turn off all electrical power to the fireplace. 3. For MN/MP/TN/TP appliances ONLY, go on to Step 4. For RN/RP appliances turn the On/Off switch to “OFF” position or set thermostat to lowest level. 4. Open control access panel. 5. Push in gas control knob slightly and turn to "OFF". clockwise OFF ON OFF 3/8" - 1/2" OFF 3 4 5 Euro SIT ON 1 2 P OFF ilot PI LO T PILOT 10. Push the control knob all the way in and hold. Immediately light the pilot by repeatedly depressing the piezo spark igniter until a flame appears. Continue to hold the control knob in for about one (1) minute after the pilot is lit. Release knob and it will pop back up. Pilot should remain lit. If it goes out, repeat steps 5 through 8. • If knob does not pop up when released, stop and immediately call your service technician or gas supplier. SIT NOVA Honeywell 6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above. If you do not smell gas, go to the next step. 7. Remove glass door before lighting pilot. (See Glass Frame Removal section). 8. Visibly locate pilot by the main burner. 9. Turn knob on gas control counter-clockwise to "PILOT". • If after several tries, the pilot will not stay lit, turn the gas control knob to "OFF" and call your service technician or gas supplier. 11. Replace glass door. 12. Turn gas control knob to “ON” position. 13. For RN/RP appliances turn the On/Off switch to “ON” position or set thermostat to desired setting. 14. Turn on all electrical power to the fireplace. To Turn Off Gas To Heater 1. Turn the On/Off switch to Off position or set the thermostat to lowest setting. 2. Turn off all electric power to the fireplace if service is to be performed. 26 3. Open louvre assembly bottom. 4. Push in gas control knob slightly and turn clockwise to "OFF". Do not force. 5. Close control access panel. 10004920 Vermont Castings, Majestic Products: DVR33 Lighting and Operating Instructions For Fireplaces equipped with SIT822 Gas Valve (EN or EP) Warning: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury and loss of life. For your safety, read the following warnings before lighting the appliance: A. This fireplace is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand. B. BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than the air and will settle on the floor. What to do if you smell gas • Do not try to light any appliance • Do not operate any electrical switch. • Do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas suppliers instructions. • If you cannot contact your gas supplier call the Fire Department C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand do not try to repair it, call a qualified service technician. Force or attempting repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and replace any part of the control system and any gas control that has been under water. Lighting Instructions 1. STOP! Read the safety information above before continuing. 5. Turn the remote switch, if used, OFF. Turn the wireless remote, if used, OFF. 2. Turn off all electrical power to the appliance. 6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas STOP. Follow instructions B in the safety warnings above. If you do not smell gas go onto the next step. 3. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand. 4. Access the gas control by lowering the lower access door (louvre assembly). 7. Close the access door. 8. Turn ON all electrical power to the appliance. 9. Turn remote switch or wireless remote to ON. 10. If the appliance will not operate, follow the instructions “Turning Off the Gas to the Appliance” (below), and call your service technician or gas supplier. LO HI Turning Off the Gas to the Appliance 1. 2. 3 4. Turn the remote switch to the “OFF” position. Turn OFF all electrical power to the fireplace if service is required. Open the lower access panel. Turn the shut-off valve on the flexible gas line to the “OFF” position. 