SAVANNAH WOOD INSERT

FOR RESIDENTIAL INSTALLATION

6" (152mm) Flue Required

MODEL:

SSI30

OWNERS MANUAL

We recommend that our products be installed and serviced by professionals who are certifi ed in the U.S. By NFI

(National Fireplace Institute) or in Canada by WETT

(Wood Energy Technical Training).

SAFETY NOTICE: Read this entire manual before you install and use your appliance. If not properly installed, a house fi re may result. To reduce the risk of fi re, follow the installation instructions. Failure to follow instructions may result in property damage, bodily injury, or even death. Contact local building, fi re offi cials or authorities having jurisdiction about permits, restrictions and installation inspection requirements in your area.

CONTENTS

Specifi cations ................................................................... 03

Questions? ......................................................................... 04

Pre-installation instructions .............................................. 05

Unpacking and installation .............................................. 07

Removing the fl ue collar ................................................... 08

Fan wiring conversion ....................................................... 09

Blower and ash lip assembly ............................................. 10

Clearances to combustibles ............................................... 11

Calculating alternate fl ooring materials ............................ 12

Chimney clearances .......................................................... 13

Insert and pipe instructions ............................................... 14

Installing insert .................................................................. 15

Operation ........................................................................... 16

Maintenance ...................................................................... 18

Replacement parts ............................................................. 21

Illustrated parts breakdown ............................................... 22

FAQs ................................................................................. 23

Warranty ............................................................. Back Cover

ACCESSORIES

1. Gold Door Trim—Part no.: SSW30GDTK

2. Nickel Door Trim—Part no.: SSW30NDTK

3. Adjustable Raised Hearth Kit—Part no.: SSI30AH

4. Offset Flue Kit—Part no.: OFC3 & OFC6

Proposition 65 Warning:

Fuels used in gas, woodburning or oil fi red 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 and Safety Code Sec. 25249.6

THIS HEATER IS EXTREMELY HOT WHILE IN OPERATION.

SERIOUS BURNS CAN RESULT FROM CONTACT.

KEEP CHILDREN, PETS, CLOTHING AND FURNITURE AWAY

• OPERATE THIS HEATER ONLY WITH THE DOOR CLOSED.

• DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS.

• DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE.

RISK OF ELECTRIC SHOCK.

DISCONNECT POWER BEFORE

SERVICING UNIT.

2

INSTALLER

Please leave these instructions with the appliance.

OWNER

Please retain these instructions for future reference.

IMPORTANT

Read these instructions carefully before installing or trying to operating this woodburning appliance.

63D4004

OVERALL DIMENSIONS

"B"

SPECIFICATIONS

"E"

"F"

"G"

"A" "D"

"A"

MODEL

SSI30

FRONT VIEW

A

20.50

B

27.50

C

22.75

D

22

"C"

SIDE VIEW

SURROUND

ADJUSTMENT

E F

14 10

44"

G

5.50

40"

34"

30"

A. 30" x 40"

SURROUND OPTIONS

B. 34" x 44"

63D4004 3

QUESTIONS?

Log Length 20"

Maximum burn time 1

Average area heated (sq.ft) 1 2,200 sq. ft.

Range of heat output

2

11,000-30,600

Maximum heat output 1 55,400

EPA emissions rating (g/h, non-catalytic) 2

1. Maximum burn times and heat outputs are based on laboratory testing and may vary in individual use depending on how the insert is operated, type and moisture content of fuel, and other factors. Maximum burn times are achieved under different operating conditions than are maximum heat outputs. These values are based on operation in building codeconforming homes under typical winter climate conditions in the U.S. If your home is of nonstandard construction (e.g. unusually well-insulated, not insulated, built underground, or if you live in a more severe and more temperate climate), these fi gures may not apply. Since so many variables affect performance, consult your Lexington Forge Authorized

Dealer to determine realistic expectations for your home.

2. Under specifi c conditions used during EPA emissions testing.

NEED TO ASK QUESTIONS? REQUIRE PARTS INFORMATION?

First, contact the Lexington Forge Dealer from whom you purchased your insert, for parts and service. Have the following information ready:

Model and product serial numbers can be found on the certifi cation label of your insert.

• Date of purchase:

• Serial number (from the back of your insert):

• Model number (from the back of your insert):

• Dealer name and phone:

If you still need assistance, contact Lexington Forge technical support (below).

WONDERING ABOUT THE WARRANTY?

See the last page of this manual for general warranty information. For additional information, contact your Lexington

Forge dealer or Lexington Forge Parts and warranty.

Lexington Forge

Technical Service, Parts & Warranty

Phone: 877-406-9180

Fax: 877-406-5647

4 63D4004

PRE-INSTALLATION INSTRUCTIONS

After reading these instructions, if you have any doubt about your ability to complete your installation in a professional like manner, you should obtain the services of an installer versed in all aspects as to the correct and safe installation. DO NOT use temporary, makeshift compromises during installation.

BEFORE INSTALLATION OF YOUR APPLIANCE

(NOTE: Before installing your appliance be sure to write down the model and serial numbers and keep them in a safe place. Once installed this information is no longer visible on your appliance.)

1. Check with the building inspector’s offi ce for compliance with local codes; a permit may be required.

2. This appliance requires a masonry or prefabricated chimney listed to ULC S629 (Canada) and UL 103HT (U.S.) sized correctly.

3. A 6" (152mm) diameter fl ue is required for proper performance.

4. Always connect this unit to a chimney and NEVER VENT TO ANOTHER ROOM OR INSIDE A BUILDING.

8. Remember the clearance distances when you place furniture or other objects within the area. DO NOT store wood, fl ammable liquids or other combustible materials too close to the unit. Refer to certifi cation label on back of your unit for required clearances.

9. Contact your local municipal or provincial fi re authority for information on how to handle a chimney fi re. Have a clearly understood plan to handle a chimney fi re. In the event of a chimney fi re, slide air control to the lowest position and CALL THE FIRE DEPARTMENT.

