Installation. Duluth Forge 170154, 170032, 170150

INSTALLATION

NOTICE: This heater is intended for use as supplemental heat.

Use this heater along with your primary heating system. Do not install this heater as your primary heat source. If you have a central heating system, you may run system’s circulating blower while using heater. This will help circulate the heat throughout the house. In the event of a power outage, you can use this heater as your primary heat source.

WARNING: A qualified service person must install heater.

Follow all local codes.

WARNING: Never install the heater

• in a bedroom or bathroom

• in a recreational vehicle

• where curtains, furniture, clothing, or other flammable objects are less than 36" from the front, top, or sides of the heater

• in high traffic areas

• in windy or drafty areas

CAUTION: This heater creates warm air currents. These currents move heat to wall surfaces next to heater. Installing heater next to vinyl or cloth wall coverings or operating heater where impurities (such as tobacco smoke, aromatic candles, cleaning fluids, oil or kerosene lamps, etc.) in the air exist, may cause walls to discolor.

IMPORTANT: Vent-free heaters add moisture to the air. Although this is beneficial, installing heater in rooms without enough ventilation air may cause mildew to form too much moisture.

See Air for Combustion and Ventilation , pages

6 and 7.

CHECK GAS TYPE

Be sure your gas supply is right for your heater. Otherwise, call dealer where you bought the heater for proper type heater.

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200253-01E

INSTALLATION

CONNECTING ELECTRICAL

SUPPLY

This fireplace insert requires an 120V electrical outlet within 4 feet of the unit. There is a power supply for the remote receiver located in the bottom of the fireplace insert. Extensions cords may be used.

The remote receiver requires 4 AA batteries.

This powers the stove in case of an electrical power outage.

1. Locate 6V DC adapter.

2. Plug connector end of adapter into the power change assembly on the back of the fireplace insert.

3. Plug adapter into a 120V electrical outlet.

Back of

Fireplace

Insert

Connector End of Adapter

Power

Change

Assembly

Figure 4 - Connecting to Power Supply

CLEARANCES TO COMBUSTIBLES

WARNING: You must maintain the minimum clearances shown in Figure 5. If you can, provide greater clearances from floor, ceiling, and joining wall.

Measure from outermost point of heater.

Minimum Wall and Ceiling

Clearances

A. Clearances from outermost point of heater to any combustible side wall should not be less than 6".

B. Clearances from the heater to the ceiling should not be less than 36".

Note: When heater is installed directly on carpeting, tile or other combustible material, other than wood flooring, the heater must be installed on a metal or wood panel extending the full width and depth of the heater.

Side

Wall

6"

Min.

Ceiling

36"

Min.

6"

Min.

Side

Wall

Front View

Figure 5 - Minimum Clearances to Wall and Ceiling

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9

INSTALLATION

GAS SELECTION

This appliance is factory preset for propane gas. No changes are required for connecting to propane.

Only a qualified installer or service technician can perform gas selection and connecting to gas supply.

Insert Gas Fitting for Propane Gas

CAUTION: Two gas line installations at the same time are prohibited.

CAUTION: To avoid gas leakage for the gas not being used at the inlet of regulator, a qualified installer or service technician must use supplied cap.

You will notice a color coded plunger on the inside of the regulator. This is normal. When the inlet connection fitting is inserted and tightened, this plunger will be pushed back by the fitting making all of the adjustments for the gas being supplied. DO

NOT REMOVE THE PLUNGER.

The regulator will not work.

The inlet regulator is color coded for identification of the correct gas type. Blue is for propane (LP gas) and yellow is for natural gas.

Insert Gas Fitting for Natural Gas

Blue Propane

Gas Plunger

Underneath Dust

Cover

Yellow Natural Gas

Plunger Underneath

Metal Cap

Figure 6 - Gas Regulator

FOR PROPANE GAS

INSTALLATION: BLUE

1. Remove blue dust cover.

Blue Dust

Cover

DO NOT REMOVE

Blue Propane Plunger

Install Gas Fitting Here

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INSTALLATION

2. Apply thread sealant to the threads on the connection fitting. While pushing in, rotate the fitting clockwise until the threads engage the regulator. After the fitting has been hand tightened into the regulator use a wrench to complete tightening of the fitting. Install additional fitting to connect to the house supply.

FOR NATURAL GAS (NG)

INSTALLATION: YELLOW

1. Remove the blue dust cover from the regulator.

2. Remove the metal cap installed over the

NG regulator inlet.