10004920 1/2" GAS SUPPLY 1/2" NPTx 1/2" FLARE SHUT-OFF VALVE 3/8" FLEX LINE (FROM VALVE) NOTE: Shut-off valve is shown in “ON” position 27 Vermont Castings, Majestic Products: DVR33 Troubleshooting – Honeywell Millivolt Valve Window Frame Assembly Should be Removed Before Service Work CHECK Gas Supply ON NO ▼ START • Supply line hooked up • Shutoff valve OPEN YES • Lockout has engaged. Wait 60 seconds and try again. Pilot lights with Piezo igniter NO ▼ ▼ • For spark at electrode while • • depressing Piezo, 1/8" gap to pilot hood needed. All wiring connections Replace Piezo igniter • • • • • • For air in the lines Thermopile needs min. 325 mv Adjust Pilot flame height All wiring connections Replace thermopile Thermocouple needs min. 14 mv YES PILOT STAYS LIT NO ▼ ▼ YES • Valve is turned ON • Wall switch is not turned ON. ▼ YES Watch for grounded wires! NO ▼ PILOT LIGHTS MAIN BURNER • Thermopile needs min. 325 mv. • Plugged burner orifice • Defective Valve: Turn to Pilot; meter should read greater than 100 mv. If not, replace. ▼ SYSTEM OK 28 10004920 Vermont Castings, Majestic Products: DVR33 Troubleshooting the Gas Control System SIT NOVA 820 MILLIVOLT VALVE Note: Before trouble shooting the gas control system, be sure external gas shut off is in the “On” position. WARNING: BEFORE DOING ANY GAS CONTROL SERVICE WORK, REMOVE GLASS FRONT. SYMPTOM 1. Spark ignitor will not light 2. Pilot will not stay lit after carefully following lighting instructions. 3. Pilot burning, no gas to main burner 4. Frequent pilot outage problem. 10004920 POSSIBLE CAUSES CORRECTIVE ACTION A. Defective or misaligned electrode at pilot. Using a match, light pilot. If pilot lights, turn off pilot and push the red button again. If pilot des not light, check gap at electrode and pilot; it should be 1/8" to have a strong spark. B. Defective ignitor (Push Button) Push Piezo Ignitor Button. Check for spark at electrode and pilot. If no spark to pilot, and elec trode wire is properly connected, replace ignitor. A. Defective pilot generator (thermocouple), remote wall switch. Check pilot flame. Must impinge on thermo couple/thermopile. Note: this pilot burner assem bly utilizes both-a thermocouple and a thermopile. The thermocouple operates the main valve operation (On and Off). Clean and or adjust pilot for maximum flame impingement on thermopile and thermocouple. B. Defective automatic valve Turn valve knob to “Pilot”. Maintain flow to pilot; millivolt meter should read greater than 10 mV. If the reading is okay and the pilot does not stay on, replace the gas valve. Note: An interrupter block (not supplied) must be used to conduct this test. A. Wall switch or wires defective Check wall switch and wires for proper connec tions. Jumper wire across terminals at wall switch, if burner comes on, replace defective wall switch. If okay, jumper wires across wall switch wires at valve, if burner comes on, wires are faulty or connections are bad. B. Thermopile may not be generating sufficient millivoltage. 1. Be sure wire connections from thermopile at gas valve terminals are tight and thermopile is fully inserted into pilot bracket. 2. One of the wall switch wires may be grounded. Remove wall switch wires from valve terminals if pilot now stays lit, trace wall switch wiring for ground. May be grounded to fireplace or gas supply. 3. Check thermopile with millivolt meter. Take reading at thermopile terminals of gas valve. Should read 250-300 millivolts (minimum 150) while holding valve knob depressed in pilot position and wall switch “Off”. Replace faulty thermopile if reading is below specified minimum. C. Plugged burner orifice. Check burner orifices for debris and remove. D. Defective automatic valve operator. Turn valve knob to “On”, place wall switch to “On” millivolt meter should read greater than 100 mV. If the reading is okay and the burner does not come on, replace the gas valve. A. Pilot flame may be too low or blowing (high) causing the pilot safety to drop out. Clean and/or adjust pilot flame for maximum flame impingement on thermopile and thermocouple. B. Possible blockage of the vent terminal. Check the vent terminal for blockage (recycling the flue gases) 29 Vermont Castings, Majestic Products: DVR33 Troubleshooting the Gas Control System SIT 822 Valve with a Honeywell Electronic Igniter NOTE: Remove glass before servicing. START TURN GAS SUPPLY OFF NO TURN ON/OFF SWITCH TO CALL FOR HEAT CHECK: POWER TO MODULE (24V NORMAL) YES APRK ACROSS IGNITOR SENSOR GAP NO LINE VOLTAGE (120VAC) LOW VOLTAGE TRANSFORMER (19.5 minimum VAC) ON/OFF SWITCH WIRING CONNECTIONS UNPLUG IGNITION LEAD AND CHECK SPARK AT MODULE (24VAC normal) NO REPLACE MODULE SPARK OK? YES YES CHECK IGNITION CABLE GROUND WIRING, CERAMIC INSULATOR AND GAP. CORRECT AS NECESSARY CHECK BOOT OF IGNITION CABLE FOR SIGNS OF MELING OR BUCKLING. TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES. TURN GAS ON NO PILOT BURNER LIGHTS? YES SPARK STOPS WHEN PILOT IS LIT? NO NO MAIN BURNER LIGHTS? YES YES TROUBLESHOOTING ENDS 30 NOTE: IF S8600B GOES INTO LOCKOUT, RESET SYSTEM. CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE. CLEAN FLAME ROD. CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROAD & MODULE. CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR. CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR. CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY BLUE ADJUST PILOT FLAME. IF PROBLEM PERSISTS, REPLACE MODULE. YES SYSTEM RUNS UNTIL ON/OFF SWITCH IS IN "OFF" POSITION CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER ORIFICE IS NOT BLOCKED. CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OEPRATOR ON GAS CONTROL. CHECK FOR 24VAC ACROSS PV-MVPV TERMIANLS ON MODULE IF VOLTAGE IS OKAY, REPLACE GAS CONTROL IF NOT, REPLACE MODULE. NO CHECK FOR 24VAC ACROSS MV-MVPV TERMINALS IF NO VOLTAGE, REPLACE MODULE. CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL. IF OKAY, REPLACE GAS CONTROL, OR GAS CONTROL OPERATOR. NOTE: IF S8600B GOES INTO LOCKOUT, RESET SYSTEM. CHECK FOR CONTINUITY OF IGNITION CABLE AND GROUND WIRE. NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT. CHECK THAT THE PILOT FLAME COVERS FLAME ROAD AND IS STEADY AND BLUE. IF CHECKS ARE OKAY, REPLACE MODULE 10004920 Vermont Castings, Majestic Products: DVR33 Fuel Conversion Instructions For RN and RP models only: The conversion of this appliance from one gas to another must be carried out by an authorized service provider. 1. Disconnect power to unit and shut off the gas supply. 2. Remove the glass (see “Window Frame Assembly Removal” section). 3. Carefully remove the logs and lava rock material. 4. Remove the pilot assembly from the bracket. 5. Remove the screws that are holding the burner housing assembly in place. 6. Remove the burner housing assembly. 7. Remove front and rear orifice and replace with the orifice supplied in the conversion kit. Use the orifice with the smallest hole for the front burner and the orifice with the largest hole for the rear burner. NOTE: On the DVRT43 (only), the adjustable air shutter on the end burner housing must be replaced. Refer to the instructions in the specific gas conversion kit for details. 8. SIT Top Convertible Pilot Gently lift off pilot hood from the pilot. (Do not remove the spring clip holding the hood in place). Using a 5/32” Allen key, unscrew the exposed orifice. Insert the new orifice supplied in the kit, do not over tighten the orifice. Replace the pilot hood ensuring the index tab aligns with the notch on the hood. Honeywell Gas Control Valve (Fig. 48): The Honeywell valve fitted to this unit is suitable for use with LP or Natural Gas. It is converted to the required gas application by installation of a color coded “conversion screw.” a) Using a suitable small screwdriver lift out the central regulator cap from the “Hi–Lo” knob on the valve. b) Unscrew the exposed conversion screw. c) Insert the new color coded conversion screw. Do not over-tighten the screw, it must be finger tight. d) Refit the regulator cap. e) Mount conversion label supplied with conversion screw to valve in a visible position. 