10. DO NOT tamper with combustion air control beyond normal adjustment.

WHY THE CORRECT FLUE SIZE IS IMPORTANT — 6 " (152 MM)

Draft is the force, which moves air from the appliance up through the chimney. The amount of draft in your chimney depends on the length of the chimney, local geography, nearby obstructions, and other factors. Too much draft may cause excessive temperatures in the appliance. An uncontrolled burn, a glowing red part or chimney connector indicates excessive draft. Inadequate draft may cause back puffi ng into the room and “plugging” of the chimney and/or cause the appliance to leak smoke into the room through appliance and chimney connector joints.

Today’s solid fuel appliances are much more effi cient than in the past. The units are designed to give you controlled combustion, as well as maximum heat transfer, using less fuel to do so. The design of your new appliance is such that the exhaust “smoke” is now at lower temperatures than in the past, therefore requiring proper chimney size to give adequate draft. If your chimney is too large, the heating appliance will have a diffi cult time to raise the “chimney fl ue” temperature to give adequate draft, therefore causing a smoke back up, poor burn, or both.

Should you experience such a problem call a local chimney expert.

With the door closed, the rate of burning is regulated by the amount of air allowed to enter the unit through the air control.

With experience you will be able to set the control for heat and burning time desired.

Once the required chimney draft is obtained, operate only with doors closed and open slowly when re-fueling. (This will reduce or eliminate smoke from entering the room.)

Attempts to achieve higher output rates that exceed heater design specifi cations can result in permanent damage to the heater. The recommended wood load is level with the top of the fi rebricks. Overloading may prevent suffi cient air entering the heater to properly fuel the fi re.

Important: For optimum heater performance at “low” burn rate, operate the fan at low speed.

63D4004 5

PRE-INSTALLATION INSTRUCTIONS

PLANNING YOUR INSTALLATION

1. Check with local building offi cial for local code requirements

2. Have your chimney and fi replace cleaned and inspected for serviceability before installing appliance. A professional chimney sweep can provide this service. They can also offer advice or install chimney liners and your insert.

a. Masonary fi replaces and chimney must be inspected for cracks, loose bricks or mortar. The chimney and fi replace must be cleaned before installing insert. Dirty chimneys can affect performance and cause fi res.

b. Factory built fi replaces should be inspected for cracks, leaky joints, corrosion, warping, and any sign of structural or mechanical weakness. Correct any faults before installing insert. Check clearances of chimney to combustible surface as you inspect joints.

3. Plan your chimney connection system that makes the most sense for your particular situation. Make a list of the component you will need. There are two basic categories of fi replaces—manufactured and masonary. Chimneys can be steel or masonary. Liners are available to size the chimney to the insert and provide best performance and safety.

The actual connection from the unit to the chimney is made with adapters. One end will fi t the 6” round fl ue collar and the other end will fi t the chimney liner. Offset adapters are used in low clearance cases where the fl ue of the fi replace is recessed quite a bit, or the back of the fi replace is tapered to a smaller dimension than the insert.

Use the dimensions guide on page 3 to help you understand if you will need an offset adapter.

4. Here are a few chimneys and connection types to give you an overview:

NOTE: Flue size is important! The cross sectional area of the chimney should not be larger than 3 times the cross sectional area of the insert.

a. Masonary chimney with sealed throat and partial liner extended above the fi replace damper—This is not a recomended system. It requires the insert be removed to clean the chimney. The mass and overall size of many masonary chimneys can cause start up problems and creosote that can lead to chimney fi res. Be sure to check the size of the fl ue.

b. Fully lined masonary chimney—This uses a fl exible or ridge liner that is directly connected to the insert using a fl exible, rigid or offset adapter. A good installation provides good performance and allows you to clean the chimney without removing the insert, in many cases.

c. Factory built chimney with full liner—Directly connected to the insert using fl exible, rigid or offset adapters.

5. Review mantel, hearth and clearance to combustibles information on page 11. Add to your list any protective shielding, hearth or surround components you will need to complete the installation.

6. Order all the installation components from your dealer. Once you have them, you are ready to begin.

6 63D4004

UNPACKING AND INSTALLATION INSTRUCTIONS

UNPACKING AND INSTALLATION INSTRUCTIONS

NOTE: The insert is extremely heavy. Do not attempt to move it without assistance.

Please read all instructions carefully before beginning.

• To remove the insert from the pallet you will need a 7/16" wrench or socket.

• If you are placing the insert on a raised hearth you might consider moving the complete unit close to the raised hearth to save some lifting later.

• Remove the two brackets on the front of the insert by removing the four bolts (save the two bolts removed from the front of the stove) shown in Figure 1.

•

•

The rear bracket is slipped over the wheel axel and held in place with onebolt shown in Figure 3.

If your hearth is not level there are three leveling points on the insert. One on each of the front corners which are easily accessed by sliding the corner of the insert just off the edge of the pallet. Figure 2

•

•

If the rear of the insert needs to be adjusted you can slide the rear wheel off the pallet and loosen the two bolts (1/2" wrench) as shown in Figure 4.

The SSI30 is shipped with the power cord for the blower on the right side. If you want to move it to the left side now is the best time as you can access it under the insert easily by sliding the insert just off the edge of the pallet. See page 9 for instructions on converting fan wire from left to right. Make sure you secure the ground wire (green wire) to the side of the insert using the star washer showin in Figure 5.

Do not attach the blower until the unit is installed in the fi replace.

Figure 1

63D4004

Figure 3

Figure 2—Leveling points

Figure 4 Figure 5

7

REMOVING FLUE COLLAR

REMOVING THE FLUE COLLAR

The Savannah insert has a removable fl ue collar to help with tight installations. You should familiarize yourself with it before you install your insert.

To remove the fl ue collar you will have to remove the secondary air tubes and the C-cast baffl e plates. See Figure 6.

1. Use a Philips head screw driver or your fi ngers to remove the drywall screws that are hanging down next to the secondary air tubes. These screws were for shipping purposes only and can be discarded.

2. To remove the tubes, start by removing the cotter pin on the left end of each tube, then slide the tube to the right until the tube can be pulled down and left, and removed from the stove. Note that each tube is marked with either M (middle) F (front) or R (rear).

Be sure you replace the tubes in their correct location to ensure your stove burns at its optimal effi ciency. Three new cotter pins have been shipped with the insert.