Metal Cap

3. Install metal cap over Propane regulator inlet. This will keep debris out of regulator.

Metal Cap

Use only the cap supplied on the regulator. Do not use an off the shelf pipe plug. This can damage the plunger. The supplied regulator cap is designed so it will not engage the unused gas type.

4. Apply thread sealant to the threads on the connection fitting. While pushing in, rotate the fitting clockwise until the threads engage the regulator. After the fitting has been hand tightened into the regulator use a wrench to complete tightening of the fitting. Install additional fitting to connect to the house supply.

DO NOT use an off the shelf 3/8"

NPT pipe plug. This will damage the plungers located inside the regulator.

DO NOT try to remove the plungers from inside the regulator. The plunger will be pushed back as the fitting is installed.

Make sure the type of gas being used is correct. Check to make sure the connection fitting is in the correct inlet on the regulator. Refer to Connecting to Gas

Supply, page 14.

If you are using natural gas and the pilot will not light, see

Troubleshooting, page 28.

DO NOT REMOVE

Yellow Natural Gas Plunger

Install Gas Fitting Here

200253-01E www.factorybuysdirect.com

11

INSTALLATION

BUILT-IN FIREPLACE INSTALLATION

WARNING: Do not allow any combustible materials to overlap the firebox front.

WARNING: Do not allow combustible or noncombustible materials to cover any necessary openings like louvered slots.

WARNING: Never modify or cover the louvered slots on the front of the firebox.

Built-in installation of this fireplace involves installing fireplace into a framed-in enclosure.

This makes the front of the fireplace flush with wall. If installing a built-in mantel above the fireplace, you must follow the clearances shown in Figure 7.

NOTICE: Surface temperatures of adjacent walls and mantels become hot during operation.

Walls and mantels above the fireplace may become hot to the touch. If installed properly, these temperatures meet the requirement of the national product standard. Follow all minimum clearances shown in this manual

(see Figure 8).

1. Frame in rough opening. Use dimensions shown in Figure 9 for the rough opening.

If installing in a corner, use dimensions shown in Figure 10 (page 13) for the rough opening. The height is 26 1 /

2

", which is the same as the wall opening above.

2. Carefully set fireplace in front of rough opening with back of fireplace inside wall opening.

3/4" Clearance to Facia

1 3 /

8

" Clearance to Sides, Back and Top

27 3 /

4

"

28 3 /

4

"

Note: Height of fireplace opening on facia to be 23 1 /

4

"

Figure 7 - Clearance to Combustibles

Note: All vertical measurements are from top of fireplace opening to bottom of mantel shelf. All measurements are in inches.

10"

8"

6"

2 1 /

2

"

Mantel

Shelf

Side of

Firebox

Figure 8 - Fireplace Clearances

23.25"

13" 16" 19"

12.75"

12

28.75"

Figure 9 - Rough Opening for Wall

Installation www.factorybuysdirect.com

200253-01E

INSTALLATION

3. Attach gas line to fireplace gas regulator.

See Connecting to Gas Supply , page 14.

4. Check all gas connections for leaks. See

Checking Gas Connections , page 16.

IMPORTANT: When finishing your firebox, combustible materials such as wall board, gypsum board, sheet rock, drywall, plywood, etc, must have 1/2" clearance to the sides and top of the firebox. Combustible materials should never overlap the firebox front.

37.4"

28.75"

53.8"

Figure 10 - Rough Opening for Corner

Installation

ASSEMBLING HOOD

Step 1 CAUTION: Do not operate fireplace without hood in place.

1. Fireplace hood is positioned on top of shipping inner pack.

2. Remove top of firebox by removing 2 screws located on each end (see Figure 11).

3. Insert the hood along the upper side of the heat insulation board (see Figure 11).

Attach hood with 3 screws.

4. Reattach firebox top by reinserting the 2 screws from step 2.

Step 2

Hood

Remove 2

Screws from Top

Firebox Panel

Insulation

Board

Step 3 Replace 2

Screws

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Figure 11 - Hood Installation www.factorybuysdirect.com

13

INSTALLATION

CONNECTING TO GAS SUPPLY

WARNING: A qualified service technician must connect heater to gas supply. Follow all local codes.

CAUTION: Avoid damage to regulator. Hold gas regulator with wrench when connecting into gas piping and/or fittings.

WARNING: This appliance requires a 3/8" NPT (National

Pipe Thread) inlet connection to the pressure regulator.

WARNING: For natural gas,

Never connect heater to private

(non-utility) gas wells. This gas is commonly known as wellhead gas.

WARNING: Do not overtighten gas connections.