10. Reassemble fireplace in the reverse order, except window frame assembly. Leave this off until after unit has been checked for leaks and the gas supply has been bled. 11. After bleeding gas line and checking for leaks with a soap solution, replace the front glass. Fire up the unit, check for flame impingement on logs, adjusting them if necessary. Check manifold and supply pressures against the appliance specifications. The procedure for converting from one gas to another is the same regardless of the initial gas used. The only variations are in orifice sizes and component part numbers. Your authorized service provider will ensure correct parts are used. PSE Pilot Using a suitable wrench on the hexagonal body unscrew the pilot hood assembly from the pilot; do not twist the hood itself. Remove the orifice and replace it with the new orifice supplied in the kit. Refit the pilot hood assembly. Do not overtighten the pilot hood. The hood must return to its original alignment. Take care to not damage the thermocouple, thermopile, or igniter. 9. SIT 820 NOVA Gas Control Valve (Fig. 47): a) Using a Torx T20 or slotted screwdriver, remove and save three (3) pressure regulator mounting screws (A), pressure regulator tower (B), and diaphram (C). b) Ensure the rubber gasket (D) is properly positioned and install the new Hi/Lo pressure regulator to valve, using the new screws (E) supplied with the kit. Tighten screws securely. (Reference torque: 25 in.lb) c) Install the enclosed identification label (F) to the valve body where it can be easily seen. 10004920 Nova SIT820 Gas Valve CO122 Fig. 47 Nova SIT 820 gas valve conversion. 31 Vermont Castings, Majestic Products: DVR33 Cleaning the Standing Pilot Control System Regulator Cap Conversion Screw Pressure Regulator Housing Honeywell Gas Valve CO123 Fig. 48 Honeywell gas valve conversion. Maintenance General Maintenance Burner and Burner Compartment It is important to keep the burner and the burner compartment clean. At least once per year the logs and lava rock/ember material should be removed and the burner compartment vacuumed and wiped out. Remove and replace the logs as per the instructions in this manual. Always handle the logs with care as they are fragile and may also be hot if the fireplace has been in use. FK24/FK12 Fan Assembly The fan unit requires periodic cleaning. At least once per month in the operating season, open the lower louvre panels and wipe or vacuum the area around the fan to remove any build up of dust or lint. The burner and control system consists of: • burner tube • gas orifice • pilot assembly • thermopile • millivolt gas valve Most of these components may require only an occasional checkup and cleaning and some may require adjustment. If repair is necessary, it should be performed by a qualified technician. 1. Turn off pilot light at gas valve side. 2. Let fireplace cool if it has been running. 3. Remove window frame assembly. (Refer to Window Frame Assembly Removal section) 4. Remove logs. 5. Vacuum burner compartment especially around orifice primary air openings. 6. Visually inspect pilot. Brush or blow away any dust or lint accumulation. 7. Reinstall logs. 8. Ignite pilot; refer to Lighting Instructions. 9. Reinstall window frame assembly. To obtain proper operation, it is imperative that the pilot and burner’s flame characteristics are steady, not lifting or floating. Typically, the top 3/8” or 1/2” of the thermopile should be engulfed in the pilot flame (Fig. 45, page 25). To adjust pilot burner (to be done by a qualified service technician): 1. Remove pilot adjustment cap. 2. Adjust pilot screw to provide properly sized flame. 3. Replace pilot adjustment cap. The primary air shutter is set at factory and should be adjusted, if necessary, only by a qualified service technician. Brass Trim Clean the brass trim pieces using a soft cloth lightly dampened with lemon oil. Do not use water or household cleaners on any brass components. Contact your local representative to arrange an annual service program. 32 10004920 Vermont Castings, Majestic Products: DVR33 8 11 1b 1a 2 12 9 2a 6 1c 1d 17 3a/b 4a/b 8 5a/b 23 6 13 14 11 10 37 16 35 33 7 31 32 34 18 38 26 36 15 21a/b ON P IL I L OH LO HI OFF PILOT ADJ 20a/b O T 22a/b 4920 DVR33 parts Vermont Castings, Majestic Products reserves the right to make changes in design, materials, specifications, prices and discontinue colors and products at any time, without notice. DVR33 10004920 33 Vermont Castings, Majestic Products: DVR33 39 40 41 19 30 42 28 24 27 25 29 4920 DVR33 parts2 Vermont Castings, Majestic Products reserves the right to make changes in design, materials, specifications, prices and discontinue colors and products at any time, without notice. DVR33 (Items marked with ‘*’ are not shown in the parts illustration.) Ref. 1. 