3. After all three tubes have been removed you can remove the two piece C-cast baffl e.

Be very careful not to damage the baffl e. Carefully lift up on the rear piece and move it as far back as possible letting it sit on top of the steel non-removable baffl e. Next, lift up on the front piece and move it to the right and allow the left side to angle down into the fi rebox until it can be removed through the door opening. You can now remove the rear piece the same way. Figures 7 and 8.

4. Remove the bricks from the rear of the insert. This will make turning the fl ue collar with the chimney liner much easier. Figure 9.

SECONDARY

AIR TUBES

C-CAST

BAFFLE

Figure 6

Figure 7 and lock. Figure 11 shows the direction the cams need to turn to lock and unlock. The fl ue collar is made of cast iron and is fairly heavy so you should use something such as a piece of wood to support it. Once the fl ue collar has been lowered into the fi rebox you can lower the chimney liner into the collar and fasten it with screws (see Figure

13). When putting the fl ue collar with the liner back in place, make sure the ceramic gasket is in place. Use only high temp ceramic fi ber gaskets available at your Lexington

Forge dealer. NOTE: The fl ue collar has one side about ½" shorter than the other

three. This shorter side must be installed toward the rear of the fi rebox. Raise the fl ue collar chimney assembly and support it in place. Carefully hammer the cam locks over the fl ue collar alternating from one side to the other until they are parallel to the back of the stove.

6. Replace the C-cast baffl e and tubes, remembering to check each tube for the letter M, F or R to be sure you replace them in the correct location. After the tubes are in place check to see that the c-cast baffl e is slid back against the steel non- removable baffl e as shown in Figure 10. Replace the rear bricks.

Figure 8

Non-removable baffl e

C-Cast baffl e

2

1

Figure 9: Removing Firebrick Figure 10

8 63D4004

FAN WIRING CONVERSION

OFF ON

Figure 11 Figure 12

FAN WIRING CONVERSION FROM RIGHT TO LEFT

1. Remove ash lip and shroud by lifting straight up. NOTE: The ash lip and shroud are held in place by a keyhole slot and bolt system.

Lifting up on the ash lip allows the bolt head to slip through the keyhole.

2. Disconnect ground from side of insert and unplug spade connectors from plug wire.

3. Feed wire through holes in side and front of insert. (Be sure to leave it connected to the fan.) Push wire through opposite side, reconnecting ground and plug wires.

Figure 13

Figure 14

Figure 15—The ash lip and shroud are held in place by a keyhole slot and bolt system.

Lifting up on the ash lip allows the bolt head to slip through the key hole.

63D4004

Figure 16—As seen from bottom.

Snapstat

9

BLOWER AND ASH LIP ASSEMBLY

BLOWER AND ASH LIP ASSEMBLY

1. Attach the wires as shown in Diagram 1 making sure you push all connections together tightly

2. Insert the snapstat into its holder as shown in Figure 16, making sure that the connectors are not touching the stove.

3. Using the two bolts saved from the front shipping bracket to secure the blower to the insert.

4. Make sure all wires are away from the stove front.

5. The ash lip and surround can now be installed by placing the keyhole cutouts over the bolt heads shown in Figure 15.

4

8 DIAGRAM 1—BLOWER WIRING

8

TAN TAN TAN

7

ON OFF

3

5

6 BLACK

WHITE

2

BLACK

1

9

WHITE

DETAIL VIEW

ASSEMBLING THE SURROUND

To assemble the surround it is best to lay the three sections face down on a soft fl at surface.

The foam package material works well for this.

Line up the two pins on the top section with the holes on the side pieces as shown in

Figure 17. carefully slide the sections together. When moving the assembled surround it is best to hold it by the sides and not the top.

SURROUND INSTALLATION

To install the surround on the insert, make sure the ratcheting brackets are in their forward most position. Lift the surround over the primary air control rod and set the spring loaded washers over the cast ratchet brackets and allow the threaded stud to slide into the notch as shown in Figure 18.

Once both sides are securely attached to the ratchet brackets gently start sliding the surround back towards the wall making sure to keep both sides even. Pushing directly in front of the brackets will help keep the surround straight.

To remove the surround from the insert, simply lift the surround straight up until it becomes free of the brackets. Remember to slide the brackets to their forward most position before trying to install the surround again.

10

Figure 17

Figure 18

63D4004

CLEARANCE TO COMBUSTIBLES

Clearance to Combustibles

A. To side wall

B. To mantel (12" max)

C. To top trim (3/4" max)

D. To side trim (3/4" max)

Floor Protection

E. In front of insert (1/2" min)

F. To side of insert

CLEARANCES TO COMBUSTIBLES

Min.

11"

23"

16"

7"

18"

8"

12" max

MANTLE

FASCIA OR TRIM

C

B

F

A

INSERT

E

D

Offset

OFFSET

ADAPTOR adapter

Figure 19—Clearances to combustibles

Figure 20—Mantel clearances

FLOOR PROTECTION

Floor protection must be at least 1/2" minimum non-combustible material with a “K” value of 0.84, extending 18" (46cm) in front of and 8" (20.5cm) to the side of the fuel loading door (in the United STates). In Canada, it must extend 450mm to the front and 200mm to the side of the unit.

63D4004 11

FLOOR PROTECTION

CALCULATING ACCEPTABLE ALTERNATE FLOOR MATERIALS

All fl oor protection must be non-combustible (i.e. metal, brick, stone, mineral fi ber, etc.). Any organic materials (i.e. plastics, wood or paper products, etc.) are combustible and must not be used. The fl oor protection specifi ed includes some form of thermal designation such as R-value (thermal resistance) or k-factor (thermal conductivity).

PROCEDURE:

R-value given. No conversion needed.

k-factor is given with a required thickness (T) in inches: R = (1/k) x T k-factor is given with a required thickness (T) in inches. R = (1/Kx12) xT r-factor is given with a required thickness (T) in inches. R = r x T

2. Determine the R-value of the proposed alternate fl oor protector.

a. Use the formula in step (1) to convert values not expressed as "R." b. For multiple layers, add R-values of each layer to dtetermine overal R-value.

3. If the overall R-value of the system is greater than the R-value of the specifi ed fl oor protector, the alternate is

acceptable.