CAUTION: Use only new, black iron or steel pipe. Internally tinned copper tubing may be used in certain areas. Check your local codes. Use pipe of

1/2" diameter or greater to allow proper gas volume to heater. If pipe is too small, undue loss of pressure will occur.

CAUTION: For natural gas, check your gas line pressure before connecting heater to gas line. Gas line pressure must be no greater than 9" of water. If gas line pressure is higher, heater regulator damage could occur.

CAUTION: For propane gas, never connect heater directly to the gas supply. This heater requires an external regulator

(not supplied). Install the external regulator between the heater and gas supply.

CAUTION: Use pipe joint sealant that is resistant to gas

(Propane or Natural Gas).

Before installing heater, make sure you have the items listed below:

• external regulator for propane unit only

(supplied by installer)

• piping (check local codes)

• sealant (resistant to natural gas and propane gas)

• equipment shutoff valve*

• test gauge connection*

• sediment trap

• tee joint

• pipe wrench

• flexible gas hose (check local codes)

* A CSA design-certified equipment shutoff valve with 1/8" NPT tap is an acceptable alternative to test gauge connection. Purchase the optional CSA design certified equipment shutoff valve from your dealer.

Typical Inlet Pipe Diameters

Use 3/8" black iron pipe or greater. Installation must include an equipment shutoff valve, union, and plugged 1/8" NPT tap. Locate NPT tap within reach for test gauge hook up. NPT tap must be upstream from heater (see Figure

12, page 15).

IMPORTANT: Install an equipment shutoff valve in an accessible location. The equipment shutoff valve is for turning on or shutting off the gas to the appliance.

For propane installations, apply pipe joint sealant lightly to male threads. This will prevent excess sealant from going into pipe. Excess sealant in pipe could result in clogged heater valves.

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INSTALLATION

The installer must supply an external regulator. The external regulator will reduce incoming gas pressure. You must reduce incoming gas pressure to between 11" and 14" of water.

If you do not reduce incoming gas pressure, heater regulator damage could occur. Install external regulator with the vent pointing down as shown in Figure 13. Pointing the vent down protects it from freezing rain or sleet.

Ground

Joint Union

3/8" NPT

Pipe Nipple

Tee Joint

Install sediment trap in supply line as shown in Figure 12. Place sediment trap where it is within reach for cleaning. Place sediment trap where trapped matter is not likely to freeze.

A sediment trap traps moisture and contaminants. This keeps them from going into heater controls. If sediment trap is not installed or is installed wrong, heater may not run properly.

Equipment

Shutoff Valve Propane

Supply Tank

External

Regulator with

Vent Pointing

Down

Test Gauge

Connection*

Reducer

Bushing to

1/8" NPT

1/8" NPT

Plug Tap

Natural Gas

From Gas Meter

(5" W.C.** to

9.5" W.C. Pressure)

Sediment

Trap

Tee Joint

Pipe Nipple

Gap

3" Minimum

Propane

From External

Regulator

(11" W.C.** to 14" W.C.

Pressure)

Figure 12 - Gas Connection

* Purchase the optional CSA design-certified equipment shutoff valve from your dealer.

Figure 13 - External Regulator with Vent Pointing Down

Gas Regulator

Inlet Connector

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Figure 14 - Gas Regulator Location and

Gas Line Access into Stove Cabinet www.factorybuysdirect.com

15

INSTALLATION

CHECKING GAS CONNECTIONS

WARNING: Test all gas piping and connections for leaks after installing or servicing. Correct all leaks at once.

WARNING: Never use an open flame to check for a leak. Apply a noncorrosive leak detection fluid to all joints. If bubbles form, there is a leak. Correct all leaks at once.

PRESSURE TESTING GAS SUPPLY

PIPING SYSTEM

Test Pressures In Excess Of 1/2 PSIG (3.5 kPa)

1. Disconnect heater with its appliance main gas valve (control valve) and equipment shutoff valve from gas supply piping system. Pressures in excess of 1/2 PSIG will damage heater regulator.

2. Cap off open end of gas pipe where equipment shutoff valve was connected.

3. Pressurize supply piping system by either opening propane supply tank valve for propane gas or opening main gas valve located on or near gas meter for natural gas or using compressed air.

4. Check all joints of gas supply piping system. Apply noncorrosive leak detection fluid to all joints. If bubbles form, there may be a leak.

5. Correct all leaks at once.

6. Reconnect heater and equipment shutoff valve to gas supply. Check reconnected fittings for leaks.

Test Pressures Equal To or Less Than

1/2 PSIG (3.5 kPa)

1. Close equipment shutoff valve (see Figure 15).

2. Pressurize supply piping system by either opening propane supply tank valve for propane gas or opening main gas valve located on or near gas meter for natural gas or using compressed air.