1a. 1b. 1c. 1d. * * 2. 2a. * 34 Description Log Set (complete) Log - Front/Rear Left Log - Rear Right Log - Front Right Log - Front Center Lava Rock 1 lb. package Lava Rock Burner Package Burner Housing Assembly, NG & LP Ceramic Tile (Single) Orifice Burner NG and LP DVR33 10004921 10004929 (A33) 10004925 (A34) 10004928 (A35) 10004927 (A36) 10001454 57897 10004901 57803 See the rating plate for orifice specifications 10004920 Vermont Castings, Majestic Products: DVR33 DVR33 (continued) (Items marked ‘*’ are not shown in the parts illustration.) Ref. Description 3a. Pilot Assembly SIT Top Convertible RN 3b. Pilot Assembly SIT Top Convertible RP 4a. Pilot Assembly SIT Top Convertible EN 4b. Pilot Assembly SIT Top Convertible EP 5a. Pilot Assembly PSE RN 5b. Pilot Assembly PSE RP 6. Pilot SIT Top Convertible 7. Pilot PSE (with Cable and Electrode) * Pilot Orifice SIT NG * Pilot Orifice SIT LP * Pilot Orifice PSE NG * Pilot Orifice PSE LP 8. Pilot Hood SIT Top Convertible 9. Thermocouple SIT 10. Thermocouple PSE 11. Thermopile 12. Ignitor Electrode with Cable, SIT RN/RP 13. Ignitor Electrode SIT EN/EP 14. Cable Ignitor SIT EN/EP 15. Piezo Ignitor Honeywell Gas Valve 16. Piezo Ignitor SIT820 Gas Valve 17. Pilot Tube with Fittings SIT 18. Pilot Tube with Fittings PSE * Manifold Tube with Fittings 19. Flexible Gas Line with ON/OFF Valve 20a. Honeywell Gas Control Valve, RN 20b. Honeywell Gas Control Valve, RP 21a. SIT820 Gas Control Valve RN 21b. SIT820 Gas Control Valve RP 22a. SIT822 Gas Control Valve EN 22b. SIT822 Gas Control Valve EP 23. Sensing Electrode (w/ Cable) EN/EP 24. Transformer 24V EN/EP 25. Ignition Module Honeywell EN/EP * Wire Harness Honeywell EN/EP * Fan Assy (FK-24 option) 26. Fan with Bracket (from FK-24 Option) * Electric Cord (from FK-24 Option) 27. Fan Temperature Sensor (from FK-24 Option) 28. Fan Speed Control (from FK-24 Option) 29. Knob Fan Speed Control (from FK-24 Option) 30. Sensor w/ Box and Wire (from FK-24 Option) * Fan Assembly (FK-12 Option) 31. Window Frame Assembly (no glass) 10004920 DVR33 10002264 10002265 10002387 10002388 10001741 10001742 10002266 10001824 10002268 10002269 10001822 10001823 10002385 53373 10001825 51827 10001297 52465 10000696 20000062 52464 10001296 10003279 57318 20002500 10001782 10001759 52677 52678 57884 57883 57885 7522409 20000005 10001979 ZA1100 54103 51865 51704 51738 51882 10004210 ZA1110 10001803 35 Vermont Castings, Majestic Products: DVR33 DVR33 Ref. 32. * 33. 34. 35. 36. 37. 38. * 39. 40. 41. 42. * 36 (continued) (Items marked ‘*’ are not shown in the parts illustration.) Description Window Glass with Gasket Assy Gasket Window Replacement Clamp Frame Window Window Trim Polished Brass with Magnets Top Louvre Assembly Bottom Louvre Assembly Hinge (Bottom Louvre) Wall ON/OFF Switch ON/OFF Switch Kit Bracket Rear Log Assy Relief Plate w/ Gasket (Burner Tray) Gasket Burner Tray Relief Plate w/ Gasket (Firebox Top) Electric Box Assy (EB-1) DVR33 10000961 57317 54174 55005 10000292 10000293 52356 51842 53875 10004906 10004192 10001035 10002032 ZA1200 10004920 Vermont Castings, Majestic Products: DVR33 Optional Accessories Fan Kits FK-12 Fan Assembly 1. Open lower louvre. 2. Install FK12 fan in back of unit between hearth supports (Fig. 49). 3. Secure fan on Velcro strips. 