EXAMPLE: The specifi ed fl oor protector should be 3/4" thick material with a k-factor of 0.84. The proposed alternate is 4" brick with and R-factor of 0.2 over 1/8" mineral board with a k-factor of 0.29.

Step A. Use formula above to convert specifi cation to R-value. R= (1/k) x T = (1/.84) x 0.75 = 0.893

Step B. Calculate R of proposed system.

4" brick of R = 0.2, therefore: R brick

= 0.2 x 4 = 0.431

1/8" mineral board of k = 0.29, therefore: R mineral board

= x 0.125 = 0.431

R total

= R brick

+ R mineral board

= 0.8 + 0.431 = 1.231

Step C. Compare proposed system R total of 1.231 to specifi ed R of 0.893. Since proposed system R total is greater than required, the system is acceptable.

R =

(ft 2 )(hr)(ºF) Btu(in) Btu(ft) (ft k =

Btu ft 2

= K x 12 K =

(hr)(ºF) ft

2 )(hr)(ºF)

2 r =

(hr)(ºF) Btu(in)

=

1 k

12 63D4004

CHIMNEY CLEARANCES

CHIMNEY

(REFER TO CHIMNEY AND CHIMNEY CONNECTOR MANUFACTURER’S INSTRUCTIONS)

Contact your local building authority for approved methods of installation

NOTE: Canadian installations require a full reline of the chimney.

1. This appliance requires a masonry or pre-manufactured chimney listed to ULCS629 (Canada) and UL 103 HT (USA) sized correctly.

2. If a masonry chimney is used it is advisable to have your chimney inspected for cracks and check the general condition before you install your unit. Re-lining may be required to reduce fl ue diameter to the appropriate functional size.

3. The chimney should extend at least 3' (914 mm) above the highest point where it passes through the roof, and at least

2' (610 mm) higher than any portion of a building within 10' (3 m). Figure 14.

4. The chimney connector shall not pass through an attic, roof space, closet, concealed space, fl oor, ceiling, wall or any partition of combustible construction.

5. The minimum overall height of your chimney should be 15' (5M) from the fl oor.

6. Do not use makeshift compromises during installation.

0 TO 10'

2' Min.

3' Min.

0 TO 10'

2' Min.

3' Min.

Reference

Point

Figure 21: The 2'-3'-10' Chimney Rule

At the very least, inspect the chimney connector and chimney at least once every month during the heating season to determine if a buildup of creosote or soot has occurred. If a signifi cant layer of creosote has accumulated (1/8" (3mm) or more], or if soot has accumulated, either should be removed to reduce the risk of a chimney fi re. Failure to keep the chimney and connector system clean can result in a serious chimney fi re.

The conditions for a chimney fi re develop as follows: When wood is burned slowly, it produces tar and other organic vapors which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney fl ue of a slow burning fi re. As a result creosote residue accumulates on the fl ue lining. Creosote is a fl ammable and, when ignited, make an extremely hot fi re within the fl ue system which can damage the chimney and overheat adjacent combustible material.

63D4004 13

INSERT AND PIPE INSTALLATIONS

NOTES ON CHIMNEY AND INSERT PIPE INSTALLATIONS:

Maintaining a clean chimney is important. Chimneys should be inspected regularly for creosote buildup. A straight chimney is easier to clean than one with 45 or 90 degree bends. A bend requires the pipe to be removed for cleaning. The insert baffl e must be removed when cleaning the chimney. Chimney sweepings will build up on top of baffl e causing a blocked fl ue and/or a fi re hazard.

Steel Chimney

Most factory made “Class A” steel chimneys have a layer of insulation around the inner fl ue. This insulation keeps the smoke warm and protects the surrounding structure from the high fl ue temperatures. Because the insulation is less dense than masonry, the inner steel liner warms up more quickly than masonry chimney; this makes the steel chimney support a good draft more quickly than masonry does.

Indoor/Outdoor Location

Because the chimney’s function is to keep the smoke warm, it is best to locate it inside the house. This location uses the house as insulation for the fl ue and allows some radiant heat release form the fl ue into the home. Since an interior chimney doesn’t continuously lose its heat to the outdoors, less heat from the insert is required to get it warm and keep it warm.

Flue Sizing

The fl ue size for a controlled-combustion appliance should be based on the cross-sectional volume of the insert fl ue outlet.

In this case, more is defi nitely not better. Hot gases lose heat through expansion; if a insert with a six-inch fl ue collar (28 square inch area) is vented into a 10" x 10" fl ue, the gases will expand to over three times their original volume. As gases cool with expansion, draft strength decreases. If the oversized fl ue is also outside the house, the heat it absorbs will be conducted to the outdoor air and the fl ue will remain relatively cool.

It is common for a masonry fl ue to be oversized for the insert. Such a chimney can take quite a while to warm up, and the insert performance will likely be disappointing. The best solution to an oversize fl ue problem is the installation of an insulated steel chimney liner of the same diameter as the appliance fl ue outlet. The liner keeps the exhaust gas warm and the result is a stronger draft. An uninsulated liner is a second choice—although the liner will keep the exhaust restricted to its original volume, the air around the liner will require time and heat energy to warm up.

Check your local codes. You may be required to install a fl ue liner in any oversize masonry fl ue.

Masonry Chimney

Although masonry is the traditional material used for chimney construction, it can have distinct performance disadvantages when used to vent a controlled combustion wood insert. Masonry forms an effective “heat sink”—that is, it absorbs and holds heat for long periods of time.

The large mass however, may take a long time to become hot enough to sustain a strong draft. The larger the chimney (in total mass) the longer it will take to warm up. Cold masonry will actually cool exhaust gases enough to diminish draft strength. This problem is worse if the chimney is located outside the home or if the chimney fl ue has a cross-sectional volume much larger than the insert outlet.

Single Venting

Your insert requires a dedicated fl ue. Do not connect the insert to a fl ue used by any other appliance. Chimney draft is a natural form of energy and follows the path of least resistance. If the insert is vented to a fl ue that also serves open replace or another appliance, the draft will also pull air through those avenues.