3. Check all joints from gas meter to equipment shutoff valve for natural gas or propane supply to equipment shutoff valve for propane (see Figure 16 or 17). Apply a noncorrosive leak detection fluid to all joints. Bubbles forming show a leak.

4. Correct all leaks at once.

Propane

Supply Tank

External Regulator with

Vent Pointing Down

Control Valve

Location

Figure 16 - Checking Gas Joints for

Propane Gas

Gas Meter

Equipment

Shutoff Valve

Equipment

Shutoff Valve

Open

Closed

Figure 15 - Equipment Shutoff Valve

Equipment Shutoff Valve

Control Valve

Location

Figure 17 - Checking Gas Joints for

Natural Gas

1.

PRESSURE TESTING HEATER GAS CONNECTIONS

Open equipment shutoff valve (see Figure 15).

2. Open main gas valve located on or near gas meter for natural gas or open propane supply tank valve.

3. Make sure control knob of heater is in the

OFF position.

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INSTALLATION

4. Check all joints from equipment shutoff valve to control valve (see Figure 16 or

17, page 16). Apply a noncorrosive leak detection fluid to all joints. Bubbles forming show a leak.

5. Correct all leaks at once.

6. Light heater (see Lighting Instructions on page 19). Check all other internal joints for leaks.

7. Turn off heater (see To Turn Off Gas Appliance , page 20).

INSTALLING LOGS

WARNING: Failure to position the parts in accordance with these diagrams or failure to use only parts specifically approved with this heater may result in property damage or personal injury.

CAUTION: After installation, and periodically thereafter, check to ensure that no flame comes in contact with any log.

With the heater set to high, check to see if flames contact any log. If so, reposition logs according to the log installation instructions in this manual. Flames contacting logs will create soot.

1. Install log 1 onto the two slots in the middle plate (see Figure 18).

2. Install log 2 onto the two slots in the left plate (see Figure 18).

3. Install log 3 onto the two slots in the right plate (see Figure 18).

4. Install the recessed hole on the bottom of log 4 onto the pin on log 1 and place onto log 3 (see Figure 19).

5. Install the recessed hole on the bottom of log 5 onto the pin on log 1 and place onto log 2 (see Figure 19).

IMPORTANT: Make sure logs do not cover any burner ports (see Figure 19). It is very important to install the logs exactly as instructed. Do not modify logs. Use only logs supplied with heater.

Log #1

Log #3

Log #2

Log #5

Figure 18 - Installing Logs 1, 2 and 3

Log #4

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Figure 19 - Installing Logs 4 and 5 www.factorybuysdirect.com

17

INSTALLATION

INSTALLING BATTERIES

CAUTION: Do not mix old and new batteries. Do not mix alka-

Receiver and Remote Control

Batteries are required in both the Remote

Control (Transmitter) (2 AAA size) and Receiver (4 AA size) (see Figure 21).

line, standard (carbon - zinc), or rechargeable (nickel - cadmium) batteries. Do not dispose of batteries in fire, batteries may explode or leak.

• Batteries are included.

Note: Be sure batteries are placed correctly.

Reversing the batteries can cause damage to the receiver and remote. Replace all batteries on a yearly basis or sooner.

Position the slide switch on the front of the receiver box in the ON position before installing batteries. Once the batteries are installed you will hear a single beep which indicates the batteries are charged. If you do not hear a beep, replace with new batteries.

• Remove batteries when depleted.

• Install/replace the batteries according to the type and quantity stated in table below.

• Be sure to observe proper polarity (+/-) when installing or replacing the batteries.

Damage due to improper battery installation may void the warranty on the product.

• For remote control systems, maximize battery life by turning off the receiver when it is not in use.

• For long periods of non-operation, remove batteries from all components for safety.

LEARN

ON

REMOTE

OFF

Receiver

AAA

AAA

Component

Ignitor

Remote Control

Remote Receiver

Type of Battery Qty.

AAA 1

AAA

AA

2 or 3*

4

Remote Control

(Transmitter)

Figure 21 - Installing Batteries in Remote

Control and Receiver

* Note: Quantity depends on model of remote

Control.

Ignitor

Unscrew ignitor cap and install a AAA battery with the + pointing out. Replace cap.

AAA

Battery

Positive

UP

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Figure 20 - Installing Battery in Ignitor www.factorybuysdirect.com

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