4. Power to the fan can be supplied by plugging the supply lead into a conveniently located wall socket or by using a hard-wired EB-1 connector box. 5. Be sure fan motor does not touch nearby metal. Side View Cold Air Box Front of Unit The fireplace, when installed must be electrically connected and grounded in accordance with local codes, or in the absence of local codes, with the current CSA C22.1 Canadian Electrical Code or for USA installations, follow local codes and the National Electrical Code, ANSI/NFPA No. 70. Hard Wire (Direct) Hook-Up FK12 Fan FP1004 Fig. 49 FK-12 Fan placement. FK-24 Fan Assembly Fan specifications: 120 volt, 60 Hz, 0.75 Amp. First connect ground wire to ground stud located on the base of either box. Black wire from supply should connect to the variable speed switch. Alternate speed switch wire connects to temperature sensor. Alternate lead from sensor connects to fan. Alternate fan lead connects back to the white supply wire (Fig. 51). Electrical Box Heat Sensor This fan does not need regular maintenance, however periodic cleaning is required. Check the area under the control door and in front of the fan and wipe or vacuum at least once a month during the operating season. Fan A E Hearth Pan Base Pan Method A Route the 6’ (1.8 m) lead fitted to the unit to a conveniently located wall socket. Method B If EB-1 receptacle box (Pt. #ZA1200) was correctly connected when the unit was installed, the fan lead can be directly plugged into the EB-1 plug socket. 5. Whether wiring directly to the fan junction box (Option A), or into EB-1 electrical receptacle box (Option B), first ensure cable is secured using box connector. TP LO OFF FF HI N O PIL T 10004920 TO Fan Speed Switch The FK-24 comes with the electrical cord attached. 1. Slide fan assembly from the left side into the fireplace opening, line up mounting holes with screw studs on back of fireplace and fasten with #10-24 hex nuts. 2. Install thermal sensor on bottom of firebox using #10-24 hex nuts. 3. Option A– Place electronic fan speed control box on bottom of fireplace base, lining up mounting holes with screw studs. Fasten fan speed control box with #10-24 hex nuts. Option B– The speed control can be installed in an electrical box at normal wall switch height for convenient access. 4. Connect the power supply in one of two ways: PILO OFF O TH Should this fan require servicing, the power supply must be disconnected. Gas Line Valve FP1026 Fig. 50 FK-24 fan placement. Fan Temperature Sensor Speed Control Black White Ground FP1025 Fig. 51 FK-24 fan wiring. Any electrical rewiring of this fan must be completed by a qualified electrician. Turn off all power before hookup. 37 Vermont Castings, Majestic Products: DVR33 Remote Controls Optional remote control units are available to control different functions of the appliance (only for RN/RP models). Model Function(s) Controlled MRC1 MRC2 MRC3 ON/OFF ON/OFF and Temperature ON/OFF and Temperature control with a digital display and a programmable 24-hour clock Wall-mounted thermostat control IMT Adjustable tab Adjustable tab Side panel Log Support Back Panel Side panel BURNER HOUSING ASSEMBLY Lower side support Lower side support Floor refractory panel FP1193 Fig. 52 Install ceramic refractory panels. Ceramic Refractory Panels Ceramic refractory panels are available to line the firebox area. Unit Kit Model DVR33 DVR33CR Take care when handling the refractory panels as they are fragile until held in place and supported. Installation (refer to Fig. 52 and Fig. 54) 1. Remove the window frame assembly 2. Remove the logs. 3. Place the lower supports for the side refractory panels on the base of the firebox. Place each support so that the slotted hole fits over the forward screw head along the edge of the base. 4. Lay the angular base panels in place on the floor of the firebox on either side of the burner housing assembly. 5. Loosely attach the top adjustable tabs to the studs located in the top of the firebox toward the front corners. 6. Place the rear refractory panel in place. Locate the ‘small brick’ edge of the panel into the two small supports on the back panel just above the rear log support. 7. Slide the side refractory panels into place to hold the rear panel secure. Adjust the top adjustable tabs to hold the side panel against the firebox wall and secure the tab. Repeat the procedure on the other side. 8. Replace the logs and window frame assembly. NOTE: For aesthetic purposes, we recommend aligning the horizontal mortar lines. 