The additional airfl ow will lower the fl ue temperatures, reduce draft strength and promote creosote development; overall insert performance will suffer. The effect is similar to that of a vacuum cleaner with a hole in the hose. In some extreme instances, the other appliances can even impose a negative draft and result in a dangerous draft reversal.

14 63D4004

INSTALLING INSERT

INSTALLING YOUR INSERT INTO A MASONRY FIREPLACE

The best installation is the complete relining of the chimney system using a 6" listed stainless steel liner. The liner must be attached to the insert and to each section of the liner with the crimped (male) end pointing toward the insert. All connections should be secured with a minimum of 3 screws, this includes the fl ue collar.

NOTE: Canadian installations require a full reline of the chimney.

The next type of installation is a direct connection to the fi rst fl ue liner in accordance with the requirements of the NFPA 211.

Secure the fi replace damper in the open position or remove it. Seal the area around the starter pipe and the damper opening with high temp sealant and or sheet metal.

The chimney should be inspected for cracks, loose mortar and any other signs of deterioration or blockage. Always check with your local building code agency before you begin your installation to ensure compliance with local codes, including the need for permits and any follow up inspections.

INSTALLATION IN CANADA

•

•

Whether installed in a masonry or heat -circulating fi replace, this fi replace insert must be installed with a continuous chimney liner of 6: (152mm) diameter extending from the fi replace insert to the top of the chimney. The chimney liner must conform to the Class 3 requirements of CAN/ULC-S635, Standard for

Lining Systems for Existing Masonry or Factory-Built Chimneys and Vents, or

CAN/ULC-S640, Standard for Lining Systems for New Masonry Chimneys.

Do not remove bricks or mortar from fi replace to accommodate insert.

The permanent metal warning label provided must be affi xed to the back of the fi replace with screws or nails, in a location readily visible should the fi replace insert be removed. This label states that the fi replace may have been altered to accommodate the insert, and must be returned to original condition for use as a conventional fi replace.

Flue tile

Full listed liner option

Mantel

Air-tight face seal

Direct connect seal option

Damper area

Minimum starter pipe option

INSTALLATION INTO A FACTORY BUILT FIREPLACE

Make sure the factory built fi replace is large enough for your insert. Do not modify the fi replace. (Exceptions: removal of the damper, removal of the smoke

Figure 22—Installation into masonry fi replace shelf or baffl e, grate, doors and or screens.) The metal label supplied with your insert must be attached to the back of the fi replace with screws or nails. This label states that the fi replace may have been altered to accommodate the insert, and must be returned to original condition for use as a conventional fi replace.

A complete chimney reline is required in most installations. Always check with the fi replace manufacturer. If a complete reline is required, the liner must be attached directly to the fl ue collar and run all the way to the chimney cap. The liner must meet type HT requirements (2100

º

F) per UL 1777. To prevent room air from escaping up the chimney cavity, seal around the liner with high temp insulation or sheet metal.

INSTALLATION OF OFFSET FLUE COLLAR

Offset fl ue collars are available in two sizes (3" and 6") from your Lexington Forge dealer for your Savannah insert. When installing an offset fl ue collar it is important that the offset adapter be secured with at least three screws into the insert fl ue collar and three screws into the chimney liner. Make sure that the offset fl ue collar is installed inside of the insert fl ue collar and the chimney liner is installed inside the offset adapter. See Figure 23.

63D4004

(Offset Flue Collar Installation ontinued on following page)

15

OPERATION

(Offset Flue Collar Installation continued)

WARNING: Never allow the offset fl ue collar to support the weight of the chimney liner. The liner must be supported at the top of the chimney.

As with all installations, fi nal approval of this installation type is contingent upon the authority having jurisdiction in your area.

OPERATION

To reduce the amount of creosote that may form, remember to provide adequate air for combustion and to strive for small, intense fi res rather than large smoldering ones. You can never be too safe. Contact your local fi re authority for information on what to do in the event of a chimney fi re, and have a clearly understood plan on how to handle one.

Towards stove

Flue gas direction

Do not use a grate or elevate fi re. Build wood fi re directly on fi rebrick. When the insert is used for the fi rst time the solvents in the paint will smoke off.

Wood

This heater is designed to burn natural wood only. Higher effi ciencies and lower emissions generally result when burning air dried seasoned hardwoods, as compared to softwoods or to green or freshly cut hardwoods. Only use dry seasoned wood. Green wood, besides burning at only 60 percent of the fuel value of dry wood, deposits creosote on the inside of your insert and along the chimney. This can cause an extreme danger of chimney fi re. To be called “seasoned,” wood must be dried for a year. Regardless of whether the wood is green or seasoned, it should be stored in a well-sheltered ventilated area to allow proper drying during the year to come. Wood should be stored beyond recommended clearance from combustibles.

Figure 23: Offset Flue Collar

Installation

Fuel

Even the best insert installation will not perform well with poor fuel. If available, always use hardwood that has been airdried (seasoned) 12-18 months. Softwood burns more rapidly than hardwood and has a high pitch content that can result in creosote. Decayed wood of any type has little heat value and should not be used.

Unseasoned (green) wood has a high moisture content. Much of its heat value will be used to evaporate moisture before the wood can burn. This signifi cantly reduces the amount of energy available to warm your home, as well as the intensity of the fi re and temperature of the exhaust gas. Incomplete combustion and cool fl ue temperatures promote creosote formation and weak draft.

You can judge the moisture content of wood by its appearance and weight or use a commercially available moisture meter for exact measurement. Unseasoned wood will be a third heavier than dry wood. Also look for cracks (checking) in the ends of the log that result from contraction as the wood dries. The longer and wider the cracks are, the dryer the wood is.

Creosote

Creosote is a by-product of low-temperature insert operation, weak draft or both. It is a tar that results when unburned gases condense inside the fl ue system at temperatures below 290 degrees F. Creosote is volatile and can generate a chimney fi re. All of the installation characteristics that adversely affect chimney draft also promote creosote condensation.

Consequently, you can minimize creosote accumulation with an effective chimney design and the use of operational techniques that encourage good draft and complete combustion.

Inspect your chimney frequently and clean it whenever accumulation exceeds 1/4".