38 Rear Refractory Panel Rear Panel Support Brackets Firebox Back Rear Log Support FP1194 Fig. 53 Place the rear panel on rear support brackets. Decorative Bay Windows The original front frame/glass assembly MUST remain in place when fitting the bay window kits. The bay window kit fits over existing front glass. Bay window kits are available for model DVR33 fireplace. Installation 1. Remove the existing louvre assembly bottom complete with the hinges. 2. Remove the louvre assembly top. 3. Assemble the Bay Window Kit according to the instructions supplied with the kit. 4. Place the 2 pieces of ceramic refractory along the base of the bay window (Fig. 54). 5. Hang the Bay Window Assembly over the existing window frame assembly. 6. Reinstall the upper louvre assembly. Do not remove the existing window frame assembly. 10004920 Vermont Castings, Majestic Products: DVR33 Louvre Assembly Top Bay Window Frame Ceramic Refractory Ceramic Refractory Bottom Brass Trim Spacers Louvre Assembly Bottom Screws Decorative Frame Trims A selection of decorative frame trim kits are available for mounting around the outside of the appliance to enhance its visual effect on the room. Installation instructions for each decorative frame trim are included with the frame trim kit. Contact your authorized distributor for details of the trim kits and ordering information for the trim kits applicable to this model appliance. FP1195 Fig. 54 Bay window. 10004920 39 LIMITED LIFETIME WARRANTY PRODUCT COVERED BY THIS WARRANTY All Vermont Castings gas stoves, gas inserts, and gas fireplaces, and all Majestic or Northern Flame brand gas fireplaces equipped with an Insta-Flame Ceramic Burner, or standard steel tube burner. BASIC WARRANTY The Vermont Castings, Majestic Products Company (hereinafter referred to collectively as the Company) warrants that your new Vermont Castings or Majestic Gas Fireplace/Stove is free from manufacturing and material defects for a period of one year from the date of purchase, subject to the following conditions and limitations. EXTENDED LIFETIME WARRANTY The heat exchanger, where applicable, and combustion chamber of every Vermont Castings or Majestic gas product is warranted for life against through wall perforation. All appliances equipped with an Insta-Flame Ceramic Burner have limited lifetime coverage on the ceramic burner plaque. Warrantees are made to the original owner subject to proof of purchase and the conditions and limitations listed on this Warranty Document • • • • COMPONENT WARRANTY CAST IRON: All external and internal cast iron parts are warranted for a period of three years. Note: On porcelain enamel finished external parts and accessories The Company offers no Warranty on chipping of enamel surfaces. Inspect all product prior to accepting it for any damage to the enamel. The salt air environment of coastal areas or a high humidity environment can be corrosive to the porcelain enamel finish. These conditions can cause rusting of the cast iron beneath the porcelain enamel finish, which will cause the finish to flake off. Dye lot variations with replacement parts and/or accessories can occur and are not covered by warranty. GLASS DOORS: Glass doors are covered for a period of one year. Glass doors are not warranted for breakage due to misuse or accident. Glass doors are not covered for discoloration or burned in stains due to environmental issues, or improper cleaning and maintenance. BRASS PLATED PARTS AND ACCESSORIES: Brass parts should be cleaned with Lemon oil only. Brass cleaners cannot be used. Mortar mix and masonry cleaners may corrode the brass finish. The Company will not be responsible for, nor will it warrant any brass parts which are damaged by external chemicals or down draft conditions. GAS VALVES: Gas valves are covered for a period of one year • • • • • • ELECTRONIC AND MECHANICAL COMPONENTS: Electronic and mechanical components of the burner assembly are covered for one year. All steel tube burners are warranted for one year. ACCESSORIES: Unless otherwise noted all components and Vermont Castings, Majestic Products company supplied accessories are covered for a period of one year. CONDITIONS AND LIMITATIONS • • • • This new Vermont Castings or Majestic product must be installed by a competent, authorized, service contractor. A licensed technician, as prescribed by the local jurisdiction must perform any installation/ service work. It must be installed and operated at all times in accordance with the Installation and Operating instructions furnished with the product. Any alteration, willful abuse, accident, or misuse of the product shall nullify this warranty. This warranty is non-transferable, and is made to the original owner, provided that the purchase was made through an authorized supplier of the Company. The customer must pay for any Authorized Dealer in-home travel fees or service charges for in-home repair work. It is the dealers option whether the repair work will be done in the customer’s home or in the dealer’s shop. If upon inspection, the damage is found to be the fault of the manufacturer, repairs will be authorized at no charge to the customer parts and/or labor. • Any part and/or component replaced under the provisions of this warranty is covered for six months or the remainder of the original warranty, whichever is longest. This warranty is limited to the repair of or replacement of part(s) found to be defective in material or workmanship, provided that such part(s) have been subjected to normal conditions of use and service, after said defect is confirmed by the Company’s inspection. The company may, at its discretion, fully discharge all obligations with respect to this warranty by refunding the wholesale price of the defective part(s) Any installation, labor, construction, transportation, or other related costs/expenses arising from defective part(s), repair, replacement, or otherwise of same, will not be covered by this warranty, nor shall the Company assume responsibility for same. Further, the Company will not be responsible for any incidental, indirect, or consequential damages except as provided by law. SOME STATES DO NOT ALLOW FOR THE EXCLUSION OR LIMITATIONS OF INCIDENTAL AND CONSEQUENTIAL DAMAGES OR LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOUR CIRCUMSTANCES. THIS WARRANTY GIVES YOU SPECIFIC RIGHTS AND YOU MAY HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. All other warranties-expressed or implied- with respect to the product, its components and accessories, or any obligations/liabilities on the part of the Company are hereby expressly excluded. The Company neither assumes, nor authorizes any third party to assume on its behalf, any other liabilities with respect to the sale of this Vermont Castings, Majestic product The warranties as outlined within this document do not apply to chimney components or other non Vermont Castings, Majestic accessories used in conjunction with the installation of this product.. Damage to the unit while in transit is not covered by this warranty but is subject to claim against the common carrier. Contact the dealer from whom you purchased your fireplace/stove (do not operate the appliance as this might negate the ability to process the claim with the carrier). The Company will not be responsible for: a) Down drafts or spillage caused by environmental conditions such as near-by trees, buildings, roof tops, hills, or mountains. b) Inadequate ventilation or negative air pressure caused by mechanical systems such as furnaces, fans, clothes dryers, etc. This warranty is void if: a) The fireplace has been operated in atmospheres contaminated by chlorine, fluorine, or other damaging chemicals. b) The fireplace has been subjected to prolonged periods of dampness or condensation c) Any damages to the fireplace, combustion chamber, heat exchanger or other components due to water, or weather damage, which is the result of but not limited to, improper chimney/venting installation. d) Any alteration, willful abuse, accident, or misuse of the product has occurred. IF WARRANTY SERVICE IS NEEDED… 1) Contact your supplier. Make sure you have your warranty, your sales receipt, and the model/serial number of your Vermont Castings, Majestic product. 2) DO NOT ATTEMPT TO DO ANY SERVICE WORK YOURSELF.