16 63D4004

OPERATION

DO NOT BURN: Treated wood, solvents, trash, coal, garbage, cardboard, colored paper

NEVER USE GASOLINE, GASOLINE-TYPE LANTERN FUEL, KEROSENE, CHARCOAL LIGHTER FLUID,

OR SIMILAR LIQUIDS TO START OR “FRESHEN UP” A FIRE IN THIS HEATER. KEEP ALL SUCH

LIQUIDS WELL AWAY FROM THE HEATER WHILE IT IS IN USE

INSTRUCTION FOR FIRST BURN – CURING THE INSERT PAINT

Your insert has been painted with the highest quality insert paint and has special break-in procedures. The heat generated by the normal operation of the insert, will serve to harden the paint.

Ventilate the house during the fi rst three times the insert is used. The paint on the insert will give off smoke, carbon dioxide and an odor. Without adequate ventilation, concentrations of smoke could irritate, or be upsetting. Open doors

and windows and use a fan if necessary. After the initial burns the paint will be cured and there should be no more smoke. Each of the initial burns should be conducted as follows:

A) The fi rst two burns should be at approximately 250° F (120° C) for approximately 20 minutes.

B) The third burn should be between 500° F and 700° F (260° to 370° C) for at least 45 minutes. The important fact is the paint should be cured slowly. Avoid hot fi res during the curing process.

The best way to achieve the fi rst burn is with kindling fi res. Prolong the fi res as needed by adding more kindling. During the curing process the paint may be gummy. Once cured the paint will remain hard. It is normal to see fl at spots on painted surfaces of the insert. The fl at spots on the paint surface indicate the hotter surfaces of the insert, and is caused by the heat radiating through the paint. It is also expected that shiny spots caused by friction from the packaging materials, will disappear during the curing of the insert.

So:

1. Remember to ventilate well.

2. Allow the insert to cure before burning for long periods at high temperatures.

3. Flat spots on the painted surfaces are normal.

4. Shiny spots on the paint surface before burning is normal.

5. Call your dealer if you have any questions.

BUILDING A FIRE

1. Open inlet air control fully.

2. Place a small amount of crumpled paper in the insert.

3. Cover the paper with a generous amount of kindling wood in a teepee fashion and a few small pieces of wood.

4. Ignite the paper and close door. If fi re dies down substantially, open door slightly.

5. Add larger pieces of wood as the fi re progresses being careful not to overload. Do not fi ll fi rebox beyond fi rebrick area.

An ideal coal bed of 1" (25mm) to 2" (50mm) should be established to achieve optimum performance.

6. This unit is designed to function most effectively when air is allowed to circulate to all areas of the fi rebox.

7. Once fuel has been loaded, close door and open air inlet control fully until fi re is well established (approx. 10 minutes) being careful not to over fi re.

Figure 24: Air Control Layout

Low High

(Building a Fire ontinued on following page)

63D4004 17

MAINTENANCE

8. Re-adjust air inlet control to desired burn rate. If excessive smoke fi lls fi rebox, open air inlet control slightly until fl ames resume and wood is suffi ciently ignited. A basic rule of thumb is “closed – low,” “½ way-medium,” and “fully open

– high.”

9. When refueling, adjust air control to the fully open position. When fi re brightens, slowly and carefully open the door.

This procedure will prevent gases from igniting causing smoke and fl ame spillage.

10. Add fuel being careful not to overload.

REMOVING BAFFLE:

To remove the tubes you will start by removing the cotter pin on the left end of each tube, then slide the tube to the right until the tube can be pulled down and left and removed from the stove. Note that each tube is marked with either M, for middle

F, for front or R for rear, be sure you replace the tubes in there right location to insure you stove burns at it best effi ciency.

3 new cotter pins have been shipped with the insert.

After all 3 tubes have been removed you can remove the 2 piece c-cast baffl e, be very careful not to damage the baffl e, carefully lift up on the rear piece and move it as far back as possible letting it set on top of the steel non-removable baffl e.

Next lift up on the front piece and move it to the right and allow the left side to angle down into the fi rebox until it can be removed thru the door opening. You can now remove the rear piece the same way. NOTE: See Figures 7 and 8 on page 8 for more information.

REMOVING FIREBRICK

To remove fi rebrick, lift up from bottom and rotate outward. See Figure 10 (page 8).

Figure 25A: Removing Baffl e Figure 25B: Removing Baffl e

CLEANING YOUR CHIMNEY

The Savannah SSI30 insert has a removable baffl e which allows the chimney to be cleaned without removing the insert from the fi replace.

Make sure the stove is cool before proceeding

To remove the rear of the baffl e, reach in through the door and lift up on the rear half of the baffl e and, very carefully with your fi ngers, walk the rear half of the baffl e up and onto of the front half of the baffl e. Make sure you slide it far enough forward so the chimney brush will not damage it when cleaning. See Figure 25A. There is no need to remove the secondary air tubes for cleaning.

After the chimney has been cleaned clean out the fi rebox and carefully replace the rear half of the baffl e. Check to see that both pieces of the baffl e are down on the steel baffl e and pushed all the way to the rear of the fi rebox. See Figure 25B.

18 63D4004

MAINTENANCE

GLASS AND GLASS GASKET REPLACEMENT

REPLACE GLASS ONLY WITH HIGH TEMPERATURE CERAMIC AVAILABLE FROM YOUR LOCAL

LEXINGTON FORGE DEALER

After extensive use, the gasket material which provides glass and door seal may need to be replaced if it fails to sustain its resilience. Inspect glass and door seal periodically to ensure proper seal: if gaskets become frayed or worn, replace immediately. Contact your dealer for approved replacement parts. Refer to replacement parts list in this manual.

NOTE: Wear safety glasses and gloves when performing any maintenance task.

The following steps should be followed for glass gasket replacement:

1. Ensure appliance is not in operation and is thoroughly cooled

2. Remove door and place on a protected fl at surface.

3. Remove screws and glass clips.

4. Lift glass out.

5. Remove old gasket and clean or replace glass.

6. Sand gasket groove and wipe clean (rubbing alcohol works well).

7. Put a thin fi lm of gasket cement on the door.

8. Replace new gasket starting at the top center of the door.

9. Trim to length and butt ends together. Remove all excess cement.

10. Replace glass in door, being sure not to over-tighten screws and clips.

DOOR GASKET REPLACEMENT

The following steps should be followed for door gasket replacement:

1. Ensure appliance is not in operation and is thoroughly cooled.

2. Remove door and place on a protected fl at surface.

3. Remove old door gasket and clean channel.

4. Sand gasket groove and wipe clean (rubbing alcohol works well).

5. Using an approved high temperature gasket cement, apply a thin coat in bottom of channel.

6. Starting at top center of door, work into channel around door unit, trim to length and butt ends.

7. Close door and allow three to four hours for cement to set before restarting appliance.

CREOSOTE

When wood is burned slowly, it produces tar and other organic vapors. These combine with moisture to form creosote.

Creosote vapors condense in the relatively cool chimney fl ue of a slow burning fi re. As a result, creosote residue accumulates on the fl ue lining. When ignited, this creosote makes an extremely hot fi re. The chimney should be inspected regularly during the heating season to determine if a creosote build-up has accumulated. If this is the case, the creosote should be removed to reduce the risk of chimney fi re.

Things to remember in case of chimney fi re:

1. Close draft control

2. Call the fi re department

63D4004 19

MAINTENANCE

KEEP UNIT FREE OF CREOSOTE

1. Burn with air control open for several minutes at numerous intervals throughout the day during the heating season, being careful not to over-fi re unit. This removes the slight fi lm of creosote accumulated during low burn periods.

2. Burn insert with draft control wide open for several minutes every time you apply fresh wood. This allows wood to achieve the charcoal stage faster and burns wood vapors which might otherwise be deposited within the systems.

3. BURN ONLY SEASONED WOOD. Avoid burning wet or green wood. Seasoned wood has been dried for at least one year.

4. A small hot fi re is preferable to a large smoldering one that can deposit creosote within the system.

5. Establish a routine for the fuel, wood burner and fi ring technique. Check daily for creosote build-up until experience shows how often you need to clean to be safe. Be aware that the hotter the fi re, the less creosote is deposited and weekly cleaning may be necessary in mild weather even though monthly cleaning may be enough in the coldest months. Contact your local municipal authority for information on how to handle a chimney fi re. Have a clearly understood plan to handle a chimney fi re.

ASH DISPOSAL

Ashes should be placed in a metal container with a tight-fi tting lid. The closed container of ashes should be placed on a non-combustible fl oor or on the ground, well away from all combustible materials, pending fi nal disposal. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until all cinders have thoroughly cooled. Other waste should not be placed in the ash container.

20 63D4004

63D4004

REPLACEMENT PARTS

ITEM PART NO.

DESCRIPTION

1 20H2032 5/16" WASHER

22

23

24

25

26

27

28

19

20

21

16

17

18

13

14

15

10

11

12

7

8

5

6

9

2

3

4

26D0619 BLOWER CORD

49D0130 BLOWER THERMO DISC

63D0026 SECONDARY AIR TUBE, MIDDLE

63D0028 SECONDARY AIR TUBE, REAR

63D0065 LEVELER BOLT

63D0112 SECONDARY AIR TUBE, FRONT

63D0185 SPRING HANDLE

63D2004 C-CAST ASSEMBLY

63D2022 TURN TIGHT CAST IRON

63D2040 SLIDER

63D2072 REAR WHEEL ASSEMBLY

63D2075 BLOWER ASSEMBLY

63D2077 CAST DOOR ASSEMBLY, COMPLETE

63D2081 SURROUND CLAMP, RIGHT

63D2082 SURROUND CLAMP, LEFT

63D2084 GLASS DOOR HANDLE ASSEMBLY

63D2085 FALL-AWAY HANDLE ASSEMBLY

63D2090 ADJUSTMENT SLIDE PLATE

63D2100 RIGHT SIDE SHROUD

63D2102 LEFT SIDE SHROUD

63D2105 BLOWER ENCLOSURE ASSEMBLY

63D2111 PIPE COLLAR ASSEMBLY

63D2113 AIR WASH ASSEMBLY

63D2130 CAST IRON PRIMARY AIR COVER ASSEMBLY

63D2145 SPRING

63D2146 CAPTURE PLATE

63D4040 LOCK NUT

21

ILLUSTRATED PARTS BREAKDOWN

16

21

7

4

5

18

17

14

22

24

13

3

25

8

6

12

2

Figure 25: Parts Breakdown

23

10

9

20

27

19

15

1

28

11

26

22 63D4004

FAQS

FREQUENTLY ASKED QUESTIONS

1) What is the correct way to start a fi re?

a) You will need small pieces of dry wood (kindling) and paper. Use only newspaper or paper that has not been coated or had unknown materials glued or applied to it. Never use coated (typically advertising fl yers) or colored paper.

b) Open the door of the wood insert.

c) Crumple several pieces of paper and place them in the center of the fi rebox and directly on to the fi rebricks of the wood insert (see page 6 of this manual). Never use a grate to elevate the fi re.

d) Place small pieces of dry wood (kindling) over the paper in a “Teepee” manner. This allows for good air circulation, which is critical for good combustion.

e) Light the crumpled paper in 2 or 3 locations. Note: It is important to heat the air in the insertpipe for draft to start.

f) Fully open the air control of the wood insert (see page 17 of this manual) and close the door until it is slightly open, allowing for much needed air to be introduced into the fi rebox. Never leave the door fully open as sparks from the kindling may occur causing injury. As the fi re begins to burn the kindling, some additional kindling may be needed to sustain the fi re. DO NOT add more paper after the fi re has started.

g) Once the kindling has started to burn, start by adding some of your smaller pieces of seasoned (dry) fi rewood.

Note: Adding large pieces at the early stages will only serve to smother the fi re. Continue adding small pieces of seasoned (dry) fi rewood, keeping the door slightly open until each piece starts to ignite. Remember to always open the door slowly between placing wood into the fi re.

h) Once the wood has started to ignite and the smoke has reduced, close the wood insert door fully. The reduction of smoke, is a good indication that the draft in the chimney has started and good combustion is now possible. Larger pieces of seasoned (dry) fi rewood can now be added when there is suffi cient space in the fi rebox. Adjust the air control setting to desired setting (see page 17).

i) Note: The lower the air control setting the longer the burn time of your fi rewood.

2) What type of wood is best to use as fi rewood?

Dry seasoned hardwood should be used. Avoid green unseasoned wood. Green wood, besides burning at only 60 percent of the fuel value of dry seasoned wood, will deposit creosote on the inside of your insert and along the inside of your chimney.

3) What does dry seasoned wood mean, and what is considered hardwood?

Wood that has been dried for a period of one year in a well-ventilated and sheltered area would be considered dry seasoned wood. Hardwoods are generally from slow growth trees (Example: Oak and Fir). Softwoods are generally from fast growth trees (Example: Pine and Spruce).

4) Will following the above listed steps for starting a fi re result in perfect results all the time?

The quick answer is most of the time. There are many variables that may affect your success rate when starting a fi re. Most of those variables and how to deal with them will be learned through experience. Your ability to start a good fi re will signifi cantly increase with time and patience. Some of the reasons for poor insert performance will be covered in the next section of these instructions

5) Why can’t I get the fi re lit?

Damp or wet wood and poor draft are the main reasons for poor results in starting a fi re. Always use dry seasoned wood for your fi re. Even wood dried for two years will be diffi cult to ignite if it has become wet.

6) Why is there always a large quantity of thick black smoke present in the fi rebox?

A large quantity of thick black smoke in the fi rebox is a good indication that the draft is poor.

63D4004 23

FAQS

7) Is it normal for soot to cover the glass at the beginning of a fi re?

Your insert has been built with an air wash system that will help keep the glass clear when the fi rebox has reached a good operating temperature, and has a good draft. Cold fi rebox temperature and poor draft cause sooting of the glass.

Once the fi rebox temperature and the draft increases, the soot will burn off.

8) What is draft?

Draft is the ability of the chimney to exhaust by-products produced during the normal combustion process.

9) What can cause a poor draft?

The most common factors for poor draft are: a. Atmospheric pressure and air supply c. Cold chimney temperature d. Poor chimney installation and maintenance a) Atmospheric Pressure and Air Supply

Atmospheric pressure affecting the draft from a chimney can be either outside the home, inside the home or both. Outside the home, a high-pressure day (clear and cool) generally creates a better draft in the chimney than a low-pressure day (overcast and damp). Inside the home normal household appliances, such as clothes dryers and forced air furnaces compete for air, resulting in inadequate amounts of air available to fuel a fi re and create a condition known as negative pressure. Under extreme conditions of negative pressure the combustion by-products can be drawn from the chimney into the house. This condition is commonly referred to as down drafting.

There are several factors that impact the amount of air available in the home. Increased amounts of insulation, vinyl windows, extra caulking in various places and door seals can all keep heat in but may also make a home too airtight. If you are in doubt about whether or not there is suffi cient air in your home for your insert, curtail from using those appliances known to consume the air where possible, or open a window or door to allow air to enter the home.

b) Environmental Conditions

High trees, low lying house location such as in a valley, tall buildings or structures surrounding your house and windy conditions can cause poor draft or down drafting.

c) Cold Chimney Temperature

Avoid cold chimney temperatures by burning a hot fi re for the fi rst fi fteen to forty minutes, being careful not to over fi re. If any part of the chimney or parts of the insert start to glow, you are over fi ring the insert. Where possible, install a temperature gauge on the chimney so temperature drops can be seen.

d) Chimney Installation and Maintenance

Avoid using too many elbows or long horizontal runs. If in doubt, contact a chimney expert and/or chimney manufacturer for help. Clean chimney, rain caps and especially spark arrester regularly, to prevent creosote build-up, which will signifi cantly reduce chimney draw and possibly a chimney fi re.

11. Should I close or open the air control fully when shutting down the insert?

Just before shutting down the insert, run on high for a few minutes. This allows the chimney temperatures to remain

24 63D4004

NOTES

63D4004 25

NOTES

26 63D4004

NOTES

63D4004 27

LEXINGTON FORGE

WOOD BURNING INSERT

LIMITED LIFETIME WARRANTY POLICY

LIMITED LIFETIME WARRANTY

The following components are warranted for life to the original owner, subject of proof of purchase: Firebox weldment and baffl e supports.

FIVE YEAR WARRANTY

The following components are warranted against deterioration not resulting from physical or handling damage for 5 years to the original owner, subject to proof of purchase: Stainless steel secondary air tubes and secondary ceramic baffl e material.

ONE YEAR WARRANTY

Lexington Forge warrants the components and materials in your wood insert to be free from manufacturing and material defects for a period of one year from date of purchase. After installation, if any of the components manufactured by Lexington Forge in the appliance are found to be defective in materials or workmanship, Lexington

Forge will, at its option, replace or repair the defective components at no charge to the original owner. Lexington

Forge will also pay for reasonable labor costs incurred in replacing or repairing such components for a period of one year from the date of installation. Any products presented for warranty repair must be accompanied by a dated proof of purchase.

This Limited Lifetime Warranty will be void if the appliance is not installed by a qualifi ed installer in accordance with the installation instructions. The Limited Lifetime Warranty will also be void if the appliance is not operated and maintained according to the operating instructions supplied with the appliance, and does not extend to (1) fi rebox/burner assembly damage by over-fi ring, over-loading, accident, neglect, misuse, abuse, alteration, negligence of others, including the installation thereof by unqualifi ed installers, (2) the costs of removal, reinstallation or transportation of defective parts on the appliance, or (3) incidental or consequential damage. All service work must be performed by an authorized service representative.

This warranty is expressly in lieu of other warranties, express or implied, including the warranty of merchantability of fi tness for purpose and of all other obligations or liabilities. Lexington Forge does not assume for it any other obligations or liability in connection with the sale or use of the appliance. In states that do not allow limitations on how long an implied warranty lasts, or do not allow exclusion of indirect damage, those limitations of exclusions may not apply to you. You may also have additional rights not covered in this Limited Lifetime Warranty.

Lexington Forge reserves the right to investigate any and all claims against the Limited Lifetime Warranty and decide upon method of settlement.

For information about this warranty, contact:

JANUARY 2008

149 Cleveland Drive

Paris, Kentucky 40361

P/N 63D4004 • Rev. 2